Club Car Tempo 2020 Maintenance And Service Manual
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Club Car Tempo 2020 Maintenance And Service Manual

Lithium-ion vehicle
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Table of Contents

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Tempo, Tempo Connect,
and Tempo 2+2
Maintenance and
Service Manual
Lithium-Ion Vehicle
Manual Number 86753090036
Edition Code D

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Summary of Contents for Club Car Tempo 2020

  • Page 1 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Lithium-Ion Vehicle Manual Number 86753090036 Edition Code D...
  • Page 3 To find your local authorized Club Car dealer, visit www.clubcardealer.com, call 1-800-ClubCar (1-800-258-2227), or scan this Quick Response (QR) code to be taken to the Club Car dealer locator. Refer to Figure 1. Download a QR code reader such as RedLaser or Barcode Scanner to your cell phone or tablet.
  • Page 4 NOTE: This manual represents the most current information at the time of publication. Club Car is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures.
  • Page 5 Serial Number Decal 2843B Figure -1 Serial Number Decal © Copyright 2020 Club Car, LLC Club Car is a registered trademark of Club Car, LLC This manual effective April, 2020 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page iii...

  • Page 7: Table Of Contents

    CONTENTS SECTION 1 — Safety Information ........................1-1 General Safety Information..........................1-1 Practice Safety ............................1-1 Safety Signal Words ..........................1-1 Safety Committee ............................1-1 Vehicle Safety Information..........................1-2 Disable The Vehicle ........................... 1-3 High Voltage Interlock Fuse........................1-4 Battery International Safety Symbols......................1-5 SECTION 2 —...
  • Page 8 Dash Assembly Installation ........................4-12 Floor Mat and Retainers..........................4-13 Floor Mat Removal ..........................4-13 Floor Mat Installation..........................4-13 Floor Mat Retainer Removal........................4-13 Floor Mat Retainer Installation ........................4-13 Kick Plate and Charger Receptacle Bezel ..................... 4-14 Kick Plate and Charger Receptacle Bezel Removal ................... 4-14 Kick Plate and Charger Receptacle Bezel Installation.................
  • Page 9 Brake Pedal Installation ..........................5-7 SECTION 6 — Wheel Brake Assemblies ......................6-1 General Information ............................6-1 Brake Shoe Removal ............................. 6-1 Brake Assembly Cleaning ..........................6-4 Brake Shoe Installation ..........................6-7 Brake Cable Equalizer Adjustment........................ 6-10 Brake Cluster .............................. 6-12 Brake Cluster Removal ..........................
  • Page 10 Wheel Assembly Installation........................8-7 SECTION 9 — Rear Suspension ........................9-1 General Information ............................9-1 Shock Absorbers ............................9-1 Rear Shock Absorber Inspection......................... 9-1 Rear Shock Absorber Removal........................9-2 Rear Shock Absorber Installation........................ 9-3 Panhard and Bracket ............................. 9-4 Panhard and Bracket Removal ........................9-4 Panhard and Bracket Installation ........................
  • Page 11 Contactor ..............................12-4 Accessories............................. 12-4 Diode, Fuse, and Relay Locations ........................ 12-5 Fuse Block Cover ............................ 12-6 Fuse Block Tables ........................... 12-7 Fuses ................................. 12-9 ATO and Mini ATM Fuse Inspection ......................12-9 Charger Fast Acting Fuse Test ......................... 12-9 Dynamic Braking Resistor (DBR) Fuse.....................12-10 Ground Locations ............................
  • Page 12 Multi-Purpose Buzzer........................... 13-4 Multi-Purpose Buzzer Removal......................... 13-4 Multi-Purpose Buzzer Installation......................13-4 Hazard Light Switch ............................. 13-5 Hazard Light Switch Removal........................13-5 Hazard Light Switch Installation ........................ 13-5 USB Receptacle ............................13-6 USB Receptacle Removal ........................13-6 USB Receptacle Installation ........................13-6 Forward/Neutral/Reverse Switch (FNR)......................
  • Page 13 SECTION 15 — Battery Charger........................15-1 General Information ............................. 15-2 IC 650 Battery Charger Specifications......................15-2 IC 900 Battery Charger Specifications......................15-3 Governmental And Industry Certifications...................... 15-4 European Conformity ..........................15-4 Federal Communications Commission ...................... 15-4 International Protection Marking ....................... 15-4 Underwriters Laboratories And Canadian Standards Association ..............
  • Page 14 Terminal Block Removal..........................16-14 Terminal Block Installation ...........................16-14 Speed Sensor Removal ..........................16-15 Speed Sensor Installation..........................16-16 SECTION 17 — Transaxle..........................17-1 Transaxle Fluid Level Check......................... 17-1 Transaxle Fluid Change ..........................17-2 Axle Shaft And Oil Seal ..........................17-2 Axle Shaft Removal ..........................17-2 Oil Seal Removal.............................

  • Page 15: Section 1 - Safety Information

    • A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could result in property damage. SAFETY COMMITTEE If the vehicle is rented or part of a fleet, Club Car recommends setting up a safety committee. The primary concern of the safety committee is safe vehicle operation. Safety committee objectives include: •...

  • Page 16: Vehicle Safety Information

    Before you operate the vehicle or do the servicing of the vehicle, read and fully understand the operators manual. • Club Car vehicles are not rated for operation in explosive areas. The vehicle or battery charger can cause flammable material and fume ignition. Do not operate the vehicle or battery charger near flammable materials and fumes.

  • Page 17: Disable The Vehicle

    SAFETY INFORMATION Vehicle Safety Information WARNING • 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.

  • Page 18: High Voltage Interlock Fuse

    Vehicle Safety Information SAFETY INFORMATION HIGH VOLTAGE INTERLOCK FUSE The high voltage interlock uses a 10A fuse. Removal of the high voltage interlock fuse (HVIL) disables the high voltage output. This disables the motor control unit (MCU), Visage display unit (VDU), vehicle control module (VCM), diagnostic receptacle, and dash display. Removal of the HVIL will cause a fault code.

  • Page 19: Battery International Safety Symbols

    SAFETY INFORMATION Vehicle Safety Information Connect the fuse holder to the red cover (2) . BATTERY INTERNATIONAL SAFETY SYMBOLS Understand and obey the international symbols on the vehicle battery before you use, repair, or service the vehicle. 1642 Figure 1-3 Battery International Safety Symbols Shield eyes Read and follow operating instructions No smoking, no open flames, no sparks...
  • Page 20 Vehicle Safety Information SAFETY INFORMATION Pagination Page Page 1-6 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 21: Section 2 - Vehicle Specifications

    SECTION 2 — VEHICLE SPECIFICATIONS DIMENSIONS Vehicle Specifications TWO- DESCRIPTION PASSENGER 2+2 VEHICLE VEHICLE Length 91.5 in. (232 cm) 104 in. (264 cm) Width 47.25 in (120 cm) 47.25 in (120 cm) Height - at steering wheel 48.0 in. (122 cm) 48.0 in.

  • Page 22: Electric Motor

    Electric Motor VEHICLE SPECIFICATIONS ELECTRIC MOTOR TWO- DESCRIPTION PASSENGER 2+2 VEHICLE VEHICLE Motor Type: 30V AC motor ● ● Motor Horsepower: 4.7 hp (3.5 kW) ● ● BATTERY TWO- DESCRIPTION PASSENGER 2+2 VEHICLE VEHICLE Battery Type: 58V Lithium-Ion ● ● Battery Quantity: 1 ●...

