2008 Club Car Precedent Electric Golf Cart Repair Manual
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2008 Electric Precedent
Maintenance and
Service Manual
IQ System and Excel System Vehicles
Manual Number 103373101
Edition Code 0907D0309C
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 representatives,
vehicle service seminars, periodic service bulletins, maintenance and service manuals, and other service publications
also represent Club Car’s continuing commitment to customer support.
Club Car offers a full line of training and continuing education classes for technicians who want to learn more about
our products. For more information, contact your local dealer or Club Car’s Technical Services department for a
list of upcoming classes.
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.
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.
Copyright © 2007 Club Car, Inc.
Club Car, Carryall, and ArmorFlex
are registered trademarks of Club Car, Inc.
This manual effective August 1, 2007
2008 Electric Precedent Maintenance and Service Manual Page i
CONTENTS
SECTION 1 — SAFETY ..................................................................................................................................... 1-1
General Warnings .......................................................................................................................................... 1-1
SECTION 2 — VEHICLE SPECIFICATIONS ....................................................................................................... 2-1
SECTION 3 — GENERAL INFORMATION.......................................................................................................... 3-1
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 ....................................................................................................................... 4-1
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 ......................................................................... 4-3
Front Body .................................................................................................................................................... 4-3
Front Body Removal .................................................................................................................................. 4-3
Front Body Installation ............................................................................................................................... 4-3
Front Bumper ................................................................................................................................................ 4-5
Instrument Panel ........................................................................................................................................... 4-5
Instrument Panel Removal – Early Model Year ............................................................................................ 4-5
Instrument Panel Installation – Early Model Year ......................................................................................... 4-6
Instrument Panel Removal – Late Model Year ............................................................................................. 4-6
Instrument Panel Installation – Late Model Year........................................................................................... 4-7
Floor Mat and Retainers ................................................................................................................................. 4-8
Floor Mat Retainer Removal ....................................................................................................................... 4-8
Floor Mat Retainer Installation .................................................................................................................... 4-8
Kick Plate and Charger Receptacle Bezel ....................................................................................................... 4-9
Kick Plate and Charger Receptacle Bezel Removal ..................................................................................... 4-9
Kick Plate and Charger Receptacle Bezel Installation................................................................................... 4-9
Rear Body – Two-Passenger Vehicles........................................................................................................... 4-10
Universal Accessory Mounting.................................................................................................................. 4-10
Backrest and Structural Accessory Module (SAM) ..................................................................................... 4-10
Rear Body Components (Two-Passenger) .................................................................................................. 4-11
Rear Body – Four-Passenger Vehicles .......................................................................................................... 4-14
Seat Backs.............................................................................................................................................. 4-14
Seat Support ........................................................................................................................................... 4-14
Foot Deck ............................................................................................................................................... 4-15
Rear Body Components (Four-Passenger) ................................................................................................ 4-16
Canopy – Two-Passenger ............................................................................................................................ 4-17
Two-Passenger Canopy Removal ............................................................................................................. 4-17
Two-Passenger Canopy Installation .......................................................................................................... 4-19
Canopy – Four-Passenger ........................................................................................................................... 4-19
Four-Passenger Canopy Removal ............................................................................................................ 4-19
Four-Passenger Canopy Installation ......................................................................................................... 4-20
SECTION 5 — ACCELERATOR AND BRAKE PEDAL GROUP .......................................................................... 5-1
Pedal Group .................................................................................................................................................. 5-1
Pedal Group Removal ................................................................................................................................ 5-1
MCOR ...................................................................................................................................................... 5-3
2008 Electric Precedent Maintenance and Service Manual Page iii
Debris Shields ........................................................................................................................................... 5-3
Brake Return Spring .................................................................................................................................. 5-3
Pawl Assembly .......................................................................................................................................... 5-3
Accelerator Return Spring .......................................................................................................................... 5-4
Pedal Group Installation ............................................................................................................................. 5-6
SECTION 6 — WHEEL BRAKE ASSEMBLIES................................................................................................... 6-1
General Information ....................................................................................................................................... 6-1
Brake Shoe Removal ..................................................................................................................................... 6-1
Brake Assembly Cleaning .............................................................................................................................. 6-5
Brake Shoe Installation .................................................................................................................................. 6-7
Brake Cable Equalizer Adjustment ................................................................................................................ 6-10
Brake Cluster Removal and Installation .......................................................................................................... 6-11
Brake Cluster Removal ............................................................................................................................. 6-11
Brake Cluster Installation .......................................................................................................................... 6-11
Brake Cable Removal and Installation ........................................................................................................... 6-13
Brake Cable Removal .............................................................................................................................. 6-13
