Club Car Precedent 2014, Maintenance And Service Manual

Page 1: ...f Car Maintenance and Service Manual Electric Vehicle with PowerDrive Battery Charger Gasoline Vehicle with Kawasaki FE350 Engine Electric Vehicle with ERIC Charging System Manual Number 105062901 Edition Code 0713A00000 ...

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Page 3: ... more information contact your local dealer or Club Car s Technical Services department for a list of upcoming classes This manual covers all aspects of typical vehicle service 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 Yo...

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Page 5: ...e 3 5 Returning the Stored Electric Vehicle to Service 3 6 Storage Gasoline Vehicle 3 7 Preparing the Gasoline Vehicle for Extended Storage 3 7 Returning the Stored Gasoline Vehicle to Service 3 8 Fueling Instructions Gasoline Vehicles 3 9 SECTION 4 BODY AND TRIM 4 1 Cleaning the Vehicle 4 1 Seat 4 1 Front and Rear Body Repair 4 2 Stress Lines or Streaks 4 2 Minor Impact Damage Deformations 4 2 Mi...

Page 6: ... Group Installation 5 3 Pedal Group Gasoline Vehicle 5 4 Pedal Group Removal 5 4 Throttle Position Sensor 5 5 Pedal Group Installation 5 6 Debris Shields 5 6 Accelerator Pedal Removal 5 6 Accelerator Pedal Installation 5 6 Brake Pedal Removal 5 7 Brake Pedal Installation 5 7 SECTION 6 WHEEL BRAKE ASSEMBLIES 6 1 General Information 6 1 Brake Shoe Removal 6 1 Brake Assembly Cleaning 6 5 Brake Shoe I...

Page 7: ... 9 1 Shock Absorber Removal and Inspection 9 1 Shock Absorber Installation 9 1 Leaf Springs Two Passenger Vehicles 9 2 Leaf Spring Removal Two Passenger Vehicles 9 2 Leaf Spring Installation Two Passenger Vehicles 9 3 Leaf Springs Four Passenger Vehicles 9 5 Leaf Spring Removal Four Passenger Vehicles 9 5 Leaf Spring Installation Four Passenger Vehicles 9 7 SECTION 10 PERIODIC MAINTENANCE 10 1 Gen...

Page 8: ...11 8 Faults Menu 11 9 System Faults 11 9 HW Failsafe 11 11 Throttle Fault 11 11 Speed sensor 11 12 Main Welded 11 12 Main Driver On 11 12 Main Driver Off 11 12 Main Coil Open 11 12 FLD Field Missing 11 13 HPD 11 13 Overvoltage 11 13 Low Battery Voltage Undervoltage 11 13 Thermal Cutback 11 13 Motor Stall 11 14 Main Dropout 1 or 2 11 14 Current Sense Fault 11 14 Incorrect Password IQDM P only 11 14...

Page 9: ...trieve Data from the Onboard Computer 13 39 CDM Troubleshooting Guide 13 40 SECTION 14 ELECTRICAL COMPONENTS ELECTRIC VEHICLE WITH POWERDRIVE CHARGER 14 1 Key Switch 14 1 Testing the Key Switch 14 1 Key Switch Removal 14 1 Key Switch Installation 14 1 Battery Warning Light 14 2 Testing the Battery Warning Light 14 2 Battery Warning Light Removal 14 2 Battery Warning Light Installation 14 3 Forward...

Page 10: ...g Voltage of Battery Set 15 2 Measuring Voltage of an Individual Battery 15 2 Battery Cell Numbering 15 2 Battery Testing 8 Volt 15 3 Fully Charge Batteries Test 15 3 Hydrometer Test 15 3 Discharge Test 15 6 Battery Regrouping 15 7 Battery Replacement 15 9 Battery Care 15 9 Water Quality 15 9 Battery Care Vehicles Equipped with the Single Point Watering System 15 11 Battery Care Vehicles Without t...

Page 11: ...ion 19 1 Troubleshooting Guide 19 1 Wiring Diagrams Throttle Position Sensor TPS 19 6 Electrical System 19 11 Test Procedures 19 11 SECTION 20 ELECTRICAL COMPONENTS GASOLINE VEHICLE 20 1 Starter Generator 20 1 Testing the Starter Generator 20 1 Starter Generator Removal 20 1 Disassembly of the Starter Generator to Service the Brushes 20 2 Brush Inspection and Replacement 20 2 Brush Spring Inspecti...

Page 12: ... Oil Warning Light 20 21 Testing the Low Oil Warning Light 20 21 Low Oil Warning Light Removal 20 21 Low Oil Warning Light Installation 20 21 Fuel Gauge 20 22 Testing the Fuel Gauge 20 22 Fuel Gauge Removal 20 22 Fuel Gauge Installation 20 22 Fuel Level Sending Unit 20 23 Testing the Fuel Level Sending Unit 20 23 Hour Meter 20 23 Testing the Hour Meter 20 23 Hour Meter Removal 20 23 Hour Meter Ins...

Page 13: ...2 3 Engine Control Linkage 22 6 General Information 22 6 Ground Speed 22 6 Governor Cable 22 6 Accelerator Cable 22 8 Closed Throttle or Idle Adjustment 22 8 Engine RPM Adjustment 22 9 Engine Backfire 22 9 Choke and Air Intake System 22 10 General Information 22 10 Choke Button 22 11 Air Intake Components Removal 22 12 Air Intake Components Installation 22 12 Air Filter 22 12 Fuel Filter 22 14 Gen...

Page 14: ...se Shifter Cable Adjustment 24 25 SECTION 25 TORQUE CONVERTER GASOLINE VEHICLE 25 1 General Information 25 1 Troubleshooting 25 2 Drive Belt 25 3 Drive Belt Removal 25 3 Drive Belt Installation 25 3 Drive Clutch 25 4 Drive Clutch Removal 25 4 Drive Clutch Cleaning and Inspection 25 6 Drive Clutch Disassembly 25 8 Inspection of Drive Clutch Parts 25 10 Drive Clutch Assembly 25 11 Drive Clutch Insta...

Page 15: ...2 Max Password Tries IQDM P only 26 12 Throttle Fault 26 12 Low Battery Voltage Undervoltage 26 12 Overvoltage 26 12 Thermal Cutback 26 13 Anti Tamper Fault 26 13 HPD 26 13 Main Drvr OverCurrent 26 13 Lockout Fault 26 13 Low SoC 26 13 Main Welded 26 14 High Speed WalkAway 26 14 Speed sensor 26 14 Main Driver On 26 14 Main Coil Open 26 14 Main Dropout 1 or 2 26 15 Motor Stall 26 15 Main Driver Off ...

Page 16: ... Testing Basics 28 16 SECTION 29 ELECTRICAL COMPONENTS ELECTRIC VEHICLE WITH ERIC CHARGING 29 1 Key Switch 29 1 Testing the Key Switch 29 1 Key Switch Removal 29 1 Key Switch Installation 29 1 Charge Indicator Light 29 2 Testing the Charge Indicator Light 29 2 Charge Indicator Light Removal 29 2 Charge Indicator Light Installation 29 3 Forward Reverse Rocker Switch 29 3 Testing the Forward Reverse...

Page 17: ...d with the Single Point Watering System 30 7 Battery Care Vehicles Without the Single Point Watering System 30 8 Self Discharge 30 9 Electrolyte Level 30 9 Vibration Damage 30 10 Single Point Watering System SPWS 30 11 Initial Maintenance of the SPWS 30 11 Watering Batteries with the SPWS 30 11 Battery Storage 30 13 Fleet Rotation 30 13 Deep Discharge 30 13 Early Excessive Discharging 30 13 SECTIO...

Page 18: ...oval 31 20 DC Cord and Strain Relief Installation 31 20 Handle Removal 31 21 Handle Installation 31 21 Foot Removal 31 21 Foot Installation 31 21 Onboard Charger Repairs 31 22 Onboard Charger Removal 31 22 Onboard Charger Installation 31 23 Terminal Block Cover Removal 31 23 Terminal Block Cover Installation 31 23 DC Cord and Strain Relief Removal 31 24 DC Cord and Strain Relief Installation 31 24...

Page 19: ... Danger is RED WARNING A WARNING indicates an immediate hazard that could result in severe personal injury or death The color associated with Warning is ORANGE CAUTION A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury The color associated with Caution is YELLOW MACHINE SAFETY CAUTION A CAUTION without the safety alert symbol ind...

Page 20: ...a well ventilated area Do not operate engine in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison The vehicle will not provide protection from lightning flying objects or other storm related hazards If caught in a storm while driving a Club Car vehicle exit the vehicle and seek shelter in accordance with applicable safety guidelines ...

Page 21: ...he OFF position and remove the key Chock the wheels when servicing the vehicle Do not leave children unattended on vehicle Disconnect charger plug before servicing vehicle Electric vehicles only Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning could result in a battery explosion or severe personal injury To avoid unintentionally...

Page 22: ...driver side of vehicle 1 Remove negative battery cable 2 Remove positive battery cable Connect battery cables in reverse order 49A Figure 1 1 Battery Cable Removal 6x8 Volt Battery Configuration 50 Figure 1 2 Battery Cable Removal Gasoline DISCONNECTING THE BATTERIES ELECTRIC VEHICLES 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 Place Tow Run switch in the TOW position before disc...

Page 23: ...l protection must be shared not only by the manufacturers of the batteries but by people who use the batteries as well Please contact your nearest Club Car dealer or distributor for information on how to properly recycle your batteries 1403 Figure 1 3 Dispose of Lead acid Batteries Properly INTERNATIONAL SAFETY SYMBOLS ON BATTERIES Anyone using repairing or servicing the vehicle must understand an...

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Page 25: ...cc 10 4 Engine Horsepower 7 8 kW rated 3600 RPM per SAE J1349 single cylinder air cooled with pressure lubrication system Fuel system Side draft carburetor with float bowl fixed jets fuel filters and impulse fuel pump Governor Automatic ground speed sensing internally geared in unitized transaxle Ignition Transistor electronic ignition with electronic RPM limiter Unitized transaxle Fully synchroni...

Page 26: ...5 5 in 166 cm Ground clearance 4 5 in 11 cm 4 5 in 11 cm 4 5 in 11 cm 4 5 in 11 cm Front wheel tread 34 5 in 88 cm 34 5 88 cm 34 5 in 88 cm 34 5 88 cm Rear wheel tread 38 6 in 98 cm 38 6 in 98 cm 38 6 in 98 cm 38 6 in 98 cm Weight standard electric vehicle with canopy with batteries 909 lb 412 5 kg 1024 lb 464 5 kg Weight standard gasoline vehicle with canopy with battery without fuel 651 lb 295 k...

Page 27: ...TIONS MODEL NUMBER IC0650 048 CC IC0650 048 COMM AC INPUT AC voltage 100 to 240 VAC 100 to 240 VAC Frequency 50 60 Hz 50 60 Hz POWER CONSUMPTION Maximum AC input current amps 7 5 7 5 DC OUTPUT Rated DC voltage VDC 48 48 Maximum DC voltage VDC 72 72 Maximum DC output current amps 13 5 13 5 DIMENSIONS WEIGHT Case overall length 9 9 in 25 2 cm 9 9 in 25 2 cm Case overall width 7 3 in 18 6 cm 7 3 in 1...

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Page 29: ...83947 Figure 3 1 The two letters 1 at the beginning of the serial number indicate the vehicle model The following four digits 2 indicate the model year and production week during which the vehicle was built The six digits 3 following the hyphen represent the unique sequential number assigned to each vehicle built within a given model year See following NOTE NOTE Have the vehicle serial number avai...

Page 30: ...s should include at a minimum Where golf cars should be driven Ensuring that proper warnings of driving hazards are displayed and visible See below for list of signs available from 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 ...

Page 31: ... If water is required fill the cells to cover the plates charge the batteries and then use distilled water to fill each cell to the correct level Electrolyte level should be from 1 2 inch 13 mm above plates to 1 4 inch 6 mm below the level indicator Figure 15 5 Immediately Prior to Storage Perform the Following Steps 1 Turn the key switch to the OFF position remove the key and leave the Forward Re...

Page 32: ...monthly to ensure that proper operation is maintained See Electrolyte Level Section 15 Page 15 13 To check charger function inspect the status indicator lights on the charger The charger is functioning properly if the blue light is ON and the triangular light is OFF CAUTION Be sure to check the batteries and charger status indicators monthly to maintain correct battery water level and to ensure th...

Page 33: ... cells to cover the plates charge the batteries and then use distilled water to fill each cell to the correct level Electrolyte level should be from 1 2 inch 13 mm above plates to 1 4 inch 6 mm below the level indicator Figure 15 5 Immediately Prior to Storage Perform the Following Steps 1 Turn the key switch to the OFF position remove the key and leave the Forward Reverse switch in the NEUTRAL po...

Page 34: ...in storage mode When the OBC detects that the storage charge cycles may have depleted the available electrolyte it will stop the charger from further operation Disconnecting then reconnecting the DC cord stationary charger or AC cord onboard charger indicates the electrolyte levels have been maintained and allows the OBC to resume operation 11 3 If AC power is off for 7 days or longer the OBC will...

Page 35: ...osition and the neutral lockout cam in the MAINTENANCE position Turn the fuel shut off valve to the closed OFF position Figure 3 2 and run the engine until fuel remaining in the carburetor and fuel lines is depleted and the engine stalls Return the neutral lockout cam to the OPERATE position 2 2 Loosen but do not remove the carburetor drain screw and drain fuel remaining in bowl into a small clean...

Page 36: ...vent 2 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 4 3 Completely open the fuel shut off valve 1 Figure 3 2 Make sure the valve is fully open A partially closed fuel shut off valve combined with the use of the choke can result in a fouled spark plug and engine failure 4 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout...

Page 37: ...ine only Whenever possible avoid using oxygenated and blended fuels Do not use any fuel with an alcohol content that exceeds 10 by volume such as E15 and E85 Ethanol is an alcohol that readily absorbs moisture causing corrosion of fuel system components It also damages neoprene and other plastic and rubber components Use of these fuels in this vehicle will void the warranty To allow for expansion ...

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Page 39: ...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 40: ... 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 41: ...Figure 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 underb...

Page 42: ...4 Front Body BODY AND TRIM 3 8 2 1 5 6 7 4 616 Figure 4 1 Front Body Page 4 4 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 43: ...ge 4 5 Each bracket is secured in place by two taptite 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 are tightened to 13 3 ft lb 18 N m 2 1 2 3 4 5 617 Figure 4 2 Bracket and Front Bumper 2014 Precedent Golf Car Maintenance and Service Manual Page 4 5 ...

Page 44: ...long horizontal line 15 1 2 inches 39 4 cm above the ground directly in front of the vehicle 3 Turn on headlight Take note where the beam strikes the vertical surface in relation to the marked horizontal line To raise the beam add washers size M6 to the lower mounting screw 1 To lower the beam add washers to both upper screws Tighten screws to 66 in lb 7 5 N m While it is possible to add washers w...

Page 45: ...e forward edge engage to front underbody Secure assembly in place with two screws 5 and plastic rivet 6 Figure 4 4 Page 4 7 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 with the corresponding...

Page 46: ...rom top of retainer 1 Figure 4 5 Page 4 8 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 5 Page 4 8 2 Ensure ...

Page 47: ...rd 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 6 Page 4 9 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 Instal...

Page 48: ...n the tabs on the top and bottom of button 5 to free the button from the kick plate Remove button 5 and spring 6 KICK PLATE AND CHOKE BUTTON INSTALLATION 1 Place spring 6 in kick plate 4 and orient the tabs on the button 5 with the slots in the kick plate Press in the button until it snaps in place in the kick plate Figure 4 7 Page 4 11 2 Insert the tabbed end of the choke rod 3 into the rear slot...

Page 49: ...hicle with two hinges 2 Figure 4 8 Page 4 11 that hook into slots in the body When replacing the hinges 2 tighten screws 3 to 75 in lb 8 5 N m When replacing hip restraints 4 tighten screws 5 to 65 in lb 7 3 N m 4 1 5 3 2 2654 Figure 4 8 Seat Bottom Hinge and Hip Restraint 2014 Precedent Golf Car Maintenance and Service Manual Page 4 11 ...

Page 50: ...e vehicle has a canopy the rear upright supports must be removed from the SAM 2 Remove four bolts 4 to release the SAM 3 from the vehicle Figure 4 10 Page 4 13 SAM Installation Position the SAM 3 over its mounting holes and secure with four screws 4 Tighten screws to 71 in lb 8 N m Seat Back The seat back 1 is secured to the SAM 3 with two screws 2 Figure 4 10 Page 4 13 When replacing the backrest...

Page 51: ... 12 Tabs on the upper edge of the basket align with holes in the bag hoop 6 for installation purposes Tighten screws 12 to 31 in lb 3 5 N m for molded plastic sweater basket Figure 4 10 Page 4 13 10 6 7 8 12 9 9 12 2 3 4 1 7 5 11 2653 Figure 4 10 Seat Back Bag Rack and SAM 2014 Precedent Golf Car Maintenance and Service Manual Page 4 13 ...

Page 52: ...eauty panel 12 and secure with two screws 14 Tighten screws to 20 in lb 2 3 N m 4 Position canopy support brackets 1 and 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 11 Page 4 15 Rear Underbody Removal 1 Remove four screws 5 attaching the rear underbody 4 to vehicle Figu...

Page 53: ... Rear Body Two Passenger Vehicles 4 11 11 10 10 18 13 16 14 5 4 5 7 6 12 15 2 3 1 17 Two Passenger Vehicles Only 2656 Figure 4 11 Rear Body Components 2014 Precedent Golf Car Maintenance and Service Manual Page 4 15 ...

Page 54: ... to seat support and remove the seat back Figure 4 12 Page 4 16 Seat Back Installation Secure seat back 8 or 11 to seat support with screws 9 or 13 Tighten screws to 51 in lb 5 8 N m Figure 4 12 Page 4 16 TYPICAL 2 PLACES 9 8 10 2 4 1 7 TYPICAL 2 PLACES 3 15 11 TYPICAL 2 PLACES 13 12 2657 Figure 4 12 Seats Four Passenger Vehicles Page 4 16 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 55: ...d remove the seat supports from the vehicle Seat Support Installation 1 Install in the reverse order of removal 2 Tighten bolts 4 to 155 in lb 17 5 N m Tighten screws 5 to 71 in lb 8 N m Tighten bolts 11 and 14 to 159 in lb 18 N m Figure 4 13 Page 4 17 3 3 4 6 6 11 12 5 4 2 9 9 14 TYPICAL 4 PLACES TYPICAL 4 PLACES 1 REAR BEAUTY PANEL NOT SHOWN FOR CLARITY 2658 Figure 4 13 Seat Supports Four Passen...

Page 56: ... TYPICAL 6 PLACES 5 3 8 7 TYPICAL 10 PLACES 11 TYPICAL 4 PLACES 4 2659 Figure 4 14 Foot Deck Four Passenger Vehicles REAR BODY COMPONENTS FOUR PASSENGER Rear Beauty Panel Removal 1 Remove seat support See Seat Support Removal on page 4 17 2 Remove four screws 13 attaching the rear beauty panel 12 Figure 4 11 Page 4 15 3 Remove two screws 14 and remove Forward Reverse switch housing 15 from vehicle...

Page 57: ...derbody from the vehicle Rear Underbody Installation Install rear underbody 4 on the vehicle Figure 4 11 Page 4 15 Install four screws 5 to secure the underbody to the vehicle Tighten screws 5 to 71 in lb 8 N m CANOPY TWO PASSENGER See General Warnings on page 1 2 CAUTION To prevent damage to the canopy do not remove the canopy supports 3 7 and 10 from the vehicle without first removing the canopy...

Page 58: ...4 Canopy Two Passenger BODY AND TRIM 13 14 4 5 3 9 11 7 12 6 10 1 8 2378 Figure 4 15 Precedent Two Passenger Canopy Page 4 20 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 59: ... 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 pro...

Page 60: ...icle 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 Sli...

Page 61: ...BODY AND TRIM Canopy Four 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 16 Precedent Four Passenger Canopy 2014 Precedent Golf Car Maintenance and Service Manual Page 4 23 ...

Page 62: ...ports 8 and 9 to gain access to bolts 10 6 Remove two bolts 10 from each front strut 8 and 9 and remove the struts from the vehicle 7 Remove the four nuts 7 and four bolts 5 securing each rear drain strut 1 and 2 and remove the struts from the vehicle Figure 4 17 Page 4 25 MONSOON CANOPY INSTALLATION 1 Secure the rear canopy supports 1 1 Position each rear canopy support 1 and 2 to the side of the...

Page 63: ...w the vehicle s profile 2 2 Align the holes in the lower portion of each front strut 8 and 9 with the corresponding holes in the vehicle Figure 4 19 Insert two M8 1 25 x 65 torx button head bolts with nylon patch 10 through each front strut into the threaded holes in the vehicle Only finger tighten the bolts at this time 2 3 Slide the front strut covers 11 over the front struts 8 and 9 The covers ...

Page 64: ...ach rear drain strut 1 and 2 with four M6 1 0 x 25 flanged head bolts 18 Tighten the hardware to 80 in lb 9 N m 6 At the bottom of each front strut 8 and 9 tighten the two M8 1 25 x 65 torx button head bolts 10 to 18 4 ft lb 25 N m 7 Secure each front strut cover 11 with one M6 hex head screw 12 Tighten the hardware to 31 in lb 3 5 N m 8 Secure the tube plugs 19 into the end of each front strut 8 ...