  • Page 23: Vehicle Weights And Load Capacities

    VEHICLE SPECIFICATIONS Vehicle Weights And Load Capacities VEHICLE WEIGHTS AND LOAD CAPACITIES WARNING • If the rated capacities of the vehicle are exceeded, property damage, serious personal injury, or death can occur. Do not exceed the rated capacity of the vehicle. Rated capacity is for level surfaces only. •...
  • Page 24 Vehicle Weights And Load Capacities VEHICLE SPECIFICATIONS Pagination Page Page 2-4 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 25: Section 3 - Extended Storage

    SECTION 3 — EXTENDED STORAGE WARNING Extended Storage • Unintentional vehicle operation can cause serious personal injury or death. Before leaving the vehicle or during vehicle maintenance, disable the vehicle. CAUTION • Extended storage of the vehicle with the Run/Tow-Stow switch set to RUN and the battery charger connected will damage batteries and reduce battery performance and life.

  • Page 26: Return To Service From Extended Storage

    Vehicle Weights And Load Capacities EXTENDED STORAGE RETURN TO SERVICE FROM EXTENDED STORAGE Set the Forward / Neutral / Reverse control (FNR) to N. Set the Run/Tow-Stow switch to RUN. Fully charge the battery. Adjust pressure in each tire to the recommended tire pressure. Lubricate the vehicle.

  • Page 27: Section 4 - Body And Trim

    SECTION 4 — BODY AND TRIM CLEANING THE WINDSHIELD Body and Trim CAUTION • Do not use a household window cleaner. Use a soft towel and water to clean the windshield. Use mild soap as necessary. CLEANING THE VEHICLE EXTERIOR CAUTION •...

  • Page 28: Body Repair

    Body Repair BODY AND TRIM Light Soiling: A solution of 10% liquid dish soap and warm water applied with a soft, damp cloth is recommended. A soft bristle brush may be used if necessary. Wipe off any residue with a water dampened cloth. Difficult Stains: Dampen a soft, white cloth with a solution of 10% household bleach (sodium hypochlorite) and 90% water.

  • Page 29: Gouges, Punctures, Tears, Large Scratches, And Abrasions

    BODY AND TRIM Body Repair Lightly buff imperfection with a clean soft cloth or buff pad. Do not use any kind of rubbing (abrasive) compound on body assemblies. Wax the entire body part to restore luster and weather protection. GOUGES, PUNCTURES, TEARS, LARGE SCRATCHES, AND ABRASIONS Touch-up is not recommended.

  • Page 30: Seat Hinge

    Seat Hinge BODY AND TRIM SEAT HINGE The seat bottom (1) is attached to the vehicle with two hinges (3) that hook into slots in the body. Figure 4-1 Seat Bottom Hinge SEAT HINGE REMOVAL Remove the seat bottom (1) from the vehicle (Figure 4-1). Remove the screws (2).

  • Page 31: Hip Restraint

    BODY AND TRIM Hip Restraint HIP RESTRAINT Figure 4-2 Hip Restraint HIP RESTRAINT REMOVAL Remove the seat bottom (1) from the vehicle (Figure 4-2). Remove the screws (2). Remove the hip restraint (3). HIP RESTRAINT INSTALLATION Align the hip restraint (3) onto the seat bottom (1) (Figure 4-2). Install the screws (2).

  • Page 32: Front Body

    Front Body BODY AND TRIM FRONT BODY G-140198-000018 Figure 4-3 Front Body Page 4-6 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 33: Front Body Removal

    BODY AND TRIM Front Body FRONT BODY REMOVAL Disconnect the two headlight harnesses (1) (Figure 4-3, Page 4-6). Remove the four screws (2). Remove the brow cap (3) from the brow and fascia assembly (4). Pull the front beauty panel (5) up and away from the brow and fascia assembly to disengage the snap tabs. If the vehicle is equipped with a canopy: 5.1.

  • Page 34: Front Bumper

    Front Bumper BODY AND TRIM FRONT BUMPER Figure 4-4 Front Bumper FRONT BUMPER REMOVAL Remove the nuts (3) (Figure 4-4). Remove the bolts (2). Remove the front bumper (1). FRONT BUMPER INSTALLATION Align the front bumper (1) onto the frame (Figure 4-4). Install the bolts (2) and nuts (3).

  • Page 35: Underbody Bracket

    BODY AND TRIM Underbody Bracket UNDERBODY BRACKET The underbody bracket (1) is connected to the front suspension on the front underbody. Figure 4-5 Underbody Bracket UNDERBODY BRACKET REMOVAL Remove the two screws (2) and washer (3) (Figure 4-5). Remove the underbody bracket (1). UNDERBODY BRACKET INSTALLATION Put the underbody bracket (1) into position on the vehicle (Figure 4-5).

  • Page 36: Headlights

    Headlights BODY AND TRIM HEADLIGHTS The headlights are not adjustable. Figure 4-6 Headlights HEADLIGHT REMOVAL Disconnect the headlight harness. Remove the front beauty panel (1) (Figure 4-6). Remove the screws (2). Remove the headlight (3). HEADLIGHT INSTALLATION Install the headlight (3) (Figure 4-6). Install the screws (2).

  • Page 37: Instrument Panel

    BODY AND TRIM Instrument Panel INSTRUMENT PANEL Figure 4-7 Instrument Panel INSTRUMENT PANEL REMOVAL Remove the screws (1 and 2) (Figure 4-7). Tilt instrument panel (3) up to release it from the dash assembly (4). Disconnect the electrical connector on the passenger side. INSTRUMENT PANEL INSTALLATION Connect the electrical connector on the passenger side (Figure 4-7).

  • Page 38: Dash Assembly

    Dash Assembly BODY AND TRIM DASH ASSEMBLY Figure 4-8 Dash Assembly DASH ASSEMBLY REMOVAL Remove the instrument panel (1) (Figure 4-8). Remove the screws (2). Disconnect the USB receptacle. Remove the dash assembly (3). DASH ASSEMBLY INSTALLATION Put the dash assembly (3) on vehicle (Figure 4-8). Make sure tabs on the forward edge engage to front underbody.

  • Page 39: Floor Mat And Retainers

    BODY AND TRIM Floor Mat and Retainers FLOOR MAT AND RETAINERS Figure 4-9 Floor Mat And Retainers FLOOR MAT REMOVAL Remove the screws (2) (Figure 4-9). Remove the floor mat (3) from under the floor mat retainers (1). FLOOR MAT INSTALLATION Install the floor mat (3) under the floor mat retainers (Figure 4-9).

  • Page 40: Kick Plate And Charger Receptacle Bezel

    Kick Plate and Charger Receptacle Bezel BODY AND TRIM Make sure that the floor mat (3) is correctly positioned beneath the top flange of the floor mat retainer. Install the two screws (2). Do not tighten the screws. Install the push rivets (4) (Figure 4-9, Page 4-13). Tighten the two screws (2) to 4.4 lb·ft (6.0 N·m).
  • Page 41 BODY AND TRIM Kick Plate and Charger Receptacle Bezel Figure 4-10 Kick Plate and Charger Receptacle Bezel Removal Use the charger bezel tool to remove charger receptacle bezel (1) from the kick plate (2) (Figure 4-10, Page 4-15). Remove the floor mat. Remove three screws (3) and washers (4).