Brake Cable Installation ........................................................................................................................... 6-14
SECTION 7 — STEERING AND FRONT SUSPENSION...................................................................................... 7-1
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 ....................................................................................................................... 7-3
Rack and Pinion ............................................................................................................................................ 7-4
Rack and Pinion Removal .......................................................................................................................... 7-4
Rack and Pinion Disassembly .................................................................................................................... 7-5
Rack and Pinion Assembly ......................................................................................................................... 7-7
Rack and Pinion Installation ....................................................................................................................... 7-8
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 ................................................................................................................. 8-1
General Information ....................................................................................................................................... 8-1
Wheels ......................................................................................................................................................... 8-1
Wheel Removal ......................................................................................................................................... 8-1
Wheel Installation ...................................................................................................................................... 8-1
Tires ............................................................................................................................................................. 8-2
Tire Removal ............................................................................................................................................. 8-2
Tire Repair ................................................................................................................................................ 8-2
Tire Installation .......................................................................................................................................... 8-3
Page iv 2008 Electric Precedent Maintenance and Service Manual
SECTION 9 — REAR SUSPENSION .................................................................................................................. 9-1
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) .......................................................................................................... 9-2
Leaf Spring Removal (Two-Passenger Vehicles) .......................................................................................... 9-2
Leaf Spring Installation (Two-Passenger Vehicles) ....................................................................................... 9-3
Leaf Springs (Four-Passenger Vehicles) ......................................................................................................... 9-4
Leaf Spring Removal (Four-Passenger Vehicles) ......................................................................................... 9-4
Leaf Spring Installation (Four-Passenger Vehicles) ...................................................................................... 9-5
SECTION 10 — PERIODIC MAINTENANCE..................................................................................................... 10-1
General Warning ......................................................................................................................................... 10-1
General Information ..................................................................................................................................... 10-3
Periodic Service Schedule............................................................................................................................ 10-3
Periodic Lubrication Schedule ...................................................................................................................... 10-5
SECTION 11 — IQ SYSTEM TROUBLESHOOTING .......................................................................................... 11-1
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
Communication Display Module (CDM) ........................................................................................................ 11-38
Using the CDM to Retrieve Data from the Onboard Computer ................................................................... 11-39
CDM Troubleshooting Guide ....................................................................................................................... 11-39
SECTION 12 — EXCEL SYSTEM TROUBLESHOOTING.................................................................................. 12-1
General Information ..................................................................................................................................... 12-1
Wiring Diagrams .......................................................................................................................................... 12-2
Troubleshooting ........................................................................................................................................... 12-7
Troubleshooting the Vehicle with the IQDM ............................................................................................... 12-7
Troubleshooting Guide 1 .......................................................................................................................... 12-7
Troubleshooting Guide 2 ......................................................................................................................... 12-11
Test Procedures ......................................................................................................................................... 12-13
Communication Display Module (CDM) ........................................................................................................ 12-38
Using the CDM to Retrieve Data from the Onboard Computer ................................................................... 12-39
CDM Troubleshooting Guide ....................................................................................................................... 12-39
SECTION 13 — IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM ............................... 13-1
Plugging the Handset into the Vehicle ........................................................................................................... 13-1
Introductory Display ..................................................................................................................................... 13-2
Menu Navigation ......................................................................................................................................... 13-2
Program (IQDM-P only) ........................................................................................................................... 13-3
Monitor ................................................................................................................................................... 13-3
Faults ..................................................................................................................................................... 13-4
Functions ................................................................................................................................................ 13-4
Information .............................................................................................................................................. 13-4
Programmer Setup .................................................................................................................................. 13-4
Monitor Menu .............................................................................................................................................. 13-4
Throttle ................................................................................................................................................... 13-4
Batt Voltage............................................................................................................................................. 13-5
Heatsink.................................................................................................................................................. 13-5
Arm Current ............................................................................................................................................ 13-5
Field Current ........................................................................................................................................... 13-5
Arm PWM ............................................................................................................................................... 13-5
2008 Electric Precedent Maintenance and Service Manual Page v
Field PWM .............................................................................................................................................. 13-5
