Club Car 2009 Precedent, Maintenance And Service Manual

Page 1: ...2009 Electric Precedent Maintenance and Service Manual IQ System and Excel System Vehicles Manual Number 103472701 Edition Code 0309A00000 ...

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Page 3: ...rmation 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 however unique situations sometimes occur when servicing a vehicle If it appears that a service question is not answered in this manual please contact your nearest authorized Club Car dealer or distributor for assistance You may also...

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Page 5: ...tainers 4 7 Floor Mat Retainer Removal 4 7 Floor Mat Retainer Installation 4 7 Kick Plate and Charger Receptacle Bezel 4 8 Kick Plate and Charger Receptacle Bezel Removal 4 8 Kick Plate and Charger Receptacle Bezel Installation 4 8 Rear Body Two Passenger Vehicles 4 9 Universal Accessory Mounting 4 9 Backrest and Structural Accessory Module SAM 4 9 Rear Body Components Two Passenger 4 11 Rear Body...

Page 6: ...allation 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 King...

Page 7: ...ide 2 11 11 Test Procedures 11 13 Communication Display Module CDM 11 35 Using the CDM to Retrieve Data from the Onboard Computer 11 36 CDM Troubleshooting Guide 11 37 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 Procedure...

Page 8: ...M 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 17 Program 13 17 Faults 13 17 Information 13 17 IQDM and IQDM P Hand...

Page 9: ... 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...

Page 10: ...5 13 Testing the Solenoid 15 13 Solenoid Removal 15 13 Solenoid Installation 15 13 Onboard Computer OBC 15 14 Testing the Onboard Computer 15 14 Onboard Computer Removal 15 14 Onboard Computer Installation 15 14 Charger Receptacle 15 15 Testing the Charger Receptacle 15 15 Charger Receptacle Inspection 15 15 Charger Receptacle Removal 15 15 Charger Receptacle Installation 15 16 Headlight Adjustmen...

Page 11: ...mbly 18 4 Motor Component Testing and Inspection 18 7 Armature Inspection and Testing 18 7 Motor Frame and Field Windings Inspection 18 9 Motor Brush Spring and Terminal Insulator Inspection 18 9 Reconditioning the Motor 18 12 Motor Specifications 18 12 Motor Assembly 18 12 Motor Installation 18 14 SECTION 19 TRANSAXLE TYPE G 19 1 Lubrication 19 1 Axle Bearing and Shaft 19 1 Axle Shaft 19 1 Axle B...

Page 12: ... Handset into the Vehicle 21 1 Program Menu 21 2 Speed Setting 21 3 Fast Accel 21 3 Pedal Up Mode 21 3 Speed Cal 21 3 S3 FWD Speed 21 4 Code A Code B and Code C 21 4 Vehicle S N 21 4 Vehicle Decal 21 4 SECTION i INDEX Page x 2009 Electric Precedent Maintenance and Service Manual ...

Page 13: ...ice that could result in minor personal injury CAUTION A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could result in property damage GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated repaired or serviced Other specific safety statements appear throughout this manual and on the vehicle DANGER Battery E...

Page 14: ... beyond factory specifications could result in severe personal injury or death Check the vehicle for proper location of all vehicle safety and operation decals and make sure they are in place and are easy to read Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose ...

Page 15: ...ery cables in reverse order TOW RUN 2 3 4 5 6 1 1 3 2 Viewed from driver side of vehicle 1 Place TOW RUN Switch in TOW before disconnecting or connecting battery cables 2 Remove negative battery cable 3 Remove positive battery cable Connect battery cables in reverse order 422 Figure 1 1 Battery Cable Removal 4 x 12 Volt Battery Configuration 49A Figure 1 2 Battery Cable Removal 6 x 8 Volt Battery ...

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Page 17: ...nt Surlyn Reflections Body finish High gloss molded in color Tires 18 x 8 5 8 tubeless 4 ply rated DIMENSIONS WEIGHT Overall length 91 5 in 232 cm 104 in 264 cm Overall width 47 25 in 120 cm 47 25 in 120 cm Overall height with canopy 68 5 in 174 cm 71 in 180 cm Overall height at steering wheel 48 0 in 122 cm 48 0 in 122 cm Wheelbase 65 5 in 166 cm 65 5 in 166 cm Ground clearance 4 5 in 11 cm 4 5 i...

Page 18: ...CIFICATIONS SPECIFICATIONS TWO PASSENGER ELECTRIC VEHICLE FOUR PASSENGER ELECTRIC VEHICLE TIRE PRESSURE Front and rear 18 20 psi 1 24 1 38 bars 18 20 psi 1 24 1 38 bars Page 2 2 2009 Electric Precedent Maintenance and Service Manual ...

Page 19: ...n a Trailer Subsequent Owner Registration Warranties SERIAL NUMBER IDENTIFICATION The serial number of the vehicle is printed on a bar code decal mounted below the passenger side cup holder Figure 3 1 Page 3 2 The two letters at the beginning of the serial number indicate the vehicle model The following four digits indicate the model year and production week during which the vehicle was built The ...

Page 20: ... Club Car Service Parts Department Who should and who should not drive golf cars Instructing first time drivers Maintaining golf cars in a safe driving condition How various rules are to be enforced The safety committee should include all these items and such others as the committee feels necessary or appropriate STORAGE See General Warnings on page 1 1 WARNING Turn the key switch OFF remove the k...

Page 21: ...attery compartment and underside of vehicle 7 Do not engage the park brake Chock the wheels to prevent the vehicle from rolling 8 Keep batteries fully charged during storage Leave chargers plugged in during storage The onboard computer will automatically activate the charger when necessary If the battery charger is left plugged in during extended storage the electrolyte should be checked monthly t...

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Page 23: ...water damage and subsequent component failure Use non abrasive wax products Do not use abrasive leveling or rubbing compounds these will permanently dull the gloss Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible stains See following CAUTION and NOTE CAUTION Use of leveling or rubbing compounds will permanently dull finish of veh...

Page 24: ... the gun on its lowest heat setting 2 Slowly wave the heat gun back and forth over the affected area until the streak fades 3 It may be necessary to move the gun closer to the body to fade the streak but under no circumstance should the gun be held closer than 6 inches 15 cm to the body See following CAUTION CAUTION Holding the heat gun too close to the body could melt the body or damage the finis...

Page 25: ...igure 4 1 Page 4 4 2 Pull the front beauty panel 3 up and away from the brow and fascia assembly 4 disengaging the snap tabs 3 If the vehicle is equipped with a canopy loosen the canopy support cover then loosen but do not remove the front canopy support bolts If there is no canopy remove the non canopy cover 4 Remove the five screws 8 and lift the brow and fascia assembly 4 from the front underbo...

Page 26: ...4 Front Body BODY AND TRIM 3 8 2 1 5 6 7 4 616 Figure 4 1 Front Body Page 4 4 2009 Electric Precedent Maintenance and Service Manual ...

Page 27: ... screws 2 tightened to 13 ft lb 17 6 N m The front bumper 3 is attached to the vehicle frame rails by nuts 5 and bolts 4 The nuts 5 need to go on top of the bumper attaching brackets always insert the bolts 4 through the bottom The nuts are tightened to 13 3 ft lb 18 N m 2 1 2 3 4 5 617 Figure 4 2 Bracket and Front Bumper 2009 Electric Precedent Maintenance and Service Manual Page 4 5 ...

Page 28: ...ake sure tabs on the forward edge engage to front underbody Secure assembly in place with two screws 5 and plastic rivet 6 Figure 4 3 Page 4 6 Tighten screws to 8 8 ft lb 12 N m 2 Install the instrument panel 2 1 Connect the electrical connector on the instrument panel to the harness connector 2 2 Position the instrument panel 3 on the dash assembly Make sure tabs on upper edge properly engage wit...

Page 29: ...rom top of retainer 1 Figure 4 4 Page 4 7 2 Remove push rivets 4 from rear corners of retainer 3 Carefully pull on retainer to separate the trim clips from their respective slots Trim clips do not normally need to be removed from the retainer FLOOR MAT RETAINER INSTALLATION 1 Position the retainer on the vehicle and press firmly to engage the trim clips to the vehicle Figure 4 4 Page 4 7 2 Ensure ...

Page 30: ...ward portion of the rear beauty panel to disengage it from the tabs on the upper portion of the kick plate 5 Remove kick plate from vehicle KICK PLATE AND CHARGER RECEPTACLE BEZEL INSTALLATION 1 Position the kick plate 2 on the vehicle and secure with three screws 1 Figure 4 5 Page 4 8 Ensure front lower edge of rear beauty panel mates with the kick plate Tighten screws to 3 3 ft lb 4 5 N m 2 Inst...

Page 31: ... mounting holes and secure with four screws 4 Tighten screws to 53 in lb 6 N m Backrest The backrest 1 is secured to the SAM 3 with two screws 2 Figure 4 7 Page 4 10 When replacing the backrest tighten screws 2 to 5 9 ft lb 8 N m Bag Rack Removal 1 Remove two screws 10 to release the bag hoop 6 and related components from the SAM 3 Figure 4 7 Page 4 10 2 Bag strap 8 may be released by removing two...

Page 32: ...4 Rear Body Two Passenger Vehicles BODY AND TRIM 10 6 7 8 12 9 9 12 11 2 3 4 1 7 5 622 Figure 4 7 Backrest and SAM Page 4 10 2009 Electric Precedent Maintenance and Service Manual ...

Page 33: ...nd 2 on vehicle and secure each with one screw 3 Tighten screws to 53 in lb 6 N m Access Panel Access panel 6 is secured to the rear underbody 4 with two push rivets 7 Figure 4 8 Page 4 12 When replacing the panel insert push rivets 7 to hold the panel in place Rear Underbody Removal 1 Remove four screws 5 attaching the rear underbody 4 to vehicle Figure 4 8 Page 4 12 2 Remove two screws 18 and wa...

Page 34: ...Passenger Vehicles BODY AND TRIM 17 13 16 14 5 4 5 7 6 8 11 11 10 10 12 15 2 3 1 9 18 23 Two Passenger Vehicles Only 656 Figure 4 8 Rear Body Components Page 4 12 2009 Electric Precedent Maintenance and Service Manual ...

Page 35: ...or 11 to seat support with screws 9 or 13 Tighten screws to 71 in lb 8 N m Figure 4 9 Page 4 13 2 4 1 7 9 8 11 13 12 10 3 15 626 Figure 4 9 Seats Four Passenger Vehicles SEAT SUPPORT Seat Support Removal 1 Remove screws 8 and 11 securing the rear hip restraints 6 and remove the hip restraints from the vehicle Figure 4 10 Page 4 14 2 Remove the screws 5 and bolts 4 from the seat support 3 and remov...

Page 36: ...e 4 10 Seat Supports Four Passenger Vehicles FOOT DECK Foot Deck Removal 1 Remove screws 8 and 11 securing the rear hip restraints 6 and remove the hip restraints from the vehicle Figure 4 10 Page 4 14 2 Remove the four bolts 2 securing the foot deck 1 to the vehicle frame Figure 4 11 Page 4 15 Foot Deck Installation 1 Install foot rest in reverse order of removal 2 Tighten bolts 2 to 71 in lb 8 N...

Page 37: ...ips 17 on the rear of the beauty panel engage the mating slot in the rear underbody Secure beauty panel in place with four screws 13 Tighten screws to 3 7 ft lb 5 N m Figure 4 8 Page 4 12 2 Connect the three wires to the Forward Reverse switch 16 as shown 3 Position the Forward Reverse switch housing 15 on the front of beauty panel 12 and secure with two screws 14 Tighten screws to 20 in lb 2 3 N ...

Page 38: ...ving the canopy 1 Figure 4 12 Page 4 17 TWO PASSENGER CANOPY REMOVAL 1 Remove the two nuts 9 and two bolts 8 from the canopy 1 and each front canopy support 7 and 10 Figure 4 12 Page 4 17 2 Remove the nuts 5 and bolts 4 from the canopy 1 and each rear support 3 3 Lift canopy 1 away from front canopy supports 7 and 10 and rear supports 3 4 Remove screws 14 securing front canopy support covers to fr...

Page 39: ...BODY AND TRIM Canopy Two Passenger 4 13 14 4 5 3 9 11 7 12 6 10 1 8 627 Figure 4 12 Precedent Two Passenger Canopy 2009 Electric Precedent Maintenance and Service Manual Page 4 17 ...

Page 40: ...or coded with blue thread lock Finger tighten the bolts to avoid cross threading the threads in the supports See following CAUTION CAUTION Using tools to thread the bolts could prevent proper feel of the bolt as it captures the female threads in the support This could result in damage to the components 4 Position the canopy on top of the front and rear supports Ensure that the front supports are p...

Page 41: ...BODY AND TRIM Canopy Two Passenger 4 5 4 2 1 6 13 9 6 11 9 1 10 12 14 16 16 8 7 6 15 628 Figure 4 13 Precedent Four Passenger Canopy 2009 Electric Precedent Maintenance and Service Manual Page 4 19 ...

Page 42: ...hicle If the supports are placed on the wrong side of the vehicle they will not follow the vehicle s profile 1 2 Align the holes in the lower portion of each front support 1 with the corresponding holes in the vehicle Insert two bolts 2 through each front support into the threaded holes in the vehicle The bolts are color coded with gold thread lock Only finger tighten the bolts at this time 1 3 Sl...

Page 43: ...eneral Warnings on page 1 1 2 Remove screws 1 Pull floor mat retainer 3 away from the vehicle Figure 5 1 Page 5 1 3 Pull floor mat 2 over the pedal group to gain access to the pedal group hardware 4 Remove fastener 10 and lift off cover plate 7 Figure 5 2 Page 5 2 5 Loosen jam nuts 4 and 5 on each side of turnbuckle 6 NOTE Nut 4 has a left hand thread 6 Loosen turnbuckle 6 until the threaded rod 8...

Page 44: ...2 Pedal Group 7 Remove two screws 2 on the driver side of the pedal group and two screws 1 on the passenger side of the pedal group 8 Disconnect six pin connector 12 from throttle position sensor 9 Lift pedal group from vehicle Page 5 2 2009 Electric Precedent Maintenance and Service Manual ...