  • Page 42: Kick Plate And Charger Receptacle Bezel Installation

    Kick Plate and Charger Receptacle Bezel BODY AND TRIM KICK PLATE AND CHARGER RECEPTACLE BEZEL INSTALLATION Figure 4-11 Kick Plate and Charger Receptacle Bezel Installation Install the kick plate (1) (Figure 4-11, Page 4-16). Make sure that the front lower edge of the rear beauty panel mates with the kick plate. Install the three screws (2) and washers (3).

  • Page 43: Access Panel

    BODY AND TRIM Access Panel ACCESS PANEL Figure 4-12 Access Panel ACCESS PANEL REMOVAL Remove the two push rivets (1) (Figure 4-12). Remove the access panel (2). ACCESS PANEL INSTALLATION Install the access panel (2) onto the rear underbody (Figure 4-12). Install the two push rivets (1).

  • Page 44: Visage Display Unit Overhead Baskets

    Visage Display Unit Overhead Baskets BODY AND TRIM VISAGE DISPLAY UNIT OVERHEAD BASKETS OVERHEAD BASKET REMOVAL Remove the screw (1) (Figure 4-13, Page 4-18). Figure 4-13 Overhead Basket Release the tab (2) and remove the overhead basket (3). OVERHEAD BASKET INSTALLATION Align the overhead basket (3) with the display unit support (Figure 4-13, Page 4-18).

  • Page 45: Overhead Speaker Basket Removal

    BODY AND TRIM Visage Display Unit Overhead Baskets OVERHEAD SPEAKER BASKET REMOVAL Remove the screw (1) (Figure 4-14, Page 4-19). Figure 4-14 Overhead Speaker Basket Release the tab (2) and remove the overhead speaker basket (3). Disconnect the electrical connector (4). OVERHEAD SPEAKER BASKET INSTALLATION Connect the electrical connector (4) (Figure 4-14, Page 4-19).

  • Page 46: Two-Passenger - Canopy

    Two-Passenger - Canopy BODY AND TRIM TWO-PASSENGER - CANOPY TWO-PASSENGER CANOPY REMOVAL CAUTION • To prevent damage to the canopy, do not remove the canopy supports from the vehicle without first removing the canopy. Figure 4-15 Two-Passenger Canopy Removal Remove the nuts (1), washer (2), and bolts (3) from the canopy (4) and each front canopy strut (Figure 4-15). Remove the nuts (6), washer (7), and bolts (8) from the canopy and each rear canopy support.

  • Page 47: Two-Passenger Canopy Installation

    BODY AND TRIM Two-Passenger - Canopy TWO-PASSENGER CANOPY INSTALLATION Figure 4-16 Two-Passenger Canopy Installation Put the canopy (4) on top of the front and rear canopy supports (Figure 4-16). Make sure that the front supports are correctly positioned between the molded tabs on the underside of the canopy. Make sure that the molded protrusions at the rear of the canopy extend into the top of the rear supports.
  • Page 48 Two-Passenger - Canopy BODY AND TRIM Figure 4-17 Two-Passenger Canopy With Visage Display Unit Removal Remove the nuts (4), washer (5), and bolts (6) from each rear canopy support. Remove the canopy (7). Disconnect the canopy harness (8). Remove the screws (9) (Figure 4-18, Page 4-22). Figure 4-18 Visage Display Unit Removal Remove the Visage display unit (VDU) (10) from the display unit support.

  • Page 49: Two-Passenger Canopy With Visage Display Unit Installation

    BODY AND TRIM Two-Passenger - Canopy TWO-PASSENGER CANOPY WITH VISAGE DISPLAY UNIT INSTALLATION Put the tabs of the display unit support (12) into the front canopy struts (Figure 4-19, Page 4-23). Figure 4-19 Visage Display Unit Installation Install the display unit support onto the front canopy struts. Connect the display unit harness (11).
  • Page 50 Two-Passenger - Canopy BODY AND TRIM Connect the strut harness to the canopy harness (8) (Figure 4-20, Page 4-24). Figure 4-20 Two-Passenger Canopy With Display Unit Installation Install the canopy (7) on top of the front and rear canopy supports. Install the bolts (3), washers (2), and nuts (1).

  • Page 51: Two-Passenger Front Canopy Strut Removal

    BODY AND TRIM Two-Passenger - Canopy TWO-PASSENGER FRONT CANOPY STRUT REMOVAL CAUTION • To prevent damage to the canopy, do not remove the canopy supports from the vehicle without first removing the canopy. • Using tools to thread the bolts could prevent proper feel of the bolt as it captures the female threads in the support.

  • Page 52: Two-Passenger Front Canopy Strut Installation

    Two-Passenger - Canopy BODY AND TRIM TWO-PASSENGER FRONT CANOPY STRUT INSTALLATION Figure 4-22 Front Canopy Strut Installation Install the front canopy strut (3) onto the vehicle (Figure 4-22). Install the front canopy strut cover (2) onto the front canopy strut. Install the screws (4).

  • Page 53: Two-Passenger Rear Canopy Support Removal

    BODY AND TRIM Two-Passenger - Canopy TWO-PASSENGER REAR CANOPY SUPPORT REMOVAL CAUTION • To prevent damage to the canopy, do not remove the canopy supports from the vehicle without first removing the canopy. • Using tools to thread the bolts could prevent proper feel of the bolt as it captures the female threads in the support.

  • Page 54: Two-Passenger Rear Canopy Support Installation

    Two-Passenger - Rear Body BODY AND TRIM TWO-PASSENGER REAR CANOPY SUPPORT INSTALLATION Figure 4-24 Rear Canopy Support Installation Install the rear canopy support (2) into the structural accessory module (SAM) (Figure 4-24). Install the screw (1). Tighten the screw to 88 lb·in (10 N·m). Install the canopy.

  • Page 55: Structural Accessory Module (Sam)

    BODY AND TRIM Two-Passenger - Rear Body STRUCTURAL ACCESSORY MODULE (SAM) Figure 4-25 SAM SAM Removal If the vehicle has a canopy, remove the rear canopy supports from the SAM (2) (Figure 4-25). Remove the four bolts (1). SAM Installation Position the SAM (2) over its mounting holes (Figure 4-25).

  • Page 56: Seat Back

    Two-Passenger - Rear Body BODY AND TRIM SEAT BACK Figure 4-26 Seat Back Seat Back Removal Remove the two screws (1) (Figure 4-26). Remove the seat back (2) from the SAM (3). Seat Back Installation Put the seat back (2) on the SAM (3) (Figure 4-26). Install the two screws (1).

  • Page 57: Bag Rack Assembly

    BODY AND TRIM Two-Passenger - Rear Body BAG RACK ASSEMBLY Figure 4-27 Bag Rack Bag Rack Removal Remove the two screws (1) (Figure 4-27). Remove the bag rack (2) from the SAM (3). Bag Rack Installation Install the bag rack (2) onto the SAM (3) (Figure 4-27). Install the two screws (1).

  • Page 58: Bag Strap

    Two-Passenger - Rear Body BODY AND TRIM BAG STRAP Figure 4-28 Bag Strap Bag Strap Removal Remove the push rivets (1) and screw (2) (Figure 4-28). Remove the bag strap (3) from the bag rack (4). Bag Strap Installation Install the bag strap (3) onto the bag rack (4) (Figure 4-28). Install the push rivets (1) and screw (2).

