Club Car 2009-20011 Electric Precedent Maintenance And Service Manual
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Club Car 2009-20011 Electric Precedent, SECTION17–ELECTRICALCOMPONENTS 17 DANGER •SeeGeneralWarningsonpage1-1. WARNING •SeeGeneralWarningsonpage1-1. KEYSWITCH SeeGeneralWarningsonpage1-1. TESTINGTHEKEYSWITCH Seetheappropriatetroubleshootingsectionforthetypeofelectricalsystemusedinthevehicle. SeeIQSystemTroubleshooting–TPSonpage11-1orIQSystemTroubleshooting–MCORonpage12-1orExcel SystemTroubleshooting–TPSonpage13-1orExcelSystemTroubleshooting–MCORonpage14-1. KEYSWITCHREMOVAL 1.Disconnectthebatteriesanddischargethecontroller.SeeDisconnectingtheBatteries–ElectricVehicles onpage1-3. 2.Removetheinstrumentpanel(Figure17-1
Club Car 2009-20011 Electric Precedent, SECTION14–EXCELSYSTEMTROUBLESHOOTING–MCOR 14 DANGER •SeeGeneralWarningsonpage1-1. WARNING •SeeGeneralWarningsonpage1-1. •Shortingofbatteryterminalscancausepersonalinjuryordeath. –Donotplacecomponentmountingplatedirectlyontopofbatterieswhenremovingorinstalling plate. –Removeplatefromvehiclecompletely. GENERALINFORMATION NOTE:Many2009modelyearPrecedentvehicleshavehadthepedalgroupreworkedtouseanMCORinplace ofthethrottlepositionsensor.Usethistroubleshootingsectionforsystemdiagnosis.Foravehiclethatstill usesthethrottlepositionsensor,seeExcelSystemTroubleshooting–TPSonpage13-1orIQSystem Troubleshooting–TPSonpage11-1. Starti
Club Car 2009-20011 Electric Precedent, 21 TransaxleInstallationTRANSAXLE(TYPEG) WARNING •MakesurethatthevehicleoperatesinthereversedirectionwhentheForward/Reverseswitchisinthe REVERSEposition.ThereversebuzzerwillsoundasawarningwhentheForward/Reverseswitch isinREVERSE. •MakesurethatthevehicledoesnotoperatewhentheForward/ReverseswitchisintheNEUTRAL position. Page21-122009-2011ElectricPrecedentMaintenanceandServiceManual
BATTERIESSinglePointWateringSystem(SPWS) 18 FLEETROTATION Rotatevehicleusage.Itisveryhardonbatteriesifthelastvehiclesinatnightaretherstonesoutinthemorning. Spreadtheworkloadevenly,givingallvehiclesthesameamountofuse.Thiswillkeepyoureetinbalanceandwill notoverworkcertainsetsofbatteries.SeefollowingNOTE. NOTE:Whenvehiclesarebeingrotated,theCDM(CommunicationDispl
Club Car 2009-20011 Electric Precedent, SECTION8–WHEELSANDTIRES..................................................................................................................8-1 GeneralInformation.......................................................................................................................................8-1 Wheels.........................................................................................................................................................8-1 WheelRemoval.........................................................................................................................................8-1 WheelInstallation..
Club Car 2009-20011 Electric Precedent, IQSYSTEMTROUBLESHOOTING–MCORTestProcedures 12 TESTPROCEDURES Usingthefollowingprocedures,theentireIQelectricalsystemcanbetestedwithoutmajordisassemblyofthevehicle. WARNING •Ifwiresareremovedorreplaced,makesurewiringandwireharnessisproperlyroutedandsecured. Failuretoproperlyrouteandsecurewiringcouldresultinvehiclemalfunction,propertydamage, personalinjury,ordeath. Formanyteststheelectronicsmodulecovermustberemovedtogainaccesstothevariouscomponentsthatare mountedonthecomponentmountingplate.SeeElectronicsModuleCoveronpage17-5.SeefollowingWARNING. WARNING •Shortingofba
Club Car 2009-20011 Electric Precedent, 12 TestProceduresIQSYSTEMTROUBLESHOOTING–MCOR –Tow/Runswitchforproperoperation.SeeTestProcedure6–Tow/RunSwitchonpage12-19. TESTPROCEDURE12–Pin6 SeeGeneralWarningsonpage1-1. Pin6inthe16-pinconnectorprovidesaconnectionpointfortheMCORlimitswitchtothespeedcontroller. 1.Disconnectthebatteriesanddischargethecontroller.SeeDisconnectingtheBatteries–ElectricVehicles onpage1-3. 2.Placechocksatthefrontwheelsandlifttherearofthevehiclewithachainhoistoroorjack.Positionjack standsundertheframerailsjustforwardofeachspringmount.SeeWARNING“Liftonlyoneend...”in GeneralWarningsonpage1-1.