Page 45: ...ive debris from contacting the moving parts of the pedal group Both shields 4 and 5 are held in place by tabs that snap into the pedal group mounting plate Figure 5 3 Page 5 4 ACCELERATOR PEDAL REMOVAL 1 Remove pedal group from vehicle See Pedal Group Removal on page 5 1 2 Remove debris shields 4 and 5 Figure 5 3 Page 5 4 3 Remove four screws 13 securing accelerator pedal assembly 9 to pedal group...

Page 46: ...l Group ACCELERATOR AND BRAKE PEDAL GROUP 5 4 10 6 8 2 12 9 11 7 3 13 000487 002 Figure 5 3 Accelerator Pedal Assembly and Brake Pedal Assembly Page 5 4 2009 Electric Precedent Maintenance and Service Manual ...

Page 47: ...ensor Figure 5 2 Page 5 2 2 Position the pedal group in vehicle and secure with two screws 2 on the driver side and two screws 1 on the passenger side Tighten driver side screws 2 to 97 in lb 11 N m Tighten passenger side screws 1 to 18 in lb 2 N m 3 Remove the turnbuckle 6 and apply Loctite 242 to the threaded ends of both the rod from the pedal group 8 and the brake actuator rod 9 Connect the ro...

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Page 49: ...eries wait 90 seconds in General Warnings on page 1 1 2 Place chocks at the front wheels Loosen but do not remove lug nuts on rear wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to support the vehicle See WARNING Lift only one end in General Warnings on page 1 1 3 Gain access to the pedal group by removing the floor mat and access pa...

Page 50: ...illustrated Figure 6 2 Page 6 2 This will release the shoes from the backing plate allowing them to pivot away from the inside of the brake drum 3 which should then allow the brake drum to be pulled free After completing step 8 skip step 9 NOTE Although step 8 allows easier access to the brake shoes it is not imperative to do so in order to remove the brake shoes 8 Remove the axle 8 1 Using 90 sna...

Page 51: ...hoe retainer clip 2 Figure 6 5 Page 6 4 CAUTION The brake shoes are under pressure and can release suddenly when brake shoe retainers are removed 10 Grasp both brake shoes and pull them together with the springs out of the brake assembly as shown Figure 6 6 Page 6 4 11 Remove adjuster wheel 1 with two washers 2 and 3 from the backing plate Figure 6 7 Page 6 4 2009 Electric Precedent Maintenance an...

Page 52: ...00 1400 18100 10222 Figure 6 5 Remove Shoe Retainer Clip 1400 17700 10225 Figure 6 6 Remove Brake Shoes 1 2 3 1 2 638 Figure 6 7 Remove Adjuster Wheel 639 Figure 6 8 Lubricate Slide and Slide Plate Page 6 4 2009 Electric Precedent Maintenance and Service Manual ...

Page 53: ...y damage or severe personal injury 4 Use a small brush to carefully apply a light coat of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent on each of the six raised bosses on the brake backing plate Figure 6 9 Page 6 5 See preceding WARNING 5 Use a small brush to carefully apply a light coat of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent to each end of both brake s...

Page 54: ...sembly Cleaning WHEEL BRAKE ASSEMBLIES 00 1 7 T 642 Figure 6 11 Apply Grease To Brake Adjuster 643 Figure 6 12 Install Adjuster Wheel Trailing Shoe Page 6 6 2009 Electric Precedent Maintenance and Service Manual ...

Page 55: ...ard the rear of the vehicle 2 Install the shoe retainer clip using pliers to compress the clip 1 while turning the retainer pin 2 into position Figure 6 13 Page 6 7 3 Attach the springs onto the trailing shoe already installed Then hold the leading shoe next to the trailing shoe correctly oriented and attach the springs to it Figure 6 14 Page 6 7 1 2 0 4 1 2 3 1 Bronze Spring 2 Silver Spring 3 Coi...

Page 56: ...he splined end of the axle shaft into the axle tube Be careful not to damage the seal on the inside of the axle tube hub Advance the shaft through to the bearing on the shaft and rotate it to align the shaft splines with the splined bore of the differential gear Continue advancing the shaft until the bearing on the axle is firmly seated within the axle tube hub seat 7 2 Using 90 internal snap ring...

Page 57: ...NOTE If drum installation is difficult the brake shoes may need to be adjusted vertically in the mounting slots 9 After the drum is installed make sure the axle and drum turn freely and then install the wheel See Wheel Installation on page 8 1 10 Remove the turnbuckle 2 and apply Loctite 242 to the threaded ends of both the rod from the pedal group 6 and the brake actuator rod 5 Figure 6 20 Page 6...

Page 58: ...th front and rear jam nuts 4 Tighten the rear jam nut first labeled 1 of 2 to 156 in lb 17 5 N m Figure 6 18 Page 6 9 then tighten the front jam nut to 156 in lb 17 5 N m See following WARNING For optimal performance drive the vehicle and apply the brakes approximately 20 times to burnish the shoes center the clusters and adjust the brake mechanism WARNING Reduced braking force could result if the...

Page 59: ...ms NOTE When servicing vehicles with self adjusting brakes with badly worn brake shoes and when the drums cannot be removed by normal methods perform Step 7 of Brake Shoe Removal on page 6 1 then continue with this procedure Although step 7 below allows easier access to the brake shoes it is not imperative to do so in order to remove the brake shoes 7 Remove the axle 7 1 Using 90 snap ring pliers ...

Page 60: ...he internal retaining ring into the axle tube hub so that it seats against the axle bearing assembly and into the machined slot in the inside wall of the axle tube hub 4 3 Place a 1 4 to 3 8 inch 6 10 mm diameter rod against the retaining ring and tap lightly at four or five locations to ensure it is properly seated See following WARNING WARNING Be sure retaining ring is properly seated in groove ...

Page 61: ...tallation of the new brake cables and brake equalizer will not replace nor eliminate the need for scheduled preventive maintenance Brake systems require preventive maintenance and should not be neglected Brake cleaning lubrication and adjustments remain the same and should be performed as shown to optimize brake performance and service life See Periodic Service Schedule Section 10 Page 10 3 1 2 1 ...

Page 62: ...me Figure 6 20 Page 6 14 10 Remove bow tie locking pin 1 and the clevis pin 2 from the brake lever on each wheel and pull the clevis 3 away from the lever Figure 6 21 Page 6 14 11 Using brake cable release tool CCI P N 102555501 compress the retaining clips on the end of the cable housing enough to slip the cable end out of the bracket 4 and remove the brake cable from the vehicle 1 2 3 4 1 2 3 65...

Page 63: ...the upright position and slip the cable head through the hole on top of the bracket Pivot the equalizer to the horizontal position to capture the cable heads in the equalizer 3 Insert the rear cable housing into the shock mount bracket 4 Figure 6 21 Page 6 14 Push the cable housing end into the bracket to ensure the clips on the housing end secure the cable in position 4 At the rear wheel brake co...

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Page 65: ...el 7 and steering column shaft 9 so when the steering wheel is removed it can be placed back in exactly the same position on steering column shaft 5 Loosen the steering wheel bolt 6 and back it off approximately 1 4 inch 6 mm Do not remove the bolt 6 If it is difficult to remove the steering wheel use the steering wheel puller CCI P N 102061201 to remove steering wheel 6 1 Place the puller anvil 4...

Page 66: ...ate 1 4 If required install the plate mounting screws 8 Tighten screws to 16 in lb 1 8 N m STEERING COLUMN See General Warnings on page 1 1 STEERING COLUMN REMOVAL 1 Disconnect the battery cables and discharge the controller as instructed See WARNINGS To avoid unintentionally starting and After disconnecting the batteries wait 90 seconds in General Warnings on page 1 1 2 Remove the steering wheel ...

Page 67: ...61 Figure 7 3 Steering Column STEERING COLUMN INSTALLATION 1 For ease of assembly and to prevent corrosion apply a light coat of anti seize or lubricating compound to the splined stud extending from the steering gear 2009 Electric Precedent Maintenance and Service Manual Page 7 3 ...

Page 68: ...ction 4 Body and Trim RACK AND PINION See General Warnings on page 1 1 2 1 5 7 3 4 6 662 Figure 7 4 Rack and Pinion Removal RACK AND PINION REMOVAL 1 Disconnect the battery cables and discharge the controller as instructed See WARNINGS To avoid unintentionally starting and After disconnecting the batteries wait 90 seconds in General Warnings on page 1 1 2 Remove the front bumper as instructed See ...

Page 69: ...emove the dust seal Figure 7 6 Page 7 7 7 Remove the large snap ring 4 Figure 7 7 Page 7 7 8 Remove pinion 5 from the housing 17 Figure 7 8 Page 7 7 If removal is difficult install the universal joint onto the pinion and place a fork or a large open end wrench under the universal joint Figure 7 8 Page 7 7 Gently pry the pinion from the housing 9 Remove the universal joint from the pinion 5 10 If t...

Page 70: ...and Pinion STEERING AND FRONT SUSPENSION 1 2 4 3 5 6 7 18 8 8 17 21 21 16 15 14 13 9 9 10 10 11 11 12 19 20 12 19 20 663 Figure 7 5 Steering Gear Page 7 6 2009 Electric Precedent Maintenance and Service Manual ...

Page 71: ...UTION In step 2 do not press against the outer race of the bearing 2 If the pinion bearing 4 was removed grease a new bearing before installation Press new bearing onto pinion shaft exerting all pressure on the inner race Then install the C type stop ring 3 See previous CAUTION 3 Install pinion 5 and bearing 4 assembly into the housing 17 Make sure the rack gear teeth will mesh with the gear teeth...

Page 72: ...3 until correct setting is achieved Tighten the nut 14 to 28 ft lb 38 N m Figure 7 12 Page 7 9 NOTE When tightening the nut 14 make sure the screw 13 does not change adjustment Figure 7 12 Page 7 9 14 Remove the 3 8 inch 1 4 drive deep well socket from the steering column end of the universal joint 2 15 Install the two dust seal bellows 9 Figure 7 5 Page 7 6 16 Install new bellows clamps wire ties...

Page 73: ...inion 7 1 2 668 Figure 7 10 Press In Dust Seal 669 Figure 7 11 Install Ball Joint 13 14 1 2 670 Figure 7 12 Rack and Pinion Adjustment 671 Figure 7 13 Rack and Pinion Resistance 2009 Electric Precedent Maintenance and Service Manual Page 7 9 ...

Page 74: ...or or ground there should be an equal amount of space between each tire and the framing square Figure 7 14 Page 7 11 2 Loosen but do not remove the four bolts 17 that secure the leaf spring 13 to the bottom spring plate 16 Figure 7 19 Page 7 16 See also Figure 7 15 Page 7 11 3 Loosen but do not remove the hex nut 8 on the adjustment eccentric 7 Figure 7 15 Page 7 11 in the center of the spring See...

Page 75: ... facing surfaces of the tires and then roll the vehicle forward one and a half wheel revolutions until the marks appear on the forward facing surfaces of the tires at about the same height from the floor Figure 7 16 Page 7 11 2 3 1 674 Figure 7 16 Check Toe In 675 Figure 7 17 Adjust Toe In 4 Measure the distance between the marks on the forward facing surfaces of the tires Figure 7 16 Page 7 11 NO...

Page 76: ...o avoid unintentionally starting and After disconnecting the batteries wait 90 seconds in General Warnings on page 1 1 2 Loosen jam nuts 13 to allow later rotation of the tie rod ends 12 Figure 7 18 Page 7 15 3 Remove the and retaining nuts 14 4 Lift male thread of tie rod from the hole in the spindle tab 5 Remove the tie rod ends from the steering gear 6 To minimize corrosion apply a light coat o...

Page 77: ...the wheels and finger tighten the lug nuts 5 Lower the vehicle and finish tightening lug nuts using a crisscross pattern to 55 ft lb 74 6 N m for steel wheels or 65 ft lb 88 N m for alloy mag wheels 6 Adjust camber and toe in See Wheel Alignment on page 7 10 KINGPIN AND STEERING SPINDLE REMOVAL 1 Disconnect the battery cables and discharge the controller as instructed See WARNINGS To avoid uninten...

Page 78: ...nd lower the vehicle onto the jack stands 3 Remove wheel 4 Remove bolts 17 and move rack and pinion to allow clearance for bolt 19 Figure 7 18 Page 7 15 5 Remove bolts 11 and 19 6 Remove the control arm 6 7 Inspect the bushings 7 and sleeves 8 and 9 in the control arm and replace them if necessary CONTROL ARM INSTALLATION 1 Install the control arm in reverse order of removal Tighten the control ar...

Page 79: ...ND FRONT SUSPENSION Front Suspension Components 7 4 8 11 10 2 5 6 7 9 6 4 1 2 14 13 12 16 17 19 18 1311 Figure 7 18 Upper Front Suspension Assembly 2009 Electric Precedent Maintenance and Service Manual Page 7 15 ...

Page 80: ...uspension Components STEERING AND FRONT SUSPENSION 1 3 4 5 4 6 7 8 9 10 11 13 14 15 16 17 18 19 3 1312 Figure 7 19 Lower Front Suspension Assembly Page 7 16 2009 Electric Precedent Maintenance and Service Manual ...

Page 81: ...al on page 8 1 2 Remove dust cap 12 and lock nut 11 Figure 7 19 Page 7 16 3 Slide the hub assembly 9 off of the spindle shaft 3 4 Lightly sand spindle shaft to clean away any light rust 5 Inspect the surface of the spindle shaft for surface damage It should be clean and smooth If severe pitting from rust or corrosion has occurred replace the spindle assembly See Kingpin and Steering Spindle Remova...

Page 82: ...7 Front Wheel Bearings and Hubs STEERING AND FRONT SUSPENSION 3 11 9 678 Figure 7 20 Front Wheel Hub Page 7 18 2009 Electric Precedent Maintenance and Service Manual ...