  • Page 59: Sweater Basket

    BODY AND TRIM Two-Passenger - Rear Body SWEATER BASKET Figure 4-29 Sweater Basket Sweater Basket Removal Remove the three screws (1) (Figure 4-29). Remove the sweater basket (2) from the bag rack (3). Sweater Basket Installation Install the sweater basket (2) onto the bag rack (3) (Figure 4-29). Install the three screws (1).

  • Page 60: Rear Beauty Panel

    Two-Passenger - Rear Body BODY AND TRIM REAR BEAUTY PANEL Two-passenger rear beauty panel procedures. Figure 4-30 Rear Beauty Panel Rear Beauty Panel Removal Remove the structural accessory module (SAM). Remove the screws (1) (Figure 4-30). Remove the canopy support brackets (2). Remove the four screws (3).

  • Page 61: Rear Underbody

    BODY AND TRIM Two-Passenger - Rear Body REAR UNDERBODY Two-passenger rear underbody procedures. Figure 4-31 Rear Underbody Rear Underbody Removal Remove the structural accessory module (SAM). Remove the rear beauty panel. Remove remove the four screws (1) (Figure 4-31). Lift the rear edge of the rear underbody (2) until the front portion slides out from beneath the front underbody. Remove the rear underbody from the vehicle.

  • Page 62: Rear Crossmember

    Two-Passenger - Rear Body BODY AND TRIM REAR CROSSMEMBER Two-passenger rear crossmember procedures. Figure 4-32 Rear Crossmember Rear Crossmember Removal Remove the four bolts (1) (Figure 4-32) . Remove the rear crossmember (2). Rear Crossmember Installation Install the rear crossmember (2) onto the vehicle (Figure 4-32). Make sure that the J-clips (3) are installed on the inside of the frame rail.

  • Page 63: 2+2 - Monsoon Canopy

    BODY AND TRIM 2+2 - Monsoon Canopy 2+2 - MONSOON CANOPY MONSOON CANOPY REMOVAL CAUTION • To prevent damage to the canopy, do not remove the canopy supports from the vehicle without first removing the canopy. Remove the nuts (1), washers (2), and bolts (3) from the front canopy strut (4) (Figure 4-33). Figure 4-33 Canopy Removal - Front Canopy Strut Remove the screws (5) (Figure 4-34).

  • Page 64: Monsoon Canopy Installation

    2+2 - Monsoon Canopy BODY AND TRIM MONSOON CANOPY INSTALLATION Put the canopy (6) on top of the front and rear canopy supports (Figure 4-35). Install the screws (5). Tighten the screws to 80 lb·in (9 N·m). Figure 4-35 Canopy Installation - Rear Canopy Support Install the bolts (3), washers (2), and nuts (1) to secure the front canopy strut (4) (Figure 4-36).

  • Page 65: 2+2 Front Canopy Strut Removal

    BODY AND TRIM 2+2 - Monsoon Canopy 2+2 FRONT CANOPY STRUT REMOVAL CAUTION • To prevent damage to the canopy, do not remove the canopy supports from the vehicle without first removing the canopy. • Using tools to thread the bolts could prevent proper feel of the bolt as it captures the female threads in the support.

  • Page 66: 2+2 Front Canopy Strut Installation

    2+2 - Monsoon Canopy BODY AND TRIM 2+2 FRONT CANOPY STRUT INSTALLATION Figure 4-38 Front Canopy Strut Installation Install the front canopy strut (3) onto the vehicle (Figure 4-38). Install the front canopy strut cover (2) onto the front canopy strut. Install the screws (4).

  • Page 67: 2+2 Rear Canopy Support Removal

    BODY AND TRIM 2+2 - Monsoon Canopy 2+2 REAR CANOPY SUPPORT REMOVAL CAUTION • To prevent damage to the canopy, do not remove the canopy supports from the vehicle without first removing the canopy. • Using tools to thread the bolts could prevent proper feel of the bolt as it captures the female threads in the support.

  • Page 68: 2+2 Rear Canopy Support Installation

    2+2 - Monsoon Canopy BODY AND TRIM 2+2 REAR CANOPY SUPPORT INSTALLATION Figure 4-40 Rear Canopy Support Installation Install the rear canopy support (3) into the rear underbody (Figure 4-40). Install the brackets (2) onto the rear canopy support. Install the screws (1). Tighten the screws to 80 lb·in (9 N·m). Page 4-42 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 69: 2+2 - Rear Body

    BODY AND TRIM 2+2 - Rear Body 2+2 - REAR BODY SEAT BACKS Seat Back Removal Figure 4-41 Seat Back Removal Remove the screws (1) from the front seat back (2) (Figure 4-41). Remove the front seat back. Remove the screws (3) from the rear seat back (4). Remove the rear seat back.
  • Page 70 2+2 - Rear Body BODY AND TRIM Seat Back Installation Figure 4-42 Seat Back Installation Install the front seat back (1) onto the seat support (2). Make sure the seat support tab (3) is installed in the front seat back (Figure 4-42). Install the screws (4).

  • Page 71: Fixed Rear Seat

    BODY AND TRIM 2+2 - Rear Body FIXED REAR SEAT 2+2 fixed rear seat procedures. Fixed Rear Seat Bottom Removal Figure 4-43 Fixed Rear Seat Bottom Remove the screws (1) (Figure 4-43). Lift and remove the rear seat bottom (2). Fixed Rear Seat Bottom Installation Install the rear seat bottom tabs into the seat supports.
  • Page 72 2+2 - Rear Body BODY AND TRIM Fixed Rear Seat Hinge Removal Figure 4-44 Fixed Rear Seat Hinge Remove the rear seat bottom. Remove the screws (1) (Figure 4-44). Remove the hinge (2). Fixed Rear Seat Hinge Installation Install the hinge (2) onto the rear seat bottom (Figure 4-44). Install the screws (1).
  • Page 73 BODY AND TRIM 2+2 - Rear Body Fixed Rear Seat Hip Restraint Removal Figure 4-45 Fixed Rear Seat Hip Restraint Remove the screws (1) (Figure 4-45). Remove the strut angle (2). Remove the screws (3). Lift and remove the hip restraint (4). Fixed Rear Seat Hip Restraint Installation Install the rear hip restraint (4) onto the foot deck.

  • Page 74: Fold-Down Rear Seat

    2+2 - Rear Body BODY AND TRIM FOLD-DOWN REAR SEAT 2+2 fold-down rear seat procedures. Fold-Down Rear Seat Bottom Removal Figure 4-46 Fold-Down Rear Seat Bottom Remove the screws (1) (Figure 4-46). Remove the rear seat bottom (2) from the fold-down hinge (3). Fold-Down Rear Seat Bottom Installation Put the rear seat bottom (2) onto the fold-down hinge (3) (Figure 4-46).
  • Page 75 BODY AND TRIM 2+2 - Rear Body Fold-Down Rear Seat Assembly Removal Figure 4-47 Fold-Down Rear Seat Assembly Remove the screws (1) (Figure 4-47). Remove the bolts (2) and nuts (3). Remove the bolts (4) washers (5), and nuts (6). Remove the rear seat assembly (7).
  • Page 76 2+2 - Rear Body BODY AND TRIM Fold-Down Rear Seat Hip Restraint Removal Figure 4-48 Fold-Down Rear Seat Hip Restraint Remove the screws (1) (Figure 4-48). Remove the strut angle (2). Remove the screws (3). Lift and remove the hip restraint (4). Fold-Down Rear Seat Hip Restraint Installation Install the rear hip restraint (4) onto the foot deck (Figure 4-48).
  • Page 77 BODY AND TRIM 2+2 - Rear Body Side Frame Removal Figure 4-49 Side Frame Remove the bolt (1), washers (2), and nut (3) (Figure 4-49). Remove the nut (4) and bolt (5). Remove the side frame (6). Side Frame Installation Install the side frame (6) onto the foot deck (Figure 4-49).

