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Club Car Precedent 2004 User Manual

Club Car Precedent 2004
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2004
Maintenance
And
Service
Manual No. 102397619 Edition Code 1203D0205C
IQ System
Electric Vehicles

Table of Contents

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Club Car Precedent 2004 Specifications

General IconGeneral
BrandClub Car
ModelPrecedent 2004
CategoryOffroad Vehicle
LanguageEnglish

Summary

2004 Club Car Precedent IQ System Electric Vehicles Maintenance and Service Manual

Foreword

Section 1: Safety

General Warnings

General safety statements to be heeded during operation, repair, or servicing.

Section 2: Vehicle Specifications

Specifications

Detailed specifications for two and four-passenger electric vehicles.

Section 3: General Information

Serial Number Identification

Procedure for identifying the vehicle's serial number using the decal.

Safety Committee

Recommendations for appointing a safety committee for golf car operations.

Storage Procedures

Guidelines and warnings for storing the electric vehicle for extended periods.

Section 1: Safety

General Warnings

General safety statements to be heeded during operation, repair, or servicing.

Section 2: Vehicle Specifications

Specifications

Detailed specifications for two and four-passenger electric vehicles.

Section 3: General Information

Serial Number Identification

Procedure for identifying the vehicle's serial number using the decal.

Safety Committee

Storage Procedures

Guidelines and warnings for storing the electric vehicle for extended periods.

Returning Vehicle to Service

Procedure for returning a stored electric vehicle back into service.

Section 4: Body and Trim

Cleaning the Vehicle

Instructions and precautions for cleaning the vehicle's body panels and seats.

Seat Cleaning

Guidelines for cleaning the vehicle seats based on the level of soiling.

Front and Rear Body Repair

Procedures for repairing minor damage, scratches, and abrasions on the body.

Front Body

Front Body Removal

Step-by-step instructions for removing the front body components.

Front Body Installation

Step-by-step instructions for installing the front body components.

Front Bumper

Floor Mat and Retainers

Floor Mat Retainer Removal

Procedure for removing the floor mat retainers from the vehicle.

Floor Mat Retainer Installation

Procedure for installing the floor mat retainers onto the vehicle.

Kick Plate and Charger Bezel

Kick Plate and Charger Bezel Removal

Steps for removing the kick plate and charger bezel assembly.

Kick Plate and Charger Bezel Installation

Steps for installing the kick plate and charger bezel assembly.

Rear Body

Universal Accessory Mounting

Information on mounting various accessories using the Structural Accessory Module (SAM).

Backrest and Structural Accessory Module

SAM Removal

Procedure for removing the Structural Accessory Module (SAM).

SAM Installation

Procedure for installing the Structural Accessory Module (SAM).

Bag Rack Removal

Steps for removing the bag rack and related components.

Bag Rack Installation

Steps for installing the bag rack.

Rear Body Components Removal

Rear Beauty Panel Removal

Procedure for removing the rear beauty panel.

Rear Beauty Panel Installation

Procedure for installing the rear beauty panel.

Access Panel

Securing the access panel to the rear underbody.

Rear Underbody Removal

Instructions for removing the rear underbody from the vehicle.

Dash Assembly

Dash Assembly Removal

Step-by-step instructions for removing the dash assembly.

Dash Assembly Installation

Step-by-step instructions for installing the dash assembly.

Section 5: Accelerator and Brake Pedal Group

Pedal Group

General information and safety warnings related to the pedal group.

Pedal Group Removal

Procedure for removing the pedal group assembly from the vehicle.

MCOR Component

Debris Shields

Brake Return Spring

Pawl Assembly

Accelerator Return Spring

Pedal Group Installation

Section 6: Wheel Brake Assemblies

General Information

Description of the self-adjusting, mechanically-expanding shoe drum brakes.

Brake Shoe Removal

Step-by-step procedure for removing brake shoes.

Brake Shoe Removal Continued

Remove Shoe Retainer Clip

Using pliers to remove the shoe retainer clip and pin.

Remove Brake Shoes

Grasping and removing brake shoes and springs from the assembly.

Remove Adjuster Wheel

Removing the adjuster wheel and washers from the backing plate.

Brake Assembly Cleaning

Brake Shoe Installation

Brake Cable Equalizer Adjustment

Brake Cluster Removal and Installation

Brake Cluster Removal

Steps for removing the brake cluster assembly from the transaxle.

Brake Cluster Installation

Steps for installing the brake cluster assembly onto the transaxle.

Brake Cable Removal and Installation

Brake Cable Removal

Procedure for disconnecting and removing brake cables.

Brake Cable Installation

Procedure for connecting and installing brake cables.

Section 7: Steering and Front Suspension

General Information

Overview of the rack and pinion steering system.