Page 83: ...battery cables and discharge the controller as instructed See WARNINGS To avoid unintentionally starting and After disconnecting the batteries wait 90 seconds in General Warnings on page 1 1 2 Slightly loosen the lug nuts on the wheel to be removed 3 Raise the end of the vehicle from which the wheel is to be removed Make sure that the wheels are off the ground See General Warnings on page 1 1 4 Re...

Page 84: ...not use excessive force when starting the bead over the edge of the rim 4 When top bead is free of the rim pull the bead from the bottom side of the rim up into the upper part of the rim well Insert the tire tool under the lower bead as shown Figure 8 1 Page 8 2 Detail C and carefully pry the lower bead over the rim flange 5 Once the lower bead is started over the rim flange the tire can be remove...

Page 85: ... flanges 4 Install the tire on the rim from the valve stem side If there is no tire machine available use a rubber mallet and tire iron 5 Remove the valve core and position tire so that both beads are on the rim flange narrow bead seats 6 Place tire and wheel assembly against wall in upright position and push it against wall while inflating tire to 30 35 psi 2 07 2 42 Bars The three point contact ...

Page 86: ...8 Tires WHEELS AND TIRES 680 Figure 8 2 Inflate Tire Page 8 4 2009 Electric Precedent Maintenance and Service Manual ...

Page 87: ...akage at the point where the shaft enters the shock absorber body Replace damaged or leaking shock absorbers Figure 9 3 Page 9 4 or Figure 9 4 Page 9 6 2 To remove a shock absorber remove the nut 5 cup washer 9 and rubber bushings 10 from the stem at the top of the shock absorber 3 Remove the nut 5 cup washer 9 and rubber bushings 10 from lower mounting stem 4 Compress the shock absorber to remove...

Page 88: ...the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 3 Place a floor jack under the transaxle differential casing to support but not lift the drivetrain Raise it just enough to relieve tension on the shock absorbers without compressing them 4 Remove the tire and wheel assembly on the side from which the spring is t...

Page 89: ...See following CAUTION CAUTION When positioning the spring on the transaxle be sure to insert the locating bolt on the spring in the locating hole in the transaxle saddle 2 Tighten the nuts on the U bolts to 25 ft lb 34 N m and tighten nuts 2 on spring mounting bolts 17 to 15 ft lb 20 3 N m Figure 9 3 Page 9 4 3 Install tire and wheel assembly See Wheel Installation Section 8 Page 8 1 2009 Electric...

Page 90: ...and Mounting Two Passenger Vehicles LEAF SPRINGS FOUR PASSENGER VEHICLES See General Warnings on page 1 1 LEAF SPRING REMOVAL FOUR PASSENGER VEHICLES 1 Disconnect the battery cables and discharge the controller as instructed See WARNINGS To avoid unintentionally starting and After disconnecting the batteries wait 90 seconds in General Warnings on page 1 1 Page 9 4 2009 Electric Precedent Maintenan...

Page 91: ...w tie locking pin 1 and the clevis pin 2 at the brake lever and brake cable connection and remove cable end 3 from the brake lever Figure 9 2 Page 9 3 Detach the brake cable from the shock mount bracket 4 See Brake Cable Removal Section 6 Page 6 13 6 Remove the nut 5 cup washer 9 and rubber bushings 10 from the lower mounting stem of the shock absorber Figure 9 4 Page 9 6 7 Remove the nuts 13 and ...

Page 92: ...les REAR SUSPENSION 15 26 27 9 10 10 9 5 4 3 4 11 3 4 12 20 13 15 2 17 17 1 2 7 17 29 31 30 2 28 683 Figure 9 4 Rear Suspension Assembly and Mounting Four Passenger Vehicles Page 9 6 2009 Electric Precedent Maintenance and Service Manual ...

Page 93: ... the vehicle Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair Follow the procedures exactly as stated in this manual and heed all DANGER WARNING and CAUTION statements in this manual as well as those affixed to the vehicle Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance ...

Page 94: ... at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 lb 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the bra...

Page 95: ...nnual periodic service PERIODIC SERVICE SCHEDULE WARNING Service repairs and adjustments must be made per instructions in the appropriate section of this manual If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal injury or death NOTE If the vehicle i...

Page 96: ...vice by owner or trained technician General vehicle Thoroughly wash vehicle including the underside Initial one time inspection by owner or trained technician after six weeks of use Batteries For vehicles newly equipped with the Single Point Watering System For vehicles newly equipped with the SPWS manually check battery electrolyte levels of all cells to verify correct valve operation See Initial...

Page 97: ...rforming as expected see Section 16 Batteries Pedal group Lubricate all rotating joints See Periodic Lubrication Schedule on page 10 6 Annual service by trained technician only every 100 hours of operation or 200 rounds of golf General Vehicle Check for loose hardware tighten if necessary 2009 Electric Precedent Maintenance and Service Manual Page 10 5 ...

Page 98: ...white lithium grease NLGI 2 Semiannually by owner or trained technician every 50 hours of operation or 100 rounds of golf Front suspension two fittings Chassis Lube EP NLGI Grade 2 Check fill transaxle to plug level 22 oz 0 67 liters SAE 30 WT API Class SE SF or SG Oil or higher Annually by trained technician only every 100 hours of operation or 200 rounds of golf Pedal group Dupont Performance Dr...

Page 99: ...y to act as an electrical brake to slow the vehicle There are three features of the IQ electrical system which will activate the motor braking function Walk Away Braking Pedal Down Motor Braking and Pedal Up Motor Braking adjustable with the IQDM P handset Walk Away Braking This prevents the vehicle from rolling away uncontrolled should the driver park on a slope and leave the vehicle without lock...

Page 100: ... YELLO W TOSLIDER OF POTEN TI OM ETER PIN 4 OPEN PIN 3 OPEN PIN 5 L T BL UE OBC PIN 9 GRA Y TOTOWSWITCHSONIC WEL D PIN 15 RED TOHIGH SIDE OF MO TOR SPEED SEN SOR PIN 16 BLU E TO FOR W AR D R EVERSE SWITCH R EV 16 8 9 1 PIN 8 BR N TOFORW ARD REVER SE SWITCH FOR PIN 7 O RG WHT TOLOWSIDE OFREVER SE BUZZER PIN 6 G REEN TOACCEL ERA TOR LIMI TSWITCH 16 PINCON NECT OR A TCONT ROLLER REARVI EW 4 PINCONNEC...

Page 101: ...IQ SYSTEM TROUBLESHOOTING Wiring Diagrams 11 WD1034969 5 R Figure 11 2 Wiring Diagram IQ System Continued 2009 Electric Precedent Maintenance and Service Manual Page 11 3 ...

Page 102: ... WHITE 16 BLUE WHITE 16 RED 16 GREE N 16 ORANGE 16 BLACK A L T E R N A T I V E USED WHEN THERE ARE TURN SIGNALS NORMALLY OPEN MOMENTARY PUSH BU TTON FOR HORN TURN SIGNAL SWITCH FLASHER UNIT 16 GRAY 16 WHITE 16 GRAY 16 BROWN 16 RED 16 GREEN 16 BLUE 16 BLACK 16 B ROWN 16 YELLOW 16 BROWN WHITE 16 YELLOW 16 WHITE 16 BLUE WHITE 16 ORANGE WD1025104E5 L Figure 11 3 Precedent Electric Vehicle Accessory Wi...

Page 103: ...16 YELLOW 16 WHITE 16 BLUE WHITE 16 RED 16 GREE N 16 ORANGE 16 BLACK 12 B LACK 12 RE D 16 PU RPLE 16 YE LLOW WHITE 18 BLU E WHITE DIODE BRAKE LIGHT RELAY SONIC WELD DC DC CONVERTER NOTE SOME WIRING COMPONENTS SHOWN ARE OPTIONALACCESSORIES SONIC WELD SONIC WELD LIGHT SWITCH SONIC WELD 18 O RANGE 16 ORAN GE 18 BROWN 18 BLUE WHITE 18 BLUE WHT 18 ORANGE SONIC WELD SONIC WELD 14 B LK 16 BLUE 16 GREE N ...

Page 104: ...E 18 PINK WARNING LIGHT REVERS E BUZZER PRO GRAMMER PLUG SONIC WELD OPTIONALBATTERY INDICATOR KEYSWITCH NOTE SOME WIRING COMPONENTS SHOWN ARE OPTIONALACCESSORIES 1 6 B L U E 18 BROWN WHITE 9 PINCONNECTOR CONNECTS TO MAINHARNESS SEE FIGURES 11 1 AND 11 2 WD1025104E6 Figure 11 5 Precedent Electric Vehicle Instrument Panel Wiring Diagram Page 11 6 2009 Electric Precedent Maintenance and Service Manua...

Page 105: ...f when this number is reached 4 determines when to activate regenerative motor braking 5 locks out vehicle movement while the charger is plugged into the vehicle charger receptacle 6 stores operating data which can be read by the Communication Display Module CDM See Communication Display Module CDM on page 11 35 TROUBLESHOOTING The following troubleshooting guides will be helpful in identifying op...

Page 106: ...epair and or connect the six pin connector to the throttle position sensor Loose or disconnected 16 pin connector at speed controller or broken wire Repair and or connect the 16 pin connector to the speed controller Test Menu THROTTLE value does not increase as the accelerator pedal is pressed or Diagnostic Menu THROTTLE FAULT 1 fault code Failed throttle position sensor Test Procedure 4 Throttle ...

Page 107: ...pacitors to discharge See WARNING To avoid unintentionally starting in General Warnings on page 1 1 Reconnect the batteries and see if the symptom returns Loose broken or disconnected wire s at solenoid or B speed controller terminal Repair and or connect the loose or disconnected wire s Loose or disconnected 16 pin connector at speed controller or broken wire Repair and or connect the 16 pin conn...

Page 108: ...eplace solenoid See Solenoid Removal on page 15 13 Loose or disconnected motor field coil wires at motor or speed controller or broken wire Repair and or connect the field coil wires Failure of the motor field windings Section 18 Motor Model EJ4 4001 and EJ8 4001A Diagnostic Menu FIELD MISSING fault code Failure of the FET s that control field current Replace the speed controller See Speed Control...

Page 109: ...and Throttle Position Sensor Limit Switch Circuit on page 11 20 See also Test Procedure 4 Throttle Position Sensor Voltage on page 11 16 Forward Reverse rocker switch Test Procedure 23 Forward Reverse Rocker Switch on page 11 32 Solenoid loose wires Test Procedure 3 Solenoid Activating Coil on page 11 15 Solenoid failed coil Test Procedure 3 Solenoid Activating Coil on page 11 15 Speed controller ...

Page 110: ...Vehicle runs slowly Tires under inflated or flat tires Section 8 Wheels and Tires Wiring improperly wired Check vehicle wiring See Wiring Diagrams on page 11 2 Vehicle operates but motor braking function does not Speed sensor disconnected or failed Test Procedure 21 Motor Speed Sensor on page 11 31 Forward Reverse rocker switch improperly wired Test Procedure 23 Forward Reverse Rocker Switch on pa...

Page 111: ...ing or installing plate Remove plate from vehicle completely After test procedures are completed be sure to replace the cover See Electronics Module Cover on page 15 5 See following CAUTION CAUTION Exposure to water may damage electronic components Do not operate vehicle without the cover properly installed Do not direct a water stream in area of the cover Index of Test Procedures 1 Batteries Volt...

Page 112: ...rse polarity Refer to Section 16 Batteries for further details on battery testing Batteries Voltage Check without the IQDM Handset 1 With batteries connected and using a multimeter set to 200 volts DC place red probe on the positive post of battery no 1 and the black probe on the negative post of battery no 4 Figure 11 6 Page 11 14 or battery no 6 Figure 11 7 Page 11 14 The multimeter should indic...

Page 113: ...le does not operate 5 1 Using a multimeter set to 200 volts DC place black probe on battery number 4 and place red probe with insulation piercing probe on light blue 18 gauge wire at OBC six pin connector 5 2 With Tow Run switch in the RUN position the voltage reading should be approximately 48 volts 6 If the dash light does not illuminate and the vehicle does not operate check the OBC activation ...

Page 114: ...h the pedal not pressed While monitoring the IQDM display screen slowly press the accelerator pedal As the pedal is pressed the IQDM should indicate a rise from 0 pedal not pressed to 100 pedal fully pressed 5 If the throttle position sensor does not operate as described in previous step proceed to Throttle Position Sensor Voltage Test without the IQDM Handset Throttle Position Sensor Voltage Test...

Page 115: ...sembly See Accelerator Pedal Removal on page 5 3 TEST PROCEDURE 5 A1 and A2 Motor Voltage See General Warnings on page 1 1 1 Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack Position jack stands under the frame rails just forward of each spring mount See WARNING Lift only one end in General Warnings on page 1 1 See also following WARNING WARNING Ke...

Page 116: ...ts DC connect the black probe to the negative post of battery no 4 4 x 12 Volt battery set or battery no 6 6 x 8 Volt battery set and connect red probe with insulation piercing probe on the pink wire close to the connector on the Tow Run switch WARNING The key switch should be placed in the OFF position and left in the OFF position for the duration of this test 2 With the Tow Run switch in the RUN...

Page 117: ...lts while under load 5 A reading of 32 46 volts indicates discharged or failed batteries Each battery should be checked with a multimeter while under load 6 A reading of 32 volts or less will not activate discharge machine If the voltage of the batteries is below 32 volts the batteries are deeply discharged or have failed 7 Recording the battery pack voltage reading while under load provides a mor...

Page 118: ...key switch position 5 3 With the key switch in the ON position press the accelerator pedal The IQDM should indicate that FOOT INPUT is ON when the accelerator pedal is pressed 6 If any reading is obtained that is not described in steps 4 and 5 perform the following steps 6 1 Check the wiring of the key switch and throttle position sensor See Wiring Diagrams on page 11 2 6 2 Check the continuity of...

