2004 Club Car Precedent Service & Repair Manual

2004 Maintenance And Service Manual No. 102397619 Edition Code 1203 D0205C IQ System Electric Vehicles

2004 Precedent IQ System Golf Car Maintenance and Service Manual Page i FOREWORD Club Car vehicles are designed and built to provide the ultimate in performance efﬁciency; however, proper maintenance and repair are essential for achieving maximum service life and continued safe and reliable operation. This manual provides detailed information for the maintenance and repair of the electric Precedent vehicles, and should be thoroughly reviewed prior to servicing the vehicle. The procedures provided herein must be properly implemented, and the DANGER, WARNING, and CAUTION statements must be heeded. This manual was written for the trained technician who already possesses knowledge and skills in electrical and mechanical repair. If the technician does not have such knowledge and skills, attempted service or repairs to the vehicle may render the vehicle unsafe. For this reason, Club Car advises that all repairs and/or service be performed by an authorized Club Car distributor/dealer representative or by a Club Car factory- trained technician. It is the policy of Club Car, Inc. to assist its distributors and dealers in continually updating their service 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 © 2003 Club Car, Inc. Club Car and PowerDrive are registered trademarks of Club Car, Inc. This manual effective October 15, 2003.

Page ii 2004 Precedent IQ System Golf Car Maintenance and Service Manual ∆ WARNING • Read Section 1 – Safety before attempting any service on the vehicle. • Before servicing vehicle, read complete section(s) and any referenced information that may be relevant to the service or repair to be performed. NOTE: This manual represents the most current information at the time of publication. Club Car, Inc. is continually working to further improve our vehicles and other products. These improvements may affect servicing procedures. Any modification and/or significant change in specifications or 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.

2004 Precedent IQ System Golf Car Maintenance and Service Manual Page iii CONTENTS SECTION 1 – SAFETY General Warnings ............................................................................................................................. 1-1 SECTION 2 – VEHICLE SPECIFICATIONS SECTION 3 – GENERAL INFORMATION Serial Number Identification .............................................................................................................. 3-1 Safety Committee ............................................................................................................................. 3-2 Storage ............................................................................................................................................. 3-2 Preparing the Electric Vehicle for Extended Off-Season Storage ................................................ 3-2 Returning the Stored Electric Vehicle to Service .......................................................................... 3-3 SECTION 4 – BODY AND TRIM Cleaning the Vehicle ......................................................................................................................... 4-1 Seat .............................................................................................................................................. 4-1 Front and Rear Body Repair ............................................................................................................. 4-2 Stress Lines or Streaks ................................................................................................................. 4-2 Minor Impact Damage/Deformations ............................................................................................ 4-2 Minor Scratches and Surface Blemishes ...................................................................................... 4-2 Gouges, Punctures, Tears, Large Scratches, and Abrasions ....................................................... 4-2 Front Body ........................................................................................................................................ 4-3 Front Body Removal ..................................................................................................................... 4-3 Front Body Installation .................................................................................................................. 4-3 Front Bumper .................................................................................................................................... 4-5 Floor Mat and Retainers ................................................................................................................... 4-6 Floor Mat Retainer Removal ......................................................................................................... 4-6 Floor Mat Retainer Installation ...................................................................................................... 4-6 Kick Plate and Charger Bezel ........................................................................................................... 4-7 Kick Plate and Charger Bezel Removal ........................................................................................ 4-7 Kick Plate and Charger Bezel Installation ..................................................................................... 4-7 Rear Body ......................................................................................................................................... 4-8 Universal Accessory Mounting ..................................................................................................... 4-8 Backrest and Structural Accessory Module .................................................................................. 4-9 Rear Body Components Removal ................................................................................................ 4-11

Page iv 2004 Precedent IQ System Golf Car Maintenance and Service Manual Dash Assembly ................................................................................................................................ 4-14 Dash Assembly Removal ............................................................................................................. 4-14 Dash Assembly Installation .......................................................................................................... 4-15 SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group ..................................................................................................................................... 5-1 Pedal Group Removal .................................................................................................................. 5-1 MCOR .......................................................................................................................................... 5-3 Debris Shields .............................................................................................................................. 5-3 Brake Return Spring ..................................................................................................................... 5-3 Pawl Assembly ............................................................................................................................. 5-4 Accelerator Return Spring ............................................................................................................ 5-4 Pedal Group Installation ............................................................................................................... 5-6 SECTION 6 – WHEEL BRAKE ASSEMBLIES General Information ......................................................................................................................... 6-1 Brake Shoe Removal ....................................................................................................................... 6-1 Brake Assembly Cleaning ................................................................................................................ 6-5 Brake Shoe Installation .................................................................................................................... 6-6 Brake Cable Equalizer Adjustment .................................................................................................. 6-8 Brake Cluster Removal and Installation ........................................................................................... 6-9 Brake Cluster Installation ............................................................................................................. 6-10 Brake Cable Removal and Installation ............................................................................................. 6-11 SECTION 7 – STEERING AND FRONT SUSPENSION General Information ......................................................................................................................... 7-1 Steering Wheel ................................................................................................................................. 7-1 Steering Wheel Removal ............................................................................................................. 7-1 Steering Wheel Installation .......................................................................................................... 7-2 Steering Column .............................................................................................................................. 7-2 Steering Column Removal ........................................................................................................... 7-2 Steering column Installation ......................................................................................................... 7-4 Rack and Pinion ............................................................................................................................... 7-4 Rack and Pinion Removal ............................................................................................................ 7-4 Rack and Pinion Disassembly ...................................................................................................... 7-5 Rack and Pinion Assembly .......................................................................................................... 7-8 Rack and Pinion Installation ......................................................................................................... 7-9 Front Suspension ............................................................................................................................. 7-10 Lubrication .................................................................................................................................... 7-10 Wheel Alignment .......................................................................................................................... 7-10