Page 65: ...BODY AND TRIM Canopy Monsoon Version Four Passenger 4 20 8 13 17 13 19 1 9 8 13 18 1 2 10 11 12 15 14 K 00835 Figure 4 19 Secure Canopy 2014 Precedent Golf Car Maintenance and Service Manual Page 4 27 ...

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Page 67: ...floor mat 2 over the pedal group to gain access to the pedal group hardware 1 2 3 629 Figure 5 1 Pedal Group Access 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 from the pedal group 11 is free of the turnbuckle Figure 5 2 Page 5 2 7 Remove t...

Page 68: ...up for the Precedent electric vehicle includes a Motor Controller Output Regulator 3 MCOR3 mounted on the side of the pedal group The MCOR3 detects the position of the GO pedal and sends a corresponding voltage to the motor controller For more information see the following procedures Test Procedure 4 MCOR3 Voltage on page 13 16 Page 5 2 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 69: ...pply Loctite 242 to the threaded ends of both the rod from the pedal group 8 and the brake actuator rod 9 Connect the rods using the turnbuckle 6 Ensure the ends of the brake cables do not slip out of the brake equalizer during this procedure 4 Adjust the brake cable equalizer tension See Brake Cable Equalizer Adjustment on page 6 10 5 Place floor cover plate 7 over the floor opening and secure wi...

Page 70: ... 5 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 from the pedal group 11 is free of the turnbuckle Figure 5 4 Page 5 5 1 2 3 629 Figure 5 3 Pedal Group Access 7 Loosen two nuts 9 on the accelerator cable and lift the cable from its mounting bracket 8 Remove two screws 2 on the driver side of the pedal group a...

Page 71: ...ator pedal assembly The throttle position sensor detects the position of the accelerator pedal and sends a voltage to the solenoid and forward reverse limit switches The throttle position sensor itself is not intended to be replaced If sensor is determined to need replacing through test procedures found in this manual the accelerator pedal assembly must be replaced See Accelerator Pedal Removal on...

Page 72: ...nstall the floor mat 2 over the pedal group Make sure tabs on floor mat sides are beneath the sill 3 Tighten screws 1 to 53 in lb 6 N m Figure 5 3 Page 5 4 8 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 4 DEBRIS SHIELDS Debris shields on the top face of the pedal group prevent excessive debris from contacting the moving parts of the pedal group Both ...

Page 73: ...4 and 5 Figure 5 5 Page 5 8 3 Remove four screws 12 securing brake pedal assembly 8 to pedal group mounting plate and pull brake pedal assembly through bottom of pedal group mounting plate BRAKE PEDAL INSTALLATION 1 Insert brake pedal assembly 8 through bottom of pedal group mounting plate and secure with four screws 12 Figure 5 5 Page 5 8 2 Tighten screws 12 to 100 in lb 11 3 N m 3 Install debris...

Page 74: ...Installation ACCELERATOR AND BRAKE PEDAL GROUP 8 5 4 9 6 2 12 11 10 3 13 7 14 000487 002 Figure 5 5 Accelerator Pedal Assembly and Brake Pedal Assembly Page 5 8 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 75: ...park plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 3 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 2 3 Gain access to the pedal group by removing the ...

Page 76: ...llustrated 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 shaft 8 1 Using 9...

Page 77: ...shoe 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 2014 Precedent Golf Car Maintenance a...

Page 78: ... 00 00 1400 18100 10222 Figure 6 5 Remove Shoe Retainer Clip 1400 17700 10225 Figure 6 6 Remove Brake Shoes 1 2 3 1 1 Slide 2732 Figure 6 7 Remove Adjuster Wheel 2733 Figure 6 8 Lubricate Slide Page 6 4 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 79: ...ersonal 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 shoes and into the sl...

Page 80: ...embly Cleaning WHEEL BRAKE ASSEMBLIES 00 1 7 T 2735 Figure 6 11 Apply Grease To Brake Adjuster 2736 Figure 6 12 Install Adjuster Wheel Trailing Shoe Page 6 6 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 81: ...rd 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 Coil...

Page 82: ...the 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 rin...

Page 83: ...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 19 Page 6...

Page 84: ...he threads for both front and rear jam nuts 4 Tighten the rear jam nut first to 208 in lb 23 5 N m then tighten the front jam nut to 208 in lb 23 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 jam nuts are not t...

Page 85: ...6 Remove lug nuts and rear wheels and then the brake drums 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 brak...

Page 86: ...internal snap ring pliers 0 090 tip P N 1012560 attach the 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 to 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 W...

Page 87: ... Loosen turnbuckle 2 until the bolt 5 is free of the turnbuckle 1 4 3 2 5 6 7 650 Figure 6 19 Loosen Brake Cables 6 Rotate the bolt 5 and equalizer bracket 4 to the upright position then slip the cable heads out of the bracket 7 Remove nut 1 from the bolt 2 that secures front of the leaf spring Figure 6 21 Page 6 14 Do not remove bolt 2 8 Remove the mounting tab 3 of the brake cable from the bolt ...

Page 88: ...ing in the hole 2 Hold the bolt 5 and the equalizer bracket 4 in 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 20 Page 6 14 Push the cable housing end into the bracket to ensure the clips on the hous...

Page 89: ...tate steering wheel to a straight ahead position NOTE Do not turn steering again until wheel has been installed 3 Remove two screws 1 securing cover 2 to steering wheel 3 Figure 7 1 Page 7 2 4 Loosen and remove the steering wheel retaining bolt 4 5 Remove the steering wheel See following NOTE NOTE The steering wheel has a tapered hex fitting A steering wheel puller CC P N 102061201 may be required...

Page 90: ...s See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 Gasoline Vehicle Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 4 STEERING COLUMN See General Warnings on page 1 2 STEERING COLUMN REMOVAL 1 Electric Vehicle Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 1 4 Gasoline Veh...

Page 91: ... 7 3 3 Align the holes in the steering column mounting bracket with holes in the vehicle frame Secure column to frame with four bolts 10 Tighten bolts to 18 4 ft lb 25 N m 4 Tighten universal joint bolt 11 to 18 4 ft lb 25 N m Verify the upper universal joint bolt 12 torque is 18 4 ft lb 25 N m 5 Install front bumper dash assembly dash insert and instrument panel See Section 4 Body and Trim 6 Inst...

Page 92: ...ch as a bent tie rod check the steering gear for abnormal free play noise binding or clunking while it is under a load With the steering system fully assembled and all four tires on the ground floor turn the steering wheel from stop to stop While turning feel for any binding clunking or tight loose spots Listen for unusual noises Replace the rack and pinion as an assembly if any is found 4 In the ...

Page 93: ...ing compound to the end of the steering column shaft 2 Simultaneously slide the universal joint over the square end of the steering column shaft and position the assembly over the mounting holes in the chassis 3 Install three screws to secure the assembly to the chassis Tighten screws to 22 ft lb 30 N m 4 Install the upper universal joint bolt 7 and tighten to 18 4 ft lb 25 N m Figure 7 4 Page 7 4...

Page 94: ...the floor or ground there should be an equal amount of space between each tire and the framing square Figure 7 5 Page 7 7 2 Loosen but do not remove the four bolts 17 that secure the leaf spring 13 to the bottom spring plate 16 Figure 7 11 Page 7 13 See also Figure 7 6 Page 7 7 3 Loosen but do not remove the hex nut 8 on the adjustment eccentric 7 Figure 7 6 Page 7 7 in the center of the spring Se...

Page 95: ... 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 7 Page 7 7 674 Figure 7 7 Check Toe In 2376 Figure 7 8 Adjust Toe In 4 Measure the distance between the marks on the forward facing surfaces of the tires Figure 7 7 Page 7 7 NOTE The front measurement must be less th...

Page 96: ... 1 4 Gasoline Vehicle Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 3 2 Loosen jam nuts 13 to allow later rotation of the tie rod ends 12 Figure 7 10 Page 7 12 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 co...

Page 97: ...thane bushings 15 and steel sleeves 14 into leaf spring eyes Figure 7 11 Page 7 13 2 Install leaf spring 13 bottom spring plate 16 and four bolts 17 Using a crisscross pattern sequence tighten bolts to 37 ft lb 50 N m 3 Install spring in kingpins 7 with bolts 8 Tighten to 30 ft lb 41 N m 4 Install the wheels and finger tighten the lug nuts 5 Lower the vehicle and finish tightening lug nuts using a...

Page 98: ...reads and install nut 1 Tighten the nut to 70 ft lb 95 N m 5 Attach the tie rod ends 12 to the spindle tabs then install and tighten the nuts 14 to 70 ft lb 95 N m Figure 7 10 Page 7 12 6 Install front hub and wheel See Hub Installation on page 7 14 7 Electric Vehicle Connect batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 Gasoline Vehicle Connect battery and spark plug...

Page 99: ...soline Vehicle Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 4 SHOCK ABSORBER REMOVAL 1 Inspect the shock absorbers for fluid leakage at the point where the shaft enters the shock absorber body Leaking shock absorbers should be replaced 2 Remove the upper bolt 18 Figure 7 10 Page 7 12 3 Remove the lower bolt 10 4 Remove the shock absorber SHOCK ABSORB...

Page 100: ...spension Components STEERING AND FRONT SUSPENSION 4 8 11 10 2 5 6 7 9 6 4 1 2 14 13 12 16 17 19 18 1311 Figure 7 10 Upper Front Suspension Assembly Page 7 12 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 101: ...AND FRONT SUSPENSION Front Suspension Components 7 1 3 4 5 4 6 7 8 9 10 11 13 14 15 16 17 18 19 3 1312 Figure 7 11 Lower Front Suspension Assembly 2014 Precedent Golf Car Maintenance and Service Manual Page 7 13 ...

Page 102: ...re 7 11 Page 7 13 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 Removal on page 7 9 HUB INSTALLATION 1 Clean and apply a light...

Page 103: ...STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs 7 3 11 9 678 Figure 7 12 Front Wheel Hub 2014 Precedent Golf Car Maintenance and Service Manual Page 7 15 ...

Page 104: ......

Page 105: ...rnings on page 1 2 WHEEL REMOVAL 1 Electric Vehicle Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 1 4 Gasoline Vehicle Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 3 2 Slightly loosen the lug nuts on the wheel to be removed 3 Raise the end of the vehicle from which the wheel is t...

Page 106: ...the tire side walls and pushing the tire bead away from the rim flange and into the rim well Figure 8 1 Page 8 2 Detail A 3 2 With the valve stem side of the wheel up use a tire tool to carefully start the upper bead over the edge of the wheel rim Figure 8 1 Page 8 2 Detail B CAUTION To avoid damage to the tire do not use excessive force when starting the bead over the edge of the rim 4 When top b...

Page 107: ...er to seat keeping the tire and rim clean is very important 3 Apply a liberal amount of tire mounting lubricant soap and water solution to both tire beads and rim 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...

Page 108: ...8 Tires WHEELS AND TIRES 680 Figure 8 2 Inflate Tire Page 8 4 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 109: ...r damage or fluid leakage at the point where the shaft enters the shock absorber body Replace damaged or leaking shock absorbers or 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 it SHOCK ABSORBER I...

Page 110: ...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 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...

Page 111: ...olt 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 18 5 ft lb 25 N m Figure 9 3 Page 9 4 3 Install tire and wheel assembly See Wheel Installation Section 8 Page 8 1 4 Electric Vehicle Connect batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 Gasoline Vehicle ...

Page 112: ...ger Vehicles REAR SUSPENSION 5 7 4 3 17 17 2 4 2 11 12 13 15 10 9 9 19 14 18 3 4 16 1 2689 Figure 9 3 Rear Suspension Assembly and Mounting Two Passenger Vehicles Page 9 4 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 113: ... 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 ...

Page 114: ...Vehicles REAR SUSPENSION 5 7 4 3 17 17 2 4 2 11 12 13 15 10 9 9 19 14 18 3 4 16 1 20 31 30 2690 Figure 9 4 Rear Suspension Assembly and Mounting Four Passenger Vehicles Page 9 6 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 115: ... 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 18 5 ft lb 25 N m Figure 9 4 Page 9 6 3 Install tire and wheel assembly See Wheel Installation Section 8 Page 8 1 4 Electric Vehicle Connect batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 Gasoline Vehicle Connect battery and spark plug wire s See Con...

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Page 117: ...om use until it is properly repaired This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions All Vehicles General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tight Safety and information decals Check to ensure that all safety and information decals are in place Tires Visually inspect tires f...

Page 118: ... the vehicle should accelerate smoothly to full speed When the pedal is released it should return to the original position All Club Car vehicles operate at reduced speed in reverse Walk Away Braking With the vehicle parked on level ground and the park brake disengaged place the Tow Run switch in the RUN position and attempt to push the vehicle Motor braking should engage and cause resistance to ro...

Page 119: ...ould result in fire property damage severe personal injury or death Only trained technicians should service or repair the vehicle or battery charger Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation Electric vehicles Hot Do not a...

Page 120: ... only Weekly service by owner Batteries For vehicles NOT equipped with the Single Point Watering System Check electrolyte level Add water if necessary See Battery Care Vehicles Without the Single Point Watering System on page 15 12 Batteries For vehicles equipped with the Single Point Watering System Water monthly or according to the established watering interval Water the batteries Observe that w...

Page 121: ...ehicles equipped with the Single Point Watering System Manually check battery electrolyte levels of all cells to verify correct valve operation See Battery Care on page 15 9 Annual service by owner or trained technician every 100 hours of operation or 200 rounds of golf Safety decals Check safety decals Replace if damaged or illegible Batteries If batteries are not performing as expected see Batte...

Page 122: ...ctrolyte level See Battery Gasoline Vehicles on page 20 28 Front wheel alignment and camber Check and adjust if necessary See Steering and Front Suspension section Electrical wiring and connections Check for tightness and damage replace if necessary Check brake shoes replace if necessary Lubricate brake system per Lubrication Schedule Check brake cables for damage replace if necessary Semiannual s...

Page 123: ...COMMENDED LUBRICANT Charger receptacle 1 WD 40 Brake system per maintenance and service manual 2 Dry Moly Lube CC P N 1012151 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 L SAE 30 WT API Class SE SF or SG Oil or higher...

Page 124: ...Chassis Lube EP NLGI Grade 2 Check fill unitized transaxle to plug level 27 oz 0 8 L 80 90 WT API Class GL 3 or 80 90 WT AGMA Class EP Gear Lube Annually by trained technician only every 100 hours of operation or every 200 rounds of golf Pedal group as required Dupont Performance Dry Multi Use Lubricant First change 100 hours additional change every 200 hours of operation or every 400 rounds of go...

Page 125: ...h the low oil warning light on the dash should warn you if your oil becomes low engine oil level should be checked monthly Vehicle should be on a level surface when checking oil Do not overfill with oil 1 3 2 1 Full level 2 Safe level 3 Low level 23 Figure 10 3 Engine Oil Level Check ENGINE OIL AND FILTER CHANGE Engine oil and oil filter should be changed after the first 100 hours of operation Aft...

Page 126: ...se allowing the residual oil in the filter port and filter to drain into the oil drain pan Figure 10 5 See following NOTE NOTE An oil drip guard can be used to prevent excess oil from dripping into the engine base plate Use an empty quart one liter container and cut the bottom off at an angle then slide the open area of the container up and under the oil filter prior to removing Position the port ...

Page 127: ...th the drain plug and the oil filter from under the vehicle and watch for oil leaks If filter leaks tighten additional 1 4 turn and retest if oil drain plug leaks re torque and retest 17 Remove the dip stick and check the engine oil as a final step Replace the dip stick 26 Figure 10 5 Remove Engine Oil Filter 27 Figure 10 6 Coat Oil Filter Rubber Seal OIL VISCOSITY Choose the viscosity according t...

Page 128: ...10 Engine Oil Gasoline Vehicles PERIODIC MAINTENANCE SAE 5 W 30 SAE 10W 30 SAE 10W 40 SAE 30 SAE 40 213 Figure 10 7 Oil Viscosity Chart Page 10 12 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 129: ...ftware releases version 14 and version 15 The software version can be viewed in the Information menu of the IQDM See Information on page 11 18 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 11 1 Page 11 1 4 Remove the dust cap from the IQDM...

Page 130: ...r check code A B C Neg IA 250 or Neg IA 300 This is an effect of excessive regen not a fault Monitor other faults Low Battery Voltage Check Battery Voltage Under a Load less than 34 volts could be an effect not a cause Overage Voltage Controller reads 72 volts or more it s an effect not a cause See other faults that accompany OV M Main Coil Open Broken or disconnected coil wire B or B a defective ...

Page 131: ...IGATION BUTTON 1 is the four arrow button located on the left side of the handset Figure 11 3 Page 11 3 This button is used to navigate through and select menus Pressing the up or down arrows allows the user to scroll through the menu items When the box beside the desired menu is blinking pressing the right arrow selects that menu item Pressing the left arrow allows the user to go back one screen ...

Page 132: ...handset PROGRAM IQDM P ONLY The program menu allows the user to view and change custom speed controller settings See Program Menu on page 12 2 MONITOR The monitor menu displays values for certain parameters to facilitate speed controller troubleshooting See Monitor Menu on page 11 5 FAULTS The faults menu displays all faults recorded by the speed controller since the history was last cleared Each ...

Page 133: ... the handset while the vehicle is in motion A technician can monitor the handset while traveling as a passenger in the vehicle Failure to heed this warning could result in severe personal injury or death The following parameters can be monitored in real time with the handset from the monitor menu SPEED Vehicle speed in mph Only visible with the IQDM P THROTTLE Indicates the position of the acceler...

Page 134: ...possible future use and has no application at this time 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 NEUTRAL position and the vehicle at rest the handset should indicate that speed pulses are off When the vehicle is gently pushed a short distance the handset should indicate that spe...

Page 135: ...hile DC cord is plugged into the vehicle MAIN CONT DRIVER Displays the present solenoid main contactor state When the charger is connected and the controller does not drive inhibited the handset indicates ON When the charger is not connected and the controller is allowed to drive the handset indicates OFF PASSWORD TRIES IQDM P ONLY A password is required to place the vehicle in private speed mode ...

Page 136: ...e Fault Count Odometers indicate the odometer reading associated with the last occurrence of each fault type Will indicate 0 0 miles if the fault occurred before the last clearing of fault history NEG IA 250 Displays how many or the last time the armature current reached 250 amps during regenerative braking version 13 or newer software NEG IA 300 Displays how many or the last time the armature cur...

Page 137: ...ys all of the faults detected by the speed controller since the last time the fault history has been cleared The faults displayed in this menu may or may not be currently active Once a fault has been detected it is stored in the memory of the 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...

Page 138: ...lly reduce the armature current limit 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 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...

Page 139: ...ELD 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 Tow Run switch is cycled BLD OVERCURRENT Not applicable at th...

Page 140: ...r on fault is detected by the speed controller What it means The controller FET controlling the energizing of the solenoid is on or energized when it should not be This causes main contactors to stay engaged What to do Replace 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 detected by the speed controlle...

Page 141: ...control and the controller must see the pedal engaged last in the following sequence key switch first FNR second and then pedal last What to do Check throttle percentage and if at 0 issue is driver error 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 What it means This is a symptom that occurs when the contro...

Page 142: ...he following components key switch MCOR batteries battery cables FNR solenoid coil solenoid contacts and controller 16 pin connector CURRENT SENSE FAULT What it means If there are problems with the armature current sensor circuitry a current sense fault is detected What to do Clear the Fault History in the IQDM If the fault does not return and the car operates normally do not replace the controlle...

Page 143: ...example if the MCOR3 Motor Controller Output Regulator 3 was disconnected and the speed controller detected a fault code associated with the throttle the fault history should be cleared so that any future problem is not diagnosed incorrectly as a throttle problem See Clear Fault History on page 11 19 FUNCTIONS MENU The functions menu is accessed by using the up or down arrow to scroll to functions...

Page 144: ...Cloning Transferring Settings from the Handset to the Vehicle on page 11 16 2 1 3 2 3 1 696 Figure 11 4 Handset Executing 697 Figure 11 5 Confirmation Message WRITE SETTINGS TO CONTROLLER This function transfers all of the speed controller settings except for private speed mode from the handset to the vehicle speed controller This enables the trained technician to clone a speed controller Once the...

Page 145: ... 11 1 Page 11 1 5 Scroll to the functions menu and select 6 Select settings 7 Select write settings to controller 8 Press on the change value button to confirm the operation 9 The handset will display an executing message for the next few seconds while the controller settings are being stored in the handset s memory Figure 11 4 Page 11 16 10 When the handset is finished transferring the speed cont...

Page 146: ... value button to confirm the operation 5 The handset will display an executing message for the next few seconds while the controller settings are being stored in the handset s memory Figure 11 4 Page 11 16 6 When the handset is finished resetting the speed controller settings a confirmation message is displayed Figure 11 7 Page 11 17 INFORMATION The information menu is accessed by using the up or ...

Page 147: ...in to any faults 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 F...

Page 148: ...21 IQDM port mounted under instrument panel assembly has failed Test Procedure 3 IQDM Ports on page 11 22 Contrast Setting is too light See Program on page 11 19 Onboard computer is in power down mode Drive the vehicle for a short distance and reconnect the handset to the vehicle Onboard computer malfunction See Section 13 Excel System Troubleshooting with PowerDrive Charger Loose vehicle wire har...

Page 149: ...st the IQDM and IQDM P handsets and the components of the Excel System vehicle that are related to the proper operation of the handset WARNING If wires are removed or replaced make sure wiring and wire harness is properly routed and secured Failure to properly route and secure wiring could result in vehicle malfunction property damage personal injury or death Index of Test Procedures 1 Handset Cor...