Speed Pulses .......................................................................................................................................... 13-5
Foot Input ............................................................................................................................................... 13-5
Forward Input .......................................................................................................................................... 13-6
Reverse Input .......................................................................................................................................... 13-6
Main Cont ............................................................................................................................................... 13-6
Key Input ................................................................................................................................................ 13-6
Password Tries (IQDM-P only) ................................................................................................................. 13-6
10.3 Transaxle......................................................................................................................................... 13-6
20+ Speed .............................................................................................................................................. 13-6
Faults Menu ................................................................................................................................................ 13-7
System Faults ......................................................................................................................................... 13-7
HW Failsafe ............................................................................................................................................ 13-9
KEY SWITCH SRO (Static Return to Off) .................................................................................................. 13-9
Throttle Fault 1 ....................................................................................................................................... 13-10
Speed sensor ......................................................................................................................................... 13-10
Main Welded .......................................................................................................................................... 13-10
Main Driver On ....................................................................................................................................... 13-10
Main Driver Off ....................................................................................................................................... 13-10
High Speed Walkaway ............................................................................................................................ 13-10
Main Coil FAULT..................................................................................................................................... 13-10
Field Missing .......................................................................................................................................... 13-11
HPD ...................................................................................................................................................... 13-11
Proc/Wiring ............................................................................................................................................ 13-11
Overvoltage............................................................................................................................................ 13-11
Low Battery Voltage ................................................................................................................................ 13-11
Thermal Cutback .................................................................................................................................... 13-11
Motor Stall.............................................................................................................................................. 13-11
Main Dropout ......................................................................................................................................... 13-11
Open Armature ....................................................................................................................................... 13-12
Incorrect Password (IQDM-P only) ........................................................................................................... 13-12
Max Password Tries (IQDM-P only) ......................................................................................................... 13-12
Fault History ........................................................................................................................................... 13-12
Clearing Fault History ............................................................................................................................. 13-12
Functions Menu .......................................................................................................................................... 13-13
Get Settings From Controller ................................................................................................................... 13-13
Write Settings to Controller ...................................................................................................................... 13-14
Reset All Settings ................................................................................................................................... 13-15
Information ................................................................................................................................................. 13-16
Model Number ........................................................................................................................................ 13-16
Serial Number ........................................................................................................................................ 13-16
MFG Date .............................................................................................................................................. 13-16
Software Version .................................................................................................................................... 13-16
Programmer Setup ..................................................................................................................................... 13-16
Program................................................................................................................................................. 13-16
Faults .................................................................................................................................................... 13-17
Information ............................................................................................................................................. 13-17
IQDM and IQDM-P Handset Troubleshooting ............................................................................................... 13-18
Test Procedures ......................................................................................................................................... 13-19
SECTION 14 — IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM ....................... 14-1
Plugging the Handset into the Vehicle ........................................................................................................... 14-1
Introductory Display ..................................................................................................................................... 14-2
Menu Navigation ......................................................................................................................................... 14-2
Program (IQDM-P only) ........................................................................................................................... 14-3
Monitor ................................................................................................................................................... 14-3
Faults ..................................................................................................................................................... 14-3
Functions ................................................................................................................................................ 14-4
Information .............................................................................................................................................. 14-4
Programmer Setup .................................................................................................................................. 14-4
Monitor Menu .............................................................................................................................................. 14-4
Speed ..................................................................................................................................................... 14-4
Throttle ................................................................................................................................................... 14-5
Page vi 2008 Electric Precedent Maintenance and Service Manual
Batt Aux Voltage ...................................................................................................................................... 14-5
