Name: Club Car 2009-20011 Electric Precedent
Brand: Club Car
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2009-201 1 Electric Precedent

Maintenance and

Service Manual

IQ System and Excel System V ehicles

Manual Number 103472701

Edition Code 0309C1 1 10B

Table of Contents5
Section 1 - Safety15
- General Warnings15
Section 2 - Vehicle Specifications19
Section 3 - General Information21
- Serial Number Identification21
- Safety Committee22
- Storage22
  - Preparing the Electric Vehicle for Extended Off-Season Storage23
  - Returning the Stored Electric Vehicle to Service24
Section 4 - Body and Trim25
- Cleaning the Vehicle25
  - Seat25
- Front and Rear Body Repair26
- Front Body27
  - Front Body Removal27
  - Front Body Installation27
- Front Bumper29
- Instrument Panel30
  - Instrument Panel Removal30
  - Instrument Panel Installation30
- Floor Mat and Retainers31
  - Floor Mat Retainer Removal31
  - Floor Mat Retainer Installation31
- Kick Plate and Charger Receptacle Bezel32
  - Kick Plate and Charger Receptacle Bezel Removal32
  - Kick Plate and Charger Receptacle Bezel Installation32
- Rear Body - Two-Passenger Vehicles33
- Rear Body - Four-Passenger Vehicles37
- Canopy - Two-Passenger40
  - Two-Passenger Canopy Removal40
  - Two-Passenger Canopy Installation42
- Canopy - Four-Passenger42
  - Four-Passenger Canopy Removal42
  - Four-Passenger Canopy Installation43
- Canopy (Monsoon Version) - Four-Passenger45
  - Monsoon Canopy Removal45
  - Monsoon Canopy Installation45
Section 5 - Accelerator and Brake Pedal Group49
- Pedal Group - Throttle Position Sensor49
- Pedal Group - MCOR51
- Debris Shields53
- Accelerator Pedal Removal54
- Accelerator Pedal Installation54
- Brake Pedal Removal54
- Brake Pedal Installation54
Section 6 - Wheel Brake Assemblies57
- General Information57
- Brake Shoe Removal57
- Brake Assembly Cleaning61
- Brake Shoe Installation63
- Brake Cable Equalizer Adjustment66
- Brake Cluster Removal and Installation67
  - Brake Cluster Removal67
  - Brake Cluster Installation67
- Brake Cable Removal and Installation69
  - Brake Cable Removal69
  - Brake Cable Installation70
Section 7 - Steering and Front Suspension73
- General Information73
- Steering Wheel73
  - Steering Wheel Removal73
  - Steering Wheel Installation74
- Steering Column74
  - Steering Column Removal74
  - Steering Column Installation75
- Rack and Pinion76
- Front Suspension83
  - Lubrication83
  - Wheel Alignment83
- Front Suspension Components85
- Front Wheel Bearings and Hubs90
Section 8 - Wheels and Tires93
- General Information93
- Wheels93
  - Wheel Removal93
  - Wheel Installation93
- Tires94
Section 9 - Rear Suspension97
- General Information97
- Shock Absorbers97
  - Shock Absorber Removal and Inspection97
  - Shock Absorber Installation97
- Leaf Springs (Two-Passenger Vehicles)98
  - Leaf Spring Removal (Two-Passenger Vehicles)98
  - Leaf Spring Installation (Two-Passenger Vehicles)99
- Leaf Springs (Four-Passenger Vehicles)100
  - Leaf Spring Removal (Four-Passenger Vehicles)100
  - Leaf Spring Installation (Four-Passenger Vehicles)101
Section 10 - Periodic Maintenance103
- General Warning103
- General Information105
- Periodic Service Schedule105
- Periodic Lubrication Schedule108
Section 11 - Iq System Troubleshooting - Tps109
- General Information109
- Wiring Diagrams110
- Troubleshooting115
- Test Procedures121
- Battery Warning Light143
- Communication Display Module (CDM)143
  - Using the CDM to Retrieve Data from the Onboard Computer144
- CDM Troubleshooting Guide146
Section 12 - Iq System Troubleshooting - Mcor147
- General Information147
- Wiring Diagrams148
- Troubleshooting153
- Test Procedures159
- Battery Warning Light184
- Communication Display Module (CDM)185
  - Using the CDM to Retrieve Data from the Onboard Computer186