Page 119: ...place black probe on battery no 4 4 x 12 Volt battery set or battery no 6 6 x 8 Volt battery set negative post and the place red probe with insulation piercing probe on the blue wire where it connects to the throttle position sensor With the key switch ON the reading should be approximately 48 volts full battery voltage 5 4 2 If the reading is zero volts check the continuity of the blue wire that ...

Page 120: ...e To key switch sonic weld Test Procedure 16 Pin 10 on page 11 27 Pin 11 Open no wire Pin 12 Blue White 18 gauge To low side of solenoid coil Test Procedure 17 Pin 12 on page 11 28 Pin 13 Black White 18 gauge Negative side of motor speed sensor and throttle position sensor Test continuity of wire and perform Test Procedure 10 Pins 1 2 and 13 on page 11 22 and Test Procedure 21 Motor Speed Sensor o...

Page 121: ... powered up and battery charger disconnected 686 Figure 11 11 Pin 5 Test 5 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m 6 Place the Tow Run switch in the RUN position 7 The multimeter should indicate zero volts DC at this time 8 While monitoring the multimeter plug the battery charger into the vehic...

Page 122: ...t or floor jack Position jack stands under the frame rails just forward of each spring mount See WARNING Lift only one end in General Warnings on page 1 1 3 Disconnect the 16 pin connector at the speed controller 4 Place a jumper wire with an alligator clip between the B terminal of the speed controller use alligator clip for this connection and pin 7 orange white wire of the 16 pin connector Figu...

Page 123: ...olts DC insert the red probe of the multimeter into pin 8 brown wire of the 16 pin connector See following CAUTION Using an alligator clip connect the black probe to the B terminal of the speed controller Figure 11 13 Page 11 26 CAUTION Do not fully insert probes into the 16 pin plug Doing so can result in a poor connection 5 Place the Tow Run switch in the TOW position and connect the battery cab...

Page 124: ... See General Warnings on page 1 1 Pin 9 in the 16 pin connector provides a connection point for the Tow Run switch to the speed controller The switch provides a 48 volt signal to the speed controller through pin 9 when the Tow Run switch is in the RUN position 1 Disconnect the battery cables and discharge the controller as instructed See WARNINGS To avoid unintentionally starting and After disconn...

Page 125: ...ch on page 11 17 TEST PROCEDURE 16 Pin 10 See General Warnings on page 1 1 Pin 10 in the 16 pin connector provides a connection point for the key switch to the speed controller The key switch provides a 48 volt signal to the speed controller through pin 10 when the key switch is in the ON position 1 Disconnect the battery cables and discharge the controller as instructed See WARNINGS To avoid unin...

Page 126: ...edure 6 Tow Run Switch on page 11 17 Key switch for proper operation See Test Procedure 8 Key Switch and Throttle Position Sensor Limit Switch Circuit on page 11 20 TEST PROCEDURE 17 Pin 12 See General Warnings on page 1 1 Pin 12 in the 16 pin connector provides a connection point for the solenoid coil to the speed controller The speed controller activates the solenoid coil by providing a ground t...

Page 127: ...ntrolled Rectifier SCR Circuit See General Warnings on page 1 1 The silicon controlled rectifier SCR located inside the onboard computer acts as a switch on the negative side of the circuit This allows the onboard computer OBC to control the battery charging current Use the following procedure to test the SCR 1 With batteries connected and using a multimeter set to 200 volts DC place the red probe...

Page 128: ...e s charger receptacle The voltage reading should drop to approximately 4 0 volts before the charger relay clicks on 3 When the charger relay is activated the reading should rise to approximately 48 volts 4 If voltage does not drop to approximately 4 0 volts when the DC cord is plugged in and then rise to approximately 48 volts when the charger relay clicks on the gray wire circuit in the OBC has ...

Page 129: ...y of the black white wire from the 16 pin connector at the speed controller to the three pin connector at the motor speed sensor If the continuity is correct replace the speed controller 4 Check voltage at the red wire 4 1 With Tow Run switch in the RUN position and using a multimeter set to 20 volts DC place the black probe on the battery no 4 4 x 12 Volt battery set or battery no 6 6 x 8 Volt ba...

Page 130: ...s instructed See WARNINGS To avoid unintentionally starting and After disconnecting the batteries wait 90 seconds in General Warnings on page 1 1 3 Disconnect the three wires that are crimped together from the forward large post of the solenoid 4 Using a multimeter set to 200k ohms place the black probe on one solenoid large post and place the red probe on the other large post The reading should b...

Page 131: ...ltimeter set to 200 ohms place the black probe on the brown wire terminal 3 position on the rocker switch and place the red probe on the orange wire terminal 2 position With the switch in NEUTRAL or REVERSE there should be no continuity With the switch in FORWARD there should be continuity If the readings are incorrect replace the switch 5 Place the black probe on the blue wire terminal 1 position...

Page 132: ... in order to reboot the OBC 2 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 3 Place Tow Run switch in the RUN position 4 Test drive the vehicle If the vehicle functions normally the problem is corrected If ...

Page 133: ...8 volts indicates that the batteries need to be charged If a reading of less than 48 volts is obtained immediately after a charge cycle there may be a problem in the charge circuit F2 Energy units removed since last charge cycle If the display reads over 75 the vehicle battery warning light should be illuminated the vehicle batteries need to be recharged before being used again This data can be us...

Page 134: ...a value appears If there is still no reading check for weak batteries in the CDM 4 1 Adjust aim of CDM 4 2 Drive vehicle a short distance to ensure OBC is not in powerdown mode 4 3 Check for weak batteries in CDM 4 4 If reading is still not obtained go to the CDM Troubleshooting Guide on page 11 37 Once a value has been obtained in the display window the CDM may be removed from its receiving posit...

Page 135: ...ace OBC Remove battery lead and discharge the speed controller See the instructions in the WARNING on page 11 1 After a short time replace the lead and restart the OBC OBC program is locked up Restart OBC by driving vehicle or by connecting charger DC plug OBC is in a powerdown mode Batteries discharged Recharge Batteries OBC Will Not Communicate With The CDM Failed Dash Light Replace Dash Light F...

Page 136: ......

Page 137: ...unction Walk Away Braking and Motor Braking adjustable with the IQDM P handset Walk Away Braking This prevents the vehicle from rolling away uncontrolled should the driver park on a slope and leave the vehicle without locking the park brake The vehicle will roll at about 1 mph 1 6 km h If the walk away braking function remains engaged for two seconds or more a warning buzzer will sound to alert th...

Page 138: ...W32 18_ORG SW_7 W35 18_GR N W36 18_GRN W37 18_BRN_ WHT SW_8 W38 18_BRN_WHT W39 18_B RN_WH T 15A W43 10_BLK INTERF ACESTO CONNECT OR FORCONTROLS INTERF ACES TO SMARTBOX INTERF ACESTO OBC PIGTAILTO B B CONNE CT ION FOR LI GHT S W49 18_BL U W50 18_GRN AMP 9 PIN CONNECTOR 1 2 3 4 5 6 7 8 9 W54 16_PINK W66 18_L T_BL U W77 16_RED_WHT W77 16_RED_WHT W90 16_L T_GRN W102 16_BL U A B W103 18_WHT W111 18_YEL...

Page 139: ... W30 16_PINK W34 18_GRN W38 18_BRN_WHT INTERF ACES TO SOLENOID 4 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 S2 M B S1 B RX GND TX 15V 5V THROTTLEINPUT GND NO CONNEC TI ON CHARGERINTERL OCK ACCELPEDALINPUT RE VERS E B UZZER G ND FORWARD B AUX KEYSWIT CH NO CONNEC TI ON SOL COILGND LINBUS SPEEDSENSORINPUT SPEEDSENSOR RE VERS E HAL F BRIDGE DC MOTOR C ONTROLLE...

Page 140: ...16 WHITE 16 BLUE WHITE 16 RED 16 GREE N 16 ORANGE 16 BLACK A L T E R N A T I V E USED WHEN THERE ARE TURN SIGNALS NORMALLY OPEN MOMENTARY PUSH BU TTON FOR HORN TURN SIGNAL SWITCH FLASHER UNIT 16 GRAY 16 WHITE 16 GRAY 16 BROWN 16 RED 16 GREEN 16 BLUE 16 BLACK 16 B ROWN 16 YELLOW 16 BROWN WHITE 16 YELLOW 16 WHITE 16 BLUE WHITE 16 ORANGE WD1025104E5 L Figure 12 3 Precedent Electric Vehicle Accessory ...

Page 141: ... 16 YELLOW 16 WHITE 16 BLUE WHITE 16 RED 16 GREE N 16 ORANGE 16 BLACK 12 B LACK 12 RE D 16 PU RPLE 16 YE LLOW WHITE 18 BLU E WHITE DIODE BRAKE LIGHT RELAY SONIC WELD DC DC CONVERTER NOTE SOME WIRING COMPONENTS SHOWN ARE OPTIONALACCESSORIES SONIC WELD SONIC WELD LIGHT SWITCH SONIC WELD 18 O RANGE 16 ORAN GE 18 BROWN 18 BLUE WHITE 18 BLUE WHT 18 ORANGE SONIC WELD SONIC WELD 14 B LK 16 BLUE 16 GREE N...

Page 142: ...GE 18 PINK WARNING LIGHT REVERS E BUZZER PRO GRAMMER PLUG SONIC WELD OPTIONALBATTERY INDICATOR KEYSWITCH NOTE SOME WIRING COMPONENTS SHOWN ARE OPTIONALACCESSORIES 1 6 B L U E 18 BROWN WHITE 9 PINCONNECTOR CONNECTS TO MAINHARNESS SEE FIGURES 11 1 AND 11 2 WD1025104E6 Figure 12 5 Precedent Electric Vehicle Instrument Panel Wiring Diagram Page 12 6 2009 Electric Precedent Maintenance and Service Manu...

Page 143: ... vehicle movement while the charger is plugged into the vehicle charger receptacle 6 stores operating data which can be read by the Communication Display Module CDM See Communication Display Module CDM on page 12 35 TROUBLESHOOTING The following troubleshooting guides will be helpful in identifying operating difficulties should they occur The guides include the symptom probable cause s and suggest...

Page 144: ...enu SPEED PULSES menu item indicates that speed pulses are OFF when the vehicle is in motion or Diagnostic Menu SPEED SENSOR fault code Failed motor speed sensor Test Procedure 21 Motor Speed Sensor on page 12 31 Loose or disconnected six pin connector at the throttle position sensor or broken wire Repair and or connect the six pin connector to the throttle position sensor Loose or disconnected 16...

Page 145: ...isconnected six pin connector at the throttle position sensor or broken wire Repair and or connect the six pin connector to the throttle position sensor Loose or disconnected 16 pin connector at speed controller or broken wire Repair and or connect the 16 pin connector to the speed controller Diagnostic Menu THROTTLE FAULT fault code Failed throttle position sensor Test Procedure 4 Throttle Positi...

Page 146: ...that control field current Replace the speed controller See Speed Controller Removal on page 15 12 Diagnostic Menu HPD high pedal detect fault code Operator error Train operators to fully remove foot from accelerator pedal before turning key switch to the ON position or changing the selected direction with the Forward Reverse switch Batteries require charging Place batteries on battery charger and...

Page 147: ...o Test Procedure 4 Throttle Position Sensor Voltage on page 12 16 Forward Reverse rocker switch Test Procedure 23 Forward Reverse Rocker Switch on page 12 32 Solenoid loose wires Test Procedure 3 Solenoid Activating Coil on page 12 15 Solenoid failed coil Test Procedure 3 Solenoid Activating Coil on page 12 15 Speed controller thermal cutback Allow controller to cool and ensure that vehicle is not...

Page 148: ...s Vehicle runs slowly Tires under inflated or flat tires Section 8 Wheels and Tires Wiring improperly wired Check vehicle wiring See Wiring Diagrams on page 12 2 Vehicle operates but motor braking function does not Speed sensor disconnected or failed Test Procedure 21 Motor Speed Sensor on page 12 31 Forward Reverse rocker switch improperly wired Test Procedure 23 Forward Reverse Rocker Switch on ...

Page 149: ...ing or installing plate Remove plate from vehicle completely After test procedures are completed be sure to replace the cover See Electronics Module Cover on page 15 5 See following CAUTION CAUTION Exposure to water may damage electronic components Do not operate vehicle without the cover properly installed Do not direct a water stream in area of the cover Index of Test Procedures 1 Batteries Volt...

Page 150: ...6 Batteries for further details on battery testing Batteries Voltage Check without the IQDM Handset 1 With batteries connected and using a multimeter set to 200 volts DC place red probe on the positive post of battery no 1 and the black probe on the negative post of battery no 4 Figure 12 6 Page 12 14 or battery no 6 Figure 12 7 Page 12 14 2 The multimeter should indicate at least 48 volts with th...

Page 151: ... not operate 5 1 Using a multimeter set to 200 volts DC place black probe on battery number 4 and place red probe with insulation piercing probe on light blue 18 gauge wire at OBC six pin connector 5 2 With Tow Run switch in the RUN position the voltage reading should be approximately 48 volts 6 If the dash light does not illuminate and the vehicle does not operate check the OBC activation circuit...

Page 152: ...s the accelerator pedal As the pedal is pressed the IQDM should indicate a rise from 0 pedal not pressed to 100 pedal fully pressed 5 If the throttle position sensor does not operate as described in previous step proceed to Throttle Position Sensor Voltage Test without the IQDM Handset Throttle Position Sensor Voltage Test without the IQDM Handset 1 Place chocks at the front wheels and lift the re...

Page 153: ...he front wheels and lift the rear of the vehicle with a chain hoist or floor jack Position jack stands under the frame rails just forward of each spring mount See WARNING Lift only one end in General Warnings on page 1 1 See also following WARNING WARNING Keep people and equipment clear from rotating rear wheels Do not allow persons under the car Contact with rotating rear wheels could result in s...

Page 154: ...timeter set on 200 volts DC connect the black probe to the negative post of battery no 4 4 x 12 Volt battery set or battery no 6 6 x 8 Volt battery set and connect red probe with insulation piercing probe on the pink wire close to the connector on the Tow Run switch WARNING The key switch should be placed in the OFF position and left in the OFF position for the duration of this test 3 With the Tow...