Steering Wheel Procedures

Safety warnings and procedures for steering wheel removal and installation.

Steering Wheel Removal

Step-by-step instructions for removing the steering wheel.

Steering Wheel Installation

Step-by-step instructions for installing the steering wheel.

Steering Column

Steering Column Removal

Procedure for removing the steering column assembly.

Steering Column Installation

Procedure for installing the steering column assembly.

Rack and Pinion

Rack and Pinion Removal

Steps for removing the rack and pinion assembly from the vehicle.

Rack and Pinion Disassembly

Remove Dust Seal

Procedure for removing the dust seal from the rack and pinion.

Pinion Snap Rings

Removing snap rings from the pinion assembly.

Remove Pinion from Housing

Procedure for removing the pinion from the rack and pinion housing.

Rack and Pinion Assembly

Rack and Pinion Installation

Front Suspension

Lubrication

Lubrication points and procedure for the front suspension components.

Wheel Alignment

Information on wheel alignment, limited to camber and toe-in adjustment.

Camber Adjustment

Procedure for checking and adjusting the camber angle of the front wheels.

Toe-in Adjustment

Toe-in Adjustment Continued

Front Suspension Components

General information on front suspension components.

Tie Rod End Removal

Steps for removing the tie rod ends from the steering gear.

Tie Rod Installation

Steps for installing the tie rod ends onto the steering gear.

Leaf Spring Removal

Leaf Spring Installation

Kingpin and Steering Spindle Removal

Kingpin and Steering Spindle Installation

Control Arm Removal

Shock Absorber Removal

Shock Absorber Installation

Front Wheel Bearings and Hubs

Front Wheel Free Play Inspection

Procedure to inspect for play in the front wheel hub assembly.

Front Hub Removal

Steps for removing the front wheel hub assembly.

Hub Installation

Section 8: Wheels and Tires

General Information

Importance of proper wheel and tire care for vehicle handling and lifespan.

Wheels

Safety warnings for wheel removal and installation procedures.

Wheel Removal

Step-by-step procedure for removing a wheel from the vehicle.

Wheel Installation

Step-by-step procedure for installing a wheel onto the vehicle.

Tires

Safety warnings regarding tire selection and handling.

Tire Removal

Tire Repair

Tire Installation

Section 9: Rear Suspension

General Information

Description of the independent rear suspension with leaf springs and shocks.

Shock Absorbers

Safety warnings and inspection for shock absorbers.

Shock Absorber Removal and Inspection

Procedure for removing and inspecting the rear shock absorbers.

Shock Absorber Installation

Procedure for installing the rear shock absorbers.

Leaf Springs

Safety warnings for leaf spring removal and installation.

Leaf Spring Removal

Procedure for removing the rear leaf springs.

Leaf Spring Installation

Section 10: Periodic Maintenance

General Information

Importance of preventive maintenance for vehicle performance and longevity.

Pre-Operation and Daily Safety Checklist

Daily checklist for ensuring proper working condition and safety.

Performance Inspection

Daily checklist for inspecting vehicle operation and performance.

Periodic Service Schedule

Periodic Service Schedule – Electric Vehicles

Periodic Lubrication Schedule

Section 11: Electrical System and Testing

General Information

Overview of the 48-volt IQ System electrical system and its components.

Shunt-Wound Motor

Description of the shunt-wound motor and speed controller function.

Motor Braking Functions

Explanation of motor braking functions: Zero Speed Detect, Pedal Down, Pedal Up.

Zero Speed Detect

Function preventing uncontrolled rolling on slopes without park brake.

Electrical Circuits

Control Circuit

Components and sub-circuits of the main control circuit.

Onboard Computer Circuit

Functions performed by the onboard computer (OBC) circuit.

OBC Wire Function

Battery Warning Light Assembly

Solid State Speed Control Circuit

Solenoid Activation

The speed control circuit's function in activating the solenoid.

Tow/Run Switch Circuit

Speed Controller 16-Pin Connector Wire Function

Power Circuit

Electric Motor Reference

Charge Circuit

Wiring Diagram

Troubleshooting

Troubleshooting with IQDM

Using the IQDM handset for troubleshooting vehicle issues.

Troubleshooting Guide 1

Guide for identifying symptoms, causes, and corrective actions using IQDM.

Troubleshooting Guide 2

Test Procedures

Index of Test Procedures

Test Procedure 1: Batteries / Voltage Check

Battery Voltage Check without IQDM

Procedure to check battery voltage using a multimeter without IQDM.

Test Procedure 2: Onboard Computer Solenoid Lockout Circuit

Test Procedure 3: Solenoid Activating Coil

Test Procedure 4: MCOR Voltage

MCOR Voltage Test with IQDM Handset

Testing MCOR voltage using the IQDM handset for accelerator pedal position.

