Club Car IQ PLUS SYSTEM User Manual

Name: Club Car IQ PLUS SYSTEM
Brand: Club Car
Rating: 5 (1 reviews)

156 pages

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Club Car

EDITION CODE 0906A00000

IQ PLUS SYSTEM

ELECTRIC VEHICLES

2006

MAINTENANCE

SERVICE

SUPPLEMENT

MANUAL NUMBER 102907708

Table of Contents5
Section 10 - Periodic Maintenance9
General Warning9
General Information11
Periodic Service Schedule12
Periodic Lubrication Schedule13
Section 11 - Electrical System and Testing15
General Information15
Wiring Diagrams16
Troubleshooting22
Troubleshooting the Vehicle with the IQDM22
Troubleshooting Guide 123
Troubleshooting Guide 226
Test Procedures28
Index of Test Procedures28
Communication Display Module (CDM)59
Using the CDM to Retrieve Data from the Onboard Computer60
CDM Troubleshooting Guide61
Section 12 - Iq Plus System Display Module (Iqdm Series 2) Diagnostics63
Plugging the Handset into the Vehicle63
Introductory Display64
Menu Navigation64
Monitor Menu66
Faults Menu70
System Faults70
Fault Recovery71
Fault Descriptions73
Clearing Fault History75
Information75
Programmer Setup76
Program76
Faults76
Information77
IQDM Series 2 Handset Troubleshooting77
Test Procedures78
Index of Test Procedures78
Section 13 - Electrical Components83
Key Switch83
Forward/Reverse Rocker Switch85
Tow/Run Switch86
Circuit Breaker87
Motor Controller Output Regulator (MCOR)88
Reverse Buzzer89
Speed Controller Cover89
Solenoid90
Onboard Computer (OBC)92
Solid State Speed Controller93
Charger Receptacle95
Receptacle Fuse Link97
Battery Warning Light98
Section 14 - Batteries99
General Information99
Battery Replacement99
Battery Care101
Preventive Maintenance101
Self-Discharge101
Electrolyte Level102
Mineral Content103
Vibration Damage103
Battery Charging103
Charger Shuts off after 16 Hours103
Deep-Discharge104
Early Excessive Discharging104
Incoming AC Service104
Fleet Rotation104
Numbering Vehicles and Chargers104
Battery Troubleshooting Chart105
Battery Testing106
Battery Charger Test106
On-Charge Voltage Test106
Hydrometer Test106
Discharge Test108
Battery Troubleshooting Examples110
Battery Storage111
Charging a Battery Pack that Has Low Voltage111
Section 15 - Battery Charger113
Refer to the Appropriate Battery Charger Maintenance and Service Manual113
Section 16 - Motor (Model Da5-4006)115
General Information115
External Motor Testing115
Motor116
Motor Removal116
Motor Disassembly118
Motor Component Testing and Inspection120
Armature Inspection and Testing120
Motor Frame and Field Windings Inspection121
Motor Brush, Spring, and Terminal Insulator Inspection121
Reconditioning the Motor125
Motor Assembly125
Motor Installation126
Section 17 - Transaxle (Type G)131
Lubrication131
Axle Bearing and Shaft131
Axle Shaft131
Axle Bearing134
Transaxle135
Transaxle Removal135
Transaxle Disassembly, Inspection, and Assembly137
Transaxle Disassembly and Inspection137
Transaxle Assembly139
Transaxle Installation140
Section 18 - Iq Plus System Display Module (Iqdm-P Series 2) Program143
Plugging the Handset into the Vehicle143
Program Menu144
M1/M2 Speed144
M1/M2 Fast Accel145
M1/M2 Pedal up145
M1/M2 Speed Cal146
Code A, Code B, and Code C147
Functions Menu147
Get Settings from Controller147
Write Settings to Controller148
Reset All Settings149
SECTION I - INDEX154

Club Car IQ PLUS SYSTEM User Manual

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Club Car IQ PLUS SYSTEM Specifications

Related product manuals

Brand	Club Car
Model	IQ PLUS SYSTEM
Category	Utility Vehicle
Language	English