Page 155: ...load 5 A reading of 32 46 volts indicates discharged or failed batteries Each battery should be checked with a multimeter while under load 6 A reading of 32 volts or less will not activate discharge machine If the voltage of the batteries is below 32 volts the batteries are deeply discharged or have failed 7 Recording the battery pack voltage reading while under load provides a more accurate diagn...

Page 156: ...y switch position 5 3 With the key switch in the ON position press the accelerator pedal The IQDM should indicate that FOOT INPUT is ON when the accelerator pedal is pressed 6 If any reading is obtained that is not described in steps 4 and 5 perform the following steps 6 1 Check the wiring of the key switch and throttle position sensor See Wiring Diagrams on page 12 2 6 2 Check the continuity of t...

Page 157: ...ck probe on battery no 4 4 x 12 Volt battery set or battery no 6 6 x 8 Volt battery set negative post and the place red probe with insulation piercing probe on the blue wire where it connects to the throttle position sensor With the key switch ON the reading should be approximately 48 volts full battery voltage 5 4 2 If the reading is zero volts check the continuity of the blue wire that goes from...

Page 158: ...signal from FNR Test Procedure 14 Pins 8 and 16 on page 12 25 Pin 9 Gray 18 gauge To Tow switch sonic weld Test Procedure 15 Pin 9 on page 12 26 Pin 10 Tan 18 gauge To key switch sonic weld Test Procedure 16 Pin 10 on page 12 27 Pin 11 Open no wire Pin 12 Blue White 18 gauge Solenoid coil ground Test Procedure 17 Pin 12 on page 12 28 Pin 13 Black White 18 gauge Negative side of motor speed sensor ...

Page 159: ...BC powered up and battery charger disconnected 686 Figure 12 11 Pin 5 Test 5 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m 6 Place the Tow Run switch in the RUN position 7 The multimeter should indicate zero volts DC at this time 8 While monitoring the multimeter plug the battery charger into the veh...

Page 160: ...oor jack Position jack stands under the frame rails just forward of each spring mount See WARNING Lift only one end in General Warnings on page 1 1 3 Disconnect the 16 pin connector at the speed controller 4 Place a jumper wire with an alligator clip between the B terminal of the speed controller use alligator clip for this connection and pin 7 orange white wire of the 16 pin connector Figure 12 1...

Page 161: ... volts DC insert the red probe of the multimeter into pin 8 brown wire of the 16 pin connector See following CAUTION Using an alligator clip connect the black probe to the B terminal of the speed controller Figure 12 13 Page 12 26 CAUTION Do not fully insert probes into the 16 pin plug Doing so can result in a poor connection 5 Place the Tow Run switch in the TOW position and connect the battery c...

Page 162: ... 9 See General Warnings on page 1 1 Pin 9 in the 16 pin connector provides a connection point for the Tow Run switch to the speed controller The switch provides a 48 volt signal to the speed controller through pin 9 when the Tow Run switch is in the RUN position 1 Disconnect the battery cables and discharge the controller as instructed See WARNINGS To avoid unintentionally starting and After disco...

Page 163: ...tch on page 12 17 TEST PROCEDURE 16 Pin 10 See General Warnings on page 1 1 Pin 10 in the 16 pin connector provides a connection point for the key switch to the speed controller The key switch provides a 48 volt signal to the speed controller through pin 10 when the key switch is in the ON position 1 Disconnect the battery cables and discharge the controller as instructed See WARNINGS To avoid uni...

Page 164: ...ocedure 6 Tow Run Switch on page 12 17 Key switch for proper operation See Test Procedure 8 Key Switch and Throttle Position Sensor Limit Switch Circuit on page 12 20 TEST PROCEDURE 17 Pin 12 See General Warnings on page 1 1 Pin 12 in the 16 pin connector provides a connection point for the solenoid coil to the speed controller The speed controller activates the solenoid coil by providing a ground...

Page 165: ...ontrolled Rectifier SCR Circuit See General Warnings on page 1 1 The silicon controlled rectifier SCR located inside the onboard computer acts as a switch on the negative side of the circuit This allows the onboard computer OBC to control the battery charging current Use the following procedure to test the SCR 1 With batteries connected and using a multimeter set to 200 volts DC place the red prob...

Page 166: ...le s charger receptacle The voltage reading should drop to approximately 4 0 volts before the charger relay clicks on 3 When the charger relay is activated the reading should rise to approximately 48 volts 4 If voltage does not drop to approximately 4 0 volts when the DC cord is plugged in and then rise to approximately 48 volts when the charger relay clicks on the gray wire circuit in the OBC has...

Page 167: ...tinuity of the purple white wire from the 16 pin connector at the speed controller to the three pin connector at the motor speed sensor If the continuity is correct replace the speed controller 4 Check voltage at red wire 4 1 With Tow Run switch in the RUN position and using a multimeter set to 20 volts DC place the black probe on the battery no 4 4 x 12 Volt battery set or battery no 6 6 x 8 Volt...

Page 168: ...as instructed See WARNINGS To avoid unintentionally starting and After disconnecting the batteries wait 90 seconds in General Warnings on page 1 1 3 Disconnect the three wires that are crimped together from the forward large post of the solenoid 4 Using a multimeter set to 200k ohms place the black probe on one solenoid large post and place the red probe on the other large post The reading should ...

Page 169: ...meter set to 200 ohms place the black probe on the brown wire terminal 3 position on the rocker switch and place the red probe on the orange wire terminal 2 position With the switch in NEUTRAL or REVERSE there should be no continuity With the switch in FORWARD there should be continuity If the readings are incorrect replace the switch 5 Place the black probe on the blue wire terminal 1 position on...

Page 170: ... discharged in order to reboot the OBC 2 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 3 Place Tow Run switch in the RUN position 4 Test drive the vehicle If the vehicle functions normally the problem is co...

Page 171: ...This displays the battery pack s current state of charge A reading of less than 48 volts indicates that the batteries need to be charged If a reading of less than 48 volts is obtained immediately after a charge cycle there may be a problem in the charge circuit F2 Energy units removed since last charge cycle If the display reads over 75 the vehicle battery warning light should be illuminated the v...

Page 172: ...lay window after 30 seconds try adjusting the aim of the CDM and repeating step 3 until a value appears If there is still no reading check for weak batteries in the CDM 4 1 Adjust aim of CDM 4 2 Drive vehicle a short distance to ensure OBC is not in powerdown mode 4 3 Check for weak batteries in CDM 4 4 If reading is still not obtained go to the CDM Troubleshooting Guide on page 12 37 Once a value...

Page 173: ...d OBC Replace OBC Remove battery lead and discharge the speed controller See the instructions in the WARNING on page 11 1 After a short time replace the lead and restart the OBC OBC program is locked up Restart OBC by driving vehicle or by connecting charger DC plug OBC is in a powerdown mode Batteries discharged Recharge Batteries OBC Will Not Communicate With The CDM Failed Dash Light Replace Da...

Page 174: ......

Page 175: ...urned OFF It has no ill effect on the operation of the vehicle and should not be interpreted as a fault that necessitates replacement of the vehicle s accelerator pedal assembly that contains the throttle position sensor There are circumstances where a legitimate Throttle Fault 1 fault code will register If the vehicle does have an issue with the throttle position sensor or it s wiring the fault c...

Page 176: ...llows the user to go back one screen 2 The CHANGE VALUE BUTTON 3 is the button located on the right side of the handset Figure 13 2 Page 13 3 This button allows the user to change values by pressing or The three yellow buttons labeled 1 2 and 3 are BOOKMARK BUTTONS 4 Figure 13 2 Page 13 3 These buttons allow the user to bookmark up to three specific screens for rapid return to those screens To boo...

Page 177: ...n the IQDM handset PROGRAM IQDM P ONLY The program menu allows the user to view and change custom speed controller settings See Program Menu on page 20 2 MONITOR The monitor menu displays values for certain parameters to facilitate speed controller troubleshooting See Monitor Menu on page 13 4 2009 Electric Precedent Maintenance and Service Manual Page 13 3 ...

Page 178: ...by using the up or down arrow to scroll to monitor and pressing the right arrow key to activate the menu All information in the monitor menu is updated in real time allowing the trained technician to troubleshoot the vehicle by monitoring the handset as the key switch is cycled Forward Reverse switch is activated etc Since the monitor menu is updated while the vehicle is in operation the trained t...

Page 179: ... at 100 FIELD PWM Displays motor field PWM pulse width modulation The range of pulse width modulation is 0 to 100 When the vehicle is in operation the pulse width modulation will fluctuate in response to the terrain and throttle input SPEED PULSES The speed pulses menu item displays the activity of the motor speed sensor With the key switch in the OFF position the Forward Reverse switch in the NEU...

Page 180: ...splays the position of the key switch OFF or ON PASSWORD TRIES IQDM P ONLY A password is required to place the vehicle in private speed mode speed setting 4 The speed controller will log unsuccessful and unauthorized attempts to place the speed controller in private speed mode If repeated attempts are unsuccessful the speed controller will permanently lock out access to private speed mode In the e...

Page 181: ... speed controller for display on the fault history menu Each detected fault is listed only once even if the fault has occurred multiple times Causes of Faults Some common causes of faults are Loose broken or disconnected wires or connectors Failed components Improper adjustment or installation of electrical or mechanical components examples brake adjustment improper throttle position sensor instal...

Page 182: ...t F Quickly reduce the armature current until speed sensor pulses occur G Reduce field current and beep reverse buzzer at a fast rate CONTROLLER FAULT CONTROLLER RESPONSE HW FAILSAFE A B C KEY SWITCH SRO C THROTTLE FAULT 1 A SPEED SENSOR D MAIN WELDED D MAIN DRIVER ON D MAIN DRIVER OFF A C HIGH SPEED WALKAWAY D MAIN COIL FAULT A FIELD MISSING A B C HPD A PROC WIRING A OVERVOLTAGE A B G LOW BATTERY...

Page 183: ...N COIL FAULT When accel pedal is cycled FIELD MISSING When accel pedal is cycled HPD When accel pedal is cycled PROC WIRING When condition clears OVERVOLTAGE When condition clears LOW BATTERY VOLTAGE When condition clears THERMAL CUTBACK When condition clears MOTOR STALL When condition clears MAIN DROPOUT When accel pedal is cycled OPEN ARMATURE When condition clears and accel pedal is cycled MAX ...

Page 184: ...tects that the solenoid contacts are welded closed a main welded fault is detected MAIN DRIVER ON If the FET that controls the closing of the solenoid contacts is found to be energized when it should not be a main driver on fault is detected by the speed controller MAIN DRIVER OFF If the FET that controls the closing of the solenoid is not energized when it should be a main driver off fault is det...

Page 185: ...ult can be caused by a failed Forward Reverse switch or improper vehicle wiring OVERVOLTAGE If the speed controller detects that the battery voltage is too high 68 4 to 75 6 volts DC the overvoltage fault is detected LOW BATTERY VOLTAGE If the battery voltage falls below 34 volts 5 the low battery voltage fault is detected by the speed controller THERMAL CUTBACK If the controller heatsink temperat...

Page 186: ...the fault history alone should not be the factor that determines when a component is replaced Some faults detected by the speed controller are not the result of a failed component and are instead the result of vehicle operator error If a fault appears in the fault history menu the trained technician should attempt to determine when and where the fault has occurred For example if the motor stall fa...

Page 187: ... handset into the vehicle 3 1 onnect one end of the cable to the port located on the bottom of the handset 3 2 Connect the cable adaptor to the IQDM cable 3 3 Remove the dust cap from the IQDM port 3 4 Align the keyed portion of the plug with the IQDM port and connect the plug to the port Figure 13 1 Page 13 2 4 Scroll to the functions menu and select 5 Select settings 6 Select get settings from c...

Page 188: ...t to the Vehicle 1 Perform this procedure with a handset that has the desired speed controller settings See Speed Controller Cloning Transferring Settings from the Vehicle to the Handset on page 13 13 2 Locate a vehicle that does not have the desired speed controller settings 3 Turn the key switch to the OFF position place the Forward Reverse handle in the NEUTRAL position and lock the park brake ...

Page 189: ...mation Message RESET ALL SETTINGS In the event that a mistake was made and one or more changes should not have been made with the handset the speed controller settings can be reverted to the original settings from the beginning of the session when the handset was plugged into the vehicle This function is similar to the undo command on a PC and will work correctly only when the handset has not been...

Page 190: ...mation menu is accessed by using the up or down arrow to scroll to information and pressing the right arrow key to activate the menu This menu selection displays information pertaining to the speed controller The information provided from this menu selection includes MODEL NUMBER Displays the model number of the speed controller SERIAL NUMBER Displays the serial number of the speed controller MFG ...

Page 191: ...ts detected in the speed controller The following faults can be detected within the handset CODE NUMBER TEXT DISPLAYED 14 Communication error with controller 15 Error in handset 16 Handset does not support this function 17 Serial port overrun error 18 Security lockout on program menu Fault History This menu displays any faults that have been detected within the handset itself Clear Fault History T...

Page 192: ...failed Test Procedure 3 IQDM Ports on page 13 20 Contrast Setting is too light See Program on page 13 17 Onboard computer is in power down mode Drive the vehicle for a short distance and reconnect the handset to the vehicle Onboard computer malfunction Section 11 IQ System Troubleshooting Loose vehicle wire harness connections Test Procedure 3 IQDM Ports on page 13 20 Speed controller malfunction ...

Page 193: ...secure wiring could result in vehicle malfunction property damage personal injury or death Index of Test Procedures 1 Handset Cord 2 Handset Cord Adaptor 3 IQDM Ports TEST PROCEDURE 1 Handset Cord See General Warnings on page 1 1 1 Using a multimeter set for 200 ohms place the red probe into one of the terminals on the end of the cord with the square plug 2 Place the black probe on each of the pin...

