2005 Club Car Precedent IQ System Electric Golf Cart Repair Manual

2005 Maintenance And Service Manual No. 102680401 Edition Code 0205C0306B IQ System Electric Vehicles

2005 Precedent IQ System Electric 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 knowledge 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 © 2005 Club Car, Inc. Club Car and PowerDrive are registered trademarks of Club Car, Inc. This manual effective August 2, 2004.

Page ii 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ý 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 its vehicles and other products. These improvements may affect servicing procedures. Any modification and/or significant change in specifications or procedures 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.

2005 Precedent IQ System Electric 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 ................................................ 3-3 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 ........................................................................................................................................ 4-4 Front Body Removal ..................................................................................................................... 4-4 Front Body Installation .................................................................................................................. 4-4 Front Bumper .................................................................................................................................... 4-4 Instrument Panel ............................................................................................................................... 4-4 Instrument Panel Removal ........................................................................................................... 4-4 Instrument Panel Installation ........................................................................................................ 4-6 Floor Mat and Retainers ................................................................................................................... 4-6 Floor Mat Retainer Removal ......................................................................................................... 4-7 Floor Mat Retainer Installation ...................................................................................................... 4-7

Page iv 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Kick Plate and Charger Receptacle Bezel ....................................................................................... 4-7 Kick Plate and Charger Receptacle Bezel Removal .................................................................... 4-7 Kick Plate and Charger Receptacle Bezel Installation ................................................................. 4-7 Rear Body – Two-Passenger Vehicles ............................................................................................ 4-8 Universal Accessory Mounting ..................................................................................................... 4-8 Backrest and Structural Accessory Module (SAM) ...................................................................... 4-10 Rear Body Components (Two-Passenger) .................................................................................. 4-10 Rear Body – Four-Passenger Vehicles ............................................................................................ 4-12 Seat Backs ................................................................................................................................... 4-12 Seat Support ................................................................................................................................ 4-13 Foot Deck ..................................................................................................................................... 4-14 Rear Body Components (Four-Passenger) .................................................................................. 4-15 Canopy – Two-Passenger ................................................................................................................ 4-16 Two-Passenger Canopy Removal ................................................................................................ 4-16 Two-Passenger Canopy Installation ............................................................................................. 4-18 Canopy – Four-Passenger ............................................................................................................... 4-20 Four-Passenger Canopy Removal ............................................................................................... 4-20 Four-Passenger Canopy Installation ............................................................................................ 4-20 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 .................................................................................................. 6-9 Brake Cluster Removal and Installation ........................................................................................... 6-9 Brake Cluster Installation ............................................................................................................. 6-10 Brake Cable Removal and Installation ............................................................................................. 6-11

2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page v 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 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 ................................................................................................................ 7-14 Shock Absorber Removal ............................................................................................................. 7-14 Shock Absorber Installation .......................................................................................................... 7-14 Front Wheel Bearings and Hubs ....................................................................................................... 7-17 Front Wheel Free Play Inspection ................................................................................................ 7-17 Front Hub Removal ....................................................................................................................... 7-17 Hub Installation ............................................................................................................................. 7-17 SECTION 8 – WHEELS AND TIRES General Information .......................................................................................................................... 8-1 Wheels .............................................................................................................................................. 8-1 Wheel Removal ............................................................................................................................ 8-1 Wheel Installation ......................................................................................................................... 8-1

Page vi 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Tires ................................................................................................................................................. 8-2 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 (Two-Passenger Vehicles) .......................................................................................... 9-1 Leaf Spring Removal (Two-Passenger Vehicles) ......................................................................... 9-1 Leaf Spring Installation (Two-Passenger Vehicles) ...................................................................... 9-4 Leaf Springs (Four-Passenger Vehicles) ......................................................................................... 9-4 Leaf Spring Removal (Four-Passenger Vehicles) ........................................................................ 9-4 Leaf Spring Installation (Four-Passenger Vehicles) ..................................................................... 9-6 SECTION 10 – PERIODIC MAINTENANCE General Information ......................................................................................................................... 10-1 Periodic Service Schedule ............................................................................................................... 10-1 Periodic Lubrication Schedule .......................................................................................................... 10-3 SECTION 11 – ELECTRICAL SYSTEM AND TESTING General Information ......................................................................................................................... 11-1 Wiring Diagrams ............................................................................................................................... 11-2 Troubleshooting ............................................................................................................................... 11-7 Troubleshooting the Vehicle with the IQDM ................................................................................. 11-7 Troubleshooting Guide 1 .............................................................................................................. 11-8 Troubleshooting Guide 2 .............................................................................................................. 11-11 Test Procedures ............................................................................................................................... 11-13 Index of Test Procedures ............................................................................................................. 11-14 Communication Display Module (CDM) ........................................................................................... 11-38 Using the CDM to Retrieve Data from the Onboard Computer .................................................... 11-39 CDM Troubleshooting Guide ............................................................................................................ 11-40