Page 150: ...k the park brake 2 Place the Tow Run switch in the TOW position disconnect the batteries negative cable first and wait 90 seconds for the speed controller capacitors to discharge See General Warnings on page 1 2 3 Check the IQDM port mounted under the instrument panel 3 1 Remove the three screws 1 that secure the instrument panel assembly 2 to the dash assembly 3 Figure 11 8 Page 11 22 3 1 2 4 5 7...

Page 151: ...o the four pin connector of the speed controller 2 Figure 11 9 Page 11 23 4 3 4 Connect the 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 11 21 See Section 13 Excel System Troubleshooting with PowerDrive Charg...

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Page 153: ...s manual spans software releases version 14 and version 15 The software version can be viewed in the Information menu of the IQDM See Information on page 11 18 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 12 1 Page 12 1 4 Remove the dust ...

Page 154: ...u is active 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 12 3 Access Program Menu 776 Figure 12 4 Change Spe...

Page 155: ...st to a stop 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 Mod...

Page 156: ...eed range 12 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 m...

Page 157: ... ATTRIBUTES OF THE EXCEL SYSTEM Excel is used in Precedent models only Excel utilizes the 1515 controller instead of the 1510A The Excel 1515 controller uses half bridge technology allowing cooler operating temperatures and increased motor braking The Excel minimum motor braking speed has been lowered to almost zero Excel has higher energy output during regenerative braking due to the lowered mini...

Page 158: ...ehicle motor acts as a generator slowing the vehicle as it creates energy that is used to charge the batteries Tow Run Switch When the Tow Run switch is in the RUN position the vehicle will function normally When the switch is in the TOW position power to the OBC and controller is shut off disabling the vehicle operating circuit and walk away braking allowing the vehicle to be towed Motor Protecti...

Page 159: ... G R E E N 18 18 BROWN WHITE 18 ORANGE 18 PINK WARNING LIGHT REVERS E BUZZER PRO GRAMMER PLUG OPTIONALBATTERY INDICATOR KEYSWITCH NOTE SOME WIRING COMPONENTS SHOWN ARE OPTIONALACCESSORIES 1 6 B L U E 18 BROWN WHITE 9 PINCONNECTOR CONNECTS TO MAINHARNESS 1 2 3 4 5 6 7 8 9 WD1025100K Figure 13 1 Precedent Electric Vehicle Instrument Panel Wiring Diagram 2014 Precedent Golf Car Maintenance and Servic...

Page 160: ...E 16 YELLOW 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 13 2 Precedent Electric Vehicl...

Page 161: ... BROWN WHITE 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 BL...

Page 162: ...W08 18_YEL W09 18_BLK W10 18_BLK_WHT W13 18_GRAY W20 18_YEL_BLK W31 16_LT_GRN W32 18_ORG W35 18_GRN W36 18_GRN W37 18_BRN_WHT W39 18_BRN_WHT W49 18_BLU W50 18_GRN K N I P _ 6 1 4 5 W W77 16_RED_WHT N R G _ T L _ 6 1 0 9 W W102 16_BLU W113 18_YEL W115 18_WHT W117 18_PUR_WHT T H W _ R U P _ 8 1 8 1 1 W D E R _ 6 1 9 1 1 W MCOR FNR SWITCH RUN TOW SWITCH 1 2 2P 1 2 3 4 SW_6 SW_5 SW_2 SW_7 SW_3 SW_9 SW...

Page 163: ...O B CONTROLLER ONBOARD COMPUTER 1 2 3 4 1 2 3 4 5 6 SW_1 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 THROTTLE INPUT GND NO CONNECTION CHARGER INTERLOCK ACCEL PEDAL INPUT REVERSE BUZZER GND FORWARD B AUX KEY SWITCH NO CONNECTION SOL COIL GND LIN BUS SPEED SENSOR INPUT SPEED SENSOR REVERSE HALF BRIDGE DC MOTOR CONTROLLER CHARGER ...

Page 164: ...ubleshooting Guide 2 If an IQDM handset is unavailable the technician should proceed to Troubleshooting Guide 2 TROUBLESHOOTING GUIDE 1 The following troubleshooting guide is intended for use with an IQDM handset See following NOTE NOTE Before troubleshooting the vehicle check the diagnostic history from the Special Diagnostics Menu Note any fault codes TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAU...

Page 165: ...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 FORWARD INPUT and or REVERSE INPUT does not indicate the correct reading Failed Forward Reverse rocker switch Test Procedure 23 Forward Reverse Rocker Switch on page 13 35 Speed controller logic malfunction Disconnect the batteries and allow the spe...

Page 166: ...e batteries and see if the symptom returns Diagnostic Menu MAIN DRIVER ON or MAIN DRIVER OFF fault code Failure of the FET that controls the solenoid coil Replace the speed controller See Speed Controller Removal on page 14 12 Diagnostic Menu MAIN COIL FAULT fault code or Diagnostic Menu MAIN DROPOUT 1 or 2 fault code Solenoid coil has failed in an open condition Replace solenoid See Solenoid Remo...

Page 167: ...e on page 13 16 Forward Reverse rocker switch Test Procedure 23 Forward Reverse Rocker Switch on page 13 35 Solenoid loose wires Test Procedure 3 Solenoid Activating Coil on page 13 15 Solenoid failed coil Test Procedure 3 Solenoid Activating Coil on page 13 15 Speed controller thermal cutback Allow controller to cool and ensure that vehicle is not over loaded before returning to operation 16 pin ...

Page 168: ...le runs slowly Tires under inflated or flat tires See Section 8 Wheels and Tires Wiring improperly wired Check vehicle wiring See Wiring Diagrams on page 13 3 Vehicle operates but motor braking function does not Speed sensor disconnected or failed Test Procedure 21 Motor Speed Sensor on page 13 34 Forward Reverse rocker switch improperly wired Test Procedure 23 Forward Reverse Rocker Switch on pag...

Page 169: ... on top of batteries when removing 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 14 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 T...

Page 170: ...ld indicate at least 48 volts with the batteries fully charged If not check for loose battery connections or a battery installed in reverse polarity Refer to Batteries Electric Vehicle with PowerDrive Charger on page 15 1 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 t...

Page 171: ...o 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 6 1 Using a multimeter set to 200 volts ...

Page 172: ... frame rails just forward of each spring mount See WARNING Lift only one end in General Warnings on page 1 2 See also following WARNING WARNING The key switch should be placed in the OFF position and left in the OFF position for the duration of this test 2 Connect the IQDM to the vehicle 3 Access the Test menu and select THROTTLE by using the SCROLL DISPLAY buttons 4 The IQDM should indicate 0 wit...

Page 173: ...ed probe with insulation piercing probe on the yellow wire at a point close to three pin connector at the MCOR3 The reading should be approximately 0 32 volts with the pedal up Slowly press the accelerator pedal and note the readings on the multimeter As the pedal is pressed the reading should increase until it reaches approximately 4 65 volts when the pedal is fully pressed 7 If reading does not ...

Page 174: ... multimeter set to 200 volts DC place the black probe on the A2 motor terminal white wire and connect the red probe to the A1 green wire motor terminal 3 With Tow Run switch in the RUN position place the Forward Reverse switch in the FORWARD position turn key switch to the ON position and slowly press accelerator pedal 4 As the accelerator pedal is pressed the voltage reading should increase from ...

Page 175: ...ce the Tow Run switch See Tow Run Switch Removal on page 14 6 Tow Run Switch Test without the IQDM Handset 1 Remove the bolt that secures the electronics module to the battery bucket and pull module forward to access Tow Run switch wires 2 With the batteries connected and using a multimeter set on 200 volts DC connect the black probe to the negative post of battery no 6 6 x 8 Volt battery set and ...

Page 176: ...ries are deeply discharged or have failed 7 Recording the battery pack voltage reading while under load provides a more accurate diagnosis of the condition of the batteries When the discharge machine is ON it places the battery pack under load and many times can help determine if one or more batteries in the set have failed Testing battery voltage while the batteries are not under load will not al...

Page 177: ...Switch Circuit Test without the IQDM Handset 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 1 4 2 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...

Page 178: ... volts test the continuity of the MCOR3 limit switch and the green wire If the limit switch does not pass the continuity test replace the MCOR3 See MCOR3 Removal on page 14 7 TEST PROCEDURE 9 16 Pin Connector See General Warnings on page 1 2 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 1 4 2 Disconnect the 16 pin connector from t...

Page 179: ...eneral Warnings on page 1 2 Pins 1 2 and 3 in the 16 pin connector provide a connection point from the MCOR3 potentiometer to the speed controller 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 1 4 2 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 fra...

Page 180: ...res in the wire harness TEST PROCEDURE 11 Pin 5 See General Warnings on page 1 2 Pin 5 in the 16 pin connector provides a connection point for the solenoid lockout circuit from the onboard computer to the speed controller 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 1 4 2 Place chocks at the front wheels and lift the rear of the ...

Page 181: ...While observing the multimeter disconnect the DC plug from the vehicle charger receptacle 12 The multimeter should indicate full battery voltage when the charger is not connected to the vehicle 13 If any other reading is obtained check the following items Continuity of the wires in the wire harness Onboard computer for proper operation See Test Procedure 19 Onboard Computer Gray Wire on page 13 33...

Page 182: ... Forward Reverse switch in the FORWARD position 7 The multimeter should indicate zero volts DC at this time 8 While monitoring the multimeter slowly press the accelerator pedal and hold the pedal at approximately 20 of full travel 9 After a short delay the onboard computer should power up come out of sleep mode 10 The multimeter should indicate full battery voltage approximately 48 volts when the ...

Page 183: ...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 13 13 Page 13 27 See following CAUTION 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 batteries See Connecting the Batteries Electric Vehicles on page...

Page 184: ...n 1 Place the Tow Run switch in the TOW position and connect the batteries See Connecting the Batteries Electric Vehicles on page 1 4 2 Place the Tow Run switch in the RUN position and the Forward Reverse switch in the NEUTRAL position The multimeter should indicate zero volts DC at this time 3 While monitoring the multimeter place the Forward Reverse switch in the REVERSE position The multimeter ...

Page 185: ...s 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 2 3 Disconnect the 16 pin connector at the speed controller 4 Using a multimeter set for 200 volts DC insert the red probe of the multimeter into pin 9 gray wire of the 16 pin connector See follo...

Page 186: ... 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 batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 1 4 2 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 eac...

Page 187: ...ee Test Procedure 6 Tow Run Switch on page 13 19 Key switch for proper operation See Test Procedure 8 Key Switch and MCOR3 Limit Switch Circuit on page 13 20 TEST PROCEDURE 17 Pin 12 See General Warnings on page 1 2 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 to the s...

Page 188: ...led Rectifier SCR Circuit See General Warnings on page 1 2 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 on t...

Page 189: ...f the reading in step 1 is 48 volts plug the DC cord into the vehicle 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 wh...

Page 190: ...e reading is zero volts check the continuity 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 the red motor speed sensor 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 bat...

Page 191: ... page 1 4 3 Disconnect the two 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 be no continuity 5 Connect the three wires crimped together to the forward large solenoid post Install washer and nut on large solenoid pos...

Page 192: ...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 the rocker switch and place the red probe on the orange wire terminal With the switch in REVERSE there should be continuity If the readings are incorrect replace the switch TEST PROCEDURE 24 Reverse Buzzer See General Warnings on page 1 2...

Page 193: ...efer to Wiring Diagrams on page 13 3 TEST PROCEDURE 26 Battery Warning Light See General Warnings on page 1 2 1 Reboot the OBC and drive the vehicle a short distance When vehicle is first driven the battery warning light should illuminate for 10 seconds See Test Procedure 25 Rebooting the Onboard Computer on page 13 37 If the battery warning light does not illuminate when rebooting the OBC proceed...

Page 194: ...nnected if AC power to the charger is interrupted The light will go out when AC power is restored The battery warning light will flash quickly after inserting the DC plug indicating the charger s voltage suppressor has failed closed COMMUNICATION DISPLAY MODULE CDM Club Car R COMMUNICATION DISPLAY MODULE DISPLAY FUNCTIONS PRESS AND HOLD BUTTON TO SHOW FUNCTION NUMBER RELEASE BUTTON TO SHOW FUNCTIO...

Page 195: ...completing the charge cycle This means there may be a problem in the charge circuit The CDM also has a low battery indicator which illuminates when CDM batteries are weak and need to be replaced Weak batteries in the CDM may cause the CDM to register inaccurate information or no information USING THE CDM TO RETRIEVE DATA FROM THE ONBOARD COMPUTER 1 Turn the CDM ON 2 Position CDM on seat bottom so ...

Page 196: ...se the following chart as a starting point for troubleshooting problems with communication between the CDM and onboard computer Contact your Club Car representative for more comprehensive information CDM battery is discharged Replace CDM battery Failed CDM unit Replace CDM Failed OBC Replace OBC Remove battery lead and discharge the speed controller See the instructions in the WARNING on page 11 1...

Page 197: ...el 3 Disconnect the wires 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 14 2 Page 14 2 KEY SWITCH INSTALLATION 1 Position the key switch and flat washer 9 in the instrument panel then ins...

Page 198: ...ATTERY WARNING LIGHT See General Warnings on page 1 2 TESTING THE BATTERY WARNING LIGHT See Test Procedure 26 Battery Warning Light on page 13 37 BATTERY WARNING LIGHT REMOVAL 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 1 4 2 Remove instrument panel See Key Switch Removal on page 14 1 3 Disconnect the wires at the warning light ...

Page 199: ...ings on page 1 2 TESTING THE FORWARD REVERSE ROCKER SWITCH See Test Procedure 23 Forward Reverse Rocker Switch on page 13 35 FORWARD REVERSE ROCKER SWITCH REMOVAL 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 1 4 2 Remove two screws 2 that hold Forward Reverse rocker switch housing 1 to the vehicle Figure 14 4 Page 14 4 3 Remove t...

Page 200: ...en to 20 in lb 2 3 N m 4 Place the Tow Run switch in the TOW position and connect the batteries See Connecting the Batteries Electric Vehicles on page 1 4 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 position Make sure that the vehicle ...

Page 201: ... cover to the battery bucket CAUTION Be careful not to break the two hooks 4 on the bottom of the cover Push the bottom of the cover up to release the hooks before pulling cover away from 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 14 5 Page 14 6 Then use the two hooks 4 to ...

Page 202: ...olt 11 that secures the electronics module to the battery bucket Figure 14 8 Page 14 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 14 6 Page 14 7 5 Remove Tow Run switch 2 from electronics module TOW RUN SWITCH INSTALLATION 1 Installation is reverse of removal Make sure flat on switch is aligned ...

Page 203: ... 20 MCOR3 REMOVAL 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 1 4 2 Remove pedal group See Pedal Group Removal Section 5 Page 5 1 3 Disconnect the two pin and three pin connectors from the MCOR3 4 Remove the T25 torx screw securing the MCOR3 to the pedal group 5 Detach the two tabs from the accelerator pedal and remove the MCOR3...

Page 204: ...d discharge the controller See Disconnecting the Batteries Electric Vehicles on page 1 4 2 Remove instrument panel See Key Switch Removal on page 14 1 3 Disconnect the 18 gauge pink and orange 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 ...

Page 205: ...ement on page 15 9 3 Remove the bolt 11 that secures the electronics module to the battery bucket 4 Pull electronics module forward and disconnect the heavy gauge wires from the controller by removing the three screws 9 5 Disconnect the 16 pin connector 4 pin connector and spade connectors from the controller 6 Remove the three self tapping screws 10 that hold the controller to the component mount...

Page 206: ...bolt 11 Figure 14 8 Page 14 11 Tighten bolt to 40 in lb 4 5 N m 6 Install the batteries and battery cables in their original locations See Battery Replacement on page 15 9 7 Place the Tow Run switch in the TOW position and connect the batteries See Connecting the Batteries Electric Vehicles on page 1 4 8 Place the Tow Run switch in the RUN position 9 Inspect the vehicle for proper operation See fo...

Page 207: ...COMPONENTS ELECTRIC VEHICLE WITH POWERDRIVE CHARGER Electronics Module 14 11 8 13 1 5 9 12 15 14 3 4 10 713 Figure 14 8 Electronics Module Removal 2014 Precedent Golf Car Maintenance and Service Manual Page 14 11 ...

Page 208: ...e 14 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 13 3 Tighten screws 9 on the controller to 9 ft lb 12 2 N m 4 Return electronics module to its original location and secure with bolt 11 Tighten bolt to 40 in lb 4 5 N m 5 Install the batteries ...

Page 209: ...13 15 and Test Procedure 22 Solenoid Continuity on page 13 35 SOLENOID REMOVAL 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 1 4 2 Remove the batteries from the vehicle to provide enough room to access the solenoid 5 Figure 14 8 Page 14 11 See Battery Replacement on page 15 9 3 Remove the bolt 11 that secures the electronics modul...

Page 210: ...e wires from OBC 5 Disconnect the 6 gauge black wire that passes through the OBC from the B terminal 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 co...

Page 211: ...THE CHARGER RECEPTACLE See Test Procedure 20 Voltage at Charger Receptacle Red Wire Socket on page 13 33 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 ...

Page 212: ...rews 1 that secure the receptacle to the bucket Tighten screws to 16 in lb 1 8 N m 4 Connect gray wire to the OBC Make sure boot is properly seated 5 Connect the black wire to the mating connector Make sure connector is fully seated 6 Connect the red wire to the positive post of battery no 1 7 Install kick plate See Kick Plate and Charger Receptacle Bezel on page 4 9 8 Place the Tow Run switch in ...

Page 213: ...ll a physician immediately 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 connections are clean and properly tightened ...

Page 214: ...ectric accessories Use of a single point watering system SPWS MEASURING VOLTAGE OF BATTERY SET 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 the reading MEASURING VOLTAGE OF AN INDIVIDUAL BATTERY Set the multimeter to 20 volts DC and place the red probe on the positive post and the black p...

Page 215: ... battery charger for proper output and operation Recharge the batteries and repeat the Fully Charge Batteries Test If after repeated attempts the charger does not fall below 6 0 amps and over 56 0 volts record the test values as measured and proceed to the Hydrometer Test HYDROMETER TEST NOTE Specific gravity is dependent on electrolyte temperature Note and record electrolyte temperature of each c...

Page 216: ...e specific gravity reading and return the electrolyte to the cell from which it was taken 8 Repeat steps 3 through 7 on all remaining cells 9 Replace vent caps 10 Using the electrolyte temperature readings from step 3 correct the specific gravity readings for temperature See Hydrometer Calibration on page 15 4 Hydrometer Calibration Most hydrometers are calibrated to read correctly at 80 F 26 7 C ...

Page 217: ...165 0 004 1 169 1 160 0 004 1 164 1 165 0 004 1 169 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 1 270 0 012 1 258 Bad no 2 Cell 69 5 80 F 26 7 C 0 000 1 250 0 1 250 1 255 0 1 255 1 230 0 1 230 1 250 0 1 250 Weak no 3 Cell Catch up Charge 38 2 100 F 37 8 C 0 008 1 200 0 008 1 208 1 180 0 008 1 188 1 170 0 008 1 178 1 180 0 008 1 188 Dischar...

Page 218: ...battery no 6 2500 30100 10411 Figure 15 3 Battery Discharge Test 6 x 8 Volt Battery Configuration 1 Be sure the batteries are fully charged and that the electrolyte level is correct in all cells 2 Using a battery thermometer CC P N 1011767 record electrolyte temperature of cell no 2 second cell from positive post in each battery 3 Connect the tester leads to the positive post of battery no 1 and n...

Page 219: ...minutes replace batteries below 6 7 volts Refer to the Discharge Time to Shut Off Point reference table for temperature corrected discharge times BATTERY REGROUPING Regrouping is now Club Car s standard battery replacement method Regrouping is the practice of placing batteries of similar condition together in one vehicle For example if there was an issue with the batteries in two cars and the batt...

Page 220: ...grouped BATTERY REGROUPING PROCESS FLOW 6 volt 8 volt and 12 volt batteries 2 Accurate and accumulative Amp Hours are requir ed for Warranty claims Make s ur e to have battery lights on hand to replace ones that may be defective s o you can capture every car s Amp Hour reading 2772 Figure 15 4 Battery Regrouping Process Flow Page 15 8 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 221: ...e 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 water 1 cup 237 mL baking soda per 1 gallon 3 8 L of water does an excellent job of neutralizing ...

Page 222: ... used determines the amount of solids or impurities which get trapped and hence the purity quality of the filtered water In addition the usage frequency of the membrane can also contribute to the filtered water quality Due to the variance in water quality consistency Club Car recommends the use of the deionizer or distilled water Tap Water While the use of tap water without filtering is an alterna...

Page 223: ...worn insulation or frayed wires should be replaced Tighten battery terminals to proper torque See Connecting the Batteries Electric Vehicles on page 1 4 See following WARNING WARNING If battery wire terminals are damaged or corroded replace or clean them as necessary Failure to do so may cause them to overheat during operation and could result in fire property damage or personal injury 3 After use...

Page 224: ...d then coat with Battery Terminal Protector Spray CC P N 1014305 See following NOTE NOTE Dispose of waste water properly 2 Check the electrolyte level weekly Figure 15 5 Add water only after charging unless the electrolyte level is below the top of the plates In this case add just enough water to cover the plates charge and then check the level again Never charge batteries if plates are exposed ab...