Page 194: ...at secure the instrument panel assembly 2 to the dash assembly 3 Figure 13 7 Page 13 20 3 1 2 4 5 700 Figure 13 7 Instrument Panel Assembly Removal and IQDM Port Connection 3 2 Disconnect the four pin connectors 4 and 5 and visually inspect the contacts for damage and corrosion Inspect the IQDM port mounted under the instrument panel assembly 2 Repair and replace parts as necessary 3 3 If no probl...

Page 195: ...e batteries positive cable first 4 3 5 If the handset functions when connected directly to the speed controller the adapter plug or vehicle wire harness should be thoroughly tested See Test Procedure 2 Handset Cord Adaptor on page 13 19 See Section 11 IQ System Troubleshooting 4 4 Replace electronics module cover See Electronics Module Cover Installation on page 15 5 4 3 2 701 Figure 13 8 IQDM Con...

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Page 197: ...ible with the Excel System See Figure 14 2 Page 14 1 PLUGGING THE HANDSET INTO THE VEHICLE 1 Connect one end of the cable to the port located on the bottom of the handset 2 Connect the cable adaptor to the IQDM cable 3 Find the IQDM port on the vehicle Figure 14 1 Page 14 1 4 Remove the dust cap from the IQDM port 5 Align the keyed portion of the plug with the IQDM port and connect the plug to the...

Page 198: ...desired menu is blinking pressing the right arrow selects that menu item Pressing the left arrow allows the user to go back one screen 2 The CHANGE VALUE BUTTON 3 is the button located on the right side of the handset Figure 14 3 Page 14 3 This button allows the user to change values by pressing or The three yellow buttons labeled 1 2 and 3 are BOOKMARK BUTTONS 4 Figure 14 3 Page 14 3 These button...

Page 199: ... on the IQDM handset PROGRAM IQDM P ONLY The program menu allows the user to view and change custom speed controller settings See Program Menu on page 21 2 MONITOR The monitor menu displays values for certain parameters to facilitate speed controller troubleshooting See Monitor Menu on page 14 4 2009 Electric Precedent Maintenance and Service Manual Page 14 3 ...

Page 200: ...ccessed by using the up or down arrow to scroll to monitor and pressing the right arrow key to activate the menu All information in the monitor menu is updated in real time allowing the trained technician to troubleshoot the vehicle by monitoring the handset as the key switch is cycled Forward Reverse switch is activated etc See following NOTE NOTE Values appearing in these menus represent approxi...

Page 201: ...ng NOTE NOTE Improper brake adjustment can sometimes cause the operating current to be higher than normal This higher current increases the temperature of the speed controller heatsink ARM CURRENT Displays the motor armature current in amperes FIELD CURRENT Displays the motor field current in amperes ARMATURE PWM Displays motor armature PWM pulse width modulation The range of pulse width modulatio...

Page 202: ...pedal is pressed and the key switch is in the ON position the display should indicate that the limit switch is on KEY INPUT Displays the position of the key switch OFF or ON FORWARD INPUT With the Forward Reverse switch in the NEUTRAL or REVERSE position the handset should indicate that the forward input is off When the Forward Reverse switch is placed in the FORWARD position the handset should in...

Page 203: ... event that private speed mode is locked out the controller must be removed and shipped to Club Car before it can ever be placed in private speed mode See Code A Code B and Code C on page 21 4 ODOMETER Displays approximate distance travelled in miles VEHICLE SPEEDS IQDM P ONLY Press right arrow to display programmed speeds for each speed setting See Code A Code B and Code C on page 21 4 PEDAL COUN...

Page 204: ...he speed controller for display on the fault history menu Each detected fault is listed only once even if the fault has occurred multiple times Causes of Faults Some common causes of faults are Loose broken or disconnected wires or connectors Failed components Improper adjustment or installation of electrical or mechanical components examples brake adjustment improper throttle position sensor inst...

Page 205: ...armature current until speed sensor pulses occur G Reduce field current and beep reverse buzzer at a fast rate CONTROLLER FAULT CONTROLLER RESPONSE HW FAILSAFE A B C THROTTLE FAULT A SPEED SENSOR D MAIN WELDED D MAIN DRIVER ON D MAIN DRIVER OFF A C MAIN COIL OPEN A FIELD MISSING A B C HPD A OVERVOLTAGE A B G LOW BATTERY E THERMAL CUTBACK E MOTOR STALL F MAIN DROPOUT 1 and 2 A C MAX PASSWORD TRIES ...

Page 206: ...l pedal is cycled MAIN COIL OPEN When accel pedal is cycled FIELD MISSING When accel pedal is cycled HPD When accel pedal is cycled OVERVOLTAGE When condition clears LOW BATTERY VOLTAGE When condition clears THERMAL CUTBACK When condition clears MOTOR STALL When condition clears MAIN DROPOUT 1 and 2 When accel pedal is cycled MAX PASSWORD TRIES When Tow Run switch is cycled INCORRECT PASSWORD When...

Page 207: ...IL OPEN If the speed controller determines that the solenoid is not closing as a result of a solenoid coil failure a main coil open fault is detected FIELD MISSING If the speed controller is operating at a duty cycle of greater than 90 almost full speed and the field current is less than 3 amps a field missing fault is detected by the speed controller HPD The HPD High Pedal Detect fault is detecte...

Page 208: ...es refer to Code A Code B and Code C See Code A Code B and Code C on page 21 4 See also Password Tries IQDM P Only on page 14 7 MAX PASSWORD TRIES IQDM P ONLY The max password tries fault is declared when the incorrect password fault has been declared several times In the event that the max password tries fault is indicated the speed controller must be removed and shipped to Club Car before it can...

Page 209: ... vehicle and transfer the stored settings into the speed controller Speed Controller Cloning Transferring Settings from the Vehicle to the Handset 1 Locate a vehicle that has the desired speed controller settings 2 Turn the key switch to the OFF position place the Forward Reverse handle in the NEUTRAL position and lock the park brake 3 Plug the handset into the vehicle 3 1 Connect one end of the c...

Page 210: ...et to the Vehicle 1 Perform this procedure with a handset that has the desired speed controller settings See Speed Controller Cloning Transferring Settings from the Vehicle to the Handset on page 14 13 2 Locate a vehicle that does not have the desired speed controller settings 3 Turn the key switch to the OFF position place the Forward Reverse handle in the NEUTRAL position and lock the park brake...

Page 211: ...irmation Message RESET ALL SETTINGS In the event that a mistake was made and one or more changes should not have been made with the handset the speed controller settings can be reverted to the original settings from the beginning of the session when the handset was plugged into the vehicle This function is similar to the undo command on a PC and will work correctly only when the handset has not be...

Page 212: ...ormation menu is accessed by using the up or down arrow to scroll to information and pressing the right arrow key to activate the menu This menu selection displays information pertaining to the speed controller The information provided from this menu selection includes MODEL NUMBER Displays the model number of the speed controller SERIAL NUMBER Displays the serial number of the speed controller MF...

Page 213: ...ults detected in the speed controller The following faults can be detected within the handset CODE NUMBER TEXT DISPLAYED 14 Communication error with controller 15 Error in handset 16 Handset does not support this function 17 Serial port overrun error 18 Security lockout on program menu Fault History This menu displays any faults that have been detected within the handset itself Clear Fault History...

Page 214: ...led Test Procedure 3 IQDM Ports on page 14 20 Contrast Setting is too light See Program on page 14 17 Onboard computer is in power down mode Drive the vehicle for a short distance and reconnect the handset to the vehicle Onboard computer malfunction Section 12 Excel System Troubleshooting Loose vehicle wire harness connections Test Procedure 3 IQDM Ports on page 14 20 Speed controller malfunction ...

Page 215: ...and secure wiring could result in vehicle malfunction property damage personal injury or death Index of Test Procedures 1 Handset Cord 2 Handset Cord Adaptor 3 IQDM Ports TEST PROCEDURE 1 Handset Cord See General Warnings on page 1 1 1 Using a multimeter set for 200 ohms place the red probe into one of the terminals on the end of the cord with the square plug 2 Place the black probe on each of the...

Page 216: ...that secure the instrument panel assembly 2 to the dash assembly 3 Figure 14 8 Page 14 20 3 1 2 4 5 700 Figure 14 8 Instrument Panel Assembly Removal and IQDM Port Connection 3 2 Disconnect the four pin connectors 4 and 5 and visually inspect the contacts for damage and corrosion Inspect the IQDM port mounted under the instrument panel assembly 2 Repair and replace parts as necessary 3 3 If no pro...

Page 217: ...vehicle batteries positive cable first 4 3 5 If the handset functions when connected directly to the speed controller the adapter plug or vehicle wire harness should be thoroughly tested See Test Procedure 2 Handset Cord Adaptor on page 14 19 See Section 12 Excel System Troubleshooting 4 4 Replace electronics module cover See Electronics Module Cover on page 15 5 4 3 2 701 Figure 14 9 IQDM Connect...

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Page 219: ...es from the key switch 4 From the back of the instrument panel push down on the retaining tabs surrounding the key switch 4 and remove the key switch cap 8 Hold the key switch and remove the switch retaining nut 6 from the outside of the instrument panel Figure 15 2 Page 15 2 KEY SWITCH INSTALLATION 1 Position the key switch and flat washer 9 in the instrument panel then install and tighten the sw...

Page 220: ...y Switch BATTERY WARNING LIGHT See General Warnings on page 1 1 TESTING THE BATTERY WARNING LIGHT See Test Procedure 26 Battery Warning Light on page 11 34 or 12 34 BATTERY WARNING LIGHT REMOVAL 1 Disconnect the battery cables and discharge the controller as instructed See WARNINGS To avoid unintentionally starting and After disconnecting the batteries wait 90 seconds in General Warnings on page 1...

Page 221: ...1 TESTING THE FORWARD REVERSE ROCKER SWITCH See Test Procedure 23 Forward Reverse Rocker Switch on page 11 32 or 12 32 FORWARD REVERSE ROCKER SWITCH REMOVAL 1 Disconnect the battery cables and discharge the controller as instructed See WARNINGS To avoid unintentionally starting and After disconnecting the batteries wait 90 seconds in General Warnings on page 1 1 2 Remove two screws 2 that hold For...

Page 222: ...nnect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 5 Place the Tow Run switch in the RUN position 6 Inspect the vehicle for proper operation WARNING Make sure that the vehicle operates in the forward direction when the Forward Reverse switch is in the FORWARD po...

Page 223: ...to release the four tabs 3 from the matching holes in the hood of the battery bucket ELECTRONICS MODULE COVER INSTALLATION 1 Install cover 5 by first hooking the four tabs 3 into the matching holes in the hood of the battery bucket Figure 15 5 Page 15 6 Then use the two hooks 4 to secure the cover to the battery bucket 2 Place access panel 2 on vehicle and secure with the two plastic rivets 1 See ...

Page 224: ... page 1 1 2 Remove the bolt 11 that secures the electronics module to the battery bucket Figure 15 8 Page 15 11 3 Pull electronics module forward and disconnect the pink wire 3 and light green wire 4 from switch 4 Remove Tow Run switch boot hex nut 1 Figure 15 6 Page 15 7 5 Remove Tow Run switch 2 from electronics module TOW RUN SWITCH INSTALLATION 1 Installation is reverse of removal Make sure fl...

Page 225: ...neral Warnings on page 1 1 TESTING THE THROTTLE POSITION SENSOR See Test Procedure 4 Throttle Position Sensor Voltage on page 11 16 and Test Procedure 8 Key Switch and Throttle Position Sensor Limit Switch Circuit on page 11 20 See Test Procedure 4 Throttle Position Sensor Voltage on page 12 16 and Test Procedure 8 Key Switch and Throttle Position Sensor Limit Switch Circuit on page 12 20 THROTTLE...

Page 226: ...white wires from reverse buzzer 4 Remove the two screws from the reverse buzzer Remove the reverse buzzer from the dash panel REVERSE BUZZER INSTALLATION 1 Install the reverse buzzer in the reverse order of removal Pink wire must be connected to the positive terminal Tighten screws to 4 in lb 0 45 N m 2 Place the Tow Run switch in the TOW position and connect the battery cables positive cable firs...

Page 227: ...troller from the vehicle 7 Remove two nuts 3 on top of the solenoid 5 posts and remove the wires from the posts 8 Disconnect the spade connectors on the front of the solenoid 9 Disconnect the 6 pin connector and all other leads from the onboard computer OBC 15 and the two wires from Tow Run switch 10 Lift the electronics module from the vehicle See following WARNING WARNING Shorting of battery ter...

Page 228: ...cle for proper operation See following WARNINGS WARNING Make sure that the vehicle operates in the forward direction when the Forward Reverse switch is in the FORWARD position Make sure that the vehicle operates in the reverse direction when the Forward Reverse switch is in the REVERSE position The reverse buzzer will sound as a warning when the Forward Reverse switch is in REVERSE Make sure that ...

Page 229: ...ELECTRICAL COMPONENTS Electronics Module 15 11 8 13 1 5 9 12 15 14 3 4 10 713 Figure 15 8 Electronics Module Removal 2009 Electric Precedent Maintenance and Service Manual Page 15 11 ...

Page 230: ...ONTROLLER INSTALLATION 1 Locate the controller 8 on the component mounting plate 14 and secure with three self tapping screws 10 Tighten screws to 5 5 ft lb 7 5 N m Figure 15 8 Page 15 11 2 Connect the 16 pin connector 4 pin connector and spade connectors to the controller 3 Connect the the heavy gauge wires to the controller per the electrical schematics See Wiring Diagrams on page 12 2 Tighten s...

Page 231: ...gure 15 8 Page 15 11 See Battery Replacement on page 16 15 3 Remove the bolt 11 that secures the electronics module to the battery bucket 4 Pull electronics module forward and remove the four wires from solenoid 5 Slide solenoid up to disengage the mounting tabs and remove from component mounting plate 14 SOLENOID INSTALLATION 1 Mount solenoid 5 onto component mounting plate 14 Figure 15 8 Page 15...

