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Club Car Electric Precedent 2008 User Manual

Club Car Electric Precedent 2008
344 pages
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2008ElectricPrecedent
Maintenanceand
ServiceManual
IQSystemandExcelSystemVehicles
ManualNumber103373101
EditionCode0907D0309C

Table of Contents

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Club Car Electric Precedent 2008 Specifications

General IconGeneral
Model Year2008
ModelPrecedent
Power SourceElectric
Seating Capacity2
Battery TypeLead-acid
Batteries6 x 8V
Overall Length91.5 inches
Ground Clearance4.5 inches
Payload Capacity800 lbs
Frame MaterialAluminum
Brake TypeMechanical drum
TypeElectric
Top Speed12-15 mph
Charger48V Charger
Overall Height (with canopy)68.5 inches
Wheelbase65.5 inches
Tire Size18 x 8.5-8
SuspensionLeaf Spring

Summary

FOREWORD

SECTION 1 - SAFETY

General Warnings

General safety statements to be heeded when operating, repairing, or servicing the vehicle.

SECTION 2 - VEHICLE SPECIFICATIONS

SECTION 3 - GENERAL INFORMATION

Storage

General warnings and guidelines for storing the vehicle, including battery preparation.

SECTION 4 - BODY AND TRIM

Cleaning the Vehicle

Provides instructions and precautions for cleaning the vehicle's exterior and interior components.

Front and Rear Body Repair

Details procedures for repairing minor impact damage, stress lines, and scratches on the body panels.

Front Body

Covers procedures related to the front body assembly of the vehicle.

Rear Body – Two-Passenger Vehicles

Details components and procedures specific to the rear body of two-passenger vehicles.

Rear Body – Four-Passenger Vehicles

Details components and procedures specific to the rear body of four-passenger vehicles.

Canopy – Two-Passenger

Procedures for installing and removing the canopy for two-passenger models.

Canopy – Four-Passenger

Procedures for installing and removing the canopy for four-passenger models.

SECTION 5 - ACCELERATOR AND BRAKE PEDAL GROUP

Pedal Group

Information regarding the accelerator and brake pedal assembly.

MCOR

Details about the Motor Controller Output Regulator (MCOR) and its function.

SECTION 6 - WHEEL BRAKE ASSEMBLIES

Brake Shoe Removal

Detailed steps for removing brake shoes, including safety warnings and notes.

Brake Assembly Cleaning

Procedures and precautions for cleaning brake assembly components, including lubrication.

Brake Shoe Installation

Step-by-step guide for installing brake shoes, including proper orientation and adjustment.

Brake Cable Equalizer Adjustment

Instructions for adjusting brake cable equalizer tension for proper brake performance.

Brake Cluster Removal and Installation

Procedures for removing and installing the brake cluster assembly and related parts.

Brake Cable Removal and Installation

Steps for removing and installing brake cables, noting design changes and component usage.

SECTION 7 - STEERING AND FRONT SUSPENSION

Rack and Pinion

Procedures for the removal, disassembly, assembly, and installation of the rack and pinion system.

Front Suspension

Details on lubrication and wheel alignment, including camber and toe-in adjustments.

Front Wheel Bearings and Hubs

Procedures for inspecting, removing, and installing front wheel bearings and hubs.

SECTION 8 - WHEELS AND TIRES

Wheels

Instructions for removing and installing vehicle wheels.

Tires

Procedures for removing, repairing, and installing vehicle tires.

SECTION 9 - REAR SUSPENSION

Shock Absorbers

Procedures for removing, inspecting, and installing shock absorbers.

Leaf Springs (Two-Passenger Vehicles)

Steps for removing and installing leaf springs on two-passenger vehicles.

Leaf Springs (Four-Passenger Vehicles)

Steps for removing and installing leaf springs on four-passenger vehicles.

SECTION 10 - PERIODIC MAINTENANCE

Periodic Service Schedule

Outlines regular service intervals for owner and technician, detailing tasks and referenced sections.

Periodic Lubrication Schedule

Details lubrication points, intervals, and recommended lubricants for various vehicle components.

SECTION 11 - IQ SYSTEM TROUBLESHOOTING

TROUBLESHOOTING THE VEHICLE WITH THE IQDM

Recommends using the IQDM handset for troubleshooting IQ System vehicles, including safety warnings.

TROUBLESHOOTING GUIDE 1

A guide for identifying symptoms, causes, and corrective actions for IQ System issues using IQDM.

SECTION 12 - EXCEL SYSTEM TROUBLESHOOTING

TROUBLESHOOTING THE VEHICLE WITH THE IQDM

Recommends using the IQDM handset for troubleshooting Excel System vehicles, including safety warnings.

TROUBLESHOOTING GUIDE 1

A guide for identifying symptoms, causes, and corrective actions for Excel System issues using IQDM.

SECTION 13 - IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM

PLUGGING THE HANDSET INTO THE VEHICLE

Instructions on how to connect the IQDM handset to the vehicle's IQDM port.

MENU NAVIGATION

Explains how to navigate the handset menus using navigation and value change buttons.