Page 225: ...s and then charge the batteries After charging fill with water to the level indicator Filling a battery to the level indicator before charging will result in overfilling because the electrolyte level will rise during charging and some of the electrolyte may bubble out of the cap This reduces the battery s capacity and corrodes the metal parts around it The electrolyte level should be checked weekl...

Page 226: ... the battery cells verifies that all the valves in the SPWS are functioning correctly If a valve fails to open the cell will eventually dry out The initial one time inspection of all cells will identify any occurrence of a valve that fails to open If a valve fails to close it will become evident due to the cell overflowing during routine watering Either failure scenario is rare but should be monit...

Page 227: ...ght on the deionizer to make sure the light is green in color indicating acceptable water quality If the light indicates unacceptable water quality the cartridge must be replaced 6 After ensuring adequate water flow rate press the grey button 7 on the end of the female coupler 8 to disconnect the purger from the pressure regulator Refilling the Batteries 1 Locate the battery fill coupling 9 on the...

Page 228: ...should be removed or unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosion WARNING Only trained technicians should repair or service the charger Contact your nearest Club Car distributor dealer Each charger should have its own dedicated 15 or 20 ampere separately protected circuit breaker or fuse single phase branch circuit in accord...

Page 229: ...in a few moments ammeter returns to previous rate of charge The charger supplied with the electric vehicle resolves the most common problems associated with battery charging Undercharging and overcharging are prevented provided the charger is allowed to shut off by itself Also all cells are automatically given an equalization charge at low current which prolongs battery life Batteries should never...

Page 230: ...plug receptacle or cords are cut worn have any exposed 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 65 F 18 3 C batteries charged in unheated areas should be placed on charge as soon as possible after use Batteries are warmest immediately after use and cold batterie...

Page 231: ...od electrical contact cleaner or lightly sprayed with WD 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 ...

Page 232: ...ervice manual FLEET 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 ca...

Page 233: ...SECTION 16 BATTERY CHARGER POWERDRIVE 16 Refer to the appropriate battery charger maintenance and service manual 2014 Precedent Golf Car Maintenance and Service Manual Page 16 1 ...

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Page 235: ... using a multimeter or continuity tester NOTE Observe the following before testing the motor This is only testing continuity Tag the motor wires for identification before disconnecting Remove motor wire from one of the A terminals and one of the F terminals if testing while motor is in vehicle When disconnecting wires from motor terminals use a second wrench on the lower nut of the terminal post t...

Page 236: ...Installation on page 17 15 6 Connect the batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 TEST PROCEDURE 2 Armature Circuit Open See General Warnings on page 1 2 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles Section 1 Page 1 4 2 Disconnect wires from the A1 and A2 terminals on the motor using two wrenches to pre...

Page 237: ...be removed from the vehicle and repaired by a qualified technician See Motor Removal on page 17 4 3 If reading is correct reconnect the motor wires See Motor Installation on page 17 15 4 Connect the batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 2014 Precedent Golf Car Maintenance and Service Manual Page 17 3 ...

Page 238: ...g 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 brakes 729 Figure 17 1 Lift Vehicle...

Page 239: ...motor 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 17 4 Speed Sensor Magnet 749 Figure 17 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 ...

Page 240: ...ere is 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 17 6 Page 17 6 6 Remove the two end cap bolts 7 Remove the end cap and armature from the motor...

Page 241: ...emove 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 17 9 Page 17 7 12 3 Remove the two screws and the brush rigging to the end cap Figure 17 10 Page 17 8 13 Inspect the terminal insulators See Terminal Insulator Inspection on page 17 10 14 Remove the bearing from the end cap 14 1 Remove the retai...

Page 242: ...page 17 5 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 determin...

Page 243: ...il 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 17 12 Page 17 9 If t...

Page 244: ... spring 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 g Figure 17 13 Page 17 11 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 17 1...

Page 245: ... cloth 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 17 14 Page 17 11 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 17 13 Brush Sprin...

Page 246: ...ng and Inspection MOTOR MODEL EJ8 4001A ELECTRIC VEHICLE 10 24 23 25 4 5 6 7 9 12 8 14 13 15 16 16 11 1 2 17 18 3 30 2613 Figure 17 15 Electric Motor EJ8 4001A Page 17 12 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 247: ...Install the retaining ring to secure the bearing Figure 17 11 Page 17 8 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 rig...

Page 248: ...e 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 17 19 Page 17 14 5 Align the match marks on the end cap and the motor frame 1 and secure with two bolts 16 Figure 17 15 Page 17 12 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 ...

Page 249: ...oximately 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 17 20 Grease on Putty Knife 742 Figure 17 21 Application of grease to Input Shaft Grooves 2 6 Check the chamfer 1 and end 2 of the input shaft to ensure t...

Page 250: ...ansaxle 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 center bolt 3 to 100 in lb 11 3 N m 4 5 Tighten the left and right bolts 1 and 2 to 100 in lb 11 3 N m 4 6 Retighten all three bolts 1 2 and 3 to 100 in lb 11 3 N m 4 7 Install the motor wires making sure they are...

Page 251: ...e and remove jack stands Lower vehicle to the floor and tighten lug nuts using a crisscross pattern to 55 ft lb 74 6 N m 10 Connect the batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 11 Place the Tow Run switch in the RUN position 12 Inspect the vehicle for proper operation See following WARNING WARNING Make sure that the vehicle operates in the forward direction when ...

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Page 253: ... 2 AXLE SHAFT Axle Shaft and Oil Seal Removal 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 1 4 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 WARNING Lift only one end in General W...

Page 254: ...e oil seal 15 from the adapter ring 39 Figure 18 3 Page 18 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 18 5 Page 18 3 If the bearing in a Type G transaxle is worn or damaged the entire axle shaft assembly 1 or 2 must be r...

Page 255: ...and Shaft 18 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 18 5 Transaxle Type G 2014 Precedent Golf Car Maintenance and Service Manual Page 18 3 ...

Page 256: ... 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 18 5 Page 18 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 bearin...

Page 257: ... Figure 18 6 Vehicle Supported on Jack Stands 651 Figure 18 7 Brake Cable 6 Disconnect the shock absorbers from their lower mounts Figure 18 8 Page 18 6 7 Disconnect the four motor wires Use two wrenches to prevent the post from turning 8 With a floor jack supporting the transaxle remove lower spring shackle nuts and bolts Position shackles so they are clear of springs Figure 18 9 Page 18 6 9 If a...

Page 258: ... 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 page 18 1 See following NOTE NOTE Recycle or dispose of used oil or lubricant in accordance with local state and federal regulations 16 Remove the brake assemblies if required See Brake Cluster Removal on page...

Page 259: ... assembly 19 Lift intermediate gear assembly and differential gear case unit out simultaneously Figure 18 5 Page 18 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 18 5 Page 18 3 See also Figure 18 12 Page 18 7 See following ...

Page 260: ... through differential gear case from one side Figure 18 5 Page 18 3 See also Figure 18 14 Page 18 8 8 5 Remove the idler gears 1 and 2 and thrust plates 3 and 4 Figure 18 15 Page 18 8 1 5 6 26 2 8 7 3 4 773 Figure 18 14 Differential Pin 774 Figure 18 15 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 ...

Page 261: ... housing 8 2 Install left half of transaxle housing 20 Figure 18 5 Page 18 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 18 5 Page 18 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 s...

Page 262: ...erential while guiding 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...

Page 263: ...ion 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 2014 Precedent Golf Car Maintenance and Service Manual Page 18 11 ...

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Page 265: ...anual TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Spark plug is partially fouled or in poor condition See Section 21 AS26 FE 350 Engine Spark plug wire is damaged or loose See Section 21 AS26 FE 350 Engine Loose wire connection at ignition coil or RPM limiter See Section 19 Troubleshooting and Electrical System Gasoline Vehicle Test Procedures 13 Ignition Spark and 14 Ignition Coil Inte...

Page 266: ...l System Gasoline Vehicle Test Procedures 13 Ignition Spark and 14 Ignition Coil Ignition coil failed See Section 19 Troubleshooting and Electrical System Gasoline Vehicle Test Procedures 13 Ignition Spark and 14 Ignition Coil Engine flooded with fuel as result of excess choking Refer to the appropriate owner s manual See Choke Kill circuit grounded See Section 19 Troubleshooting and Electrical Sy...

Page 267: ...ine power Torque converter is not backshifting properly See Section 25 Torque Converter Gasoline Vehicle Incorrect plug See Section 21 AS26 FE 350 Engine Spark plug wire is damaged See Section 21 AS26 FE 350 Engine Unsuitable fuel or incorrect rich fuel mixture Fuel System on page 22 1 Ignition coil failed See Section 19 Troubleshooting and Electrical System Gasoline Vehicle Test Procedures 13 Ign...

Page 268: ...d with fuel Fuel System on page 22 1 Loose or broken wire in starter generator circuit Test Procedure 10 Starter Generator Generator Function on page 19 21 Generator field coil is shorted Test Procedure 10 Starter Generator Generator Function on page 19 21 Brushes are worn or commutator is dirty See Section 20 Electrical Components Gasoline Vehicle Starter generator belt is loose or slipping Belt ...

Page 269: ...Engine RPM Adjustment on page 22 9 Drive belt is worn cracked glazed or frayed See Section 25 Torque Converter Gasoline Vehicle Drive clutch malfunction See Section 25 Torque Converter Gasoline Vehicle Driven clutch malfunction See Section 25 Torque Converter Gasoline Vehicle Torque converter does not shift smoothly Governor is sticking See Section 24 Unitized Transaxle Gasoline Vehicle Kill circu...

Page 270: ...18_BL U_WHT W07 18_BL U_WHT W07 18_BL U W35 18_BL U W35 18_WHT_BLK W10 16_BLK_WHT _ STP W38 16_BLK_WHT_STP W38 16_WHT W39 16_YEL W12 16_YEL W12 18_ORG W13 18_ORG W13 16_RED_W HT W14 16_RED_W HT W14 16_BLK_WHT W28 16_BLK_WHT W45 16_BLK_WHT W43 16_BLK_WHT W44 16_RED W40 12_BLU W41 CONNECTS TO 9 PIN CONNECTOR FORLIGHT S CONNECTSTO 9 PINCONNEC TOR FORIPCONTR OLS 3 PIN CONNECTOR 3 PINCONNECT OR 20 AM P...

Page 271: ... 18_ORG W49 16_WHT W39 18_YEL W31 18_RE D W47 16_RE D W48 6_GRE EN_HIGH_TE MP W51 VOL TAGE REGULATOR 18 YEL 18 RED 18 BLK OILSENDINGUNIT ENGINEKIL LHOOKUP FRAME GR OUND ENGINEGR OUND FORWARD REVERSE LI MITSWITCHES THROTTLE POSITION SENSOR 10 AMP FU SE 3 PINCONNECTOR 10_BLK W119 6_WHT W32 6_BL K W27 6_RE D W19 16_RE D W46 A B C D E F Sonic_9 Sonic_6 Sonic_1 Sonic_5 Sonic_2 18_BLU W120 16_GR N W09 1...

Page 272: ... BROWN 16 YELLOW 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 WD1025145Y4 L Figure 19 3 Precedent Gasoline V...

Page 273: ...HITE 14 BLUE 14 Y ELLOW 16 BROWN WHITE 16 BROWN 16 YELLOW 16 YELLOW 16 WHITE 16 BLUE WHITE 16 RED 16 RED 16 RED 16 GREE N 16 ORANGE 16 BLACK DIODE BRAKE LIGHT RELAY NOTE SOME WIRING COMPONENTS SHOWN ARE OPTIONALACCESSORIES SONIC WELD SONIC WELD LIGHT SWITCH Voltage Limiter SONIC WELD 18 O RANGE 16 ORAN GE 18 BLUE WHITE 18 BLUE WHT 18 BLACK SONIC WELD 14 B LK 16 BLUE 16 GREE N 16 B LK 16 B LUE 16 B...

Page 274: ...TE 16 RED 18 RED WHITE 18 RED WHITE 18 ORANGE 18 BLUE 18 BLUE 16 RED REVERSE BUZZER OIL LIGHT KEYSWITCH I G S M FUEL GAUGE NOTE SOME WIRING COMPONENTS SHOWN ARE OPTIONALACCESSORIES 18 BLUE 18 BLACK 9 PINCONNECTOR CONNECTS TO MAINHARNESS SEE FIGURES 11 1 AND 11 2 WD1025145Y5 Figure 19 5 Precedent Gasoline Vehicle Instrument Panel Wiring Diagram Page 19 10 2014 Precedent Golf Car Maintenance and Ser...

Page 275: ...e the troubleshooting flow charts in the circuit testing section to find the proper test procedure to correct the electrical problem TEST PROCEDURES Index of Test Procedures 1 Battery 2 Fuse 3 Ground Cables 4 Key Switch Starter Circuit 5 Throttle Position Sensor TPS 6 Solenoid 7 Neutral Lockout Limit Switch 8 Starter Generator Starter Function 9 Wire Continuity 10 Starter Generator Generator Funct...

Page 276: ...he neutral lockout cam in the MAINTENANCE position put the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Check for loose or corroded battery terminal connections Remove the negative cable first and clean tighten and replace connections as necessary Hydrometer Test A hydrometer P N 1011478 measures the specific gravity The greater the specific gravity the greater the state o...

Page 277: ...6 C above 80 F 27 C add 0 004 to the reading For each 10 F 5 6 C below 80 F 27 C subtract 0 004 from the reading Interpreting the Results of the Hydrometer Test The approximate state of charge can be determined by referring to the following table SPECIFIC GRAVITY TEMPERATURE CORRECTED APPROXIMATE STATE OF CHARGE 1 250 to 1 280 100 1 220 to 1 240 75 1 190 to 1 210 50 1 160 to 1 180 25 If the differ...

Page 278: ...C 9 3 V 30 F 1 C 9 1 V 20 F 7 C 8 9 V 10 F 12 C 8 7 V 0 F 18 C 8 5 V 4 If the battery is found to be good or if the electrical problem continues after the battery has been replaced with a good one test the electrical circuits TEST PROCEDURE 2 Fuse See General Warnings on page 1 2 The fuse red 10 amp is located in the wiring harness Figure 19 8 Page 19 15 1 Disconnect battery See Disconnecting the ...

Page 279: ...y clean and tighten cable connections If the connections are good repair or replace the cable 3 Check the engine ground cable 3 1 Place the red probe of the multimeter on the ground cable terminal end located on the oil filler bracket on the engine Figure 19 10 Page 19 15 Place the black probe on the vehicle frame The reading should be continuity If the reading is incorrect clean and tighten cable...

Page 280: ...0 ohms Place the red probe on the terminal for the fuel tank ground connection and place the black probe on the vehicle frame Figure 19 12 Page 19 16 The reading should be continuity If there is no continuity clean and tighten all cable connections If the connections are good repair or replace the cable 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A CO...

Page 281: ...of the circuit used to energize the starter solenoid NOTE Keep the battery connected while performing this test procedure 1 Place the neutral lockout cam in the MAINTENANCE position put the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Disconnect the spark plug wire from the spark plug 3 Disconnect white black wire bullet connector located on the front of engine Figure 19 2...

Page 282: ...at rest in the fully raised position the meter should indicate approximately 1 0 volt 6 Press the accelerator to engage the starter and engine With accelerator pedal pressed the meter should indicate an over limit no continuity condition If either reading is incorrect replace the accelerator pedal assembly See Accelerator Pedal Removal on page 5 6 TEST PROCEDURE 6 Solenoid See General Warnings on ...

Page 283: ... the large post that does not have wires connected to it Place the black probe on the vehicle frame Turn key switch to the ON position press accelerator pedal and listen for solenoid click The meter should read full battery voltage If the reading is incorrect replace the solenoid Figure 19 16 Page 19 19 9 Disconnect the 10 gauge black cables from the negative post of the battery before reconnectin...

Page 284: ...hat wires are connected correctly and are tight If they are not rewire or tighten as necessary 3 Disconnect the wires from all the terminals on the starter generator Then place the black probe of a multimeter set to 200 ohms on the starter generator housing scratch through the paint to ensure a good ground While holding the black probe against the housing place the red probe one at a time on the A...

Page 285: ...n 20 Electrical Components Gasoline Vehicle 7 With the wires still disconnected using a multimeter set on 200 ohms place the red probe on the DF terminal and the black probe on the F1 terminal The reading should be between 4 5 and 5 5 ohms If the reading is incorrect a possible grounded DF terminal and or grounded field coil may be the cause The starter generator will need to be removed from the v...

Page 286: ...n page 1 2 NOTE Keep the battery connected while performing this test procedure 1 Place the neutral lockout cam in the MAINTENANCE position put the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Ensure that the wires are connected correctly and are tight If they are not rewire or tighten as necessary 3 Check the engine RPM setting to ensure that it is correctly adjusted See ...

Page 287: ...hite black wire Figure 19 22 Page 19 24 3 Start the engine in a well ventilated area Turn the key switch to the ON position Press the accelerator pedal to start the engine 4 If the engine begins to run test the engine kill circuit for a shorted wire or other failed components in the engine kill circuit See Key Switch Engine Kill Circuit on page 19 28 See following WARNING WARNING When the white bl...

Page 288: ...ect spark Figure 19 21 Page 19 24 2 1 Adjust the tester probes to approximately 18 000 volts 18 Kv setting SE Small Engine Setting on the Thexton 404 tool Connect the tester to the spark plug wire and connect the alligator clip to a solid engine ground 2 2 Start the engine There should be a strong blue spark between the probes of the spark gap tester If there is no spark or if the spark is a faint...

Page 289: ... given in these tests reflect a tolerance of 40 Please note that these values are rough standard and it is impossible to reach an exact conclusion with the resistance reading Ignition Coil In Vehicle Test 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 1 Page 1 3 2 Using an analog multimeter set to x1k ohms measure the primary coil resistance 2 1 ...

Page 290: ... or frame Figure 19 24 Page 19 26 3 2 If the resistance is between 8 6k to 20 2k ohms the secondary coil and spark plug cap are within acceptable limits proceed to step 5 If the resistance is not between 8 6k to 20 2k ohms the spark plug cap and secondary coil must be tested independently from each other 4 Test the spark plug cap separately from the secondary coil 4 1 Remove the rubber gasket 1 on...

Page 291: ...ed V V A x10 x1 0 0 30 15 0 30 300 300 30 600 x100 x1k 600 OFF 2 1 1 x1K Ohm Setting 2 Spark Plug Cap 2651 Figure 19 27 Spark Plug Cap Test 5 If the preceding tests indicate that the ignition coil resistance readings are within acceptable ranges but the coil fails to function properly proceed to the following bench test procedures Ignition Coil Bench Test 1 Remove the coil from the engine See Igni...

Page 292: ...t previously tested test the spark plug cap separately from the secondary coil 4 1 Remove the rubber gasket 1 on the plug cap 2 by rolling back the gasket onto the spark plug wire 3 Figure 19 25 Page 19 27 4 2 Remove the cap from the wire by turning the cap counterclockwise three or four revolutions while gently pulling it off the wire Figure 19 26 Page 19 27 4 3 Using a multimeter set to 20k ohms...

Page 293: ... 24 3 Connect red probe of multimeter to the male bullet terminal on the white black wire and connect the black probe to the vehicle frame 4 Turn the key switch ON place the Forward Reverse handle in FORWARD and press the accelerator pedal There should be no continuity If there is continuity check for worn insulation on the white black wire that may be allowing the engine kill wire to ground to th...

Page 294: ...se of used oil 4 Turn the key switch ON closing the circuit The low oil warning light should illuminate If the low oil warning light does not illuminate the oil level sensor needs to be replaced See Oil Level Sensor on page 20 27 5 Install a new oil filter and fill the engine with new oil before returning the vehicle to service See Engine Oil Gasoline Vehicles on page 10 9 TEST PROCEDURE 20 Low Oi...

Page 295: ...ng is over 9 6 volts with an electrolyte temperature of 70 F 21 C check the starter generator See following NOTE NOTE The voltage reading listed is for electrolyte at 70 F 21 C At lower electrolyte temperatures the voltage reading will be lower 5 If the reading is below 9 6 volts with an electrolyte temperature of 70 F 21 C check the battery See Test Procedure 1 Battery on page 19 12 6 If the read...

Page 296: ...re from the fuel level sending unit to the fuel gauge Leave the battery disconnected while checking continuity Also check the continuity of the blue wire from the fuel gauge to the key switch and the black ground wires at the fuel level sending unit and at the fuel gauge See Fuel Gauge Removal on page 20 22 7 If the readings are correct according to the position of the float but give an incorrect ...

Page 297: ...REMOVE 18 GAUGE ORANGE WIRE 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200mA MAX 1000 750V FUSED 1 I G S REAR VIEW OF FUEL GAUGE 18 GAUGE ORANGE WIRE 2429 Figure 19 32 Fuel Gauge Test 2430 Figure 19 33 Fuel Gauge Voltage Test TEST PROCEDURE 25 Hour Meter See General Warnings on page 1 2 NOTE Keep the battery connected while performing this test...

Page 298: ......

Page 299: ...AL DF F2 5 11 4 9 12 1 10 7 2 F1 A2 A1 14 13 1389 Figure 20 1 Starter Generator Removal 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 3 2 Remove the access panel on the vehicle 3 Mark and disconnect the wires from the starter generator 1 Loosen the two pivot nuts 7 and bolts 5 Figure 20 1 Page 20 1 4 Remove the mounting adjustment nut 12 washe...