MCOR Voltage Test without IQDM Handset

Testing MCOR voltage using a multimeter without IQDM.

MCOR Voltage Test without IQDM Handset Continued

Test Procedure 5: A1 and A2 Motor Voltage

Testing voltage at the A1 and A2 motor terminals.

Test Procedure 6: Tow/Run Switch

Tow/Run Switch Test with IQDM Handset

Testing the Tow/Run switch using the IQDM handset.

Tow/Run Switch Test without IQDM Handset

Testing the Tow/Run switch using a multimeter.

Test Procedure 7: Battery Pack Voltage (Under Load)

Test Procedure 8: Key Switch and MCOR Limit Switch Circuit

Key Switch and MCOR Limit Switch Test with IQDM Handset

Testing key switch and MCOR limit switch with IQDM handset.

Key Switch and MCOR Limit Switch Test without IQDM Handset

Testing key switch and MCOR limit switch with multimeter.

Test Procedure 9: 16-Pin Connector

Test Procedure 9A: Pins 1, 2, and 3

Testing MCOR potentiometer connections to the speed controller.

Test Procedure 9B: Pin 5

Testing the solenoid lockout circuit connection at pin 5.

Test Procedure 9C: Pin 6

Test Procedure 9D: Pin 7

Test Procedure 9E: Pins 8 and 16

Test Procedure 9F: Pin 9

Test Procedure 9G: Pin 10

Test Procedure 9H: Pin 12

Test Procedure 10: Onboard Computer SCR Circuit

Test Procedure 11: Onboard Computer Gray Wire

Test Procedure 12: Voltage at Charger Receptacle Red Wire Socket

Test Procedure 13: Motor Speed Sensor

Motor Speed Sensor Test with IQDM Handset

Testing the motor speed sensor using the IQDM handset.

Motor Speed Sensor Test without IQDM Handset

Testing the motor speed sensor using a multimeter.

Test Procedure 14: Solenoid Continuity

Test Procedure 15: Forward/Reverse Rocker Switch

Forward/Reverse Rocker Switch Test with IQDM Handset

Testing the Forward/Reverse switch using the IQDM handset.

Forward/Reverse Rocker Switch Test without IQDM Handset

Testing the Forward/Reverse switch using a multimeter.

Test Procedure 16: Reverse Buzzer

Test Procedure 17: Rebooting the Onboard Computer

Test Procedure 18: Battery Warning Light

Communication Display Module (CDM)

Using the CDM to Retrieve Data from the Onboard Computer

CDM Troubleshooting Guide

Section 12: Electrical Components

Key Switch

Safety warnings and testing procedures for the key switch.

Key Switch Removal

Step-by-step instructions for removing the vehicle's key switch.

Key Switch Installation

Step-by-step instructions for installing the vehicle's key switch.

Battery Warning Light

Battery Warning Light Removal

Procedure for removing the battery warning light assembly.

Battery Warning Light Installation

Procedure for installing the battery warning light assembly.

Forward/Reverse Rocker Switch

Forward/Reverse Rocker Switch Removal

Procedure for removing the Forward/Reverse rocker switch.

Forward/Reverse Rocker Switch Installation

Procedure for installing the Forward/Reverse rocker switch.

Electronics Module Cover

Electronics Module Cover Removal

Procedure for removing the electronics module cover.

Electronics Module Cover Installation

Procedure for installing the electronics module cover.

Tow/Run Switch

Tow/Run Switch Removal

Procedure for removing the Tow/Run switch.

Tow/Run Switch Installation

Procedure for installing the Tow/Run switch.

Motor Controller Output Regulator (MCOR)

MCOR Removal

Procedure for removing the Motor Controller Output Regulator (MCOR).

MCOR Installation

Reverse Buzzer

Reverse Buzzer Removal

Procedure for removing the reverse buzzer.

Reverse Buzzer Installation

Procedure for installing the reverse buzzer.

Electronics Module

Electronics Module Removal

Procedure for removing the electronics module assembly.

Solid State Speed Controller

Speed Controller Removal

Procedure for removing the solid state speed controller.

Speed Controller Installation

Procedure for installing the solid state speed controller.

Solenoid

Solenoid Removal

Procedure for removing the solenoid.

Solenoid Installation

Onboard Computer (OBC)

Onboard Computer Removal

Procedure for removing the onboard computer (OBC).

Onboard Computer Installation

Procedure for installing the onboard computer (OBC).

Charger Receptacle

Charger Receptacle Inspection

Inspection of the charger receptacle for wear and damage.

Charger Receptacle Removal

Procedure for removing the charger receptacle.

Charger Receptacle Installation

Procedure for installing the charger receptacle.