Club Car 2009-20011 Electric Precedent, 7 RackandPinionSTEERINGANDFRONTSUSPENSION 4.Removerackscrewnut(14),rackguidescrew(13),rackguidepressurespring(15)andtherackguide(16). 5.Removebolt(6)andslideuniversaljointoffthepinionshaft(Figure7-4,Page7-5). 6.Removethedustseal(Figure7-6,Page7-8). 7.Removethelargesnapring(4)(Figure7-7,Page7-8). 8.Removepinion(5)fromthehousing(17)(Figure7-8,Page7-8).Ifremovalisdifcult,installtheuniversaljoint ontothepinionandplaceaforkoralargeopen-endwrenchundertheuniversaljoint(Figure7-8,Page7-8). Gentlyprythepinionfromthehousingandthenremovetheuniversaljoint. 9.Iftheballbearing(4)(Figure7-5,Page7-7)hasbeendamaged,removetheC-typestopri
Club Car 2009-20011 Electric Precedent, 13 TroubleshootingEXCELSYSTEMTROUBLESHOOTING–TPS TROUBLESHOOTINGGUIDE1 SYMPTOMPOSSIBLECAUSESCORRECTIVEACTION Looseordisconnectedsix-pinconnectoratthe throttlepositionsensororbrokenwire Repairand/orconnectthesix-pinconnectorto thethrottlepositionsensor Looseordisconnected16-pinconnectorat speedcontrollerorbrokenwire Repairand/orconnectthe16-pinconnector tothespeedcontroller DiagnosticMenu–THROTTLEFAULTfault code Failedthrottlepositionsensor TestProcedure4–ThrottlePositionSensor Voltageonpage13-16 ArmaturedriveFET’s(eld-effecttransistors) insidespeedcontrollerhavefailed Replacethespeedcont
Club Car 2009-20011 Electric Precedent, SECTION3–GENERALINFORMATION 3 DANGER •SeeGeneralWarningsonpage1-1. WARNING •SeeGeneralWarningsonpage1-1. Importantfeaturesuniquetothedifferentmodelscoveredinthismanualarehighlighted.ClubCar,LLCrecommends theowner/operatorreadandunderstandthismanualandpayspecialattentiontofeaturesspecictotheirvehicle(s). Refertotheowner’smanualprovidedwiththevehicleforinformationonthefollowingtopics: •Pre-OperationandDailySafetyChecklist •ControlsandIndicators •DrivingInstructions •Towing •TransportingonaTrailer •SubsequentOwnerRegistration •Warranties SERIALNUMBERIDENTIFICATION Theser
Club Car 2009-20011 Electric Precedent, IQDISPLAYMODULE(IQDM)ANDIQDM-P DIAGNOSTICS:EXCELSYSTEMMenuNavigation 16 MENUNAVIGATION TheNAVIGATIONBUTTON(1)isthefour-arrowbuttonlocatedontheleftsideofthehandset(Figure16-3,Page 16-2).Thisbuttonisusedtonavigatethroughandselectmenus.Pressingtheupordownarrowsallowstheuserto scrollthroughthemenuitems.Whentheboxbesidethedesiredmenuisblinking,pressingtherightarrowselectsthat menuitem.Pressingtheleftarrowallowstheusertogobackonescreen(2). TheCHANGEVALUEBUTTON(3)isthebuttonlocatedontherightsideofthehandset(Figure16-3,Page16-2). Thisbuttonallowstheusertochangevaluesbypressing+or–. Thethreeyellowbuttonslabeled1,2and3areBOOKMARKBUTTONS(4)(Figure16-3,Pa