- CDM Troubleshooting Guide186
Section 13 - Excel System Troubleshooting - Tps189
- General Information189
  - Differences between the Excel and IQ Systems189
  - Features190
- Wiring Diagrams191
- Troubleshooting196
- Test Procedures201
- Battery Warning Light223
- Communication Display Module (CDM)223
  - Using the CDM to Retrieve Data from the Onboard Computer224
- CDM Troubleshooting Guide226
Section 14 - Excel System Troubleshooting - Mcor227
- General Information227
  - Differences between the Excel and IQ Systems227
  - Features228
- Wiring Diagrams229
- Troubleshooting234
- Test Procedures239
- Battery Warning Light264
- Communication Display Module (CDM)264
  - Using the CDM to Retrieve Data from the Onboard Computer265
- CDM Troubleshooting Guide266
Section 15 - Iq Display Module (Iqdm) and Iqdm-Pdiagnostics: Iq System267
- Plugging the Handset into the Vehicle267
- Introductory Display267
- Menu Navigation268
- Monitor Menu270
- Faults Menu273
- Functions Menu279
- Information282
- Programmer Setup283
- IQDM and IQDM-P Handset Troubleshooting284
- Test Procedures285
Section 16 - Iq Display Module (Iqdm) and Iqdm-Pdiagnostics: Excel System289
- Plugging the Handset into the Vehicle289
- Introductory Display290
- Menu Navigation291
- Monitor Menu292
- Faults Menu296
- Functions Menu302
- Information305
- Programmer Setup306
- IQDM and IQDM-P Handset Troubleshooting307
- Test Procedures308
Section 17 - Electrical Components311
- Key Switch311
- Battery Warning Light312
- Forward/Reverse Rocker Switch313
- Electronics Module Cover315
  - Electronics Module Cover Removal315
  - Electronics Module Cover Installation315
- Tow/Run Switch316
- Throttle Position Sensor (TPS)317
  - Testing the Throttle Position Sensor317
  - Throttle Position Sensor Replacement317
- Motor Controller Output Regulator (MCOR)318
- Reverse Buzzer318
- Electronics Module319
  - Electronics Module Removal319
  - Electronics Module Installation320
- Speed Controller322
- Solenoid323
- Onboard Computer (OBC)324
- Charger Receptacle325
- Headlight Adjustment326
  - Aiming the Headlight Beam326
- Ferrite Beads - CE Mark Vehicles328
Section 18 - Batteries329
- General Information329
- Battery Troubleshooting Chart330
- Battery Testing - 12 Volt331
- Battery Testing - 8 Volt337
- Battery Replacement343
- Battery Care344
- Battery Charger - High Frequency348
- Battery Charger - Ferroresonant349
- Single Point Watering System (SPWS)353
  - Initial Maintenance of the SPWS353
  - Watering Batteries with the SPWS354
- Battery Storage356
- Charging a Battery Pack that Has Low Voltage356
Section 19 - Battery Charger357
Section 20 - Motor (Model Ej4-4001 and Ej8-4001A)359
- General Information359
- Motor Identification359
- External Motor Testing360
- Motor361
  - Motor Removal361
  - Motor Disassembly363
- Motor Component Testing and Inspection365
- Reconditioning the Motor370
  - Motor Specifications370
- Motor Assembly370
- Motor Installation372
Section 21 - Transaxle (Type G)375
- Lubrication375
- Axle Bearing and Shaft375
  - Axle Shaft375
  - Axle Bearing378
- Transaxle379
  - Transaxle Removal379
- Transaxle Disassembly, Inspection, and Assembly382
  - Transaxle Disassembly and Inspection382
  - Transaxle Assembly384
- Transaxle Installation385
Section 22 - Iq Display Module Programmer (Iqdm-P): Iq System387
- Plugging the Handset into the Vehicle387
- Program Menu388
Section 23 - Iq Display Module Programmer (Iqdm-P): Excel System391
- Plugging the Handset into the Vehicle391
- Program Menu392

Club Car 2009-20011 Electric Precedent User Manual

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Club Car 2009-20011 Electric Precedent Specifications

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Brand	Club Car
Model	2009-20011 Electric Precedent
Category	Offroad Vehicle
Language	English