Club Car
EDITION CODE 0205B1006A
IQ SYSTEM
ELECTRIC VEHICLES
2005
MAINTENANCE
SERVICE
SUPPLEMENT
MANUAL NUMBER 102680408
2005 IQ System Electric Vehicle Maintenance and Service Supplement 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 supplement provides detailed information for the maintenance and repair of IQ System™ electric vehi-
cles and should be used in conjunction with the appropriate maintenance and service manual.
If you do not have the appropriate maintenance and service manual, you may order one from your local Club
Car representative. Maintenance and service manuals available include the following:
This supplement and corresponding maintenance and service manual should be thoroughly reviewed prior to
servicing the vehicle. The procedures provided must be properly implemented, and the DANGER, WARNING,
and CAUTION statements must be heeded.
This supplement was written for the trained technician who already has 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 tech-
nician.
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 supplement, used in conjunction with the appropriate maintenance and service manual, covers all
aspects of typical vehicle service; however, unique situations do sometimes occur when servicing a vehicle.
If it appears that a service question is not answered in this supplement, you may write to us at: Club Car, Inc.,
P.O. Box 204658; Augusta, Georgia 30917-4658, USA, Attention: Technical Services, or contact a Club Car
Technical Service Representative at (706) 863-3000, ext. 3580.
This supplement does not contain maintenance and service procedures for the battery charger. Contact your
local Club Car representative for information on how to obtain the appropriate battery charger maintenance
and service manual.
2005 DS Golf Car Maintenance & Service Manual Publication Part No. 102680403
2005 Turf/Carryall Vehicle Maintenance & Service Manual Publication Part No. 102680404
2005 Transportation Vehicle Maintenance & Service Manual Publication Part No. 102680405
Copyright © 2005, 2006 Club Car, Inc.
Club Car is a registered
trademark of Club Car, Inc.
This manual effective August 2, 2004
Page ii 2005 IQ System Electric Vehicle Maintenance and Service Supplement
ý WARNING
• Read Section 1 – Safety in the appropriate maintenance and service manual 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 supplement 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 distributors/dealers and will, when applicable, appear in
future editions of this supplement.
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 supplement. 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 Administration.
2005 IQ System Electric Vehicle Maintenance and Service Supplement Page iii
CONTENTS
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 ................................................................................................................................ 11-6
Troubleshooting the Vehicle with the IQDM ................................................................................. 11-6
Troubleshooting Guide 1 .............................................................................................................. 11-7
Troubleshooting Guide 2 .............................................................................................................. 11-10
Test Procedures ............................................................................................................................... 11-12
Index of Test Procedures .............................................................................................................. 11-12
Communication Display Module (CDM) ............................................................................................ 11-38
Using the CDM to Retrieve Data from the Onboard Computer .................................................... 11-39
CDM Troubleshooting Guide ........................................................................................................ 11-40
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
Faults Menu ...................................................................................................................................... 12-6
Functions Menu ................................................................................................................................ 12-10
Get Settings From Controller ........................................................................................................ 12-10
Write Settings to Controller ........................................................................................................... 12-12
Reset All Settings ......................................................................................................................... 12-13
Information ........................................................................................................................................ 12-14
Programmer Setup ........................................................................................................................... 12-14
Program ........................................................................................................................................ 12-14
Faults ............................................................................................................................................ 12-14
Information .................................................................................................................................... 12-15
IQDM and IQDM-P Handset Troubleshooting .................................................................................. 12-15
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2005 Club Car Villager 6 Electric Factory Service & Work Shop Manual
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Description
Upon purchasing this manual, you will receive a .PDF file containing an email contact. After contacting us, you will receive a reply with a link to access the manual for your 2005 Club Car Villager 6 Electric.
This comprehensive manual covers every aspect of your machine, providing detailed guidance for various tasks from routine maintenance like oil changes to more complex procedures such as transmission swaps. With hundreds of pages, it includes numerous illustrations and easy-to-understand text to assist you throughout the process. The manual also features a search function, allowing you to quickly find relevant information and print necessary pages.
Designed as a Factory Service Repair Manual, it offers a step-by-step approach to maintaining and repairing your vehicle, equipping you with the knowledge that factory-trained technicians possess. By utilizing the insights provided in this manual, both professional mechanics and DIY enthusiasts can confidently make informed decisions regarding the upkeep and repair of their machine.
Our commitment extends beyond providing a high-quality service manual; we also ensure excellent customer service, guaranteeing your satisfaction with your purchase.