  • Page 78: Seat Support

    2+2 - Rear Body BODY AND TRIM SEAT SUPPORT 2+2 seat support procedures. Figure 4-50 2+2 Seat Support Seat Support Removal Remove the seat backs. Remove the hip restraints. Remove the rear seat bottom assembly. Remove the screws (1) (Figure 4-50). Remove the screw (2).

  • Page 79: Foot Deck - 2+2

    BODY AND TRIM 2+2 - Rear Body FOOT DECK - 2+2 2+2 foot deck procedures. Foot Deck Removal Figure 4-51 Foot Deck (2+2) Removal Support the foot deck. Remove the screws (1) (Figure 4-51). Remove the screws (2). Remove the bolts (3) and the foot deck. Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 4-53...
  • Page 80 2+2 - Rear Body BODY AND TRIM Foot Deck Disassembly Figure 4-52 Foot Deck (2+2) Disassembly Remove the push rivets (1) (Figure 4-52). Remove the floormat (2). Remove the screws (3). Remove the foot deck (4). Remove the screws (5). Remove the handrail (6) from the foot deck support (7).
  • Page 81 BODY AND TRIM 2+2 - Rear Body Foot Deck Assembly Figure 4-53 Foot Deck (2+2) Assembly Make sure the J-clips (1) are installed on the foot deck support (2) (Figure 4-53). Install the handrail (3) into the foot deck support. Install the screws (4).
  • Page 82 2+2 - Rear Body BODY AND TRIM Foot Deck Installation Figure 4-54 Foot Deck (2+2) Installation Support the foot deck. Install the bolts (3) (Figure 4-54). Tighten the bolts to 22 lb·ft (30 N·m). Install the screws (2). Tighten the screws to 13 lb·ft (18 N·m). Install the screws (1).

  • Page 83: Rear Beauty Panel (2+2 Vehicles)

    BODY AND TRIM 2+2 - Rear Body REAR BEAUTY PANEL (2+2 VEHICLES) 2+2 rear body component procedures. Figure 4-55 2+2 Rear Beauty Panel Rear Beauty Panel Removal Remove the front seat bottom. Remove the rear seat assembly. Remove the forward / neutral / reverse (FNR) control. Remove the screws (1) (Figure 4-55).

  • Page 84: Rear Underbody

    2+2 - Rear Body BODY AND TRIM REAR UNDERBODY Figure 4-56 2+2 Rear Underbody Rear Underbody Removal Remove the rear beauty panel. Remove the access panel. Remove the screws (1) (Figure 4-56). Lift the rear edge of the rear underbody (2) until the front portion slides out from beneath the front underbody. Remove the rear underbody from the vehicle.

  • Page 85: Section 5 - Accelerator And Brake Pedal Group

    SECTION 5 — ACCELERATOR AND BRAKE PEDAL GROUP PEDAL GROUP REMOVAL Accelerator and Brake Pedal Group Disable the vehicle. Set the Run/Tow-Stow switch to TOW/STOW. Remove the high voltage interlock fuse (HVIL). Remove the floor mat retainer (1) (Figure 5-1). Figure 5-1 Pedal Group Access Pull the floor mat (2) over the pedal group.
  • Page 86 Pedal Group Removal ACCELERATOR AND BRAKE PEDAL GROUP Remove the fastener (3) (Figure 5-2). Figure 5-2 Pedal Group Removal Remove the cover (4). Loosen the jam nuts on each side of the turnbuckle (5). Remove the turnbuckle from the pedal assembly. Disconnect the wire harnesses (6).

  • Page 87: Pedal Group Installation

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Installation PEDAL GROUP INSTALLATION Connect the wire harnesses (1) (Figure 5-3). Figure 5-3 Pedal Group Installation Install the driver side screws (2). Tighten the driver side screws to 97 lb·in (11 N·m). Install the passenger side screws (3). Tighten the passenger side screws to 18 lb·in (2 N·m). Remove the turnbuckle (4).
  • Page 88 Pedal Group Installation ACCELERATOR AND BRAKE PEDAL GROUP Install the floor mat (8) over the pedal group (Figure 5-4). Figure 5-4 Floor Mat and Retainer Installation Install the floor mat retainer (9). Install the high voltage interlock fuse (HVIL). Page 5-4 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 89: Debris Shields

    ACCELERATOR AND BRAKE PEDAL GROUP Debris Shields DEBRIS SHIELDS Debris shields on the top face of the pedal group prevent excessive debris from contacting the moving parts of the pedal group. Figure 5-5 Debris Shields DEBRIS SHIELDS REMOVAL Use a flat blade screw driver to release the tabs (1) and remove the primary debris shield (2) (Figure 5-5). Remove the auxiliary debris shield (3).

  • Page 90: Accelerator Pedal

    Accelerator Pedal ACCELERATOR AND BRAKE PEDAL GROUP ACCELERATOR PEDAL Figure 5-6 Accelerator Pedal ACCELERATOR PEDAL REMOVAL Remove the pedal group. Remove the debris shields. Remove the screws (1) (Figure 5-6). Turn the accelerator pedal assembly (2) and remove through bottom of pedal group mounting plate. ACCELERATOR PEDAL INSTALLATION Install the accelerator pedal assembly (2) through bottom of pedal group mounting plate (Figure 5-6).

  • Page 91: Brake Pedal

    ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal BRAKE PEDAL Figure 5-7 Brake Pedal BRAKE PEDAL REMOVAL Remove the pedal group. Remove the debris shields. Remove the screws (1) (Figure 5-7). Remove the brake pedal assembly (2) through bottom of pedal group mounting plate. BRAKE PEDAL INSTALLATION Install the brake pedal assembly (2) through bottom of pedal group mounting plate (Figure 5-7).
  • Page 92 Brake Pedal ACCELERATOR AND BRAKE PEDAL GROUP Pagination Page Page 5-8 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 93: Section 6 - Wheel Brake Assemblies

    SECTION 6 — WHEEL BRAKE ASSEMBLIES WARNING Wheel Brake Assemblies Asbestos Dust Warning • Some aftermarket brake shoes contain asbestos fiber, and asbestos dust is created when these brake mechanisms are handled. Wear approved eye and respiratory protection when disassembling and cleaning brake mechanisms.
  • Page 94 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES Loosen the left-hand thread jam nut (1) and right-hand thread jam nut (2) (Figure 6-1). Figure 6-1 Loosen the turnbuckle (3) to release tension on the bell crank. Remove the lugs nuts from the rear wheel. Remove the rear wheel.
  • Page 95 WHEEL BRAKE ASSEMBLIES Brake Shoe Removal Using needle nose pliers, turn the retainer pin (1) 90° to remove the shoe retainer clip (2) (Figure 6-3). CAUTION • The brake shoes are under pressure and can release suddenly when brake shoe retainers are removed. Figure 6-3 Hold both brake shoes and pull them, together with the springs, out of the brake assembly (Figure 6-4).