Section 13: Batteries

General Information

Explanation of deep-cycle batteries and their components.

Common Misconceptions About Batteries

Chart addressing common misconceptions about deep-cycle battery care.

Battery Replacement

Safety warnings and procedure for replacing vehicle batteries.

Battery Replacement Continued

Battery Care

Preventive maintenance steps to keep batteries in sound operating condition.

Preventive Maintenance

Regular steps for maintaining battery health and preventing corrosion.

Self-Discharge

Electrolyte Level

Mineral Content

Vibration Damage

Battery Charging

Charger Shuts Off After 16 Hours

Deep-Discharge

Early Excessive Discharging

Incoming AC Service

Fleet Rotation

Numbering Vehicles and Chargers

Battery Troubleshooting Chart

Battery Testing

Battery Charger Test

Easiest method to monitor battery condition by observing charger ammeter.

On-Charge Voltage Test

Procedure to check battery set and individual battery voltages after charging.

Hydrometer Test

Measuring the specific gravity of battery electrolyte for state of charge.

Performing the Hydrometer Test

Step-by-step instructions for performing the hydrometer test.

Hydrometer Test Continued

Hydrometer Calibration

How to correct hydrometer readings for temperature variations.

Interpreting Hydrometer Test Results

Table correlating specific gravity readings to approximate battery state of charge.

Discharge Test

Performing the Discharge Test

Procedure for conducting a discharge test to simulate vehicle operating conditions.

Discharge Test Continued

Interpreting Discharge Test Results

Table for interpreting discharge test results based on battery voltage and time.

Battery Troubleshooting Examples

Battery Storage

Charging a Battery Pack with Low Voltage

Section 14: Battery Charger

Section 15: Motor

General Information

Description of the 48-volt DC shunt-wound traction motor.

External Motor Testing

Tests performed on the motor without disassembly using a multimeter.

Test Procedure 1: Internal Short Circuits

Procedure to test for internal short circuits in the motor.

Test Procedure 2: Armature Circuit Open

Test Procedure 3: Field Circuit Open

Motor Removal

Motor Disassembly

Motor Component Testing and Inspection

Armature Visual Inspection

Detailed inspection points for armature abnormalities and commutator condition.

Armature Ground Test

Procedure to test the armature for ground faults.

Field Windings Inspection

Inspection of field windings for signs of overheating or damage.

Motor Components

Bearing Inspection

Bearing Removal

Bearing Installation

Speed Sensor Magnet Inspection

Speed Sensor Magnet Removal

Speed Sensor Magnet Installation

Reconditioning the Motor

Motor Specifications

Motor Assembly

Motor Installation

Motor Speed Sensor

Motor Speed Sensor Removal

Procedure for removing the motor speed sensor.

Motor Speed Sensor Installation

Procedure for installing the motor speed sensor.

Section 16A: Transaxle (Type G)

Transaxle Identification

How to identify Type G transaxles by gear case bolt head orientation.

Lubrication

Lubrication points and procedure for the Type G transaxle.

Axle Bearing and Shaft

General information on axle bearings and shafts for Type G transaxle.

Axle Shaft and Oil Seal Removal

Procedure for removing the axle shaft and its oil seal.

Axle Shaft and Oil Seal Installation

Procedure for installing a new axle shaft oil seal and adapter ring.

Install Rear Axle onto Transaxle

Procedure for installing the rear axle onto the transaxle housing.

Transaxle

Transaxle Removal

Step-by-step instructions for removing the transaxle from the vehicle.

Transaxle Disassembly, Inspection, and Assembly

Transaxle Disassembly and Inspection

Procedure for disassembling, inspecting, and reassembling the transaxle.

Transaxle Assembly

Transaxle Installation

Section 16B: Transaxle (Type K)

Transaxle Identification

How to identify Type K transaxles by gear case bolt head orientation.

Lubrication

Lubrication points and procedure for the Type K transaxle.

Axle Bearing and Shaft

General information on axle bearings and shafts for Type K transaxle.

Axle Shaft and Oil Seal Removal

Procedure for removing the axle shaft and its oil seal for Type K.

Axle Shaft and Oil Seal Installation

Procedure for installing axle shaft and oil seal for Type K transaxle.

Axle Bearing

Axle Bearing Removal

Procedure for removing axle bearings and collars.

Axle Bearing Installation

Procedure for installing axle bearings and collars.

Axle Shaft and Oil Seal Installation

Transaxle

Transaxle Removal

Step-by-step instructions for removing the Type K transaxle.

Transaxle Disassembly, Inspection, and Assembly

Transaxle Disassembly and Inspection

Procedure for disassembling, inspecting, and reassembling the Type K transaxle.

Transaxle Assembly

Transaxle Installation

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