2004 Precedent IQ System Golf Car Maintenance and Service Manual Page v Front Suspension Components ........................................................................................................ 7-12 Tie Rod End Removal ................................................................................................................... 7-12 Tie Rod Installation ....................................................................................................................... 7-12 Leaf Spring Removal .................................................................................................................... 7-13 Leaf Spring Installation ................................................................................................................. 7-13 Kingpin and Steering Spindle Removal ........................................................................................ 7-13 Kingpin and Steering Spindle Installation ..................................................................................... 7-13 Control Arm Removal ................................................................................................................... 7-14 Control Arm Installation ................................................................................................................ 7-17 Shock Absorber Removal ............................................................................................................. 7-17 Shock Absorber Installation .......................................................................................................... 7-17 Front Wheel Bearings and Hubs ...................................................................................................... 7-17 Front Wheel Free Play Inspection ................................................................................................ 7-17 Front Hub Removal ....................................................................................................................... 7-17 Hub Installation ............................................................................................................................. 7-18 SECTION 8 – WHEELS AND TIRES General Information .......................................................................................................................... 8-1 Wheels .............................................................................................................................................. 8-1 Wheel Removal ............................................................................................................................ 8-1 Wheel Installation ......................................................................................................................... 8-1 Tires .................................................................................................................................................. 8-1 Tire Removal ................................................................................................................................ 8-2 Tire Repair .................................................................................................................................... 8-2 Tire Installation ............................................................................................................................. 8-3 SECTION 9 – REAR SUSPENSION General Information .......................................................................................................................... 9-1 Shock Absorbers .............................................................................................................................. 9-1 Shock Absorber Removal and Inspection ..................................................................................... 9-1 Shock Absorber Installation .......................................................................................................... 9-1 Leaf Springs ..................................................................................................................................... 9-1 Leaf Spring Removal .................................................................................................................... 9-1 Leaf Spring Installation ................................................................................................................. 9-4 SECTION 10 – PERIODIC MAINTENANCE General Information .......................................................................................................................... 10-1 Pre-Operation and Daily Safety Checklist ........................................................................................ 10-1 Performance Inspection ................................................................................................................ 10-1 Periodic Service Schedule ................................................................................................................ 10-2

Page vi 2004 Precedent IQ System Golf Car Maintenance and Service Manual Periodic Lubrication Schedule .......................................................................................................... 10-4 SECTION 11 – ELECTRICAL SYSTEM AND TESTING General Information ......................................................................................................................... 11-1 Electrical Circuits .............................................................................................................................. 11-3 Control Circuit .............................................................................................................................. 11-3 Onboard Computer Circuit ........................................................................................................... 11-3 Power Circuit ................................................................................................................................ 11-9 Charge Circuit .............................................................................................................................. 11-10 Wiring Diagram ................................................................................................................................ 11-11 Troubleshooting ............................................................................................................................... 11-12 Troubleshooting the Vehicle with the IQDM ................................................................................. 11-12 Troubleshooting Guide 1 .............................................................................................................. 11-12 Troubleshooting Guide 2 .............................................................................................................. 11-15 Test Procedures ............................................................................................................................... 11-17 Index of Test Procedures ............................................................................................................. 11-18 Communication Display Module (CDM) ........................................................................................... 11-42 Using the CDM to Retrieve Data from the Onboard Computer .................................................... 11-43 CDM Troubleshooting Guide ............................................................................................................ 11-44 SECTION 12 – ELECTRICAL COMPONENTS Key Switch ....................................................................................................................................... 12-1 Battery Warning Light ....................................................................................................................... 12-3 Forward/Reverse Rocker Switch ...................................................................................................... 12-4 Electronics Module Cover ................................................................................................................ 12-5 Tow/Run Switch ............................................................................................................................... 12-6 Motor Controller Output Regulator (MCOR) ..................................................................................... 12-7 Reverse Buzzer ................................................................................................................................ 12-8 Electronics Module ........................................................................................................................... 12-9 Solid State Speed Controller ............................................................................................................ 12-11 Solenoid ........................................................................................................................................... 12-12 Onboard Computer (OBC) ............................................................................................................... 12-13 Charger Receptacle ......................................................................................................................... 12-14 SECTION 13 – BATTERIES General Information ......................................................................................................................... 13-1 Common Misconceptions About Batteries ....................................................................................... 13-3 Battery Replacement ........................................................................................................................ 13-3

