2004 Club Car Precedent Electric Factory Service & Work Shop Manual
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2004
Maintenance
And
Service
Manual No. 102397619 Edition Code 1203 D0205C
IQ System
Electric Vehicles
2004 Precedent IQ System Golf Car Maintenance and Service Manual Page i
FOREWORD
Club Car vehicles are designed and built to provide the ultimate in performance efficiency; however, proper
maintenance and repair are essential for achieving maximum service life and continued safe and reliable
operation.
This manual provides detailed information for the maintenance and repair of the electric Precedent vehicles,
and should be thoroughly reviewed prior to servicing the vehicle. The procedures provided herein must be
properly implemented, and the DANGER, WARNING, and CAUTION statements must be heeded.
This manual was written for the trained technician who already possesses knowledge and skills in electrical
and mechanical repair. If the technician does not have such knowledge and skills, attempted service or
repairs to the vehicle may render the vehicle unsafe. For this reason, Club Car advises that all repairs and/or
service be performed by an authorized Club Car distributor/dealer representative or by a Club Car factory-
trained technician.
It is the policy of Club Car, Inc. to assist its distributors and dealers in continually updating their service knowl-
edge and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical rep-
resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and
other service publications also represent Club Car’s continuing commitment to customer support.
This manual covers all aspects of typical vehicle service; unique situations, however, do sometimes occur
when servicing a vehicle. If it appears that a service question is not answered in this manual, you may write
to us at: Club Car, Inc.; P.O. Box 204658; Augusta, Georgia 30917; Attention: Technical Services, or contact
a Club Car Technical Service Representative at (706) 863-3000, ext. 3580.
Copyright © 2003 Club Car, Inc.
Club Car and PowerDrive are registered
trademarks of Club Car, Inc.
This manual effective October 15, 2003.
Page ii 2004 Precedent IQ System Golf Car Maintenance and Service Manual
∆ WARNING
• Read Section 1 – Safety before attempting any service on the vehicle.
• Before servicing vehicle, read complete section(s) and any referenced information that may
be relevant to the service or repair to be performed.
NOTE: This manual represents the most current information at the time of publication. Club Car, Inc. is
continually working to further improve our vehicles and other products. These improvements may
affect servicing procedures. Any modification and/or significant change in specifications or proce-
dures will be forwarded to all Club Car dealers and will, when applicable, appear in future editions
of this manual.
Club Car, Inc. reserves the right to change specifications and designs at any time without notice
and without the obligation of making changes to units previously sold.
There are no warranties expressed or implied in this manual. See the limited warranty found in the
vehicle owner’s manual or write to Club Car, Inc., P.O. BOX 204658, Augusta, Georgia 30917-4658
USA, Attention: Warranty Department.
2004 Precedent IQ System Golf Car Maintenance and Service Manual Page iii
CONTENTS
SECTION 1 – SAFETY
General Warnings ............................................................................................................................. 1-1
SECTION 2 – VEHICLE SPECIFICATIONS
SECTION 3 – GENERAL INFORMATION
Serial Number Identification .............................................................................................................. 3-1
Safety Committee ............................................................................................................................. 3-2
Storage ............................................................................................................................................. 3-2
Preparing the Electric Vehicle for Extended Off-Season Storage ................................................ 3-2
Returning the Stored Electric Vehicle to Service .......................................................................... 3-3
SECTION 4 – BODY AND TRIM
Cleaning the Vehicle ......................................................................................................................... 4-1
Seat .............................................................................................................................................. 4-1
Front and Rear Body Repair ............................................................................................................. 4-2
Stress Lines or Streaks ................................................................................................................. 4-2
Minor Impact Damage/Deformations ............................................................................................ 4-2
Minor Scratches and Surface Blemishes ...................................................................................... 4-2
Gouges, Punctures, Tears, Large Scratches, and Abrasions ....................................................... 4-2
Front Body ........................................................................................................................................ 4-3
Front Body Removal ..................................................................................................................... 4-3
Front Body Installation .................................................................................................................. 4-3
Front Bumper .................................................................................................................................... 4-5
Floor Mat and Retainers ................................................................................................................... 4-6
Floor Mat Retainer Removal ......................................................................................................... 4-6
Floor Mat Retainer Installation ...................................................................................................... 4-6
Kick Plate and Charger Bezel ........................................................................................................... 4-7
Kick Plate and Charger Bezel Removal ........................................................................................ 4-7
Kick Plate and Charger Bezel Installation ..................................................................................... 4-7
Rear Body ......................................................................................................................................... 4-8
Universal Accessory Mounting ..................................................................................................... 4-8
Backrest and Structural Accessory Module .................................................................................. 4-9
Rear Body Components Removal ................................................................................................ 4-11
Page iv 2004 Precedent IQ System Golf Car Maintenance and Service Manual
Dash Assembly ................................................................................................................................ 4-14
Dash Assembly Removal ............................................................................................................. 4-14
Dash Assembly Installation .......................................................................................................... 4-15
SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP
Pedal Group ..................................................................................................................................... 5-1
Pedal Group Removal .................................................................................................................. 5-1