Page 300: ...hes 2 Remove the two bolts 20 and pull commutator end cover 23 free of starter generator housing 24 Figure 20 2 Page 20 2 3 Remove terminal hardware 31 screws and lock washers 25 brush holder assembly 26 brush springs 28 and brushes 27 Make note of the routing of the brushes and wires between the brush holder assembly and the inside of the commutator end cover for later reassembly Figure 20 3 Page...

Page 301: ...n the brush holder assembly 26 and the inside of the commutator end cover cover 23 and assemble using the screws and lock washers 25 Using a spring scale test brush spring tension If any spring has a tension less than 14 8 ounce force ozf 419 6 gram force gf replace all four springs Figure 20 5 Page 20 3 See following CAUTION CAUTION When checking brush spring tension do not push springs beyond th...

Page 302: ... terminal Install the remaining three brush covers 29 in the openings in the commutator end cover 23 Figure 20 3 Page 20 2 1341 Figure 20 6 Pull Brushes Away from Center of the Commutator End Cover DISASSEMBLY OF THE STARTER GENERATOR TO SERVICE THE ARMATURE COMMUTATOR 1 Remove the commutator end cover to prevent damage to the brushes and armature See Disassembly of the Starter Generator to Servic...

Page 303: ... A and radial B play Figure 20 8 Page 20 5 2 Replace the bearing if it is noisy does not spin smoothly or has excessive play Check the bearings and replace if rusted worn cracked or if there is an abnormal color change in the metal of the bearing Bearings should be replaced if there is extensive wear or pitting on the balls or on the rolling surfaces Do not remove the bearings unless they are to b...

Page 304: ...ipe 6 Press against armature shaft 7 Use bearing puller if a press is not available 494 Figure 20 9 Bearing Removal FIELD COIL ASSEMBLY Replace entire field coil housing assembly if coils pole shoes or terminals are damaged Figure 20 10 Page 20 7 VISUAL INSPECTION OF ARMATURE Obvious defects can be seen by examining the armature If an armature has frayed or charred insulation broken wires or throw...

Page 305: ...two places 90 degrees apart 496 Figure 20 11 Inspect Commutator 1 Clean the carbon dust dirt and oil from the commutator Visually inspect the commutator for worn burned or glazed areas Check for loose or raised commutator bars Slight roughness of the commutator can be polished away with 400 grit or finer sandpaper See following CAUTION 2014 Precedent Golf Car Maintenance and Service Manual Page 20...

Page 306: ...ultimeter set on 200 ohms place the positive probe on the commutator bars and the negative probe on the armature core The reading should be no continuity If the reading is incorrect replace the armature and the two bearings Figure 20 12 Page 20 8 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 1 3 2 1 200 Ohms Setting 2 Com...

Page 307: ... the housing with field coils over the armature Use the tapped mounting holes to align housing to the cover rotate and orient as shown NOTE The terminal insulators should be on the commutator end of the housing 5 To prevent contact between the brushes and commutator as the commutator cover is installed and possible damage to the brushes lift the brush springs out of the notches in the brushes and ...

Page 308: ... going through the bracket Install a lock nut 7 onto each bolt Tighten to finger tight Figure 20 14 Page 20 11 2 Install the adjustment bolt 11 through the adjusting bracket 4 and then through the starter generator Install a lock washer 9 and 5 16 inch nut 12 onto the end of the adjustment bolt 11 Tighten to finger tight 3 Install the belt 3 then tighten the mounting bolts See Belt Tension Adjustm...

Page 309: ...tall the starter generator belt 3 around the pulley 10 on the end of the starter generator 5 Position a pry bar 13 between the top of the starter generator mounting bracket 2 and the underside of the starter generator by passing the pry bar under the exhaust header 6 While holding the pry bar measure the belt tension using a Krikit gauge 1 available at NAPA Auto Parts stores or equivalent Proper t...

Page 310: ...20 Starter Generator ELECTRICAL COMPONENTS GASO LINE VEHICLE 1 2 1 Belt Tension Gauge 2 End View 499 Figure 20 15 Belt Tension Gauge Page 20 12 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 311: ...1 3 2432 Figure 20 16 Voltage Regulator VOLTAGE REGULATOR INSTALLATION 1 Position the voltage regulator 1 and install the mounting screw 2 Figure 20 16 Page 20 13 Tighten screw to 23 in lb 2 6 N m 2 Connect the voltage regulator three pin connector 3 to the wire harness 3 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 4 4 Place Forward Reverse handle i...

Page 312: ... 2 Figure 20 17 Page 20 14 2 2 Rotate the instrument panel up and away from the dash to disengage the tabs at the top of the instrument panel 2 3 Disconnect the electrical connector 3 to the instrument panel 2 1 1 3 4 9 6 8 2433 Figure 20 17 Instrument Panel Removal 703 Figure 20 18 Key Switch 3 Disconnect the wires from the key switch 4 From the back of the instrument panel push down on the retai...

Page 313: ...onnect all the wires from the solenoid 3 Remove the two screws securing the solenoid in place 4 Remove the solenoid SOLENOID INSTALLATION 1 Install the solenoid in the vehicle Use two screws to secure the solenoid and tighten to 14 in lb 1 6 N m 2 Connect the ring terminal with the 10 gauge white wire and the 16 gauge red wire on a large post on the solenoid See Wiring Diagrams Throttle Position S...

Page 314: ...ith a higher amp rating is used damage to the vehicle electrical system may occur 2 Install the cover on the fuse holder 3 Connect battery See Connecting the Battery Gasoline Vehicles on page 1 4 LIMIT SWITCHES ACCELERATOR PEDAL LIMIT SWITCH See General Warnings on page 1 2 Testing the Accelerator Pedal Limit Switch See Test Procedure 5 Throttle Position Sensor TPS on page 19 17 The accelerator pe...

Page 315: ...Disconnecting the Battery Gasoline Vehicles on page 1 3 2 Disconnect the wires from the neutral lockout limit switch 5 located on the back of the Forward Reverse shifter assembly Figure 20 19 Page 20 17 3 Remove two nuts 2 and washers 6 from the neutral lockout limit switch 5 and slide the neutral lockout limit switch off of the screws Neutral Lockout Limit Switch Installation 1 Install the neutra...

Page 316: ... See General Warnings on page 1 2 If the cam lobes have worn to the point where they will no longer activate the neutral lockout limit switch the cam must be replaced TESTING THE NEUTRAL LOCKOUT CAM See Test Procedure 21 Neutral Lockout Cam on page 19 31 NEUTRAL LOCKOUT CAM REMOVAL 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 3 2 Remove the e...

Page 317: ... 3 5 in lb 0 40 N m Figure 20 21 Page 20 19 2 Connect the black wire 1 from the wire harness to the negative terminal on the buzzer 3 Connect the red white wire 4 from the wire harness to the positive terminal on the buzzer 4 Install the instrument panel 4 1 Connect the electrical connector 3 Figure 20 17 Page 20 14 4 2 Position the instrument panel 2 on the dash assembly Make sure tabs on upper e...

Page 318: ...he reverse buzzer limit switch off the screws REVERSE BUZZER LIMIT SWITCH INSTALLATION 1 Install the reverse buzzer limit switch 4 and then install two spacers 9 against the limit switch Figure 20 19 Page 20 17 2 Install the neutral lockout limit switch 5 with two washers 6 and two nuts 2 Tighten to 5 in lb 0 6 N m See following CAUTION CAUTION Do not overtighten the retaining nuts If the nuts are...

Page 319: ...w Oil Warning Light LOW OIL WARNING LIGHT INSTALLATION 1 Push a new unit into hole in instrument panel until plastic tabs engage Figure 20 22 Page 20 21 2 Connect yellow and yellow white wires from the wire harness to the low oil warning light 3 Install the instrument panel 3 1 Connect the electrical connector 3 Figure 20 17 Page 20 14 3 2 Position the instrument panel 2 on the dash assembly Make ...

Page 320: ... gauge from the instrument panel 3 5 4 2 BLACK ORANGE BLUE Bracket 5 may vary in appearance 2437 Figure 20 23 Fuel Gauge Installation FUEL GAUGE INSTALLATION 1 Install a new fuel gauge into hole in instrument panel until flange seats against panel Figure 20 23 Page 20 22 2 Slide the mounting bracket 5 onto the two threaded studs on the fuel gauge and secure with two lock washers 4 and two hex nuts...

Page 321: ...he fuel tank TESTING THE FUEL LEVEL SENDING UNIT See Test Procedure 23 Fuel Level Sending Unit on page 19 31 HOUR METER See General Warnings on page 1 2 TESTING THE HOUR METER See Test Procedure 25 Hour Meter on page 19 33 The hour meter displays the number of hours of use in increments of 0 1 hour HOUR METER REMOVAL 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline...

Page 322: ...the wire harness to the stiffener 1 and remove the bolts 2 and nuts 3 securing the stiffener to the mounting plate 4 Figure 20 25 Page 20 25 5 Remove the pan head bolts 5 securing the fan shroud 8 to the fan housing 9 Figure 20 26 Page 20 25 6 Loosen but do not remove the three bolts 6 attaching the fan housing as shown 7 Remove the remaining four bolts 10 attaching the fan housing as shown Figure...

Page 323: ...t must be removed from the old coil and installed on the new coil See steps 1 through 8 for procedures to remove and install these existing parts If the existing ignition coil will be remounted proceed to step 9 1 Remove the rubber gasket 1 on the plug cap 2 by rolling back the gasket onto the spark plug wire Figure 20 28 Page 20 26 2 Remove the cap 2 from the wire by turning the cap counterclock ...

Page 324: ... bronze feeler gauge to set the air gap between the ignition coil and the flywheel magnet Tighten the two mounting bolts 6 to 30 in lb 3 4 N m Figure 20 29 Page 20 26 11 Connect the 18 gauge black wire to the spade terminal on the coil 12 Position the fan housing close to the engine crankcase and slide the plug wire grommet into the notch on the housing 13 When installing fan housing make sure the...

Page 325: ...OR INSTALLATION See Oil Level Sensor Installation on page 21 6 BATTERY See General Warnings on page 1 2 DANGER Due to the danger of an exploding battery wear a full face shield and rubber gloves when working around a battery Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full...

Page 326: ...re 1 Battery on page 19 12 BATTERY GASOLINE VEHICLES See General Warnings on page 1 2 DANGER Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries Tools wires and metal objects can cause sparks when shorted across ...

Page 327: ...tes Electrolyte level at least 1 2 inch 13 mm above plates or to level indicator 72 Figure 20 30 Gasoline Vehicle Battery 22 Figure 20 31 Electrolyte Level for Battery PREVENTIVE MAINTENANCE To keep the battery in good operating condition follow these steps on a regular basis 1 Any corrosion build up on or around the battery should be removed immediately Post connections should be clean and tight ...

Page 328: ...r or when the battery becomes old 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 22 Figure 20 32 Battery Water Level VIBRATION DAMAGE The battery hold down clamp should always be tight enough to keep the battery from bouncing Battery life may be severely shortened if the clamp is too loose Excessive vibration shortens the life of...

Page 329: ... also DANGER on page 20 27 1 Charge the battery using an automotive type 12 volt battery charger Follow all warnings and procedures supplied by the battery charger manufacturer 2 Attach the positive charger cable to the positive battery post 3 Attach the negative charger cable to the negative battery post 4 The battery may be charged with a slow charge 3 to 10 amps or a fast charge 20 to 30 amps C...

Page 330: ...eriodically A battery that is discharged and left in a cold environment can freeze and crack If the specific gravity drops below 1 220 the battery should be recharged See following WARNING WARNING If the battery is frozen or the container is bulged discard battery A frozen battery can explode 6 The frequency of recharging required depends on the temperature of the storage area but it is recommende...

Page 331: ...ELECTRICAL COMPONENTS GASOLINE VEHICLE Ground Cables 20 TESTING THE GROUND CABLES See Test Procedure 3 Ground Cables on page 19 15 2014 Precedent Golf Car Maintenance and Service Manual Page 20 33 ...

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Page 333: ...nkcase assembly See following NOTE NOTE Engine rotation is clockwise as viewed from the clutch side of the engine This section contains information for removing and replacing the engine For complete instruction on engine disassembly repair rebuilding and reassembly see your authorized dealer BEFORE SERVICING Carefully read the applicable information and instructions before beginning engine service...

Page 334: ...is too rich White burned or melted electrodes indicate the fuel is too lean or pre igniting Oily deposits on the plug electrode are an indication of worn rings valve guides cylinder wall etc Also examine the spark plug wire Remove rubber boot and inspect internal spring for damage Inspect spark plug wire for damage and be sure spring coil is securely attached to spark plug See following WARNING WA...

Page 335: ...gine through the piston rings oil seals or gaskets The breather has a reed valve which limits the direction of air flow caused by the piston moving up and down Air can flow out of the crankcase but the one way reed valve blocks return flow and therefore maintains a vacuum in the crankcase Oil laden air in the crankcase passes through the reed valve and expands into the rocker chamber In the rocker...

Page 336: ...ne 1 Remove the powertrain See Unitized Transaxle Removal on page 24 10 See following NOTE NOTE The crankshaft has left hand threads at the clutch mounting hole 2 Remove starter generator See Starter Generator on page 20 1 3 Remove drive clutch See Drive Clutch Removal on page 25 4 and preceding NOTE 4 Remove muffler See Muffler Removal on page 23 1 5 Remove engine mounting hardware items 1 2 5 an...

Page 337: ...mps at two ended bolts 1 and 2 Figure 21 5 Page 21 5 3 Remove eight bolts 3 and remove the crankcase cover 4 See following NOTE NOTE If the crankcase cover sticks tap lightly with a plastic mallet on alternate sides near the dowel pins 5 Figure 21 5 Page 21 5 4 Remove the crankcase cover gasket completely It may stick to the flanged surface of the crankcase 11 12 3 4 1 2 5 5 526 Figure 21 4 Oil Le...

Page 338: ...the cord connection 1 Figure 21 7 Page 21 7 3 Remove the screw 3 from the wire clamp 4 4 Remove the two mounting screws from the inside of the crankcase cover and remove the oil level sensor and bracket 5 If necessary remove the three screws 7 that hold the sensor to the bracket 5 Oil Level Sensor Installation 1 If the oil level sensor was removed from the bracket install sensor 6 into bracket 5 a...

Page 339: ...e warped 1 Clean the gasket surfaces on the crankcase cover to fit a new gasket during installation and inspect the oil seal for wear and damage 2 Install crankcase cover Using HANDS ONLY seat cover completely against the crankcase If the cover will not seat the camshaft is not installed correctly 3 Install and finger tighten evenly the eight cover mounting bolts 4 Tighten the cover mounting bolts...

Page 340: ...ing Figure 21 9 Page 21 8 2 Disconnect the ignition coil 11 from its primary lead wire at the connector 12 Remove the two bolts 10 and take out the ignition coil Figure 21 10 Page 21 8 2 1 1 12 11 13 10 531 Figure 21 9 Flywheel Housing 510 Figure 21 10 Ignition Coil 3 Hold the flywheel 4 not the fan 7 with a strap wrench 5 and using a 25 mm socket remove the flywheel nut and flat washer by turning...

Page 341: ... in the crankshaft Then align the keyway in the flywheel to the key and push the flywheel and fan assembly onto the crankshaft until it seats Install flat washer and nut finger tight 2 Use a strap wrench 3 to keep the flywheel and fan assembly 1 from turning while tightening the flywheel nut to 63 ft lb 85 4 N m Figure 21 13 Page 21 10 See following CAUTION CAUTION The flywheel nut has right hand ...

Page 342: ... Drive Clutch Installation on page 25 12 3 Install drive belt See Drive Belt Installation on page 25 3 4 Install muffler See Muffler Installation on page 23 1 5 Install starter generator and belt See Starter Generator on page 20 1 6 Install the powertrain See Unitized Transaxle Installation on page 24 18 7 Install oil drain plug in the crankcase and tighten to 20 ft lb 27 1 N m Apply a light film ...

Page 343: ...ne Oil Level 10 Install a new or cleaned spark plug gapped between 0 027 to 0 031 inch 0 69 to 0 79 mm and connect plug wire to plug 11 Connect battery See Connecting the Battery Gasoline Vehicles on page 1 4 12 Adjust the engine RPM setting See Engine RPM Adjustment on page 22 9 13 Test drive vehicle to ensure all systems are functional and correctly adjusted 2014 Precedent Golf Car Maintenance a...

Page 344: ...in plug M14 20 ft lb 27 1 N m Fan housing screws M6 90 in lb 10 N m Fan shroud screws M6 25 in lb 2 8 N m Bolts marked with 4 when used with nuts M8 M6 M5 130 in lb 15 N m 50 in lb 5 9 N m 30 in lb 3 4 N m ADJUSTMENTS AND SETTINGS ITEM LIMITS Spark plug gap standard 0 027 to 0 031 in 0 69 to 0 79 mm Ignition coil air gap standard 0 012 in 0 304 mm Compression pressure min 128 psig 883 kPa Cylinder...

Page 345: ...condition Check the following items Spark plug and gap condition See Spark Plug Cleaning Inspection and Repair on page 21 2 Air filter element See Air Filter on page 22 12 Fuel filter See Fuel Filter on page 22 14 Choke and air intake system for restriction of air flow See Choke and Air Intake System on page 22 10 Fuel pump See Fuel Pump on page 22 16 Fuel lines from fuel tank to filter to pump to...

Page 346: ...r FUEL SYSTEM 000 000 22 23 19 7 6 18 000 000 000 000 000 000 1 2 3 4 13 15 12 30 21 26 10 21 5 11 14 16 17 9 8 2698 Figure 22 1 Carburetor Mounting Page 22 2 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 347: ...uretor end only Temporarily plug the end of the fuel line to prevent fuel leakage 2 7 Remove the carburetor retaining nuts 19 intake pipe 17 and carburetor 12 See following NOTE NOTE Note the orientation of the gasket 16 between the carburetor intake pipe 17 and the carburetor body 12 so that it can be replaced in the same orientation Figure 22 1 Page 22 2 When removing the carburetor body the thr...

Page 348: ...ot fall out of the carburetor body after the fuel bowl is removed 7 Remove the main jet 8 from the carburetor body and discard it Figure 22 4 Page 22 4 See following NOTE NOTE Make sure the fuel nozzle 7 does not fall out of the carburetor body after removal of the main jet This is best accomplished by positioning the carburetor upside down during main jet removal 1 2 3 4 5 7 8 6 9 11 12 10 1 Carb...

Page 349: ...ring looks like this 2 then adjust spring to look like this by 3 holding float firmly and rotating valve counterclockwise to seat spring in seat of float bowl 4 Check for coil located in groove above both ears 5 Check for spring seated in recess of float 538 Figure 22 5 Inspect Float Valve Spring Assembly Adjust If Required 11 Install the fuel bowl retaining screw and tighten it to 61 in lb 6 9 N ...

Page 350: ... performance and or damage to the engine components GROUND SPEED NOTE If possible the manufacturer recommends measuring ground speed when setting engine RPM This vehicle should reach a ground speed of at least 12 5 mph 20 1 km h If the ability to measure vehicle ground speed is not available the closest engine RPM setting to achieve 12 5 mph 20 1 km h is 2750 RPM GOVERNOR CABLE Governor Cable Remo...

Page 351: ...er arm rearward until the carburetor throttle is in the wide open throttle WOT position 4 While holding the arm and shaft in the fully counterclockwise position tighten the governor arm lever nut to 36 in lb 4 0 N m 5 Check engine RPM adjustment See Engine RPM Adjustment on page 22 9 3 10 6 4 5 11 7 7 8 3 9 1 2 12 2440 Figure 22 6 Governor and Accelerator Cables 2014 Precedent Golf Car Maintenance...

Page 352: ...icle on page 5 4 2 Connect the end of the accelerator cable 7 to the governor lever arm Figure 22 6 Page 22 7 3 Press on the cable 7 to snap it in place in bracket 9 4 Adjust two lock nuts 12 to remove excess slack in the accelerator cable Finger tighten the two lock nuts 5 Before tightening the cable housing lock nuts make sure the engine RPM adjustment is correct See Engine RPM Adjustment on pag...

Page 353: ...elt and torque converter wear can also prevent proper RPM adjustment Check them for excessive wear See Section 25 Torque Converter Gasoline Vehicle 9 Check vehicle ground speed See Governor Cable on page 22 6 ENGINE BACKFIRE If the pedal start Kawasaki FE350 engine is backfiring it is most likely a lean backfire originating in the exhaust system due a lean fuel air mixture A lean backfire has the ...

Page 354: ... hose to the carburetor Figure 22 8 Page 22 10 The choke system aids in starting the engine in cold weather When starting a cold engine the spring loaded choke cover is pushed in by hand This restricts the air flow creating a fuel rich mixture in the carburetor The choke cover is held in until the engine starts and then is released The air flow to the engine is no longer restricted and the engine ...

Page 355: ...ism via a rod that connects to the button and the choke Figure 22 8 Page 22 10 Pressing in the button actuates the choke A spring clip attaches the rod to the choke If the choke button requires service the kick plate must be removed See Kick Plate and Choke Button Bezel on page 4 10 2014 Precedent Golf Car Maintenance and Service Manual Page 22 11 ...

Page 356: ...n Bezel on page 4 10 AIR FILTER General Information The air filter should be checked every year or 100 hours More frequent service may be required in extremely dirty operating environments Need for immediate servicing will be indicated by a loss of power sluggish acceleration or an engine which runs roughly with excessive black exhaust smoke Air Filter Replacement 1 Access the engine compartment 2...

