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Precedent 2004
Club Car Precedent 2004 User Manual
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2004
Maintenance
And
Ser
vice
Ma
n
ual No
.
1
02397619
Edition Code 1203
D0205C
IQ System
Electric
V
ehic
les
2
Table of Contents
Default Chapter
5
Table of Contents
5
Section 1 - Safety
11
General Warnings
11
Section 2 - Vehicle Specifications
13
Section 3 - General Information
15
Serial Number Identification
15
Safety Committee
16
Storage
16
Preparing the Electric Vehicle for Extended Off-Season Storage
16
Returning the Stored Electric Vehicle to Service
17
Section 4 - Body and Trim
19
Cleaning the Vehicle
19
Seat
19
Front and Rear Body Repair
20
Stress Lines or Streaks
20
Minor Impact Damage/Deformations
20
Minor Scratches and Surface Blemishes
20
Gouges, Punctures, Tears, Large Scratches, and Abrasions
20
Front Body
21
Front Body Removal
21
Front Body Installation
21
Front Bumper
23
Floor Mat and Retainers
24
Floor Mat Retainer Removal
24
Floor Mat Retainer Installation
24
Kick Plate and Charger Bezel
25
Kick Plate and Charger Bezel Removal
25
Kick Plate and Charger Bezel Installation
25
Rear Body
26
Universal Accessory Mounting
26
Backrest and Structural Accessory Module
27
Rear Body Components Removal
29
Dash Assembly
32
Dash Assembly Removal
32
Dash Assembly Installation
33
Section 5 - Accelerator and Brake Pedal Group
35
Pedal Group Removal
35
Mcor
37
Debris Shields
37
Brake Return Spring
37
Pawl Assembly
38
Accelerator Return Spring
38
Pedal Group Installation
40
Section 6 - Wheel Brake Assemblies
43
General Information
43
Brake Shoe Removal
43
Brake Assembly Cleaning
47
Brake Shoe Installation
48
Brake Cable Equalizer Adjustment
50
Brake Cluster Removal and Installation
51
Brake Cluster Installation
52
Brake Cable Removal and Installation
53
Section 7 - Steering and Front Suspension
55
General Information
55
Steering Wheel
55
Steering Wheel Removal
55
Steering Wheel Installation
56
Steering Column
56
Steering Column Removal
56
Steering Column Installation
58
Rack and Pinion
58
Rack and Pinion Removal
58
Rack and Pinion Disassembly
59
Rack and Pinion Assembly
62
Rack and Pinion Installation
63
Front Suspension
64
Lubrication
64
Wheel Alignment
64
Front Suspension Components
66
Tie Rod End Removal
66
Tie Rod Installation
66
Leaf Spring Removal
67
Leaf Spring Installation
67
Kingpin and Steering Spindle Removal
67
Kingpin and Steering Spindle Installation
67
Control Arm Removal
68
Control Arm Installation
71
Shock Absorber Removal
71
Shock Absorber Installation
71
Front Wheel Bearings and Hubs
71
Front Wheel Free Play Inspection
71
Front Hub Removal
71
Hub Installation
72
Section 8 - Wheels and Tires
73
General Information
73
Wheels
73
Wheel Removal
73
Wheel Installation
73
Tires
73
Tire Removal
74
Tire Repair
74
Tire Installation
75
Section 9 - Rear Suspension
77
General Information
77
Shock Absorbers
77
Shock Absorber Removal and Inspection
77
Shock Absorber Installation
77
Leaf Springs
77
Leaf Spring Removal
77
Leaf Spring Installation
80
Section 10 - Periodic Maintenance
81
General Information
81
Pre-Operation and Daily Safety Checklist
81
Performance Inspection
81
Periodic Service Schedule
82
Periodic Lubrication Schedule
84
Section 11 - Electrical System and Testing
85
General Information
85
Electrical Circuits
87
Control Circuit
87
Onboard Computer Circuit
87
Electric Motor
93
Power Circuit
93
Charge Circuit
94
Wiring Diagram
95
Troubleshooting
96
Troubleshooting the Vehicle with the IQDM
96
Troubleshooting Guide 1
96
Troubleshooting Guide 2
97
Test Procedures
101
Index of Test Procedures
102
Communication Display Module (CDM)
126
Using the CDM to Retrieve Data from the Onboard Computer
127
CDM Troubleshooting Guide
128
Section 12 - Electrical Components
129
Key Switch
129
Battery Warning Light
131
Forward/Reverse Rocker Switch
132
Electronics Module Cover
133
Tow/Run Switch
134
Motor Controller Output Regulator (MCOR)
135
Reverse Buzzer
136
Electronics Module
137
Solid State Speed Controller
139
Solenoid
140
Onboard Computer (OBC)
141
Charger Receptacle
142
Section 13 - Batteries
145
General Information
145
Common Misconceptions about Batteries
147
Battery Replacement
147
Battery Care
148
Preventive Maintenance
148
Self-Discharge
149
Electrolyte Level
149
Mineral Content
150
Vibration Damage
150
Battery Charging
150
Charger Shuts off after 16 Hours
151
Deep-Discharge
151
Early Excessive Discharging
151
Incoming AC Service
151
Fleet Rotation
151
Numbering Vehicles and Chargers
151
Battery Troubleshooting Chart
152
Battery Testing
153
Battery Charger Test
153
On-Charge Voltage Test
153
Hydrometer Test
153
Discharge Test
155
Battery Troubleshooting Examples
157
Battery Storage
158
Charging a Battery Pack that Has Low Voltage
158
Section 14 - Battery Charger
159
Section 15 - Motor
161
General Information
161
External Motor Testing
161
Motor
163
Motor Component Testing and Inspection
165
Armature
165
Field Windings Inspection
166
Motor Components
167
Bearing Inspection
167
Bearing Removal
169
Bearing Installation
169
Speed Sensor Magnet Inspection
169
Speed Sensor Magnet Removal
169
Speed Sensor Magnet Installation
169
Reconditioning the Motor
169
Motor Assembly
170
Motor Installation
172
Motor Speed Sensor
175
Section 16A - Transaxle (Type G)
177
Transaxle Identification
177
Lubrication
177
Axle Bearing and Shaft
177
Axle Shaft
177
Axle Bearing
181
Transaxle
181
Transaxle Removal
181
Transaxle Disassembly, Inspection, and Assembly
183
Transaxle Disassembly and Inspection
183
Transaxle Assembly
186
Transaxle Installation
187
Section 16B - Transaxle (Type K)
189
Transaxle Identification
189
Lubrication
189
Axle Bearing and Shaft
189
Axle Shaft
189
Axle Bearing
192
Transaxle
194
Transaxle Removal
194
Transaxle Disassembly, Inspection, and Assembly
196
Transaxle Disassembly and Inspection
196
Transaxle Assembly
198
Shimming the Transaxle
200
Transaxle Installation
201
4
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Club Car Precedent 2004 Specifications
General
Brand
Club Car
Model
Precedent 2004
Category
Offroad Vehicle
Language
English
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