  • Page 96: Brake Assembly Cleaning

    Brake Assembly Cleaning WHEEL BRAKE ASSEMBLIES Remove adjuster wheel (1) with two washers (2 and 3) from the backing plate (Figure 6-5). Figure 6-5 Clean the brake assembly. BRAKE ASSEMBLY CLEANING Carefully clean the brake backing plate (1) and all of its mechanical components (Figure 6-6). Figure 6-6 Remove the dust cover (2) from backing plate and wipe with a clean damp cloth.
  • Page 97 WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning Lubricate the slide (1) with dry moly lubricant (Figure 6-7). Figure 6-7 Make sure that the slide can easily move back and forth. Install the dust cover onto the backing plate. WARNING • Apply grease carefully when performing the following steps. Do not allow any grease to get onto the friction surfaces of the brake shoe pads or the brake drum.
  • Page 98 Brake Assembly Cleaning WHEEL BRAKE ASSEMBLIES 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 slots in the brake shoe mounting block as shown (Figure 6-9).

  • Page 99: Brake Shoe Installation

    WHEEL BRAKE ASSEMBLIES Brake Shoe Installation BRAKE SHOE INSTALLATION WARNING • When installing brake shoes, the shoes must be oriented with tips stamped 10 inserted into the mounting block anchor piston slots rather than into the brake actuator slots. Incorrectly installed brake shoes will be too tight and make adjustment of the brake impossible.
  • Page 100 Brake Shoe Installation WHEEL BRAKE ASSEMBLIES Install the first shoe (1) in the slots in the mounting block anchor piston (2) and the brake actuator (3) (Figure 6-13). Make sure that the stamped end of the shoe in the mounting block anchor piston. See detail A. NOTE: 10 is stamped into one of the shoe flanges.
  • Page 101 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation Use a flatblade screwdriver to lift the adjusting arm (1) off of the adjusting wheel (2) (Figure 6-15). Figure 6-15 Turn the adjusting wheel upward until it stops. Remove the screwdriver. Install the axle shaft. Install the brake drum.

  • Page 102: Brake Cable Equalizer Adjustment

    Brake Cable Equalizer Adjustment WHEEL BRAKE ASSEMBLIES Adjust the brake cable equalizer. Install the high voltage interlock fuse (HVIL). Set the Run/Tow-Stow switch to RUN. BRAKE CABLE EQUALIZER ADJUSTMENT Make sure that the brake pedal is in the fully up position. Adjust the turnbuckle (1) until the distance (A) between the top of the brake cable equalizer (2) and the upper flange surface (3) is 2 inches (±1/16) (51 mm (±1.6) (Figure 6-17).
  • Page 103 WHEEL BRAKE ASSEMBLIES Brake Cable Equalizer Adjustment WARNING • Reduced braking force could result if the jam nuts are not tightened in the proper sequence. Tighten the rear jam nut first to 208 lb·in (23.5 N·m), then tighten the front jam nut to 208 lb·in (23.5 N·m). 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.

  • Page 104: Brake Cluster

    Brake Cluster WHEEL BRAKE ASSEMBLIES BRAKE CLUSTER BRAKE CLUSTER REMOVAL Disable the vehicle. Set the Run/Tow-Stow switch to TOW/STOW. Remove the high voltage interlock fuse (HVIL). Loosen the lug nuts on the rear wheel. Lift the rear of the vehicle. WARNING •...
  • Page 105 WHEEL BRAKE ASSEMBLIES Brake Cluster Remove and discard the bow tie pin (1) (Figure 6-20). Figure 6-20 Remove the clevis pin (2). Remove the brake cable (3) from the brake actuator arm. Remove the brake drum (1) (Figure 6-21). If the brake drum cannot be easily removed: NOTE: When servicing vehicles with severely worn brake shoes and when the drums cannot be removed by normal methods, use the following steps to minimize damage to the brake cluster and brake components.

  • Page 106: Brake Cluster Installation

    Brake Cluster WHEEL BRAKE ASSEMBLIES Remove the bolts (1) and lock nuts (2) (Figure 6-22). Discard the lock nuts. Figure 6-22 Remove the brake cluster (3). BRAKE CLUSTER INSTALLATION CAUTION • Before installing axle shaft, clean any residual oil from the exposed end of the axle tube and from the oil seal area.
  • Page 107 WHEEL BRAKE ASSEMBLIES Brake Cluster Install the brake cable (1) on the brake actuator arm (Figure 6-24). Figure 6-24 Install the brake cable clevis pin (2). Install the new bow tie pin (3). Install the rear wheels. Lower the rear of the vehicle. Adjust the brake cable equalizer.

  • Page 108: Brake Cable

    Brake Cable WHEEL BRAKE ASSEMBLIES BRAKE CABLE BRAKE CABLE REMOVAL Special Tools Needed Brake Cable Release Tool NOTE: Refer to the Illustrated Parts Catalog for service tool part numbers. Disable the vehicle. Set the Run/Tow-Stow switch to TOW/STOW. Remove the high voltage interlock fuse (HVIL). Remove the floor mat.
  • Page 109 WHEEL BRAKE ASSEMBLIES Brake Cable Lift the brake actuator rod and equalizer bracket (1) (Figure 6-26). Figure 6-26 Remove the brake cables (2) from the equalizer bracket. Remove the nut (1) (Figure 6-27). Do not remove bolt (2). Figure 6-27 Remove the mounting tab (3) of the brake cable from the bolt.
  • Page 110 Brake Cable WHEEL BRAKE ASSEMBLIES Use a brake cable release tool to compress the retaining clips (1) on the end of the cable housing enough to slide the cable end out of the hole in the frame (Figure 6-28). Figure 6-28 Remove and discard the bow tie locking pin (1) (Figure 6-29).

  • Page 111: Brake Cable Installation

    WHEEL BRAKE ASSEMBLIES Brake Cable BRAKE CABLE INSTALLATION NOTE: The driver-side and passenger-side brake cables are not interchangeable. The driver-side cable is shorter than the passenger-side cable. Make sure the correct cable is used on the correct side. Be sure to orient the cable so that the clevis end goes to the wheel rather than to the equalizer bracket. Insert the end of the new brake cable through the hole in the frame (Figure 6-30).
  • Page 112 Brake Cable WHEEL BRAKE ASSEMBLIES Insert the rear cable housing into the shock mount bracket (1) (Figure 6-32). Figure 6-32 Make sure that the clips on the housing end secure the cable in position. Install the brake cable (2) on the brake actuator arm. Install the brake cable clevis pin (3).

  • Page 113: Section 7 - Steering And Front Suspension

    SECTION 7 — STEERING AND FRONT SUSPENSION DANGER Steering and Front Suspension • WARNING • GENERAL INFORMATION Steering is controlled through a rack and pinion steering assembly that is connected by a steering column to a steering wheel. No manual adjustment to the rack and pinion gear assembly is required. A spring loaded self-adjusting mechanism is incorporated into the assembly.