Page 357: ...ment air filters P N 102558201 or equivalent The use of other air filters could result in engine damage If the air filter is too small the cover will seat before the filter can seal leaving space for dirt to pass into the engine on all sides of the element This will damage the engine and void the warranty 1 2 3 4 2688 Figure 22 10 Air Filter 2014 Precedent Golf Car Maintenance and Service Manual P...

Page 358: ...alve 5 on the fuel tank 1 Figure 22 11 Page 22 15 to the closed OFF position Figure 22 13 Page 22 21 5 Remove the clamps 6 and fuel lines 9 and 10 from the filter 7 and plug the fuel lines Figure 22 11 Page 22 15 FUEL FILTER INSTALLATION CAUTION Fuel filter is marked with flow direction arrows Make sure that the filter is installed with arrows pointing in the direction of fuel flow from tank to th...

Page 359: ...FUEL SYSTEM Fuel Filter 22 13 15 12 3 8 2 1 4 5 7 17 9 6 10 10 11 18 20 16 19 14 1 TO CRANKCASE 2699 Figure 22 11 Fuel and Vent Lines 2014 Precedent Golf Car Maintenance and Service Manual Page 22 15 ...

Page 360: ...e following WARNING WARNING Carefully drain any fuel remaining in the pump into an approved container Add drained fuel back into fuel tank or dispose of properly 6 Remove hardware 11 and fuel pump 8 FUEL PUMP INSTALLATION NOTE This gasoline vehicle complies with the California Air Resources Board CARB evaporative emissions regulations when equipped with MARK 4 DAYPERM C U 06 030 or AVON GREENBAR G...

Page 361: ... only unleaded fuel to the tank Do not put oil in the fuel tank FUEL TANK REMOVAL 1 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout cam in the MAINTENANCE position 2 Turn fuel shut off valve to the closed OFF position and run the engine until fuel remaining in the carburetor fuel pump and fuel lines is used up and the engine stalls Figure 22 13 Page 22 21 3 Turn th...

Page 362: ...Remove the vent tube 14 and fuel line 9 from the fuel tank Figure 22 11 Page 22 15 10 Remove two screws 3 holding the forward end of the fuel tank hold down 2 Lift up on the forward end of the hold down and release the rear end from the fuel bracket 11 Lift the fuel tank 1 out of the vehicle TANK CONNECTION BLACK WIRE TO GROUND ORANGE WIRE WITH SENDING UNIT BLACK WIRE TO GROUND WITHOUT SENDING UNI...

Page 363: ...black wire from the fuel gauge to one of the fuel level sending unit screws Connect the orange wire to the center stud and install the flat washer lock washer and nut Tighten to 18 in lb 2 0 N m Slide the rubber boot over the stud Figure 22 12 Page 22 18 If not equipped with fuel level sending unit connect black wire to ground screw on fuel tank Tighten to 18 in lb 2 0 N m WARNING Static electrici...

Page 364: ...lter 7 The fuel filter has an arrow indicating fuel flow direction Figure 22 11 Page 22 15 Fuel line 10 runs directly from the fuel filter to the fuel inlet of the fuel pump Fuel line 13 runs directly from the fuel outlet of the fuel pump to the carburetor Small spring steel band clamps are used on all hose connections except at the carburetor A screw band clamp 15 should be used at the carburetor...

Page 365: ...e engine will not run properly due to fuel starvation Figure 22 13 Page 22 21 CARBON CANISTER WARNING If the carbon canister is damaged only use an OEM Club Car replacement that is specifically designed and approved for use on this vehicle Do not attempt to repair it See the following canister removal procedure CARBON CANISTER REMOVAL 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 R...

Page 366: ...Figure 22 14 Carbon Canister Hoses and Routing CARBON CANISTER INSTALLATION 1 Align canister mounting tabs with slots in mounting bracket 6 and push canister 5 into bracket Figure 22 14 Page 22 22 Force it in until fully seated 2 Attach hoses 2 3 and 4 to appropriate locations on carbon canister and secure with hose clamps 1 3 Install and or lower seat bottom Page 22 22 2014 Precedent Golf Car Mai...

Page 367: ...er is removed from the vehicle install a new muffler clamp 6 CC P N 1017689 and muffler gasket 12 FE350 CC P N 1016904 Figure 23 1 Page 23 2 1 Loosely secure muffler 1 to muffler bracket 2 with clamp 6 2 Place a new gasket 12 on the cylinder block exhaust stud bolts 3 Attach muffler manifold with lock washers 11 and hex nuts 10 and finger tighten 4 Loosely secure muffler 1 mounting bracket and gov...

Page 368: ...eaks and proper engine operation See following DANGER DANGER Do not operate gasoline vehicle in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison 11 Return the neutral lockout cam to the OPERATE position Figure 24 2 Page 24 2 1 2 3 4 5 7 11 8 12 000 000 6 10 9 13 550 Figure 23 1 Exhaust System Page 23 2 2014 Precedent Golf Car Mainte...

Page 369: ...2396501 SHIFTER LEVER A shifter lever connected to a shifter arm is used to change the gears to one of three shift positions FORWARD F NEUTRAL N or REVERSE R Figure 24 3 Page 24 3 Bring the vehicle to a complete stop before changing FORWARD or REVERSE direction NEUTRAL LOCKOUT During normal vehicle operation the neutral lockout feature prevents the engine from running when the Forward Reverse hand...

Page 370: ...9 Figure 24 2 Neutral Lockout Operate GOVERNOR SYSTEM The governor system regulates vehicle ground speed It is mounted inside the unitized transaxle and is driven by transaxle gears If any of the governor linkages are removed in order to service other components readjustment of the governor linkage is required See Governor Cable Installation and Adjustment on page 22 6 UNITIZED TRANSAXLE SERVICE T...

Page 371: ...river Small punch or scratch awl 5 8 in Socket 3 8 in drive 5 16 in nut driver 1 4 in diameter drift or metal rod 12 mm Socket 3 8 in drive Small knife or wire snippers Bearing puller wedge attachment P N 1012812 Axle seal tool P N 1014162 Governor gear shaft installation tool P N 101933101 10 mm socket 3 8 in drive Internal snap ring pliers P N 1012560 Brake cable removal tool P N 102555501 13 mm...

Page 372: ... 3 Loosen the lug nuts on the wheel to be removed 4 Place chocks at the front wheels and lift the rear of the vehicle with a floor jack Then place jack stands under the axle tubes to support the vehicle See WARNING Lift only one end of the vehicle in General Warnings on page 1 2 5 Remove the rear wheel and brake drum 6 Use 90 internal snap ring pliers 0 090 inch 2 28 mm tip to remove internal reta...

Page 373: ...wheel mounting flange and the bearing Figure 24 8 Page 24 6 See also Figure 24 9 Page 24 8 See following CAUTION CAUTION Do not tighten the bearing puller wedge attachment against the axle shaft This could damage the axle shaft when pressing the bearing and collar off 2 Press the bearing 71 and collar 73 off together Figure 24 8 Page 24 6 See also Figure 24 9 Page 24 8 See following NOTE NOTE It m...

Page 374: ...bearing is flush against axle shoulder Figure 24 8 Page 24 6 3 Apply two drops of Loctite 271 to inside of the collar See following CAUTION CAUTION Apply Loctite 271 to the inside of the collar only not to the shaft so that the Loctite will be pushed away from the bearing as the collar and bearing are pressed on If Loctite gets on or in the bearing the bearing must be replaced The collar should be...

Page 375: ...ge 24 8 See following NOTE NOTE The new seal can be installed by tapping the axle seal tool with a mallet CAUTION Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to installing the axle shaft 3 Clean the axle shaft and splines and then insert the shaft splined end first through the seal and into the axle tube Be careful not to damage the seal Then adva...

Page 376: ...See Section 8 Wheels and Tires 4 Use 90 internal snap ring pliers to remove the internal retaining ring 1 from the axle tube Figure 24 11 Page 24 9 5 Remove the axle shaft 2 retaining ring and bearing assembly by pulling the axle shaft straight out of the housing 6 If necessary remove the axle oil seal and adapter ring 6 1 Use a bearing puller P N 1016417 to remove the axle seal and adapter ring f...

Page 377: ... entire axle shaft assembly must be replaced 0 0 1 2 762 Figure 24 11 Remove Internal Retaining Ring 763 Figure 24 12 Axle Seal and Adapter Ring Removal 15 39 A A Adapter Ring Lip 764 Figure 24 13 Axle Seal and Adapter Ring 765 Figure 24 14 Axle Seal and Adapter Ring Installation AXLE BEARING Do not remove the axle bearing from a Graziano axleshaft If bearing is worn or damaged the entire axleshaf...

Page 378: ...ng pliers to install the retaining ring 1 inside 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 Figure 24 11 Page 24 9 NOTE If the retaining ring axle bearing or sleeve must be replaced the entire axle shaft assembly must be replaced 2 3 Place a 1 4 to 3 8 inch 6 to 10 mm diameter rod against the retaining ring an...

Page 379: ...he line can be plugged with a 1 4 inch bolt Figure 24 18 Page 24 11 2644 Figure 24 17 Impulse Line 2645 Figure 24 18 Fuel Line 4 5 Disconnect the throttle cable from the pedal group See Pedal Group Removal on page 5 4 Loosen the cable mounting nuts 1 and ensure the cable can move freely through the hole in the frame Figure 24 19 Page 24 12 4 6 Remove retaining nut and disconnect the engine ground ...

Page 380: ...age 24 12 1 2 3 DF F2 DF 1 2 3 1 Yellow Wire 2 White Wire 3 Ground Wire at A2 Terminal 2399 Figure 24 21 Shifter Cable Top View 1350 Figure 24 22 Generator Wires Model 114 01 4005 shown 4 9 Disconnect the engine oil level sensor wire 18 gauge yellow at the connector just to the rear of the starter generator Figure 24 23 Page 24 13 4 10 Disconnect the engine kill switch wire 18 gauge white black fr...

Page 381: ...rake cable clevis pins 2 and using tool P N 1025555 compress tangs on cable end and remove cable from bracket 4 Figure 24 25 Page 24 13 1 2 3 4 651 Figure 24 25 Brake Cable Rear View 6 Remove the lower shock mounting hardware from both rear shocks Figure 24 26 Page 24 14 7 Position a floor jack under the rear of the vehicle Figure 24 27 Page 24 14 2014 Precedent Golf Car Maintenance and Service Ma...

Page 382: ...s to their front mounts Figure 24 29 Page 24 14 2700 Figure 24 28 Rear Shackles 2401 Figure 24 29 Spring Retainer Bolts 10 Continue raising vehicle until frame is higher than the top of the unitized transmission enough to allow transaxle and engine to be rolled under and out of vehicle Figure 24 30 Page 24 15 11 Position jack stands adjusted to support the vehicle at this height under the aluminum...

Page 383: ...he floor Figure 24 32 Page 24 15 The powertrain should be completely disconnected from the vehicle and resting on the floor 14 Grasp the ends of the leaf springs at the rear of the vehicle and roll the powertrain out from under the vehicle Figure 24 33 Page 24 15 2 1 2404 Figure 24 32 Snubber and Bracket 2405 Figure 24 33 Remove Powertrain 15 Place blocks under the engine pan so they will complete...

Page 384: ...n Powertrain on Wood Blocks 580 Figure 24 35 Remove Drive Belt 17 Remove the driven clutch retaining bolt and remove the driven clutch from the unitized transaxle Figure 24 36 Page 24 16 18 Loosen but do not remove the governor arm retaining bolt 1 Figure 24 37 Page 24 16 Remove the governor arm from the shaft Do not disconnect cables 1 581 Figure 24 36 Driven Clutch 582 Figure 24 37 Governor Arm ...

Page 385: ...ransaxle to the engine 21 1 Remove four transaxle mounting bolts and flat washers one at each corner of the transaxle mounting plate Figure 24 40 Page 24 17 21 2 Remove two middle transaxle mounting nuts from the engine block studs 22 Remove leaf springs wheels and brake assemblies from the transaxle 585 Figure 24 40 Transaxle Mounting 2014 Precedent Golf Car Maintenance and Service Manual Page 24...

Page 386: ...se Tighten the mounting screws to 134 in lb 15 1 N m Figure 24 38 Page 24 17 8 Install governor lever arm on governor shaft Figure 24 42 Page 24 18 8 1 With the governor lever arm loose on the governor shaft turn the governor arm shaft counterclockwise until it stops Then pull the governor lever arm rearward until the carburetor throttle is in the wide open throttle WOT position Figure 24 42 Page ...

Page 387: ...and install the bolts and lock nuts Ensure the brackets on the brake cables are placed over the bolts before the lock nuts are installed Tighten to 15 ft lb 20 3 N m 15 Adjust the vehicle height with the floor jack to position the leaf springs for mounting in the shackles Install the mounting bolts and lock nuts Figure 24 46 Page 24 19 Tighten lock nuts to 18 5 ft lb 25 N m 2409 Figure 24 45 Leaf ...

Page 388: ... post and tighten both wires to 48 in lb 5 4 N m Connect the 16 gauge yellow wire to the DF post on the starter generator and tighten to 30 in lb 3 4 N m Figure 24 50 Page 24 20 DF F2 DF 1 2 3 1 Yellow Wire 2 White Wire 3 Ground Wire at A2 Terminal 568 Figure 24 49 Oil Level Sensor Jumper wire 1350 Figure 24 50 Starter Generator Model 114 01 4005 shown 21 Route shifter cable through the shifter ca...

Page 389: ...ts to 23 in lb 2 6 N m Figure 24 53 Page 24 21 24 Remove the 1 4 inch bolt from the fuel line and connect the fuel line to the carburetor and secure with a screw type hose clamp Figure 24 54 Page 24 21 See following NOTE Tighten screw clamp to 9 in lb 1 0 N m NOTE Ensure the nylon washer is in place on fuel inlet nipple prior to connecting the fuel line to the carburetor 1 1 2398 Figure 24 53 Conn...

Page 390: ...at all wiring is secured properly See following WARNING WARNING If wires are removed or replaced make sure wiring and wiring harness is properly routed and secured to vehicle frame Failure to properly route and secure wiring could result in vehicle malfunction property damage or personal injury 31 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 4 32 Tur...

Page 391: ...ud 17 3 Loosen retaining nuts 28 to release cable from bracket 10 4 Release the wire tie 25 that is clipped to the bucket and secure the cable 5 Use a screwdriver or flat blade to pry cable end off the stud on the lever arm 6 Compress clips on boot enough to push boot through the cable bracket 24 Remove cable from vehicle FORWARD REVERSE SHIFTER CABLE INSTALLATION 1 From the Forward Reverse shifte...

Page 392: ...NITIZED TRANSAXLE GASOLINE VEHICLE 19 18 27 26 28 28 17 15 16 7 20 10 8 8 11 13 12 12 14 14 2 6 5 9 4 3 24 1 22 23 21 2 25 2408 Figure 24 58 Forward Reverse Shifter Cable Page 24 24 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 393: ...engaged in ball joint socket at least 1 4 inch 6 35 mm If ball joint socket comes loose from the cable the Forward Reverse shifter will not operate properly For major adjustments the cable retaining nuts 28 must be loosened and adjusted When the cable is properly adjusted with the Forward Reverse handle 20 Figure 24 58 Page 24 24 in the NEUTRAL position the shift lever of the transaxle will also b...

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Page 395: ...n the clutch increasing the diameter of the belt loop As the diameter of the belt loop increases at the drive clutch the driven clutch is forced open as the diameter of its belt loop decreases At governed top speed the ratio of drive clutch to driven clutch is 0 92 to 1 On steep grades or when the vehicle is heavily loaded higher torques are achieved through the use of a torque sensing ramp device...

Page 396: ...Inspect the driven clutch for dirt and dust buildup on its component parts Clean the driven clutch with water to remove any dust or dirt then drive the vehicle and check for proper operation 3 If cleaning the driven clutch does not solve the problem disassemble and thoroughly clean all parts of the drive clutch Be sure to clean the plastic drive buttons 10 Figure 25 7 Page 25 7 CC P N 1014496 CC P...

Page 397: ... Lift upward on the belt to force the sheaves of the DRIVEN clutch apart then roll the belt off the DRIVEN clutch by rotating the clutch counterclockwise Figure 25 2 Page 25 3 See following CAUTION CAUTION Make sure fingers are not underneath the belt when rolling the belt off the driven clutch 3 Remove the belt from the drive clutch 1 2 594 Figure 25 2 Drive Belt Removal DRIVE BELT INSTALLATION 1...

Page 398: ...rator mounting and adjusting hardware and then remove the starter belt See WARNING Moving parts Do not in General Warnings on page 1 2 WAR NING 1 2 3 CCI P N 1014496 2 1 595 Figure 25 3 Loosen Retaining Bolt 596 Figure 25 4 Drive Clutch Removal 3 Remove the lower shock mounting hardware from both rear shocks Figure 25 5 Page 25 5 4 Place chocks at the front wheels and lift the rear of the vehicle ...

Page 399: ... the wheels lock the brakes 6 Remove the drive clutch retaining bolt 17 and mounting washer 19 Figure 25 7 Page 25 7 See also Figure 25 3 Page 25 4 See following NOTE NOTE The drive clutch mounting bolt has left hand threads The crankshaft has left hand threads at the clutch mounting hole 6 1 Use the drive clutch holder tool 1 while tightening or loosening the drive clutch retaining bolt 2 Figure ...

Page 400: ...ere with proper clutch operation Use only a dry cloth to lightly wipe the shaft of the fixed face assembly 7 Figure 25 7 Page 25 7 Do not use a brush or steel wool These will damage the surface of the shaft Do not use solvents Solvents will damage the lubricating characteristics of the bushings 2 Inspect the belt contact surfaces of the clutch sheaves for wear If any area of a sheave contact surfa...

Page 401: ...RQUE CONVERTER GASOLINE VEHICLE Drive Clutch 25 2 1 3 13 4 5 6 7 11 12 12 16 15 14 22 20 21 17 19 10 597 Figure 25 7 Drive Clutch Assembly 2014 Precedent Golf Car Maintenance and Service Manual Page 25 7 ...

Page 402: ...er 1 P N 1014497 into clutch until the stop nut touches the clutch then back the bolt out one half turn Figure 25 9 Page 25 8 2 3 Thread the three small bolts of the puller 1 into corresponding holes in the clutch Tighten bolts evenly making sure the face of the puller plate is parallel to the face of the clutch Figure 25 9 Page 25 8 2 4 Unscrew the puller center bolt out of the clutch to pull dri...

Page 403: ...5 9 5 2 Pull the weight assemblies 3 with pins from slots 4 in the clutch See following NOTE NOTE Before removing note the orientation of the wave washer 1 and secondary weight 2 on the primary weight 3 Figure 25 12 Page 25 9 5 3 Remove the plastic washers weights 2 and 3 and wave washer 1 from the pin 4 Retain all parts 2 3 4 1 602 Figure 25 12 Primary and Secondary Weights Wave Washer and Pin 20...

Page 404: ...ECTION OF DRIVE CLUTCH PARTS 1 Inspect the idler bearing 6 for smooth rotation or seal damage Figure 25 7 Page 25 7 See following NOTE NOTE It is normal for a small amount of grease to be present at the edge of seal 2 Inspect the bore of the moveable face assembly 14 for scarring or wear The moveable face assembly must be replaced if the bore is worn to a diameter of 0 883 inch 22 4 mm or larger F...

Page 405: ...ide pin protruding from it Figure 25 12 Page 25 9 9 Install the secondary weights 2 onto the mounting pins 4 with the weight pins on the secondary weights pointing away from the primary weights 3 The wave washers should be between the primary and secondary weights Figure 25 12 Page 25 9 10 Install white plastic flat washers on each end of the mounting pin and push them against the outside surfaces...

Page 406: ...e 25 7 See following NOTE NOTE The drive clutch retaining bolt has left hand threads The manufacturer recommends replacing the drive clutch retaining bolt PN 103345701 when installing the drive clutch If a new bolt is not available clean the threads of the original bolt and apply Loctite 242 to the threaded end prior to installation 2 Tighten the drive clutch retaining bolt 17 to 25 ft lb 33 9 N m...

Page 407: ... Connecting the Battery Gasoline Vehicles on page 1 4 9 Drive the vehicle and check for proper operation DRIVEN CLUTCH See General Warnings on page 1 2 DRIVEN CLUTCH REMOVAL 1 Remove the drive belt as instructed See Drive Belt Removal on page 25 3 2 Remove the bolt 11 and mounting washer 12 from the clutch shaft Figure 25 21 Page 25 15 3 Grasp the driven clutch assembly and slide it off the shaft ...

Page 408: ...shaft 8 4 3 2 1 608 Figure 25 19 Remove Retaining Ring 609 Figure 25 20 Driven Clutch Disassembly DRIVEN CLUTCH INSPECTION 1 Inspect the cam 4 for excessive wear Replace it if necessary Figure 25 21 Page 25 15 2 Inspect the drive buttons 6 for excessive wear Replace if necessary To remove the drive buttons remove the socket head cap screws and then the buttons 3 Inspect the smooth surface on the f...

Page 409: ... and tighten them to 8 in lb 0 9 N m Figure 25 21 Page 25 15 2 Slide the moveable face assembly 7 onto the fixed face shaft 8 3 Place the end of the spring 5 into the hole in the moveable face assembly 4 Install the key 3 into the keyway of the fixed face assembly 8 shaft 2 3 4 5 6 7 8 11 12 1 10 9 610 Figure 25 21 Driven Clutch Assembly 2014 Precedent Golf Car Maintenance and Service Manual Page ...