2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page vii SECTION 12 – ELECTRICAL COMPONENTS Key Switch ........................................................................................................................................ 12-1 Battery Warning Light ....................................................................................................................... 12-3 Forward/Reverse Rocker Switch ...................................................................................................... 12-3 Electronics Module Cover ................................................................................................................. 12-5 Tow/Run Switch ................................................................................................................................ 12-6 Motor Controller Output Regulator (MCOR) ..................................................................................... 12-7 Reverse Buzzer ................................................................................................................................ 12-8 Electronics Module ........................................................................................................................... 12-10 Solid State Speed Controller ............................................................................................................ 12-11 Solenoid ............................................................................................................................................ 12-12 Onboard Computer (OBC) ................................................................................................................ 12-13 Charger Receptacle .......................................................................................................................... 12-13 SECTION 13 – BATTERIES General Information .......................................................................................................................... 13-1 Battery Replacement ........................................................................................................................ 13-1 Battery Care ...................................................................................................................................... 13-2 Preventive Maintenance ............................................................................................................... 13-2 Self-Discharge .............................................................................................................................. 13-3 Electrolyte Level ........................................................................................................................... 13-3 Mineral Content ............................................................................................................................ 13-4 Vibration Damage ......................................................................................................................... 13-4 Battery Charging ............................................................................................................................... 13-4 Charger Shuts Off After 16 Hours ................................................................................................. 13-5 Deep-Discharge ............................................................................................................................ 13-5 Early Excessive Discharging ........................................................................................................ 13-5 Incoming AC Service .................................................................................................................... 13-5 Fleet Rotation ............................................................................................................................... 13-5 Numbering Vehicles and Chargers ............................................................................................... 13-5 Battery Troubleshooting Chart .......................................................................................................... 13-6 Battery Testing .................................................................................................................................. 13-7 Battery Charger Test .................................................................................................................... 13-7 On-Charge Voltage Test ............................................................................................................... 13-7 Hydrometer Test ........................................................................................................................... 13-7 Discharge Test .............................................................................................................................. 13-9 Battery Troubleshooting Examples ............................................................................................... 13-11 Battery Storage ................................................................................................................................. 13-12

Page viii 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Charging a Battery Pack that has Low Voltage ................................................................................ 13-12 SECTION 14 – BATTERY CHARGER SECTION 15A – MOTOR (MODEL 5BC59JBS6365) General Information ......................................................................................................................... 15a-1 Motor Identification ........................................................................................................................... 15a-1 External Motor Testing ..................................................................................................................... 15a-1 Motor ................................................................................................................................................ 15a-3 Motor Component Testing and Inspection ....................................................................................... 15a-5 Armature ...................................................................................................................................... 15a-5 Field Windings Inspection ............................................................................................................ 15a-6 Motor Components ....................................................................................................................... 15a-7 Bearing Inspection ....................................................................................................................... 15a-7 Bearing Removal .......................................................................................................................... 15a-9 Bearing Installation ....................................................................................................................... 15a-9 Speed Sensor Magnet Inspection ................................................................................................ 15a-9 Speed Sensor Magnet Removal .................................................................................................. 15a-9 Speed Sensor Magnet Installation ............................................................................................... 15a-9 Reconditioning the Motor ................................................................................................................. 15a-9 Motor Assembly ............................................................................................................................... 15a-10 Motor Installation .............................................................................................................................. 15a-12 Motor Speed Sensor ........................................................................................................................ 15a-15 SECTION 15B – MOTOR (MODEL EJ4-4001) General Information ......................................................................................................................... 15b-1 Motor Identification ........................................................................................................................... 15b-1 External Motor Testing ..................................................................................................................... 15b-1 Motor ................................................................................................................................................ 15b-2 Motor Removal ............................................................................................................................. 15b-2 Motor Disassembly ....................................................................................................................... 15b-4 Motor Component Testing and Inspection ....................................................................................... 15b-6 Armature Inspection and Testing ................................................................................................. 15b-6 Motor Frame and Field Windings Inspection ................................................................................ 15b-8 Motor Brush, Spring, and Terminal Insulator Inspection .............................................................. 15b-8 Reconditioning the Motor ................................................................................................................. 15b-11 Motor Assembly ............................................................................................................................... 15b-11

2005 Club Car Precedent IQ System Electric Golf Cart Repair Manual

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