MCOR .......................................................................................................................................... 5-3
Debris Shields .............................................................................................................................. 5-3
Brake Return Spring ..................................................................................................................... 5-3
Pawl Assembly ............................................................................................................................. 5-4
Accelerator Return Spring ............................................................................................................ 5-4
Pedal Group Installation ............................................................................................................... 5-6
SECTION 6 – WHEEL BRAKE ASSEMBLIES
General Information ......................................................................................................................... 6-1
Brake Shoe Removal ....................................................................................................................... 6-1
Brake Assembly Cleaning ................................................................................................................ 6-5
Brake Shoe Installation .................................................................................................................... 6-6
Brake Cable Equalizer Adjustment .................................................................................................. 6-8
Brake Cluster Removal and Installation ........................................................................................... 6-9
Brake Cluster Installation ............................................................................................................. 6-10
Brake Cable Removal and Installation ............................................................................................. 6-11
SECTION 7 – STEERING AND FRONT SUSPENSION
General Information ......................................................................................................................... 7-1
Steering Wheel ................................................................................................................................. 7-1
Steering Wheel Removal ............................................................................................................. 7-1
Steering Wheel Installation .......................................................................................................... 7-2
Steering Column .............................................................................................................................. 7-2
Steering Column Removal ........................................................................................................... 7-2
Steering column Installation ......................................................................................................... 7-4
Rack and Pinion ............................................................................................................................... 7-4
Rack and Pinion Removal ............................................................................................................ 7-4
Rack and Pinion Disassembly ...................................................................................................... 7-5
Rack and Pinion Assembly .......................................................................................................... 7-8
Rack and Pinion Installation ......................................................................................................... 7-9
Front Suspension ............................................................................................................................. 7-10
Lubrication .................................................................................................................................... 7-10
Wheel Alignment .......................................................................................................................... 7-10
2004 Precedent IQ System Golf Car Maintenance and Service Manual Page v
Front Suspension Components ........................................................................................................ 7-12
Tie Rod End Removal ................................................................................................................... 7-12
Tie Rod Installation ....................................................................................................................... 7-12
Leaf Spring Removal .................................................................................................................... 7-13
Leaf Spring Installation ................................................................................................................. 7-13
Kingpin and Steering Spindle Removal ........................................................................................ 7-13
Kingpin and Steering Spindle Installation ..................................................................................... 7-13
Control Arm Removal ................................................................................................................... 7-14
Control Arm Installation ................................................................................................................ 7-17
Shock Absorber Removal ............................................................................................................. 7-17
Shock Absorber Installation .......................................................................................................... 7-17
Front Wheel Bearings and Hubs ...................................................................................................... 7-17
Front Wheel Free Play Inspection ................................................................................................ 7-17
Front Hub Removal ....................................................................................................................... 7-17
Hub Installation ............................................................................................................................. 7-18
SECTION 8 – WHEELS AND TIRES
General Information .......................................................................................................................... 8-1
Wheels .............................................................................................................................................. 8-1
Wheel Removal ............................................................................................................................ 8-1
Wheel Installation ......................................................................................................................... 8-1
Tires .................................................................................................................................................. 8-1
Tire Removal ................................................................................................................................ 8-2
Tire Repair .................................................................................................................................... 8-2
Tire Installation ............................................................................................................................. 8-3
SECTION 9 – REAR SUSPENSION
General Information .......................................................................................................................... 9-1
Shock Absorbers .............................................................................................................................. 9-1
Shock Absorber Removal and Inspection ..................................................................................... 9-1
Shock Absorber Installation .......................................................................................................... 9-1