Page 410: ...onto the cam tap the end of the fixed face shaft lightly with a plastic mallet until the cam seats against the retaining ring See following CAUTION CAUTION Do not use a metal hammer to tap the fixed face hub A metal hammer will damage the shaft 3 1 2 5 1 2 3 2 4 6 611 Figure 25 22 Cam Press Tool 612 Figure 25 23 Cam Installation Tool 5 2 Field Assembly Process NOTE This process is for field assemb...

Page 411: ... 5 2 8 Remove the cam press hub 6 and installation tool and install the retaining ring NOTE The retaining ring can be reused if the O D does not exceed 1 607 inches 40 82 mm otherwise it must be replaced with a new ring P N 1014080 DRIVEN CLUTCH INSTALLATION 1 To install the driven clutch reverse the removal procedure Make sure that the washer 12 is mounted with the flat portion of the washer agai...

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Page 413: ...e releases version 34 and version 35 The software version can be viewed in the Information menu of the IQDM See Information on page 26 20 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 26 1 Page 26 1 4 Remove the dust cap from the IQDM port...

Page 414: ...ncorrect Password Incorrect code being entered into controller check code A B C Motor Stall If car moves freely issue not with vehicle operator error Lockout Fault This is a symptom not a cause Inspect and test the charger interlock circuit If no problems are found in the charger interlock circuit replace the controller Overvoltage Controller reads 72 volts or more it s a symptom not a cause See o...

Page 415: ... a few seconds the screen displays the following menu items Program IQDM P only Monitor Faults Functions Information Programmer Setup In the event that the handset does not display any information or the screen is difficult to read refer to the IQDM troubleshooting procedures See IQDM and IQDM P Handset Troubleshooting on page 26 22 2 3 1 1 2 3 4 695 Figure 26 3 Handset Controls 2014 Precedent Gol...

Page 416: ...he bookmarked screen rapidly press and release the appropriate bookmark button See following NOTE NOTE When going to a bookmarked display screen be sure to rapidly press and release the button If the button is pressed and held for too long the bookmark will be overridden with the current screen The three yellow buttons also allow for quicker input of serial number and car decal number Press and ho...

Page 417: ...ed etc See following NOTE NOTE Values appearing in these menus represent approximate measurements made by the controller and may differ from measurements made by external instruments Since the monitor menu is updated while the vehicle is in operation the trained technician has the ability to monitor the status of several components in conditions or locations where a problem with vehicle performanc...

Page 418: ...oller 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 modulation is 0 to 100 When the vehicle is operating at full speed the pulse width modulation should be at 100 FIELD PWM Displays motor field PWM pulse width modulation The range ...

Page 419: ...e input is off When the Forward Reverse switch is placed in the REVERSE position the handset should indicate that the reverse input is on MODE SWITCH INPUT This menu is reserved for possible future use and has no application at this time CHARGER INHIBIT Displays charger connection When the charger is connected and the controller does not drive inhibited the handset indicates ON When the charger is...

Page 420: ...e C on page 27 5 ODOMETER Displays approximate distance travelled in miles AMP HOURS DISPLAY Amp Hours Displays total accumulated amp hours removed since initial vehicle start up 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 27 5 PEDAL COUNTERS Accumulates accelerator pedal usage FAULT COUNTERS The Fault Counte...

Page 421: ... all of the faults detected by the speed controller since the last time the fault history has been cleared The faults displayed in this menu may or may not be currently active Once a fault has been detected it is stored in the memory of the 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 S...

Page 422: ...EHICLE RESPONSE HW FAILSAFE A B C Vehicle comes to a stop THROTTLE FAULT A C Vehicle comes to a stop SPEED SENSOR D Vehicle runs at slow speed MAIN WELDED D Vehicle runs at slow speed MAIN DRIVER ON A B Vehicle comes to a stop MAIN DRIVER OFF A C Vehicle comes to a stop MAIN COIL OPEN A Vehicle comes to a stop FIELD MISSING A B C Vehicle comes to a stop HPD A Vehicle comes to a stop OVERVOLTAGE A ...

Page 423: ...s cycled THROTTLE FAULT When condition clears SPEED SENSOR When condition clears MAIN WELDED When condition clears MAIN DRIVER ON When condition clears MAIN DRIVER OFF When accel 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...

Page 424: ...voltage seen by the controller coming out of the MCOR is not within specified limits this fault occurs and the controller de energizes the solenoid coil Perform additional diagnostic if vehicle is running What to do Replace MCOR See following NOTE NOTE Newer controllers may infrequently read voltages above or below limits and give a false fault LOW BATTERY VOLTAGE UNDERVOLTAGE If the battery volta...

Page 425: ...the pedal limit switch has failed closed What it means The pedal is depressed before the key switch and or the FNR is switched on This is a safety control and the controller must see the pedal engaged last in the following sequence key switch first FNR second and then pedal last What to do Check throttle percentage and if at 0 issue is driver error MAIN DRVR OVERCURRENT If the current on the relay...

Page 426: ...cted What it means Speed sensor is not working Check connection What to do Replace speed sensor 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 What it means The controller FET controlling the energizing of the solenoid is on or energized when it should not be This...

Page 427: ... In rare cases it could be a controller or drivetrain issue If the vehicle rolls the drivetrain is okay Check to see if Armature Current spikes to 250 amps when accelerator pedal is pressed If so replace 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 detected by the speed controller What it means This is...

Page 428: ...ault history menu the trained technician should attempt to determine when and where the fault has occurred For example if the motor stall fault is present in the fault history the trained technician may be able to determine the location on the course where an operator has held the vehicle on a hill by using the accelerator pedal CLEAR FAULT HISTORY After a repair has been made the fault history sh...

Page 429: ...3 4 Align the keyed portion of the plug with the IQDM port and connect the plug to the port Figure 26 1 Page 26 1 4 Scroll to the functions menu and select 5 Select settings 6 Select get settings from controller 7 Press on the change value button to confirm the operation 8 The handset will display an executing message for the next few seconds while the controller settings are being stored in the h...

Page 430: ... the Handset 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 26 17 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 ...

Page 431: ...26 7 Confirmation 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 h...

Page 432: ...ion 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 SOFTWARE VERSION Displays the speed controller software version See following NOTE NOTE This manual spans software releases version 34 and version 35 HAR...

Page 433: ...to any faults 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 Faul...

Page 434: ...sembly has failed Test Procedure 3 IQDM Ports on page 26 24 Contrast Setting is too light See Program on page 26 21 Controller is in power down mode vehicle unused and not charged for 72 hours Connect charger or drive the vehicle a short distance and reconnect the handset to the vehicle Charger has been connected and charging for more than 10 minutes Disconnect charger wait 30 seconds and reconnec...

Page 435: ... IQDM P handsets and the components of the Excel System vehicle that are related to the proper operation of the handset WARNING If wires are removed or replaced make sure wiring and wire harness is properly routed and secured Failure to properly route and secure wiring could result in vehicle malfunction property damage personal injury or death Index of Test Procedures 1 Handset Cord 2 Handset Cor...

Page 436: ...the park brake 2 Place the Tow Run switch in the TOW position disconnect the batteries negative cable first and wait 90 seconds for the speed controller capacitors to discharge See General Warnings on page 1 2 3 Check the IQDM port mounted under the instrument panel 3 1 Remove the three screws 1 that secure the instrument panel assembly 2 to the dash assembly 3 Figure 26 8 Page 26 24 3 1 2 4 5 700...

Page 437: ...o the four pin connector of the speed controller 2 Figure 26 9 Page 26 25 4 3 4 Connect the 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 26 23 See Section 28 Excel System Troubleshooting with ERIC Charging 4 ...

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Page 439: ...ual spans software releases version 34 and version 35 The software version can be viewed in the Information menu of the IQDM See Information on page 26 20 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 27 1 Page 27 1 4 Remove the dust cap f...

Page 440: ...s active 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 27 3 Access Program Menu 776 Figure 27 4 Change Speed ...

Page 441: ...ttings 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 1 2 See Speed Setting on page 27 3 When going down an incline with the a...

Page 442: ...ugh S4 Fwd Speed Rev Speed and Speed Cal parameters 2 ES Protocol UpLink Uses maximum speeds assigned to a particular location or area as defined by the fleet operator however these defined speeds can not override previously set values from other control mode options To avoid this after changing the control mode to 2 cycle power to the controller by placing the Tow Run Switch in the TOW position f...

Page 443: ...set Trip Amp Hours The reset trip amp hours menu item allows the user to reset counter to zero 0 To reset set to ON and then immediately back to OFF ACCESS CODES Code A Code B and Code C The code entries are used to place the vehicle in private speed mode speed setting code 4 Each vehicle has a unique code for placing the vehicle in this mode A vehicle programmed for private speed mode speed setti...

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Page 445: ...gray wire with a female bullet connector located behind the instrument panel CHARGE INDICATOR LIGHT Excel vehicles with ERIC Charging system feature a dash mounted charge indicator light below the steering column that serves two functions 1 Battery low state of charge warning and 2 Charging confirmation The charge indicator light is controlled by pin 11 of the controller Battery Low State of Charg...

Page 446: ...ition the three throttle circuit resistors are now internal to the controller New B wire assembly which replaces the one integral to the onboard computer OBC With the OBC gone the New B wire assembly is needed to connect the B terminal of the controller to the negative post of battery no 6 6 x 8 Volt battery set New battery charge indicator light in the instrument panel This light is an LED and is...

Page 447: ...n incline with the accelerator pedal pressed half way the motor braking function will activate to assist the operator in maintaining a speed approximately half of the speed setting defined in the Program Menu Regenerative Braking When motor braking is activated the vehicle motor acts as a generator slowing the vehicle as it creates energy that is used to charge the batteries Tow Run Switch When th...

Page 448: ...TROUBLESHOOTING WITH ERIC CHARGING WIRING DIAGRAMS FORWARD REVERSE FNR SWITCH RUN TOW SWITCH WD1040232_DGM_B L Figure 28 1 Wiring Diagram Excel System with ERIC Charging Page 28 4 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 449: ...TH ERIC CHARGING Wiring Diagrams 28 BULLET CONN ECTOR CONNEC TOR 30 A CONNEC TOR WD1040232_DGM_B R Figure 28 2 Wiring Diagram Excel System with ERIC Charging Continued 2014 Precedent Golf Car Maintenance and Service Manual Page 28 5 ...

Page 450: ...TERY CHARGING LED OPTIONAL INDICATOR NOTE SOME WIRING COMPONENTS SHOWN ARE OPTIONALACCESSORIES 2 1 OFF ON KEY SWITCH WD1039915_DGM_C1 Figure 28 3 Instrument Panel Wiring Diagram Precedent with ERIC Charging Page 28 6 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 451: ...ing Diagrams 28 6_BLK 4_RED To Solenoid Lead for DC DC Converter To B Terminal on Controller WD_6x8V_Batteries_ERIC_Charging Figure 28 4 Battery Wiring Diagram Precedent with ERIC Charging 2014 Precedent Golf Car Maintenance and Service Manual Page 28 7 ...

Page 452: ...6 YELLOW 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 28 5 Precedent Electric Vehicle A...

Page 453: ...ROWN WHITE 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...

Page 454: ...Sonic Weld 7 Sonic Weld 8 Sonic Weld 3 To Forward Reverse Switch To MCOR 16 Pin Connector to Controller To Motor Speed Sensor To Tow Run Switch 15 Amp Fuse 2 Amp Fuse To Instument Panel Harness 9 Pin Connector To Connected Car Device i e Guardian or Visage 2783 Figure 28 7 Sonic Weld and 10k Ohm Resistor Locations Approximate Page 28 10 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 455: ...ng Guide 2 If an IQDM handset is unavailable the technician should proceed to Troubleshooting Guide 2 TROUBLESHOOTING GUIDE 1 The following troubleshooting guide is intended for use with an IQDM handset See following NOTE NOTE Before troubleshooting the vehicle check the diagnostic history from the Special Diagnostics Menu Note any fault codes TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORREC...

Page 456: ...r disconnected 16 pin connector at speed controller or broken wire Repair and or connect the 16 pin connector to the speed controller Monitor Menu FORWARD INPUT and or REVERSE INPUT does not indicate the correct reading Failed Forward Reverse rocker switch Test Procedure 6 Forward Reverse Rocker Switch on page 28 22 Speed controller logic malfunction Disconnect the batteries and allow the speed co...

Page 457: ...e batteries and see if the symptom returns Diagnostic Menu MAIN DRIVER ON or MAIN DRIVER OFF fault code Failure of the FET that controls the solenoid coil Replace the speed controller See Speed Controller Removal on page 29 11 Diagnostic Menu MAIN COIL FAULT fault code or Diagnostic Menu MAIN DROPOUT 1 or 2 fault code Solenoid coil has failed in an open condition Replace solenoid See Solenoid Remo...

Page 458: ...d MCOR Limit Switch Circuit on page 28 21 See also Test Procedure 11 MCOR Voltage on page 28 27 Forward Reverse rocker switch Test Procedure 6 Forward Reverse Rocker Switch on page 28 22 Solenoid loose wires Test Procedure 7 Solenoid Activating Coil on page 28 24 Solenoid failed coil Test Procedure 7 Solenoid Activating Coil on page 28 24 Speed controller thermal cutback Allow controller to cool a...

Page 459: ...or accelerate MCOR malfunction Test Procedure 11 MCOR Voltage on page 28 27 Vehicle reaches top speed before 100 pedal travel is reached Speed controller failed throttle resistor s Replace speed controller See Speed Controller Removal on page 29 11 Wiring improperly wired Check vehicle wiring See Wiring Diagrams on page 28 4 Vehicle operates but motor braking function does not Speed sensor disconn...

Page 460: ... without the cover properly installed Do not direct a water stream in area of the cover TESTING BASICS To use the IQDM the Tow Run switch must be in the RUN position The Tow Run switch provides power to the logic board and power board inside the controller Battery Pack Voltage BPV will be referenced throughout the test procedures BPV is accessed in Test Procedure 1 Batteries Voltage Check BPV on p...

Page 461: ...witch 4 15 Amp Fuse 5 Key Switch and MCOR Limit Switch Circuit 6 Forward Reverse Rocker Switch 7 Solenoid Activating Coil 8 Pre Charge Resistor 9 Solenoid Continuity 10 Charger Interlock 11 MCOR Voltage 12 Motor Speed Sensor 13 A1 and A2 Motor Voltage 14 Voltage at Charger Receptacle Red Wire Socket 15 16 Pin Connector 16 Reverse Buzzer 17 Charge Indicator Light 18 4 Pin Connector for Connected Ca...

Page 462: ...igure 28 8 Page 28 18 3 The multimeter should indicate at least 48 volts If not check for loose battery connections or a battery installed in reverse polarity Refer to Batteries Electric Vehicle with ERIC Charging on page 30 1 for further details on battery testing 2 3 4 5 6 1 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED...

Page 463: ...g while under load provides a more accurate diagnosis of the condition of the batteries When the discharge machine is ON it places the battery pack under load and many times can help determine if one or more batteries in the set have failed Testing battery voltage while the batteries are not under load will not always indicate the true condition of the batteries For more information about the batt...

Page 464: ...cess the Tow Run switch but do not disconnect wires 3 With the Tow Run switch in the RUN position 3 1 The pink wire should show BPV coming to the switch 3 2 The light green wire should also show BPV If it shows less than 5 volts the switch has failed OPEN and must be replaced 4 With the Tow Run switch in the TOW position 4 1 The light green wire should show less than 5 volts If it still shows BPV ...

Page 465: ...he key switch functions as described proceed to the following step See following NOTE NOTE The key switch MUST function properly in order to test the MCOR limit switch with the IQDM handset 5 Test the MCOR limit switch 5 1 Select FOOT INPUT on the Monitor menu by using the SCROLL DISPLAY buttons on the IQDM 5 2 The IQDM should indicate that FOOT INPUT is OFF when the accelerator pedal is not press...

Page 466: ...lation piercing probe check voltage of the blue wire in the MCOR 2 pin connector It should show BPV coming to the MCOR If not check wiring With an insulation piercing probe check voltage of the green wire in the MCOR 2 pin connector It should show zero 0 volts with the accelerator pedal at rest Press the accelerator pedal and the green wire should show BPV passing through the MCOR to the controlle...

Page 467: ...orange wire provides power to the switch and should show BPV coming to the switch in all three positions If the orange wire does not show BPV check the 15 amp fuse Tow Run switch red to pink wire spade terminal connection and related wiring 4 2 Brown Wire The brown wire should show BPV in FORWARD The brown wire should show zero 0 volts in NEUTRAL and REVERSE If the brown wire shows voltage in NEUT...

Page 468: ... the solenoid A reading of 180 to 190 ohms should be obtained for service replacement solenoids Figure 28 12 Page 28 24 If not replace the solenoid 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 1 Figu...

Page 469: ...ils just forward of each spring mount See WARNING Lift only one end in General Warnings on page 1 2 3 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 1 4 4 Disconnect the 6 gauge yellow wire and pre charge resistor from large post of solenoid See following NOTE NOTE When disconnecting heavy gauge wires from solenoid use a second wrenc...

Page 470: ...le cover See Electronics Module Cover Removal Section 29 Page 29 5 3 Check 15 amp fuse See Test Procedure 4 15 Amp Fuse on page 28 20 4 Check power Using a multimeter set to 200 volts DC place red probe with insulation piercing probe on the light blue wire pin 5 of the 16 pin connector and black probe on B terminal of controller The reading should be approximately 42 to 46 volts If the reading is ...

Page 471: ...ation of this test 2 Connect the IQDM to the vehicle 3 Access the Monitor menu and select THROTTLE by using the SCROLL DISPLAY buttons 4 The IQDM should indicate 0 with 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 steady incremental rise from 0 pedal not pressed to 100 pedal fully pressed See fo...

Page 472: ...lose to the three pin connector at the MCOR The reading should be approximately 4 65 volts 5 If reading is zero volts check the white wire continuity from the three pin connector at the MCOR to the 16 pin connector at the speed controller Check terminal positions in three pin connector at the MCOR and the 16 pin connector If all of the continuity readings are correct and the connectors are wired c...

Page 473: ...on 2 Connect the IQDM to the vehicle 3 Access the Monitor menu and select SPEED PULSES by using the SCROLL DISPLAY buttons The IQDM should indicate OFF when the vehicle is at rest 4 While monitoring the IQDM display screen slowly push the vehicle a short distance about 3 feet 1 meter The IQDM should indicate ON for speed sensor pulses while the wheels are in motion 5 If the IQDM does not indicate ...

Page 474: ...no 6 6 x 8 Volt battery set negative post and place the red probe with insulation piercing probe on the green wire between the three pin connector and the motor speed sensor 6 1 Raise one rear wheel off ground Slowly turn the rear wheel to rotate the motor armature As the armature rotates the voltage reading should alternate from zero to approximately 4 85 volts The voltage reading will fluctuate ...

Page 475: ... Check continuity on A1 and A2 motor terminal posts and continuity of the F1 and F2 motor terminal posts Also check continuity of all motor wires See Section 17 Motor Model EJ8 4001A Electric Vehicle TEST PROCEDURE 14 Voltage at Charger Receptacle Red Wire Socket See General Warnings on page 1 2 NOTE This is a voltage test 1 If necessary see Testing Basics on page 28 16 2 Probe the charger recepta...

Page 476: ...n the 16 pin connector After each terminal has been pushed into the housing gently pull on the wire to ensure it is locked into place 3 Check wires in the plug to make sure none are broken at the terminal pin crimp Repair or replace as required 4 Check the wire colors of each wire and make sure that the colors for each pin position match the wire colors as shown in Figure 28 13 Page 28 32 5 When c...

Page 477: ...propriate test result for each pin If results differ from those described in the procedure check the continuity of the wires in the wire harness and test the connected components with the appropriate test procedures See Index of Test Procedures Testing Controller Inputs CONTROLLER INPUTS PERFORM TEST WITH 16 PIN CONNECTED TO CONTROLLER IF YES BACK PROBE TO TEST TEST PROCEDURE THROTTLE INPUT Pin 2 ...

Page 478: ...Blue Yellow Supplies a positive controlled current source to power the charge indicator light on the instrument panel Yes Do not back probe for this test Start a charging session After a few seconds light should flash Can also be seen under LED Driver in the Monitor menu of the IQDM CONNECTED CAR OUTPUT Pin 13 White Black Supplies approximately 13 volts to the Guardian Visage unit Yes Approximatel...

Page 479: ...t properly seated repair or replace as required 8 4 If the orange white wire continuity and 16 Pin connector are correct and there is no voltage at the orange wire replace the controller TEST PROCEDURE 17 Charge Indicator Light See General Warnings on page 1 2 1 With batteries connected Tow Run switch in the RUN position and the key switch in the OFF position connect charger DC cord to vehicle 2 I...

Page 480: ... 1 and no 2 3 Probe pin 2 red white wire It should show BPV If not check 2 amp fuse See following NOTE NOTE The red white wire has BPV with the Run Tow switch in either position 4 Probe pin 4 white black wire It should show approximately 13 volts supplied by the controller If not check wiring and then controller See following NOTE NOTE The white black wire only has voltage with the Run Tow switch ...

Page 481: ...el 3 Disconnect the wires 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 29 2 Page 29 2 KEY SWITCH INSTALLATION 1 Position the key switch and flat washer 9 in the instrument panel then ins...

