2006-2007 Club Car Precedent Electric Vehicle Repair Manual
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2006-2007
Maintenance
And
Service
Manual No. 102907701 Edition Code 1106A00000
IQ System
Electric Vehicles
2006-2007 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 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 © 2006 Club Car, Inc.
Club Car and PowerDrive are registered
trademarks of Club Car, Inc.
This manual effective July 31, 2005.
Page ii 2006-2007 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 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.
2006-2007 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 2006-2007 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
2006-2007 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 2006-2007 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 Warning .............................................................................................................................. 10-1
General Information ......................................................................................................................... 10-2
Periodic Service Schedule ............................................................................................................... 10-3
Periodic Lubrication Schedule .......................................................................................................... 10-4
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
2006-2007 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page vii
SECTION 12 – IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS
Plugging the Handset into the Vehicle .............................................................................................. 12-1
Introductory Display .......................................................................................................................... 12-2
Menu Navigation ............................................................................................................................... 12-2
Monitor Menu .................................................................................................................................... 12-4
Throttle .......................................................................................................................................... 12-4
Batt Voltage .................................................................................................................................. 12-4
Heatsink ........................................................................................................................................ 12-4
Arm Current .................................................................................................................................. 12-5
Field Current ................................................................................................................................. 12-5
Arm PWM ..................................................................................................................................... 12-5
Field PWM .................................................................................................................................... 12-5
Speed Pulses ................................................................................................................................ 12-5
Foot Input ...................................................................................................................................... 12-5
Forward Input ................................................................................................................................ 12-5
Reverse Input ............................................................................................................................... 12-5
Main Cont ..................................................................................................................................... 12-5
Key Input ....................................................................................................................................... 12-5
Password Tries (IQDM-P only) ..................................................................................................... 12-6
10.3 Transaxle .............................................................................................................................. 12-6
20+ Speed .................................................................................................................................... 12-6
Page viii 2006-2007 Precedent IQ System Electric Golf Car Maintenance and Service Manual
Faults Menu ..................................................................................................................................... 12-6
System Faults ............................................................................................................................... 12-6
HW Failsafe .................................................................................................................................. 12-9
KEY SWITCH SRO (Static Return to Off) .................................................................................... 12-9
Throttle Fault 1 ............................................................................................................................. 12-9
Speed sensor ............................................................................................................................... 12-9
Main Welded ................................................................................................................................ 12-9
Main Driver On ............................................................................................................................. 12-9
Main Driver Off ............................................................................................................................. 12-9
High Speed Walkaway ................................................................................................................. 12-9
Main Coil FAULT .......................................................................................................................... 12-9
Field Missing ................................................................................................................................ 12-10
HPD .............................................................................................................................................. 12-10
Proc/Wiring ................................................................................................................................... 12-10
Overvoltage .................................................................................................................................. 12-10
Low Battery Voltage ..................................................................................................................... 12-10
Thermal Cutback .......................................................................................................................... 12-10
Motor Stall .................................................................................................................................... 12-10
Main Dropout ................................................................................................................................ 12-10
Open Armature ............................................................................................................................. 12-10
Incorrect Password (IQDM-P only) ............................................................................................... 12-10
Max Password Tries (IQDM-P only) ............................................................................................. 12-11
Fault History ................................................................................................................................. 12-11
Clearing Fault History ................................................................................................................... 12-11
Functions Menu ................................................................................................................................ 12-11
Get Settings From Controller ........................................................................................................ 12-11
Write Settings to Controller .......................................................................................................... 12-13
Reset All Settings ......................................................................................................................... 12-14
Information ....................................................................................................................................... 12-15
Programmer Setup ........................................................................................................................... 12-15
Program ....................................................................................................................................... 12-15
Faults ........................................................................................................................................... 12-15
Information ................................................................................................................................... 12-16
IQDM and IQDM-P Handset Troubleshooting .................................................................................. 12-16
Test Procedures ............................................................................................................................... 12-18
Index of Test Procedures ............................................................................................................. 12-18
SECTION 13 – ELECTRICAL COMPONENTS
Key Switch ....................................................................................................................................... 13-1
Battery Warning Light ....................................................................................................................... 13-3
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- The repair manual covers the following machines:
- 2006 Club Car Precedent Electric Vehicle
- 2007 Club Car Precedent Electric Vehicle
Our repair manuals are essential resources for both professional mechanics and DIY enthusiasts. They provide comprehensive information on various topics, including:
- General Information
- Routine Maintenance
- Engine Removal and Installation
- Fuel System
- Lubrication and Cooling System
- Engine Specifications
- Transmission, Drive Chain & Sprockets
- Steering System
- Shocks
- Body Work
- Intake & Exhaust
- Electrical System
- Advanced Troubleshooting
- And more!
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