Leaf Springs ..................................................................................................................................... 9-1
Leaf Spring Removal .................................................................................................................... 9-1
Leaf Spring Installation ................................................................................................................. 9-4
SECTION 10 – PERIODIC MAINTENANCE
General Information .......................................................................................................................... 10-1
Pre-Operation and Daily Safety Checklist ........................................................................................ 10-1
Performance Inspection ................................................................................................................ 10-1
Periodic Service Schedule ................................................................................................................ 10-2
Page vi 2004 Precedent IQ System Golf Car Maintenance and Service Manual
Periodic Lubrication Schedule .......................................................................................................... 10-4
SECTION 11 – ELECTRICAL SYSTEM AND TESTING
General Information ......................................................................................................................... 11-1
Electrical Circuits .............................................................................................................................. 11-3
Control Circuit .............................................................................................................................. 11-3
Onboard Computer Circuit ........................................................................................................... 11-3
Power Circuit ................................................................................................................................ 11-9
Charge Circuit .............................................................................................................................. 11-10
Wiring Diagram ................................................................................................................................ 11-11
Troubleshooting ............................................................................................................................... 11-12
Troubleshooting the Vehicle with the IQDM ................................................................................. 11-12
Troubleshooting Guide 1 .............................................................................................................. 11-12
Troubleshooting Guide 2 .............................................................................................................. 11-15
Test Procedures ............................................................................................................................... 11-17
Index of Test Procedures ............................................................................................................. 11-18
Communication Display Module (CDM) ........................................................................................... 11-42
Using the CDM to Retrieve Data from the Onboard Computer .................................................... 11-43
CDM Troubleshooting Guide ............................................................................................................ 11-44
SECTION 12 – ELECTRICAL COMPONENTS
Key Switch ....................................................................................................................................... 12-1
Battery Warning Light ....................................................................................................................... 12-3
Forward/Reverse Rocker Switch ...................................................................................................... 12-4
Electronics Module Cover ................................................................................................................ 12-5
Tow/Run Switch ............................................................................................................................... 12-6
Motor Controller Output Regulator (MCOR) ..................................................................................... 12-7
Reverse Buzzer ................................................................................................................................ 12-8
Electronics Module ........................................................................................................................... 12-9
Solid State Speed Controller ............................................................................................................ 12-11
Solenoid ........................................................................................................................................... 12-12
Onboard Computer (OBC) ............................................................................................................... 12-13
Charger Receptacle ......................................................................................................................... 12-14
SECTION 13 – BATTERIES
General Information ......................................................................................................................... 13-1
Common Misconceptions About Batteries ....................................................................................... 13-3
Battery Replacement ........................................................................................................................ 13-3
2004 Precedent IQ System Golf Car Maintenance and Service Manual Page vii
Battery Care ...................................................................................................................................... 13-4
Preventive Maintenance ............................................................................................................... 13-4
Self-Discharge .............................................................................................................................. 13-5
Electrolyte Level ........................................................................................................................... 13-5
Mineral Content ............................................................................................................................ 13-6
Vibration Damage ......................................................................................................................... 13-6
Battery Charging ............................................................................................................................... 13-6
Charger Shuts Off After 16 Hours ................................................................................................. 13-7
Deep-Discharge ............................................................................................................................ 13-7
Early Excessive Discharging ........................................................................................................ 13-7
Incoming AC Service .................................................................................................................... 13-7
Fleet Rotation ............................................................................................................................... 13-7
Numbering Vehicles and Chargers ............................................................................................... 13-7
Battery Troubleshooting Chart .......................................................................................................... 13-8
Battery Testing ................................................................................................................................. 13-9
Battery Charger Test .................................................................................................................... 13-9