Page 482: ...GE INDICATOR LIGHT See General Warnings on page 1 2 TESTING THE CHARGE INDICATOR LIGHT See Test Procedure 17 Charge Indicator Light on page 28 35 CHARGE INDICATOR LIGHT REMOVAL 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 1 4 2 Remove instrument panel See Key Switch Removal on page 29 1 3 Disconnect the wires at the warning light...

Page 483: ...ngs on page 1 2 TESTING THE FORWARD REVERSE ROCKER SWITCH See Test Procedure 6 Forward Reverse Rocker Switch on page 28 22 FORWARD REVERSE ROCKER SWITCH REMOVAL 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 1 4 2 Remove two screws 2 that hold Forward Reverse rocker switch housing 1 to the vehicle Figure 29 4 Page 29 4 3 Remove the...

Page 484: ...to 20 in lb 2 3 N m 4 Place the Tow Run switch in the TOW position and connect the batteries See Connecting the Batteries Electric Vehicles on page 1 4 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 position Make sure that the vehicle ope...

Page 485: ...to the battery bucket CAUTION Be careful not to break the two hooks 4 on the bottom of the cover Push the bottom of the cover up to release the hooks before pulling cover away from 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 29 5 Page 29 6 Then use the two hooks 4 to secure ...

Page 486: ...of the Tow Run switch 2 See Electronics Module Cover Removal on page 29 5 3 Remove Tow Run switch boot hex nut 1 Figure 29 6 Page 29 7 4 Remove Tow Run switch 2 from electronics module and disconnect the pink wire 3 and light green wire 4 TOW RUN SWITCH INSTALLATION 1 Installation is reverse of removal Make sure flat on switch is aligned with flat part of D shaped hole in electronics module Figure...

Page 487: ...rom the MCOR 4 Remove the T25 torx screw securing the MCOR to the pedal group 5 Detach the two tabs from the accelerator pedal and remove the MCOR from vehicle MCOR INSTALLATION 1 Align the two tabs of the MCOR 2 with the slots in the accelerator pedal on the pedal group Insert the MCOR into the accelerator pedal until the tabs engage See following NOTE NOTE Rotate the pedal back and forth if nece...

Page 488: ...ge 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 batteries See Connecting the Ba...

Page 489: ...ent on page 30 5 3 Remove the bolt 2 that secures the electronics module 3 to the battery bucket 4 Pull electronics module 3 forward and disconnect the heavy gauge wires from the controller 1 and solenoid 4 5 Disconnect the 16 pin connector 4 pin connector and spade connectors from the controller 1 6 Disconnect the spade connectors on the front of the solenoid 4 7 Disconnect the two wires from Tow...

Page 490: ...it tilted forward 2 Complete connections to the controller 1 the Tow Run switch 5 and the solenoid 4 per the electrical schematics See Wiring Diagrams on page 28 4 3 Tighten bolts 6 on the controller to 108 in lb 12 2 N m 4 Tighten nuts 7 on the solenoid to 6 4 ft lb 8 7 N m 5 Set electronics module in place and secure with bolt 2 Figure 29 8 Page 29 10 Tighten bolt to 40 in lb 4 5 N m Page 29 10 ...

Page 491: ...2 Motor Voltage on page 28 30 SPEED CONTROLLER REMOVAL 1 Disconnect the batteries and discharge the controller 1 See Disconnecting the Batteries Electric Vehicles on page 1 4 2 Remove the electronics module cover 8 to access the controller 1 See Electronics Module Cover Removal on page 29 5 3 Disconnect the heavy gauge wires from the controller by removing the three screws 6 Figure 29 8 Page 29 10...

Page 492: ...e Vehicle Number Decal 7 6 Select Program Vehicle ID Vehicle Date of Manufacture and enter the number on the model year and week from the vehicle serial number 7 7 Select Information Software Version and verify the value is 13 or higher If not contact a Club Car Technical Representative 7 8 Place the Tow Run switch in the TOW position for 30 seconds Then return it to RUN 8 Inspect the vehicle for ...

Page 493: ... 4 Place the Tow Run switch in the TOW position and connect the batteries See Connecting the Batteries Electric Vehicles on page 1 4 CHARGER RECEPTACLE See General Warnings on page 1 2 The charger cord plug and receptacle are wear items and should be inspected daily Visually inspect them for cracks loose connections and frayed wiring they must be replaced when worn or damaged If charger plug or re...

Page 494: ...o the bucket CHARGER RECEPTACLE INSTALLATION 1 Insert the wires through the hole in the bucket 2 Insert receptacle 2 into bucket 3 Install the three screws 1 that secure the receptacle to the bucket Tighten screws to 16 in lb 1 8 N m 4 Connect 10 gauge red wire to solenoid Tighten nut 72 to 84 in lb 8 to 9 5 N m 5 Connect 10 gauge black wire to controller B terminal Tighten bolt to 108 in lb 12 2 ...

Page 495: ... a physician immediately 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 connections are clean and properly tightened Se...

Page 496: ...orientation of batteries i e terminal posts Poor fair or proper cleanliness of batteries Added electric accessories Use of a single point watering system SPWS MEASURING VOLTAGE OF BATTERY SET 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 the reading BATTERY CELL NUMBERING 1 2 3 4 1 Cell 1 ...

Page 497: ... two cars and the battery test indicated three failed batteries in each car after removing the failed batteries there will be six good batteries remaining Install the six remaining good batteries together in one car and install NEW batteries in the other car We recommend regrouping batteries in as many cars as possible at a given opportunity to minimize mixing old and new batteries together in one...

Page 498: ...ouped BATTERY REGROUPING PROCESS FLOW 6 volt 8 volt and 12 volt batteries 2 Accurate and accumulative Amp Hours are requir ed for Warranty claims Make s ur e to have battery lights on hand to replace ones that may be defective s o you can capture every car s Amp Hour reading 2772 Figure 30 2 Battery Regrouping Process Flow Page 30 4 2014 Precedent Golf Car Maintenance and Service Manual ...

Page 499: ...atteries to one hour 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 o...

Page 500: ...he deionizer per the manufacturer s recommendations The Service Parts Department at Club Car offers two different deionizer systems one for vehicles equipped with the Single Point Watering System SPWS CC P N AM1240701 and the other for vehicles without SPWS CC P N AM10974 Alternate Methods Reverse Osmosis Reverse osmosis involves forcing water through a membrane that allows water to pass while tra...

Page 501: ...scharge of negative plates BATTERY CARE VEHICLES EQUIPPED WITH 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 per 1 gallon 3 8 L of water Rinse solution off of the bat...

Page 502: ...ill identify any occurrence of a valve that fails to open If a valve fails to close it will become evident due to the cell overflowing during routine watering Either failure scenario is rare but should be monitored in the initial inspection and during routine watering sessions Replace malfunctioning valves to ensure maximum battery life See following CAUTION CAUTION After checking the electrolyte ...

Page 503: ...peration and could result in fire property damage or personal injury 4 After use charge the batteries The batteries should never be left discharged any longer than absolutely necessary do not leave discharged overnight SELF DISCHARGE Contaminants on dirty batteries can provide a path for a small current draw that can slowly discharge batteries thus wasting valuable energy To prevent self discharge...

Page 504: ... 3 Page 30 10 Never allow the electrolyte level to fall below the tops of the plates because this will cause the exposed part of the plate to become permanently inactive For best results use a battery watering gun to add water to batteries Check the electrolyte level more frequently in hot weather or when batteries are old VIBRATION DAMAGE The battery hold downs should always be tight enough to ke...

Page 505: ...inspection of all cells will identify any occurrence of a valve that fails to open If a valve fails to close it will become evident due to the cell overflowing during routine watering Either failure scenario is rare but should be monitored in the initial inspection and during routine watering sessions Replace malfunctioning valves to ensure maximum battery life After the initial six week inspectio...

Page 506: ... color indicating acceptable water quality If the light indicates unacceptable water quality the cartridge must be replaced 6 After ensuring adequate water flow rate press the grey button 7 on the end of the female coupler 8 to disconnect the purger from the pressure regulator Refilling the Batteries 1 Locate the battery fill coupling 9 on the driver side of the battery compartment remove the dust...

Page 507: ...ts of batteries See following NOTE NOTE When vehicles are being rotated the IQDM IQ Display Module can be a very helpful service tool Monitoring the value of the Odometer or Amp Hours with the IQDM simplifies vehicle usage scheduling See Monitor Menu Section 26 Page 26 5 DEEP DISCHARGE Never discharge batteries to the point the vehicle will no longer operate This will considerably shorten the cycl...

Page 508: ......

Page 509: ...on Fire or personal injury can result Have a qualified technician replace the damaged parts Do not use near fuels grain dust solvents thinners or other flammables Chargers can ignite flammable materials and vapors Do not expose to rain or any liquid Keep the charger dry When the charger is on the charger DC cord may be disconnected from the vehicle receptacle slowly Jerking or pulling the DC cord ...

Page 510: ...ce procedures pertaining to the external high frequency battery charger model number IC0650 048 CC and onboard high frequency battery charger model number IC0650 048 COMM Do not attempt to service a battery charger that has not been properly identified If a charger cannot be properly identified contact your local Club Car dealer or distributor How To Identify A Vehicle That Uses This High Frequenc...

Page 511: ... when the port is not in use UL AND CSA LISTING High frequency charging system battery chargers have been listed by UL and by the Canadian Underwriters and meet the criteria of the Canadian Standards Association CE COMPLIANCE This battery charger is compliant with the EU EMC Directive 2004 108 EC PLUG AND RECEPTACLE The charger cord plug and receptacle are wear items and should be inspected daily ...

Page 512: ...if the voltage is within the 100 to 240 VAC range The charger also will function outside of that range down to 85 VAC and up to 270 VAC although charging times will be longer Outside of the 85 to 270 VAC range the charger will not operate THERMAL CUTBACK The charger operates at full power in ambient temperatures between 40 F 40 C and 104 F 40 C The charger also will function outside of that range ...

Page 513: ... green Charging is complete Battery pack is fully charged Flashing green Solid green Charging is in progress Battery pack has reached a high state of charge Off Flashing green Charging is in progress Battery pack has NOT reached a high state of charge Solid blue AC power to charger is present LONG TERM STORAGE High frequency chargers are designed to be left connected with AC power to the charger d...

Page 514: ...arger Figure 31 3 Position the charger so that is has adequate ventilation and the charger status indicator panel is visible The charger can be mounted in any orientation right side up upside down etc provided the cooling fins are unobstructed it has adequate ventilation Figure 31 4 To help ensure optimal charge times mount the charger in an area where ambient temperatures during charging remain b...

Page 515: ...wire outlet within the voltage and frequency range shown on the charger Do not use an adapter to plug the charger with a three prong plug into a two prong outlet Improper connection of the equipment grounding conductor can result in a fire or an electrical shock Place all cords so they will not be stepped on tripped over or otherwise subjected to damage or stress NOTE Make sure that the AC cord pr...

Page 516: ...arger should be avoided If one must be used heed the following WARNING WARNING An extension cord or electrical outlet must accept a three prong plug The extension cord should be a three wire No 12 AWG American Wire Gauge or no 14 British Standard Wire Gauge and be as short as possible no more than 12 feet 3 7 m The use of an improper extension cord could result in fire or an electrical shock THE C...

Page 517: ...lug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 31 8 Page 31 11 Do not pull on the DC cord Figure 31 9 Page 31 11 Do not twist rock or bend the plug To disconnect the charger plug from the vehicle receptacle grasp the plug by the handle and pull the plug straight out of the receptacle Do not connect a charger to ...

Page 518: ...ave to be above 32 volts for charging to begin When temperatures fall below 65 F 18 3 C 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 Batteries should be put on charge even if they have been used for only a short period 9 holes of golf or 10 minutes Becaus...

Page 519: ...dash mounted charge indicator light will flash three times and the reverse buzzer simultaneously will sound three times to indicate charging has begun The number of flashes and beeps can vary depending on the Beep Option setting See Beep Option Section 27 Page 27 5 4 The charger monitors battery voltage charge current and charge time to determine when the batteries are properly charged The charger...

Page 520: ... 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 Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the charger Do not expose charger to oil dirt mud or direct heavy water spray when cleaning vehicle Keep all AC connections clean and dry Keep all cooling fins ...

Page 521: ...d the chargers and returning each vehicle to its designated charger each night can significantly reduce the amount of time spent troubleshooting a problem USB SERVICE PORT NOTE The triangular charge status light doubles as the USB light Flashing green means data transfer from the USB is occurring Solid green means data transfer is complete Use the USB service port for charging algorithm updates so...

Page 522: ... the DC cord to the vehicle 5 If the triangular status indicator light comes on contact your Club Car dealer If the light does not come back on attempt to charge the car as usual RESETTING POWER ONBOARD CHARGER The triangular status indicator light on the charger comes on in a solid red state to communicate a significant charger hardware or software failure See Charger Status Indicators on page 31...

Page 523: ...r See Resetting Power External Charger on page 31 14 3 Battery low voltage Ensure battery set is rated 48 volts and composed of 24 cells Also check the voltage of each individual battery See Battery Voltage Using Multimeter on page 31 16 If not replace with correct battery set Reset charger power See Resetting Power External Charger on page 31 14 4 Charge timeout caused by battery pack not reachin...

Page 524: ...eptacle 3 Battery Condition Using Charger 4 On Charge Battery Voltage Using Charger And Multimeter 5 AC Power and Continuity Test of AC Circuit 6 Charger DC Circuit Continuity Test 7 Charger Output Test TEST PROCEDURE 1 Battery Voltage Using Multimeter 1 Check battery pack voltage See Measuring Voltage of Battery Set Section 30 Page 30 2 2 Normal no load voltage should be between 50 and 52 volts f...

Page 525: ...C Charging Continued poor performance may indicate a problem in the vehicle electrical system brakes or battery charger If the problem is not found in the vehicle or charging system proceed to the on charge voltage test If the upper half of the battery shaped status indicator does not stop flashing the batteries should be tested further using the on charge voltage test TEST PROCEDURE 4 On Charge B...

Page 526: ... 39 8 in lb 4 5 N m NOTE The positive symbol and negative symbol are molded into the terminal block for easy identification 6 Install terminal block cover See Terminal Block Cover Installation on page 31 20 TEST PROCEDURE 7 Charger Output Test Without a Meter Connect DC cord and start a charge cycle If buzzer sounds three times then charger is functioning Both a confirmed connection with the charg...

Page 527: ... the AC cord from the AC outlet NOTE This charger has no internals to service or repair It only has a few external repairs that can be performed If an internal component needs repair the charger must be replaced 2 1 8 9 5 10 6 4 7 3 11 2790 Figure 31 10 External High Frequency Charger Components TERMINAL BLOCK COVER REMOVAL 1 Disconnect DC cord 1 from vehicle 2 Disconnect AC cord 2 from AC outlet ...

Page 528: ...e two torx screws 5 securing strain relief 6 to charger 4 Remove terminal block cover 3 See Terminal Block Cover Removal on page 31 19 5 Remove torx screw 7 securing each DC cord wire to terminal block 4 DC CORD AND STRAIN RELIEF INSTALLATION 1 Attach DC cord white wire to positive terminal and black wire to negative terminal with torx screws 7 See following NOTE Tighten screws 7 to 39 8 in lb 4 5...

Page 529: ...hten screws 8 to 39 8 in lb 4 5 N m FOOT REMOVAL 1 Disconnect DC cord 1 from vehicle 2 Disconnect AC cord 2 from AC outlet 3 If mounted detach charger from shelf or wall 4 Squeeze barbs on back side of foot 10 and push foot out of charger mounting tab Repeat for other feet if necessary FOOT INSTALLATION 1 Push foot 10 into hole in charger mounting tab until the barbs come through and secure foot i...

Page 530: ...harger has no internals to service or repair It only has a few external repairs that can be performed If an internal component needs repair the charger must be replaced 6 10 7 5 8 9 12 11 13 4 2 1 3 2792 Figure 31 12 Onboard High Frequency Charger Mounting ONBOARD CHARGER REMOVAL 1 If connected disconnect AC cord 1 from AC outlet Figure 31 12 Page 31 22 2 Disconnect the batteries and discharge the...

Page 531: ... 11 in lb 1 25 N m 4 Connect 14 pin plug 8 to onboard charger 4 5 Connect DC charging harness 6 to onboard charger DC cord 7 6 Ensure sleeve 5 is in place on charger s AC socket and connect lead 3 from AC cord reel to onboard charger 4 7 Lower rear facing seat bottom 2 8 Place the Tow Run switch in the TOW position and connect the batteries See Connecting the Batteries Electric Vehicles on page 1 ...

Page 532: ... to terminal block 3 DC CORD AND STRAIN RELIEF INSTALLATION 1 Attach DC cord red wire to positive terminal and black wire to negative terminal with torx screws 6 Figure 31 13 Page 31 24 See following NOTE Tighten screws 6 to 39 8 in lb 4 5 N m NOTE The positive symbol and negative symbol are molded into the terminal block for easy identification 2 With DC cord 1 seated properly in the terminal blo...

Page 533: ...re from solenoid DC CHARGING HARNESS INSTALLATION 1 Connect 10 gauge red wire to solenoid Tighten nut 72 to 84 in lb 8 to 9 5 N m 2 Connect 10 gauge black wire to controller B terminal Tighten bolt to 108 in lb 12 2 N m 3 Connect blue wire to main wire harness at bullet connector with light blue wire 4 Install electronics module cover and access panel See Electronics Module Cover Installation Sect...

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Page 535: ...tion damage 15 13 30 10 battery 20 27 charging 20 31 20 32 hydrometer test 19 12 installation 20 32 load test 19 14 maintenance 20 29 mineral content 20 30 removal 20 31 self discharge 20 30 storage 20 32 testing 19 12 19 31 vibration damage 20 30 voltage test 19 13 water level 20 30 battery charger ERIC 31 1 AC service incoming 31 13 numbering vehicles and chargers 31 13 resetting power external ...

Page 536: ... troubleshoot ing 25 2 clutch drive see drive clutch 25 4 clutch driven see driven clutch 25 13 column steering see steering column 7 2 communication display module CDM function codes 13 38 retrieving data from 13 39 troubleshooting 13 40 connector 16 pin see test procedures 13 22 28 32 connector 4 pin see test procedures 28 36 crankcase cover installation 21 7 removal 21 5 cylinder head 21 3 D DA...

Page 537: ...rward reverse cable adjustment 24 25 installation 24 23 removal 24 23 handle lever 24 1 switch installation 14 4 29 4 removal 14 3 29 3 testing 13 35 28 22 front body see body front 4 3 front bumper 4 5 fuel filter 22 1 installation 22 14 removal 22 14 fuel gauge hour meter fuel gauge circuit 19 11 testing 19 32 fuel level sending unit testing 19 31 installation 20 22 20 23 removal 20 22 20 23 fue...

Page 538: ... 9 Test Procedures 11 21 26 23 Troubleshooting 11 20 26 22 Write Settings to Controller 11 16 26 18 Excel system with ERIC charging diagnostics 26 1 Excel system with PowerDrive charger diagnostics 11 1 IQDM P Excel system amp hours 27 5 anti tamper speed 27 4 audible charging indicator 27 5 battery type 27 5 code a code b and code c 12 4 27 5 control mode 27 4 deterrent demo speed 27 4 excel brak...

Page 539: ...18 testing 19 31 limit switch installation 20 17 removal 20 17 testing 19 19 O oil level sensor installation 20 27 21 6 removal 20 27 21 6 testing 19 30 oil light see also low oil warning light 19 11 onboard computer OBC 13 2 installation 14 14 rebooting 13 37 removal 14 14 retrieving data from 13 39 testing 13 15 13 32 13 33 P pedal group installation 5 3 Gen II 5 6 removal 5 1 Gen II 5 4 periodi...

Page 540: ...st procedures 13 22 28 32 installation 14 12 29 11 removal 14 12 29 11 starter generator armature 20 4 ground test 20 8 armature inspection 20 6 assembly 20 4 20 9 bearing cleaning 20 6 inspection 20 6 removal 20 6 belt tension adjustment 20 11 brush spring inspection 20 3 replacement 20 3 brushes 20 2 inspection 20 2 replacement 20 2 commutator 20 4 armature replacement 20 7 cleaning 20 7 inspect...

Page 541: ...3 33 Forward Reverse rocker switch 13 35 index of 13 13 key switch 13 20 MCOR3 13 16 MCOR3 limit switch 13 20 motor A1 and A2 voltage 13 18 OBC gray wire and fuse 13 33 OBC rebooting 13 37 onboard computer SCR 13 32 onboard computer solenoid lockout circuit 13 15 reverse buzzer 13 36 solenoid 13 35 solenoid activating coil 13 15 solenoid diode 13 15 speed sensor motor 13 34 Tow Run switch 13 19 te...

Page 542: ...g 13 3 28 4 communication display module CDM 13 40 IQDM and IQDM P handset 11 20 26 22 torque converter 25 2 troubleshooting guide 1 13 8 28 11 troubleshooting guide 2 13 11 28 14 vehicle troubleshooting guide 19 1 U unitized transaxle installation 24 18 lubrication 24 3 removal 24 10 service 24 2 universal accessory mounting 4 12 V Valve Clearance Check and Adjustment 21 3 Visage connector 4 pin ...

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Page 546: ...lity In order to help us better serve you please rate this publication in the following categories Poor Fair Average Good Excellent 5 If you are reviewing a Kit Instruction were all indicated parts included in your kit Yes No I am Distributor Dealer Individual Owner Club Car Associate Representative Technician Golf Course Superintendent Other Contact Information Optional Name Title Company Address...

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