Page 232: ... on the controller 6 Loosen but do not remove the two self tapping screws 12 holding OBC to component mounting plate 14 7 Slide OBC upwards to align heads of self tapping screws 12 with the two key holes in the OBC face plate and remove OBC ONBOARD COMPUTER INSTALLATION 1 Install the OBC onto the component mounting plate by engaging the two key holes on the OBC face plate with the self tapping scr...

Page 233: ...oltage at Charger Receptacle Red Wire Socket on page 11 30 or 12 30 See also the appropriate battery charger maintenance and service manual CHARGER RECEPTACLE INSPECTION Inspect the receptacle for cracks loose connections and frayed wiring NOTE Disassembly of the charger receptacle for the purpose of removal or installation is not recommended 1 2 A Gray to OBC B Black to Connector C Red to Battery...

Page 234: ...ttery Terminal Protector Spray CCI P N 1014305 to minimize corrosion HEADLIGHT ADJUSTMENT Headlights are available as an accessory on this vehicle To raise or lower the headlight beam washers can be added to the mounting hardware between the headlight and the bumper assembly See General Warnings on page 1 1 AIMING THE HEADLIGHT BEAM 1 Park the vehicle on a level surface 5 feet away from and facing...

Page 235: ...ELECTRICAL COMPONENTS Headlight Adjustment 15 1 3 2 715 Figure 15 10 Headlight Aiming 2009 Electric Precedent Maintenance and Service Manual Page 15 17 ...

Page 236: ...res 10 Ga Orange and 10 Ga Blue near the motor just before the wires split to terminals F1 and F2 4 This bead goes around the motor speed sensor harness black conduit just before the three pin connector at the motor 5 This wire tie goes around the motor speed sensor harness black conduit and 2 wires 6 Ga White and 6 Ga Green between the bead item 4 and three pin connector 6 This wire tie goes arou...

Page 237: ...ections Use extreme caution to avoid shorting of components or wiring WARNING Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubber gloves when working on or near batteries Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Ensure battery co...

Page 238: ...eeTroubleshooting Guide If problem is not found go to on charge voltage test Any reading below 9 3 volts and not within 0 7 volts of those batteries above 9 3 volts replace battery Replace any battery with a variation of more than 50 points of specific gravity between cells or has a cell with no reading at all Entire battery set with specific gravity readings below 1 250 is being consistently unde...

Page 239: ...ividual batteries Set the multimeter to 200 volts DC Place the red probe on the positive post of battery no 1 and the black probe on the negative post of battery no 4 Figure 16 6 Page 16 16 Record reading Then set multimeter to 20 volts DC and place the red probe on the positive post and the black probe at the negative post of each battery Record the readings The on charge voltage for the set shou...

Page 240: ...hydrometer from the cell and release the pressure from the bulb 5 Hold the hydrometer vertically ensuring that the float is not touching the sides of the barrel Hold the hydrometer at eye level and read the scale at the level of electrolyte Figure 16 2 Page 16 4 6 Record the reading and return the electrolyte to the cell from which it was taken Replace vent cap 7 Repeat steps 2 through 6 on all ce...

Page 241: ... NO ELEC TROLYTE TEMPER ATURE CORREC TION FACTOR CELL 1 CELL 2 CELL 3 CELL 4 CELL 5 CELL 6 REQUIRED ACTION 12 1 20 F 6 6 C 0 024 1 275 0 024 1 251 1 280 0 024 1 256 1 280 0 024 1 256 1 275 0 024 1 251 1 280 0 024 1 256 1 280 0 024 1 256 Sound Battery Fully Charged 54 3 50 F 10 C 0 012 1 260 0 012 1 248 1 200 0 012 1 188 1 270 0 012 1 258 1 265 0 012 1 253 1 270 0 012 1 258 1 260 0 012 1 248 Bad no...

Page 242: ...of the battery packs Check cell no 2 second cell from positive post in each battery 4 Reset discharge machine and turn the tester ON 5 When the batteries have been discharging for approximately 60 minutes set the discharge machine to function 3 and check battery set voltage Check voltage every 10 minutes throughout the rest of the test As soon as the battery set voltage reaches 0 5 volts above the...

Page 243: ...typically not hold a charge for an entire work shift However discharge time is dependent on the electrolyte temperature The table shown gives the discharge times at various temperatures of a set of batteries that delivers 62 minutes at 80 F 26 7 C ELECTROLYTE TEMPERATURE DISCHARGE TIME TO SHUT OFF POINT ELECTROLYTE TEMPERATURE DISCHARGE TIME TO SHUT OFF POINT 40 49 F 4 9 C 40 Minutes 85 89 F 29 32...

Page 244: ... that battery no 1 is the problem Next the discharge test was performed Discharge test results BATTERY NO 1 2 3 4 Discharge Voltage 8 16 V 10 99 V 11 60 V 10 72 V After a discharge test which lasted 45 minutes battery no 1 is clearly shown to be the problem Battery no 4 should be watched a little more closely but appears to be okay Battery no 1 should be replaced with a battery that has about the ...

Page 245: ...l as the individual batteries Set the multimeter to 200 volts DC Place the red probe on the positive post of battery no 1 and the black probe on the negative post of battery no 6 Record reading Then set multimeter to 20 volts DC and place the red probe on the positive post and the black probe at the negative post of each battery Record the readings The on charge voltage for the set should be betwe...

Page 246: ...ydrometer from the cell and release the pressure from the bulb 5 Hold the hydrometer vertically ensuring that the float is not touching the sides of the barrel Hold the hydrometer at eye level and read the scale at the level of electrolyte Figure 16 4 Page 16 10 6 Record the reading and return the electrolyte to the cell from which it was taken Replace vent cap 7 Repeat steps 2 through 6 on all ce...

Page 247: ...O BATTERY NO ELECTROLYTE TEMPERATURE CORRECTION FACTOR CELL 1 CELL 2 CELL 3 REQUIRED ACTION 12 1 20 F 6 6 C 0 024 1 275 0 024 1 251 1 280 0 024 1 256 1 280 0 024 1 256 Sound Battery Fully Charged 35 6 90 F 32 2 C 0 004 1 155 0 004 1 159 1 165 0 004 1 169 1 160 0 004 1 164 Discharged Battery Recharge 54 3 50 F 10 C 0 012 1 260 0 012 1 248 1 200 0 012 1 188 1 270 0 012 1 258 Bad no 2 Cell 69 5 80 F ...

Page 248: ...trolyte temperature of the battery packs Check cell no 2 second cell from positive post in each battery 4 Reset discharge machine and turn the tester ON 5 When the batteries have been discharging for approximately 60 minutes set the discharge machine to function 3 and check battery set voltage Check voltage every 10 minutes throughout the rest of the test As soon as the battery set voltage reaches...

Page 249: ...charge test will typically not hold a charge for an entire work shift However discharge time is dependent on the electrolyte temperature The table shown gives the discharge times at various temperatures of a set of batteries that delivers 62 minutes at 80 F 26 7 C ELECTROLYTE TEMPERATURE DISCHARGE TIME TO SHUT OFF POINT ELECTROLYTE TEMPERATURE DISCHARGE TIME TO SHUT OFF POINT 40 49 F 4 9 C 40 Minu...

Page 250: ... no 1 is the problem Next the discharge test was performed Discharge test results BATTERY NO 1 2 3 4 5 6 Discharge Voltage 5 44 V 7 33 V 7 73 V 7 15 V 7 43 V 7 41 V After a discharge test which lasted 45 minutes battery no 1 is clearly shown to be the problem Battery no 4 should be watched a little more closely but appears to be okay Battery no 1 should be replaced with a battery that has about th...

Page 251: ...ur of operation between charges for the first two months vehicle is in service Batteries should be fully charged before first use of new vehicle before first use of a vehicle after storage and before use each day 3 If the battery cables are to be reused inspect them for broken or frayed wires damaged terminals or worn insulation Remove any corrosion on the connectors A solution of baking soda and ...

Page 252: ... Spray CCI P N 1014305 See following NOTE NOTE Dispose of waste water properly 2 The battery hold downs should be tight enough so that the batteries do not move while the vehicle is in motion but not so tight as to crack or buckle the battery case Tighten hold down retaining nuts to the proper torque See step 5 of Battery Replacement on page 16 15 The terminal connections should be clean and tight...

Page 253: ...after long term storage or any other period of vehicle inactivity See preceding CAUTION BATTERY CARE VEHICLES WITHOUT THE SINGLE POINT WATERING SYSTEM To keep batteries in good working condition follow this maintenance program on a regular basis 1 Keep the batteries clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water 1 cup 237 mL baking soda pe...

Page 254: ...om battery caps or hydrometer to drip onto the front or rear body of the vehicle Battery acid will cause permanent damage Wash immediately 1 3 2 1 Level Indicator 2 Cap 3 Plates Electrolyte level at least 1 2 inch 13 MM above plates or to level indicator 17 Figure 16 8 Battery Electrolyte Level Add water only after charging unless the electrolyte is below the level of the plates If the electrolyte...

Page 255: ...the battery It may also cause acid to leak out of the vent caps and corrosion to build up on surrounding metal parts The acid which is lost reduces the capacity of the battery and cannot be replaced Battery hold downs should NOT be so tight as to crack or buckle the battery case This may cause leaks which would dry out a cell or cause internal short circuits See Battery Replacement on page 16 15 B...

Page 256: ...ed wires or are damaged in any way Using the charger with any of the above symptoms could result in a fire property damage personal injury or death NOTE When temperatures fall below 18 3 C 65 F batteries charged in unheated areas should be placed on charge as soon as possible after use Batteries are warmest immediately after use and cold batteries require more time to fully charge Insert the charg...

Page 257: ...D 40 brand spray lubricant The plug should then be inserted and removed several times to ensure ease of insertion ease of removal and good electrical contact See following NOTE NOTE If the warning tag has been damaged or removed from the DC cord have it replaced immediately CHARGER SHUTS OFF AFTER 16 HOURS This may be due to 1 new batteries 2 hard use or 3 cold temperatures A catch up charge may b...

Page 258: ...T ROTATION Rotate vehicle usage It is very hard on batteries if the last vehicles in at night are the first ones out in the morning Spread the workload evenly giving all vehicles the same amount of use This will keep your fleet in balance and will not overwork certain sets of batteries See following NOTE NOTE When vehicles are being rotated the CDM Communication Display Module can be a very helpfu...

Page 259: ...irements as stated in the vehicle s appropriate maintenance and service manual See Mineral Content on page 16 19 WATERING BATTERIES WITH THE SPWS Checking the Water Flow Rate 1 Connect the water hose with the built in screen filter 2 to the water faucet 1 Figure 16 11 Page 16 23 See following CAUTION CAUTION Make sure the screen filter is clean Do not use a longer garden hose than provided with th...

Page 260: ...ries are being filled See following CAUTION CAUTION If at any time water overflows from the batteries immediately stop the refill process disconnect the pressure regulator from the battery fill coupling and call for service 3 When the red flow indicator balls stop moving immediately press the grey button to disconnect the hose end assembly from the battery fill coupling 9 and squeeze the dust cove...

Page 261: ...a The colder the area in which the batteries are stored the less the batteries will self discharge Batteries stored at 0 F 17 8 C will discharge very little over a four month period Batteries stored at 80 F 26 7 C will have to be recharged every few weeks 5 48 volt electric vehicles and compatible battery chargers are designed to be left connected with AC power to the charger ON during off season ...

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Page 263: ...SECTION 17 BATTERY CHARGER 17 Refer to the appropriate battery charger maintenance and service manual 2009 Electric Precedent Maintenance and Service Manual Page 17 1 ...

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Page 265: ...1A motors are from the same manufacturer share some internal components but differ in the following aspects MOTOR TERMINAL STUDS INTERNAL PARTS MOUNTING BOLTS USED EJ4 4001 All four studs are 5 16 8mm diameter Brush plate assembly stoning hole cover frame field assembly 4 EJ8 4001A A1 and A2 studs stay 5 16 8mm diameter F1 and F2 studs are 1 4 6 35mm diameter Brush plate assembly stoning hole cove...

Page 266: ... from the A1 and A2 terminals on the motor using two wrenches to prevent posts from turning Set a multimeter to 200 ohms and place the red probe on the A1 terminal and black probe on the A2 terminal The multimeter should indicate continuity If the reading is incorrect a possible open or poor contact in a brush assembly and or open armature windings may be the cause The motor will need to be remove...

Page 267: ...vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 lb 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock ...

Page 268: ...tor disengages 10 Carefully slide the motor away from the transaxle until the motor spline disengages the input shaft and remove the motor from the vehicle 748 Figure 18 4 Speed Sensor Magnet 749 Figure 18 5 End Cap MOTOR DISASSEMBLY 1 Before beginning disassembly place match marks on the motor end cap and motor frame 2 Remove speed sensor and magnet 2 1 Remove the two screws 25 that secure the sp...

Page 269: ...s sufficient thread engagement of the end cap bolts before proceeding Performing the procedure without having adequate thread engagement could damage the motor frame end cap or end cap bolts 5 2 Gently tap each bolt alternating between blows until the end cap and motor frame become disengaged Figure 18 6 Page 18 5 6 Remove the two end cap bolts 7 Remove the end cap and armature from the motor fram...

Page 270: ...ove the brush rigging 12 1 Mark the brush terminal posts A1 and A2 12 2 Remove the two nuts securing the brush terminals A1 and A2 to the end cap Figure 18 9 Page 18 6 12 3 Remove the two screws and the brush rigging to the end cap Figure 18 10 Page 18 7 13 Inspect the terminal insulators See Terminal Insulator Inspection on page 18 9 14 Remove the bearing from the end cap 14 1 Remove the retainin...

Page 271: ...ge 18 4 Visual Inspection Burned charred or cracked insulation Improperly cured varnish Thrown solder Flared armature windings Damaged armature core laminations Worn burned or glazed commutators Dirty or oily commutators Raised commutator bars Worn armature bearing or shaft A dirty or oily commutator should be cleaned and wiped dry Abnormalities identified during the inspection can help determine ...