2004 Precedent IQ System Golf Car Maintenance and Service Manual Page vii Battery Care ...................................................................................................................................... 13-4 Preventive Maintenance ............................................................................................................... 13-4 Self-Discharge .............................................................................................................................. 13-5 Electrolyte Level ........................................................................................................................... 13-5 Mineral Content ............................................................................................................................ 13-6 Vibration Damage ......................................................................................................................... 13-6 Battery Charging ............................................................................................................................... 13-6 Charger Shuts Off After 16 Hours ................................................................................................. 13-7 Deep-Discharge ............................................................................................................................ 13-7 Early Excessive Discharging ........................................................................................................ 13-7 Incoming AC Service .................................................................................................................... 13-7 Fleet Rotation ............................................................................................................................... 13-7 Numbering Vehicles and Chargers ............................................................................................... 13-7 Battery Troubleshooting Chart .......................................................................................................... 13-8 Battery Testing ................................................................................................................................. 13-9 Battery Charger Test .................................................................................................................... 13-9 On-Charge Voltage Test ............................................................................................................... 13-9 Hydrometer Test ........................................................................................................................... 13-9 Discharge Test .............................................................................................................................. 13-11 Battery Troubleshooting Examples ............................................................................................... 13-13 Battery Storage ................................................................................................................................. 13-14 Charging a Battery Pack that has Low Voltage ................................................................................ 13-14 SECTION 14 – BATTERY CHARGER SECTION 15 – MOTOR General Information .......................................................................................................................... 15-1 External Motor Testing ...................................................................................................................... 15-1 Motor ................................................................................................................................................. 15-3 Motor Component Testing and Inspection ........................................................................................ 15-5 Armature ....................................................................................................................................... 15-5 Field Windings Inspection ............................................................................................................. 15-6 Motor Components ....................................................................................................................... 15-7 Bearing Inspection ........................................................................................................................ 15-7 Bearing Removal .......................................................................................................................... 15-9 Bearing Installation ....................................................................................................................... 15-9 Speed Sensor Magnet Inspection ................................................................................................. 15-9 Speed Sensor Magnet Removal ................................................................................................... 15-9 Speed Sensor Magnet Installation ................................................................................................ 15-9 Reconditioning the Motor .................................................................................................................. 15-9

Page viii 2004 Precedent IQ System Golf Car Maintenance and Service Manual Motor Assembly ............................................................................................................................... 15-10 Motor Installation .............................................................................................................................. 15-12 Motor Speed Sensor ........................................................................................................................ 15-15 SECTION 16A – TRANSAXLE (TYPE G) Transaxle Identification .................................................................................................................... 16a-1 Lubrication ........................................................................................................................................ 16a-1 Axle Bearing and Shaft .................................................................................................................... 16a-1 Axle Shaft ..................................................................................................................................... 16a-1 Axle Bearing ................................................................................................................................. 16a-5 Transaxle ......................................................................................................................................... 16a-5 Transaxle Removal ...................................................................................................................... 16a-5 Transaxle Disassembly, Inspection, and Assembly ......................................................................... 16a-7 Transaxle Disassembly and Inspection ........................................................................................ 16a-7 Transaxle Assembly ..................................................................................................................... 16a-10 Transaxle Installation ....................................................................................................................... 16a-11 SECTION 16B – TRANSAXLE (TYPE K) Transaxle Identification .................................................................................................................... 16b-1 Lubrication ........................................................................................................................................ 16b-1 Axle Bearing and Shaft .................................................................................................................... 16b-1 Axle Shaft ..................................................................................................................................... 16b-1 Axle Bearing ................................................................................................................................. 16b-4 Transaxle ......................................................................................................................................... 16b-6 Transaxle Removal ...................................................................................................................... 16b-6 Transaxle Disassembly, Inspection, and Assembly ......................................................................... 16b-8 Transaxle Disassembly and Inspection ........................................................................................ 16b-8 Transaxle Assembly ..................................................................................................................... 16b-10 Shimming the Transaxle .............................................................................................................. 16b-12 Transaxle Installation ....................................................................................................................... 16b-13

2004 Club Car Precedent Service & Repair Manual

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