On-Charge Voltage Test ............................................................................................................... 13-9
Hydrometer Test ........................................................................................................................... 13-9
Discharge Test .............................................................................................................................. 13-11
Battery Troubleshooting Examples ............................................................................................... 13-13
Battery Storage ................................................................................................................................. 13-14
Charging a Battery Pack that has Low Voltage ................................................................................ 13-14
SECTION 14 – BATTERY CHARGER
SECTION 15 – MOTOR
General Information .......................................................................................................................... 15-1
External Motor Testing ...................................................................................................................... 15-1
Motor ................................................................................................................................................. 15-3
Motor Component Testing and Inspection ........................................................................................ 15-5
Armature ....................................................................................................................................... 15-5
Field Windings Inspection ............................................................................................................. 15-6
Motor Components ....................................................................................................................... 15-7
Bearing Inspection ........................................................................................................................ 15-7
Bearing Removal .......................................................................................................................... 15-9
Bearing Installation ....................................................................................................................... 15-9
Speed Sensor Magnet Inspection ................................................................................................. 15-9
Speed Sensor Magnet Removal ................................................................................................... 15-9
Speed Sensor Magnet Installation ................................................................................................ 15-9
Reconditioning the Motor .................................................................................................................. 15-9
Page viii 2004 Precedent IQ System Golf Car Maintenance and Service Manual
Motor Assembly ............................................................................................................................... 15-10
Motor Installation .............................................................................................................................. 15-12
Motor Speed Sensor ........................................................................................................................ 15-15
SECTION 16A – TRANSAXLE (TYPE G)
Transaxle Identification .................................................................................................................... 16a-1
Lubrication ........................................................................................................................................ 16a-1
Axle Bearing and Shaft .................................................................................................................... 16a-1
Axle Shaft ..................................................................................................................................... 16a-1
Axle Bearing ................................................................................................................................. 16a-5
Transaxle ......................................................................................................................................... 16a-5
Transaxle Removal ...................................................................................................................... 16a-5
Transaxle Disassembly, Inspection, and Assembly ......................................................................... 16a-7
Transaxle Disassembly and Inspection ........................................................................................ 16a-7
Transaxle Assembly ..................................................................................................................... 16a-10
Transaxle Installation ....................................................................................................................... 16a-11
SECTION 16B – TRANSAXLE (TYPE K)
Transaxle Identification .................................................................................................................... 16b-1
Lubrication ........................................................................................................................................ 16b-1
Axle Bearing and Shaft .................................................................................................................... 16b-1
Axle Shaft ..................................................................................................................................... 16b-1
Axle Bearing ................................................................................................................................. 16b-4
Transaxle ......................................................................................................................................... 16b-6
Transaxle Removal ...................................................................................................................... 16b-6
Transaxle Disassembly, Inspection, and Assembly ......................................................................... 16b-8
Transaxle Disassembly and Inspection ........................................................................................ 16b-8
Transaxle Assembly ..................................................................................................................... 16b-10
Shimming the Transaxle .............................................................................................................. 16b-12
Transaxle Installation ....................................................................................................................... 16b-13
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$39.99
Upon purchasing this manual, you will receive a .PDF file containing an email address for further assistance. After contacting the provided email, you will receive a reply with a link to access the manual for your 2004 Club Car Precedent Electric.
This comprehensive manual covers every aspect of your machine, providing detailed guidance on every procedure from basic maintenance to complex repairs such as transmission swaps. With its extensive content spanning hundreds of pages, the manual includes numerous illustrations to assist you along with easy-to-understand textual instructions. The search function allows for easy navigation, and you can conveniently print the necessary pages as needed.
Designed as a Factory Service Repair Manual, it offers a step-by-step approach to equip both professional mechanics and DIY enthusiasts with the essential knowledge required for maintenance and repair tasks. By following the instructions outlined in this manual, any owner can confidently make informed decisions regarding the upkeep and repair of their machine.
Rest assured, in addition to the high-quality service manual, we are committed to providing excellent customer service, ensuring your satisfaction with your purchase.