Page 272: ... seal Armature Ground Test CAUTION Do not submerge the armature in solvent NOTE Before testing the armature wipe it clean with a clean cloth Remove any carbon dust and metal particles from between the commutator bars 1 With a multimeter set to 200 ohms place one probe on the commutator 1 and the other on the armature core 2 The multimeter should indicate no continuity Figure 18 12 Page 18 8 If the...

Page 273: ...ring tension do not over extend the spring Using excessive force will damage the spring 4 4 Replace springs which require a force of less than 35 oz 990 grams Figure 18 13 Page 18 10 See following NOTE NOTE When installing new brushes remove and replace brushes one at a time This method ensures the terminals and brushes will be properly positioned in the rigging Refer to Motor Assembly on page 18 ...

Page 274: ...loth to wipe the carbon dust off of the bearing Inspect the bearing by spinning it by hand and checking for both axial A and radial B play Figure 18 14 Page 18 10 4 Replace the bearing if it is noisy does not spin smoothly or has excessive play Check the bearing and replace if rusted worn cracked or if there is an abnormal color change in the metal of the bearing A B 756 Figure 18 13 Brush Spring ...

Page 275: ...mponent Testing and Inspection 18 10 24 23 25 4 5 6 7 9 12 8 14 13 15 16 16 11 19 20 22 21 1 2 17 18 3 30 Items 19 20 21 and 22 Used only on EJ4 4001 motor 757 Figure 18 15 Motor 2009 Electric Precedent Maintenance and Service Manual Page 18 11 ...

Page 276: ...stall the retaining ring to secure the bearing Figure 18 11 Page 18 7 2 Install the brushes and brush rigging See following NOTE NOTE When installing new brushes remove and replace brushes one at a time This method ensures the terminals and brushes will be properly positioned in the rigging When replacing brushes replace all four brushes Never replace only two Install the brushes in the same riggi...

Page 277: ...brushes can be easily damaged by this weight 4 Gently press each brush with a small screwdriver until the spring rests on the end of each brush as shown Figure 18 19 Page 18 13 5 Align the match marks on the end cap and the motor frame 1 and secure with two bolts 16 Figure 18 15 Page 18 11 Tighten bolts to 130 in lb 14 7 N m 6 Install the speed sensor magnet 24 with screw 23 Tighten to 65 in lb 7 ...

Page 278: ...rooves to a width of approximately 3 8 inch 9 5 mm 2 5 Use a flat screwdriver to clean the grease out of one of the grooves and allow air to escape when the motor is pushed onto the input shaft 1 2 1 2 mm inch 1 2 1 1 2 mm inch 1 8 INCH 3 1 MM 3 8 INCH 9 5 MM 741 Figure 18 20 Grease on Putty Knife 742 Figure 18 21 Application of grease to Input Shaft Grooves 2 6 Check the chamfer 1 and end 2 of th...

Page 279: ...llowing CAUTION and NOTE CAUTION Make sure the motor is properly seated in the transaxle housing NOTE Failure to install and tighten the motor mounting bolts in the proper sequence and to the proper tightness may result in motor noise during operation 4 4 Tighten the right bolt 1 to 65 in lb 7 3 N m 4 5 Tighten the left bolt 2 to 65 in lb 7 3 N m 4 6 Tighten the center bolt 3 to 65 in lb 7 3 N m 4...

Page 280: ...sing a crisscross pattern to 55 ft lb 74 6 N m for steel wheels or 65 ft lb 88 N m for alloy mag wheels 10 Place the Tow Run switch in the TOW position and connect the batteries positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 11 Place the Tow Run switch in the RUN position 12 Inspect...

Page 281: ...onnect the battery cables and discharge the controller as instructed See WARNINGS To avoid unintentionally starting and After disconnecting the batteries wait 90 seconds in General Warnings on page 1 1 2 Place chocks at the front wheels Loosen lug nuts on rear wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to support the vehicle See ...

Page 282: ... seal 15 from the adapter ring 39 Figure 19 3 Page 19 2 Retain the adapter ring and discard the oil seal 7 Inspect the axle shaft assembly to be sure the bearing and collar have not slipped and are still seated against the shoulder on the axle shaft 8 Inspect bearing 5 Figure 19 5 Page 19 3 If the bearing in a Type G transaxle is worn or damaged the entire axle shaft assembly 1 or 2 must be replac...

Page 283: ...haft 19 1 3 14 15 39 24 26 13 33 36 32 8 10 11 12 20 18 19 16 16 16 17 23 21 25 36 22 35 13 27 30 31 29 2 3 8 36 27 30 28 37 38 5 6 4 15 39 766 Figure 19 5 Transaxle Type G 2009 Electric Precedent Maintenance and Service Manual Page 19 3 ...

Page 284: ...the shaft through to the bearing on the shaft then rotate it to align the shaft splines with the splined bore of the differential side gear 27 Figure 19 5 Page 19 3 Continue advancing the shaft until the bearing on the axle is firmly seated within the axle tube hub seat 2 2 Use a pair of snap ring pliers to install the retaining ring 6 inside axle tube hub so that it seats against the axle bearing...

Page 285: ... 1 and brake cable clevis pins 3 Use tool CCI P N 102555501 to compress tangs on cable end and remove cable end from bracket 4 Figure 19 7 Page 19 5 1 2 3 4 682 Figure 19 6 Vehicle Supported on Jack Stands 651 Figure 19 7 Brake Cable 6 Disconnect the shock absorbers from their lower mounts Figure 19 8 Page 19 6 7 Disconnect the four motor wires Use two wrenches to prevent the post from turning 8 W...

Page 286: ... transaxle and allow the springs to rest on the floor 13 Remove the U bolts attaching the transaxle to the leaf springs Figure 19 10 Page 19 7 14 Carefully lift each end of the transaxle off its positioning pin on the leaf spring and slide the transaxle to the rear and out of the vehicle 15 Drain the lubricant from the transaxle and remove the axle shafts See Axle Shaft and Oil Seal Removal on pag...

Page 287: ...dent 2 Villager 4 1 2 3 4 769 Figure 19 10 Leaf Springs 770 Figure 19 11 Motor Mounting Bolts 24 25 745 Figure 19 12 Motor Positioning Bolt EJ4 4001 and 5BC59JBS6390 Motors Only 2009 Electric Precedent Maintenance and Service Manual Page 19 7 ...

Page 288: ...mbly 19 Lift intermediate gear assembly and differential gear case unit out simultaneously Figure 19 5 Page 19 3 See following CAUTION CAUTION Do not damage gears Use extreme care when handling them 5 Use a bearing puller or arbor press to remove bearings 16 from the input pinion gear If the oil seal 10 is damaged replace it Figure 19 5 Page 19 3 See also Figure 19 13 Page 19 8 See following CAUTI...

Page 289: ...ugh differential gear case from one side Figure 19 5 Page 19 3 See also Figure 19 15 Page 19 9 8 5 Remove the idler gears 1 and 2 and thrust plates 3 and 4 Figure 19 16 Page 19 9 1 5 6 26 2 8 7 3 4 773 Figure 19 15 Differential Pin 774 Figure 19 16 Left Differential 8 6 Remove the differential gears 5 and 6 and thrust plates 7 and 8 8 7 Inspect the bearings 13 of the differential case 26 and repla...

Page 290: ...ng 8 2 Install left half of transaxle housing 20 Figure 19 5 Page 19 3 8 3 Install bolts 24 in the case housing and tighten to 19 ft lb 25 7 N m Type G transaxles have no shims or gasket 8 4 Install axle tube 14 and 35 with bolts 8 Figure 19 5 Page 19 3 Tighten the bolts to 37 ft lb 50 2 N m 9 Install the brake assemblies as instructed See Brake Cluster Installation on page 6 11 10 Apply a small a...

Page 291: ...the leaf springs into the rear spring shackles Then raise the jack stands to support the transaxle 6 Connect the motor wires making sure they are connected to the correct motor terminals and that the terminal orientation is correct Hold the bottom nut of stud with wrench and tighten the terminal retaining nuts For 5 16 inch 8mm diameter studs tighten the nuts to 100 in lb 11 N m For 1 4 inch 6 3mm...

Page 292: ...ke sure that the vehicle operates in the reverse direction when the Forward Reverse switch is in the REVERSE position The reverse buzzer will sound as a warning when the Forward Reverse switch is in REVERSE Make sure that the vehicle does not operate when the Forward Reverse switch is in the NEUTRAL position Page 19 12 2009 Electric Precedent Maintenance and Service Manual ...

Page 293: ...ted in this section addresses the series 2 versions of the IQDM P and IQDM handsets PLUGGING THE HANDSET INTO THE VEHICLE 1 Connect one end of the cable to the jack located on the bottom of the handset 2 Connect the cable adaptor to the IQDM cable 3 Find the IQDM jack on the vehicle Figure 20 1 Page 20 1 4 Remove the dust cap from the IQDM jack 5 Align the keyed portion of the plug with the IQDM j...

Page 294: ...e the up or down arrows on the navigation button to go to the desired item in the program menu Again press the right arrow to select the menu item Use the change value button to change the values of the selected item as necessary The following parameters can be programmed with the handset from the program menu 1 2 3 2 1 3 775 Figure 20 2 Access Program Menu 776 Figure 20 3 Change Speed Setting Pag...

Page 295: ... by pressing or on the change value button NOTE Pedal up mode does not affect top vehicle speed If the accelerator pedal is released when the vehicle is going down an incline the motor braking function will activate slowing the vehicle to the speed setting defined in the Program menu See Speed Setting on page 20 3 PEDAL UP MODE SETTING MODE OPERATION DESCRIPTION 0 Off Pedal up motor braking is dis...

Page 296: ... tow switch had been placed in the tow position 2 the DC plug of the charger had been plugged into the vehicle 3 the battery set had been disconnected or 4 if the vehicle had gone into sleep mode and the accelerator was pressed while the key switch was switched on The KEY SWITCH SRO fault detect that is controlled by the ksi sro enable parameter is disabled off by default M2 MAX SPEED The m2 max s...

Page 297: ...ets are not compatible with the Excel System See Figure 21 2 Page 21 1 PLUGGING THE HANDSET INTO THE VEHICLE 1 Connect one end of the cable to the jack located on the bottom of the handset 2 Connect the cable adaptor to the IQDM cable 3 Find the IQDM jack on the vehicle Figure 21 1 Page 21 1 4 Remove the dust cap from the IQDM jack 5 Align the keyed portion of the plug with the IQDM jack and conne...

Page 298: ...use the up or down arrows on the navigation button to go to the desired item in the program menu Again press the right arrow to select the menu item Use the change value button to change the values of the selected item as necessary The following parameters can be programmed with the handset from the program menu 1 2 3 2 1 3 775 Figure 21 3 Access Program Menu 776 Figure 21 4 Change Speed Setting P...

Page 299: ... when the accelerator pedal is released See following NOTE Change the settings of the Pedal Up Mode by pressing or on the change value button NOTE Pedal Up Mode does not affect top vehicle speed When the vehicle is going down an incline the motor braking function will activate to prevent the vehicle from exceeding the speed setting defined in the Program menu regardless of Pedal Up Mode setting 0 ...

Page 300: ...2 4 to 14 8mph 20 0 to 23 8 km h 1 Access the program menu then the speed setting menu with the navigation keys 2 Select Speed Setting 3 with the change value buttons 3 Access the program menu and the s3 fwd speed menu with the navigation keys 4 Use the change value buttons to select desired speed CODE A CODE B AND CODE C The code entries are used to place the vehicle in private speed mode speed s...

Page 301: ... battery warning light installation 15 3 removal 15 2 testing 11 34 12 34 bearing axle see transaxle type g axle bearing 19 4 bearing motor see motor bearing 18 10 body front 4 3 4 9 installation 4 3 removal 4 3 see also repair front and rear body 4 3 body rear removal 4 9 see also repair front and rear body 4 9 4 13 brake pedal installation 5 5 removal 5 5 brakes adjustment 6 10 cable installatio...

Page 302: ...pe g 19 8 instrument panel installation 4 6 removal 4 6 IQ Display Module IQDM Excel system diagnostics 14 1 IQ system diagnostics 13 1 IQ Display Module Programming IQDM P Excel system 21 1 diagnostics 14 1 IQ system 20 1 diagnostics 13 1 IQDM Excel system diagnostics 14 1 Faults Menu 14 8 Functions Menu 14 13 Get Settings From Controller 14 13 handset 14 1 Handset Cord 14 19 Handset Cord Adaptor...

Page 303: ...18 7 assembly 18 12 bearing inspection 18 10 braking motor braking 12 1 pedal down motor braking 11 1 pedal up motor braking 11 7 brush inspection 18 9 brush spring inspection 18 9 disassembly 18 4 features 11 1 12 1 field winding inspection 18 9 identification 18 1 installation 18 14 motor braking 11 1 12 1 protection circuit 11 7 12 7 reconditioning 18 12 removal 18 3 service specifications 18 1...

Page 304: ...val 15 12 steering rack and pinion assembly 7 7 disassembly 7 5 installation 7 8 removal 7 4 steering column 7 2 disassembly 7 2 installation 7 3 removal 7 2 steering wheel installation 7 2 removal 7 1 storage electric vehicle 3 2 stress lines see repair front and rear body 4 2 suspension front camber adjustment 7 10 components control arm installation 7 14 control arm removal 7 14 kingpin and ste...

Page 305: ...2 20 tie rod and drag link installation 7 12 removal 7 10 tire installation 8 3 removal 8 2 repair 8 2 Tow Run switch 11 7 12 7 installation 15 6 removal 15 6 testing 11 17 12 17 transaxle type g assembly 19 10 axle bearing 19 4 axle shaft installation 19 4 removal 19 1 disassembly 19 8 inspection 19 8 installation 19 11 lubrication 19 1 oil seal installation 19 4 removal 19 1 removal 19 5 trouble...

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Page 309: ...ir Average Good Excellent Comments Suggestions In order to help us better serve you please rate this publication in the following catgories Your Comments Are Appreciated Please selec tyou r category Distributor Dealer Individual Owner Club Car Associate Representative Technician Golf Course Superintendent Other _____________________ 2009 Electric Precedent Maintenance and Service Manual ...

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