  • Page 114: Steering Wheel Installation

    Steering Wheel STEERING AND FRONT SUSPENSION Remove the screws (1) (Figure 7-1). Figure 7-1 Remove the cover (2). Remove the steering wheel retaining bolt (3). Put the puller anvil (4) through the top opening of the steering wheel (5). Insert the anvil feet through the two slots in the base plate (marked “B”) (6). Turn the anvil screw (7) clockwise until the base plate contacts the bottom of the steering wheel at the steering column.

  • Page 115: Steering Column

    STEERING AND FRONT SUSPENSION Steering Column Install steering wheel retaining bolt (3). Tighten the bolt to 37 lb·ft (50 N·m). Put the cover (4) on the steering wheel. Install the screws (5). Tighten the screws to 15 lb·in (1.7 N·m). STEERING COLUMN STEERING COLUMN REMOVAL Figure 7-3 Steering Column Removal...

  • Page 116: Steering Column Installation

    Rack and Pinion STEERING AND FRONT SUSPENSION STEERING COLUMN INSTALLATION Figure 7-4 Steering Column Installation Apply a light coat of anti-seize or lubricating compound to the pinion shaft (1) (Figure 7-4). Install the universal joint (2) onto pinion shaft. Install the bolt (3) and tighten by hand. Do not fully tighten the bolt. Install the steering column mounting bracket (4) on the vehicle frame.

  • Page 117: Rack And Pinion Inspection

    STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION INSPECTION Look for obvious damage to the chassis, where the rack and pinion is mounted, and the rack and pinion housing. Particularly check the housing for broken mounting points. Compare the toe-in against the specification. See Tow-in Adjustment. If obvious visible damage is found, such as a bent tie rod, check the steering gear for abnormal free-play, noise, binding or clunking while it is under a load.

  • Page 118: Rack And Pinion Installation

    Rack and Pinion STEERING AND FRONT SUSPENSION Remove the bolt (5) from the universal joint (6). Remove the universal joint from the pinion shaft (7). Remove the rack and pinion assembly. RACK AND PINION INSTALLATION Apply a light coat of anti-seize lubricating compound to the pinion shaft (1) (Figure 7-6). Figure 7-6 Rack and Pinion Installation Install the universal joint (2) onto the pinion shaft.

  • Page 119: Front Suspension

    STEERING AND FRONT SUSPENSION Front Suspension FRONT SUSPENSION LUBRICATION Two grease fittings are provided (one in each spindle housing). Lubricate these fittings at the recommended interval with the proper lubricant. See Periodic Lubrication Schedules on page 10-5. CAUTION • To ensure proper lubrication, raise front of vehicle to lubricate. WHEEL ALIGNMENT Wheel alignment is limited to equalizing the camber angle of each front wheel and adjusting toe-in of the front wheels.
  • Page 120 Front Suspension STEERING AND FRONT SUSPENSION If there is not an equal amount of space (B) between each tire and the framing square (Figure 7-7), go to step 4. Loosen the four bolts (1). Do not remove the bolts (Figure 7-8). Figure 7-8 Adjust Camber Loosen the nut (2) on the adjustment eccentric (3) in the center of the spring.
  • Page 121 STEERING AND FRONT SUSPENSION Front Suspension Measure the distance between the marks on the forward-facing surfaces of the tires (Figure 7-9). NOTE: The front measurement must be less than the rear measurement. Figure 7-9 Check Toe-In Subtract the measurement on the front of the tires from the measurement on the rear of the tires. The difference is the toe-in.

  • Page 122: Front Suspension Components

    Front Suspension Components STEERING AND FRONT SUSPENSION Figure 7-11 9.5. Tighten the jam nuts on both ends of each drag link to 26 lb·ft (35 N·m). 9.6. Check the toe-in. 9.7. Repeat the adjustment procedure if necessary. 9.8. After the toe-in adjustment is made and with wheels in the straight ahead position, the steering wheel should be at the center of its travel.

  • Page 123: Tie Rod Installation

    STEERING AND FRONT SUSPENSION Front Suspension Components Loosen the jam nut (1) (Figure 7-12). Figure 7-12 Remove the retaining nut (2). Lift the tie rod (3) from the hole in the spindle tab. Remove the tie rod end from the drag link. Apply a light coat of anti-seize lubricating compound to the threads (4).

  • Page 124: Leaf Spring Removal

    Front Suspension Components STEERING AND FRONT SUSPENSION Install the retaining nut (3). Adjust the wheel toe-in. Install the high voltage interlock fuse (HVIL). Set the Run/Tow-Stow switch to RUN. LEAF SPRING REMOVAL Disable the vehicle. Set the Run/Tow-Stow switch to TOW-STOW. Remove the high voltage interlock fuse (HVIL).

  • Page 125: Leaf Spring Installation

    STEERING AND FRONT SUSPENSION Front Suspension Components Remove the bolts (1) from the bottom of each kingpin (2) (Figure 7-14). Figure 7-14 Remove the four bolts (3) and bottom spring plate (4). Remove the leaf spring (5). Check the condition of the urethane bushings (6) and steel sleeves (7). Replace any that are worn or damaged. LEAF SPRING INSTALLATION Install the urethane bushings (1) and steel sleeves (2) into leaf spring eyes (Figure 7-15).

  • Page 126: Kingpin And Steering Spindle Removal

    Front Suspension Components STEERING AND FRONT SUSPENSION KINGPIN AND STEERING SPINDLE REMOVAL Disable the vehicle. Set the Run/Tow-Stow switch to TOW-STOW. Remove the high voltage interlock fuse (HVIL). Remove the front wheels. Remove and discard the lock nut (1) (Figure 7-16). Figure 7-16 Remove the front hub (2).

  • Page 127: Kingpin And Steering Spindle Installation

    STEERING AND FRONT SUSPENSION Front Suspension Components 12.2. If the wave washer bottom to crest height dimension is less than 0.040 inch (1 mm), replace the washer. Remove the bolt (6) and the kingpin. Inspect the kingpin and spindle. If either is worn or damaged, it must be replaced. Inspect the spindle bushings.
  • Page 128 Front Suspension Components STEERING AND FRONT SUSPENSION Install the tie rod end (1) to the spindle tab (2) (Figure 7-19, Page 7-16). Figure 7-19 Install the nut (3). Tighten the nut to 70 lb·ft (95 N·m). Install the front hubs (4). Install the nut (5).

  • Page 129: Control Arm Removal

    STEERING AND FRONT SUSPENSION Front Suspension Components CONTROL ARM REMOVAL Disable the vehicle. Set the Run/Tow-Stow switch to TOW-STOW. Remove the high voltage interlock fuse (HVIL). Remove the front wheels. Remove the bolts (1) (Figure 7-20). Figure 7-20 Move the rack and pinion (2) to allow clearance for the control arm bolts. Remove the bolts (1 and 2) (Figure 7-21).

  • Page 130: Control Arm Installation

    Front Suspension Components STEERING AND FRONT SUSPENSION CONTROL ARM INSTALLATION Put the control arm (1) into position on the vehicle (Figure 7-22). Figure 7-22 Install the bolts (2 and 3). Tighten the bolts to 30 lb·ft (41 N·m). Move the rack and pinion (1) into position (Figure 7-23). Figure 7-23 Install the bolts (2).Tighten the bolts to 22 lb·ft (30 N·m).