Temperature ............................................................................................................................................ 14-5
Arm Current ............................................................................................................................................ 14-5
Field Current ........................................................................................................................................... 14-5
Armature PWM........................................................................................................................................ 14-5
Field PWM .............................................................................................................................................. 14-5
Brake Volts In .......................................................................................................................................... 14-5
Speed Pulses .......................................................................................................................................... 14-6
Foot Input ............................................................................................................................................... 14-6
Key Input ................................................................................................................................................ 14-6
Forward Input .......................................................................................................................................... 14-6
Reverse Input .......................................................................................................................................... 14-6
Charger Inhibit ......................................................................................................................................... 14-6
Main Cont Driver ..................................................................................................................................... 14-6
Password Tries (IQDM-P Only) ................................................................................................................. 14-7
Odometer ................................................................................................................................................ 14-7
Vehicle Speeds (IQDM-P Only)................................................................................................................. 14-7
Pedal Counters........................................................................................................................................ 14-7
Fault Counters......................................................................................................................................... 14-7
Fault Count Odometers ............................................................................................................................ 14-7
Faults Menu ................................................................................................................................................ 14-8
System Faults ......................................................................................................................................... 14-8
HW Failsafe ........................................................................................................................................... 14-10
Throttle Fault .......................................................................................................................................... 14-10
Speed sensor ......................................................................................................................................... 14-11
Main Welded .......................................................................................................................................... 14-11
Main Driver On ....................................................................................................................................... 14-11
Main Driver Off ....................................................................................................................................... 14-11
Main Coil Open....................................................................................................................................... 14-11
Field Missing .......................................................................................................................................... 14-11
HPD ...................................................................................................................................................... 14-11
Overvoltage............................................................................................................................................ 14-11
Low Battery Voltage ................................................................................................................................ 14-12
Thermal Cutback .................................................................................................................................... 14-12
Motor Stall.............................................................................................................................................. 14-12
Main Dropout (1 or 2) .............................................................................................................................. 14-12
Incorrect Password (IQDM-P only) ........................................................................................................... 14-12
Max Password Tries (IQDM-P only) ......................................................................................................... 14-12
Fault History ........................................................................................................................................... 14-12
Clearing Fault History ............................................................................................................................. 14-13
Functions Menu .......................................................................................................................................... 14-13
Get Settings From Controller ................................................................................................................... 14-13
Write Settings to Controller ...................................................................................................................... 14-14
Reset All Settings ................................................................................................................................... 14-15
Information ................................................................................................................................................. 14-16
Model Number ........................................................................................................................................ 14-16
Serial Number ........................................................................................................................................ 14-16
MFG Date .............................................................................................................................................. 14-16
Software Version .................................................................................................................................... 14-16
Programmer Setup ..................................................................................................................................... 14-16
Program................................................................................................................................................. 14-16
Faults .................................................................................................................................................... 14-17
Information ............................................................................................................................................. 14-17
IQDM and IQDM-P Handset Troubleshooting ............................................................................................... 14-18
Test Procedures ......................................................................................................................................... 14-19
SECTION 15 — ELECTRICAL COMPONENTS ................................................................................................ 15-1
Key Switch .................................................................................................................................................. 15-1
Testing the Key Switch ............................................................................................................................. 15-1
Key Switch Removal ................................................................................................................................ 15-1
Key Switch Installation ............................................................................................................................. 15-1
Battery Warning Light................................................................................................................................... 15-2
Testing the Battery Warning Light.............................................................................................................. 15-2
2008 Electric Precedent Maintenance and Service Manual Page vii