MONITOR

Explains the monitor menu for viewing real-time parameters to aid in speed controller troubleshooting.

FAULTS

Describes the faults menu, which displays recorded faults from the speed controller.

FUNCTIONS

Explains the functions menu for transferring settings between the speed controller and the handset.

SECTION 14 - IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM

PLUGGING THE HANDSET INTO THE VEHICLE

Instructions for connecting the IQDM-P handset to the Excel System vehicle's IQDM port.

MENU NAVIGATION

Explains how to navigate the handset menus for Excel System vehicles.

MONITOR

Explains the monitor menu for viewing real-time parameters for Excel System speed controller troubleshooting.

FAULTS

Describes the faults menu, which displays faults detected by the Excel System speed controller.

FUNCTIONS

Explains the functions menu for transferring settings between the Excel System speed controller and the handset.

SECTION 15 - ELECTRICAL COMPONENTS

KEY SWITCH

Procedures for testing, removing, and installing the key switch.

FORWARD/REVERSE ROCKER SWITCH

Procedures for testing, removing, and installing the Forward/Reverse rocker switch.

MOTOR CONTROLLER OUTPUT REGULATOR (MCOR)

Procedures for testing and removing the MCOR component.

ELECTRONICS MODULE – STYLE A BATTERY CONFIGURATION

Procedures for removing and installing the electronics module for Style A battery configurations.

ELECTRONICS MODULE – STYLE B AND C BATTERY CONFIGURATIONS

Procedures for removing and installing the electronics module for Style B and C battery configurations.

SPEED CONTROLLER – STYLE A BATTERY CONFIGURATION

Procedures for testing, removing, and installing the speed controller for Style A configurations.

SPEED CONTROLLER – STYLE B AND C BATTERY CONFIGURATIONS

Procedures for testing, removing, and installing the speed controller for Style B and C configurations.

ONBOARD COMPUTER (OBC) – STYLE A BATTERY CONFIGURATION

Procedures for testing, removing, and installing the Onboard Computer for Style A configurations.

ONBOARD COMPUTER (OBC) – STYLE B AND C BATTERY CONFIGURATIONS

Procedures for testing, removing, and installing the Onboard Computer for Style B and C configurations.

CHARGER RECEPTACLE

Information on testing, inspecting, and removing the charger receptacle.

SECTION 16 - BATTERIES

BATTERY TROUBLESHOOTING CHART

A flowchart to diagnose battery problems based on test results and symptoms.

BATTERY TESTING – 12 VOLT

Details four progressive tests to diagnose battery problems, starting with basic checks.

BATTERY REPLACEMENT

Step-by-step instructions for safely replacing vehicle batteries, including safety warnings.

BATTERY CARE

Guidelines for maintaining batteries in good working condition, covering cleaning and connections.

ELECTROLYTE LEVEL

Instructions on checking and maintaining battery electrolyte level, including adding water.

BATTERY CHARGER

General information about the battery charger and its automatic functions.

SECTION 17 - BATTERY CHARGER

SECTION 18 - MOTOR (MODEL 5BC59JBS6390)

MOTOR IDENTIFICATION

Details how to identify the two types of motors used in the vehicles.

EXTERNAL MOTOR TESTING

Outlines tests for the motor without disassembly using a multimeter or continuity tester.

MOTOR REMOVAL

Step-by-step instructions for removing the motor from the vehicle, including safety precautions.

MOTOR COMPONENT TESTING AND INSPECTION

Procedures for inspecting and testing motor components like armature, field windings, and brushes.

SECTION 19 - MOTOR (MODEL EJ4-4001)

MOTOR IDENTIFICATION

Details how to identify the two types of motors used in the vehicles.

EXTERNAL MOTOR TESTING

Outlines tests for the motor without disassembly using a multimeter or continuity tester.

MOTOR REMOVAL

Step-by-step instructions for removing the motor from the vehicle, including safety precautions.

MOTOR COMPONENT TESTING AND INSPECTION

Procedures for inspecting and testing motor components like armature, field windings, and brushes.

SECTION 20 - TRANSAXLE (TYPE G)

LUBRICATION

Instructions for checking and filling the transaxle lubricant level.

AXLE BEARING AND SHAFT

Procedures for removing and installing axle shafts, seals, and bearings.

TRANSAXLE DISASSEMBLY, INSPECTION, AND ASSEMBLY

Comprehensive guide for disassembling, inspecting, and reassembling the transaxle.

SECTION 21 - IQ DISPLAY MODULE PROGRAMMER (IQDM-P): IQ SYSTEM

PLUGGING THE HANDSET INTO THE VEHICLE

Instructions on how to connect the IQDM-P handset to the vehicle's IQDM port for IQ System.

PROGRAM MENU

Explains how to access and use the program menu to adjust speed controller settings.

SECTION 22 - IQ DISPLAY MODULE PROGRAMMER (IQDM-P): EXCEL SYSTEM

PLUGGING THE HANDSET INTO THE VEHICLE

Instructions for connecting the IQDM-P handset to the Excel System vehicle's IQDM port.

PROGRAM MENU

Explains how to access and use the program menu to adjust speed controller settings for Excel System.

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