Club Car 2009-20011 Electric Precedent, 14 TestProceduresEXCELSYSTEMTROUBLESHOOTING–MCOR TESTPROCEDURE7–BatteryPackVoltage(UnderLoad) SeeGeneralWarningsonpage1-1. 1.Besurethebatteriesarefullychargedandthattheelectrolyteleveliscorrectinallcells. 2.Connectthetesterleadstothepositive(+)postofbatteryno.1andnegative(–)postofbatteryno.4(Figure 14-10,Page14-20)orbatteryno.6(Figure14-11,Page14-20). POS NEG POS NEG 2 4 1 3 POS POS NEG NEG (–) 1 (+) 2 TESTER (Viewedfromdriversideofvehicle) 1.REDprobetobatteryno.1(+). 2.BLACKprobetobatteryno.4(-). 2 3 4 5 6 + 1 (–) (+) 1 2 TESTER (Viewedfromdriversideofvehicle) 1.REDprobetobatteryno.1(+). 2.BLACKprobetobatteryno.6(-). Figure14-10BatteryDischargeTest–Style
14 TestProceduresEXCELSYSTEMTROUBLESHOOTING–MCOR 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 200DCVSetting(readingwithT ow/RunswitchinRUNposition) 690 Figure14- 17Pin9Test 8.WiththeTow/RunswitchintheRUNposition,themultimetershouldindicatefullbatteryvoltage(approximately48 volts).
Club Car 2009-20011 Electric Precedent, IQDISPLAYMODULE(IQDM)ANDIQDM-P DIAGNOSTICS:IQSYSTEMFaultsMenu 15 FIELDMISSING Ifthespeedcontrollerisoperatingatadutycycleofgreaterthan90%(almostfullspeed)andtheeldcurrentisless than3amps,aeldmissingfaultisdetectedbythespeedcontroller. HPD TheHPD(HighPedalDetect)faultisdetectediftheacceleratorpedalisalreadydepressedwhenthekeyswitchis turnedtotheONposition.Thisfaultisalsodetectediftheacceleratorpedalispressedwhentheselecteddirection ischangedbypressingtheForward/Reverseswitch.Thisfault,whennotcausedbytheoperator,canindicate thatthepedallimitswitchhasfailedclosed. PROC/WIRING ThisfaultisdetectediftheForward/Rever
Club Car 2009-20011 Electric Precedent, BATTERIESBatteryTesting–8Volt 18 InterpretingDischargeTestResults 1.Ifdischargetimeis60minutesorhigher,theproblemisnotwiththebatteries. 2.Ifdischargetimesarelow(lessthan60minutes),replacebatteriesbelow6.7volts. BATTERYVOLTAGES 123456 BATTERYCONDITION 7.00 V 7.00 V 7.00 V 7.00 V 7.00 V 7.00 V Excellent 7.07 V 7.07 V 7.22 V 6.50 V 7.07 V 7.07 V Batteryno.4isnearendofusefullife. 7.20 V 7.20 V 6.67 V 7.33 V 6.27 V 7.33 V Batterynos.3and5arenearendofusefullife. 3.Ingeneral,batterysetsthatdischargeinlessthan6
EXCELSYSTEMTROUBLESHOOTING–TPSWiringDiagrams 13 #1 8 BLACK #18 BLUE /WHITE 20 AMP FUS E S ONIC WELD S ONIC WELD #14 B LACK #16 B LUE CONNE CTS TO MAIN HARNESS. S EE FIGURE S 11-1 AND 11-2. DIODE HEADLIGHT AS S E MBLY HORN #16 GR EE N/WHITE #18 BLUE /WHITE #18 GR EE N #16 BRO WN/WHITE #16 YE LLOW #16 BRO WN #16 BLACK/WHITE #16 WHITE #18 BLUE /WHITE #18 OR ANG E #1