Battery Warning Light Removal ................................................................................................................ 15-2
Battery Warning Light Installation .............................................................................................................. 15-3
Forward/Reverse Rocker Switch ................................................................................................................... 15-3
Testing the Forward/Reverse Rocker Switch.............................................................................................. 15-3
Forward/Reverse Rocker Switch Removal ................................................................................................. 15-3
Forward/Reverse Rocker Switch Installation .............................................................................................. 15-4
Electronics Module Cover – Style A Battery Configuration .............................................................................. 15-5
Electronics Module Cover Removal .......................................................................................................... 15-5
Electronics Module Cover Installation........................................................................................................ 15-5
Electronics Module Cover – Style B and C Battery Configurations................................................................... 15-6
Electronics Module Cover Removal .......................................................................................................... 15-6
Electronics Module Cover Installation........................................................................................................ 15-6
Tow/Run Switch – Style A Battery Configuration ............................................................................................ 15-7
Testing the Tow/Run Switch ...................................................................................................................... 15-7
Tow/Run Switch Removal ......................................................................................................................... 15-7
Tow/Run Switch Installation ...................................................................................................................... 15-8
Tow/Run Switch – Style B and C Battery Configurations ................................................................................. 15-8
Testing the Tow/Run Switch ...................................................................................................................... 15-8
Tow/Run Switch Removal ......................................................................................................................... 15-8
Tow/Run Switch Installation ...................................................................................................................... 15-9
Motor Controller Output Regulator (MCOR) ................................................................................................... 15-9
Testing the MCOR ................................................................................................................................... 15-9
MCOR Removal ...................................................................................................................................... 15-9
MCOR Installation .................................................................................................................................. 15-10
Reverse Buzzer .......................................................................................................................................... 15-10
Testing the Reverse Buzzer ..................................................................................................................... 15-10
Reverse Buzzer Removal ........................................................................................................................ 15-10
Reverse Buzzer Installation ..................................................................................................................... 15-11
Electronics Module – Style A Battery Configuration ....................................................................................... 15-11
Electronics Module Removal ................................................................................................................... 15-11
Electronics Module Installation ................................................................................................................ 15-12
Electronics Module – Style B and C Battery Configurations ........................................................................... 15-14
Electronics Module Removal ................................................................................................................... 15-14
Electronics Module Installation ................................................................................................................ 15-14
Speed Controller – Style A Battery Configuration .......................................................................................... 15-17
Testing the Solid State Speed Controller .................................................................................................. 15-17
Speed Controller Removal ...................................................................................................................... 15-17
Speed Controller Installation.................................................................................................................... 15-17
Speed Controller – Style B and C Battery Configurations............................................................................... 15-18
Testing the Solid State Speed Controller .................................................................................................. 15-18
Speed Controller Removal ...................................................................................................................... 15-18
Speed Controller Installation.................................................................................................................... 15-18
Solenoid – Style A Battery Configuration ...................................................................................................... 15-19
Testing the Solenoid ............................................................................................................................... 15-19
Solenoid Removal .................................................................................................................................. 15-19
Solenoid Installation................................................................................................................................ 15-19
Solenoid – Style B and C Battery Configurations........................................................................................... 15-20
Testing the Solenoid ............................................................................................................................... 15-20
Solenoid Removal .................................................................................................................................. 15-20
Solenoid Installation................................................................................................................................ 15-20
Onboard Computer (OBC) – Style A Battery Configuration ............................................................................ 15-21
Testing the Onboard Computer ................................................................................................................ 15-21
Onboard Computer Removal ................................................................................................................... 15-21
Onboard Computer Installation ................................................................................................................ 15-21
Onboard Computer (OBC) – Style B and C Battery Configurations................................................................. 15-22
Testing the Onboard Computer ................................................................................................................ 15-22
Onboard Computer Removal ................................................................................................................... 15-22
Onboard Computer Installation ................................................................................................................ 15-22
Charger Receptacle .................................................................................................................................... 15-23
Testing the Charger Receptacle ............................................................................................................... 15-23
Charger Receptacle Inspection ................................................................................................................ 15-23
Charger Receptacle Removal .................................................................................................................. 15-23
Charger Receptacle Installation ............................................................................................................... 15-24
Headlight Adjustment .................................................................................................................................. 15-25
Page viii 2008 Electric Precedent Maintenance and Service Manual
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