ELECTRICALCOMPONENTSElectronicsModuleCover 17 ELECTRONICSMODULECOVER SeeGeneralWarningsonpage1-1. Theelectronicsmodulecoverneedstoberemovedtogainaccesstothespeedcontroller,T ow/Runswitch,and onboardcomputer. ELECTRONICSMODULECOVERREMOVAL 1.Disconnectthebatteriesanddischargethecontroller.SeeDisconnectingtheBatteries–ElectricVehicles onpage1-3. 2.Removethetwopl
Club Car 2009-20011 Electric Precedent, 15 FaultsMenu IQDISPLAYMODULE(IQDM)ANDIQDM-P DIAGNOSTICS:IQSYSTEM Thespeedcontroller,afterdetectingafault,willrespondinoneormoreofthefollowingways: •A.Reducevehiclespeedtozerobyreducingarmaturecurrent •B.Reducevehiclespeedtozerobyreducingeldcurrenttozero •C.Turnoffthesolenoid •D.Causethevehicletorunathalfspeed •E.Graduallyreducethearmaturecurrentlimit •F.Quicklyreducethearmaturecurrentuntilspeedsensorpulsesoccur •G.Reduceeldcurrentandbeepreversebuzzeratafastrate CONTROLLERFAULTCONTROLLERRESPONSE HWFAILSAFEA,B,C KEYSWITCHSROC THROTTLEFAULT1A SPEEDSENSORD MAINWELDED
Club Car 2009-20011 Electric Precedent, IQDISPLAYMODULE(IQDM)ANDIQDM-P DIAGNOSTICS:EXCELSYSTEMFaultsMenu 16 Whattodo:MonitorHeatsinkTemp,batteryvoltage,brakesdragging,carunderextremeloads,lowornoair pressureintire(s). MOTORSTALL Ifthemotorcurrentishighandthereisnomovementofthevehiclewheelsforashortperiodoftime,amotorstallis detectedbythespeedcontroller.Thisfaultcanbecausedbyanoperatorholdingthevehicleonahillbydepressing theacceleratorpedalinsteadofthebrakepedal. Whatitmeans:Thisfaultappearsanytimecurrentisrunningtothemotorandnomovementofthearmature isregistered. Whattodo:Inmostcasesthisisanoperatorissueholdingthevehicleonaninclinewiththeacceleratorpedal, notthebrakepedal. MAINDROPOUT(1OR2) Ifthecontrollerdetectsthatthesolenoi
Club Car 2009-20011 Electric Precedent, VehicleS/N.............................................................................................................................................23-4 VehicleDecal..........................................................................................................................................23-4 SECTIONi–INDEX 2009-2011ElectricPrecedentMaintenanceandServiceManualPagexi
Club Car 2009-20011 Electric Precedent, 14 WiringDiagramsEXCELSYSTEMTROUBLESHOOTING–MCOR 10_BLACK FROM CONTROLLER B- W13 18_GRAY W13 18_GRAY #1 6 BRO WN #1 6 BLK/WHT #1 6 BRO WN #1 6 BLK/WHT #1 6 BLK/WHT BRAKE LIGHT S WITCH CON NECT S T O 12 POSITION CON NECT OR FOR DC-D C CON VERTE R OR LIGH TS. #1 2 BLUE #1 2 BLUE #12 BLUE #1 2 BLACK/WHITE LE FT TAILLIGHT RIGHT TAILLIGHT #1 6 W HITE #1 6 BLACK/WHITE #1 6 BRO WN #1 6 YELLOW #1 6 TAN #1 6 RED #1 8 BLACK/LT BLUE #1 8 G RAY #1 2 BLACK #18 BLK #18 BRN #18 RED #18 BLK #18 BRN #18 RED 10-AMP FUSE WD1034035B-L Figure14-4WiringDiagram–ExcelSystemwithMCOR Page14-62009-2011ElectricPrecedentMaintenanceandServiceManual
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