  • Page 131: Front Shock Absorber Inspection

    STEERING AND FRONT SUSPENSION Front Suspension Components FRONT SHOCK ABSORBER INSPECTION Examine the area (1) where the shaft enters the shock absorber body (Figure 7-24). 1.1. If there is fluid leakage, replace the shock absorber. Figure 7-24 FRONT SHOCK ABSORBER REMOVAL Disable the vehicle.

  • Page 132: Front Shock Absorber Installation

    Front Suspension Components STEERING AND FRONT SUSPENSION Remove the upper bolt (1) (Figure 7-25). Figure 7-25 Remove the lower bolt (2). Remove the shock absorber (3). FRONT SHOCK ABSORBER INSTALLATION Make sure that the front shock absorbers (3) have the same part number (Figure 7-25). Install the shock absorber.

  • Page 133: Front Wheel Hubs

    STEERING AND FRONT SUSPENSION Front Wheel Hubs FRONT WHEEL HUBS FRONT WHEEL FREE PLAY INSPECTION NOTE: The front wheel bearings are pressed into the spindle and are not serviceable. If excessive free-play is detected the entire hub should be replaced. Disable the vehicle.

  • Page 134: Front Wheel Hub Installation

    Front Wheel Hubs STEERING AND FRONT SUSPENSION FRONT WHEEL HUB INSTALLATION Apply a light coat of anti-seize lubricant to the spindle shaft (1) (Figure 7-27). Figure 7-27 Install the hub assembly (2) onto the spindle shaft. Install the new lock nut (3). Tighten the lock nut to 50 lb·ft (68 N·m). Rotate the hub.

  • Page 135: Section 8 - Wheels And Tires

    SECTION 8 — WHEELS AND TIRES DANGER Wheels and Tires • WARNING • GENERAL INFORMATION Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care. • Keep tires properly inflated. • Keep lug nuts properly tightened. •...

  • Page 136: Lift The Front Of The Vehicle

    Lift The Vehicle WHEELS AND TIRES LIFT THE FRONT OF THE VEHICLE Use a jack and jack stands rated for the vehicle. Figure 8-1 Disable the vehicle. Set the Run/Tow-Stow switch to TOW-STOW. Remove the high voltage interlock fuse (HVIL). Place the jack in the center of the lift point (Figure 8-1, Page 8-2).

  • Page 137: Lower The Rear Of The Vehicle

    WHEELS AND TIRES Lift The Vehicle Figure 8-2 Disable the vehicle. Set the Run/Tow-Stow switch to TOW-STOW. Remove the high voltage interlock fuse (HVIL). Place the jack in the center of the lift point. Lift the rear of the vehicle. Put jack stands under the frame rails.

  • Page 138: Tires

    Tires WHEELS AND TIRES TIRES TIRE PRESSURE MEASUREMENT Disable the vehicle. Remove the valve stem cap. Use a pressure gauge to measure the tire pressure. Adjust the tire pressure to meet the recommended tire pressure. Go to the approved wheel and tire assemblies matrix on http://www.clubcar.com for information regarding tire type, inflation pressure, and lug nut torque.

  • Page 139: Tire Repair

    Small holes in the casing can be plugged using a standard automotive tubeless tire repair kit available at your local Club Car dealer. When the cause of the air leak has been determined, remove tire from the rim and repair as required. See Tire Removal.

  • Page 140: Wheel Assembly

    Wheel Assembly WHEELS AND TIRES Place tire and wheel assembly against wall in upright position and push it against wall while inflating tire to 30 to 35 psig (207 to 242 kPa). The three-point contact (wall, floor, and hand) will help ensure that beads snap into place and form a proper seal as tire is inflated (Figure 8-4, Page 8-6).

  • Page 141: Wheel Assembly Installation

    WHEELS AND TIRES Wheel Assembly WHEEL ASSEMBLY INSTALLATION Disable the vehicle. Align the wheel assembly onto the hub of the vehicle. NOTE: Make sure that the valve stem points to the outer side of the vehicle. NOTE: Make sure that the tire tread is in the correct direction of travel. Install the lug nuts with the taper to the vehicle.
  • Page 142 Wheel Assembly WHEELS AND TIRES Pagination Page Page 8-8 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 143: Section 9 - Rear Suspension

    SECTION 9 — REAR SUSPENSION See General Warnings Section. Rear Suspension GENERAL INFORMATION The rear suspension and powertrain of the vehicle move independently from the vehicle frame. It consists of two leaf springs controlled by two shock absorbers mounted between the springs and the vehicle frame. SHOCK ABSORBERS The following procedures are the same for all vehicles.

  • Page 144: Rear Shock Absorber Removal

    Shock Absorbers REAR SUSPENSION REAR SHOCK ABSORBER REMOVAL Figure 9-2 Rear Shock Absorber Removal Disable the vehicle. Set the Run/Tow-Stow switch to TOW-STOW. Remove the high voltage interlock fuse (HVIL). Remove the nut (1), cup washer (2), and rubber bushing (3) from the top of the shock absorber (Figure 9-2, Page 9-2).

  • Page 145: Rear Shock Absorber Installation

    REAR SUSPENSION Shock Absorbers REAR SHOCK ABSORBER INSTALLATION Figure 9-3 Rear Shock Absorber Installation Install the cup washers (1) and rubber bushings (2) onto the shock absorber (3) (Figure 9-3, Page 9-3). Install the bottom stem of the shock absorber into the shock mount bracket (4). Install the top stem of the shock absorber into the frame shock mount (5).

  • Page 146: Panhard And Bracket

    Panhard and Bracket REAR SUSPENSION PANHARD AND BRACKET Figure 9-4 Panhard and Bracket PANHARD AND BRACKET REMOVAL Disable the vehicle. Set the Run/Tow-Stow switch to TOW-STOW. Remove the high voltage interlock fuse (HVIL). Remove the bolts (1) (Figure 9-4, Page 9-4). Remove the panhard (2).

  • Page 147: Leaf Springs (Two-Passenger)

    REAR SUSPENSION Leaf Springs (Two-Passenger) LEAF SPRINGS (TWO-PASSENGER) LEAF SPRING REMOVAL (TWO-PASSENGER) WARNING • Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold vehicle in raised position.
  • Page 148 Leaf Springs (Two-Passenger) REAR SUSPENSION Remove the nut (5), cup washer (6), and rubber bushing (7) from the bottom stem of the shock absorber (Figure 9-6). Figure 9-6 Leaf Spring Removal - Two-Passenger Remove the nuts (8) and the U-bolt (9) securing the spring to the transaxle. Remove the shock mount bracket (10) and the U-bolt.

  • Page 149: Leaf Spring Installation (Two-Passenger)

    REAR SUSPENSION Leaf Springs (Two-Passenger) LEAF SPRING INSTALLATION (TWO-PASSENGER) CAUTION • When positioning the spring on the transaxle, be sure to insert the locating bolt on the spring in the locating hole in the transaxle saddle. Install the front of the leaf spring (1) onto the vehicle frame (Figure 9-7). Figure 9-7 Leaf Spring Installation - Two-Passenger Install the bolt (2) and nut (3).

  • Page 150: Leaf Springs (Four-Passenger)

    Leaf Springs (Four-Passenger) REAR SUSPENSION Install the brake cable onto the shock mount bracket (1) (Figure 9-8). Figure 9-8 Install the cable end (2) onto the brake lever. Install the clevis pin (3) and the bow tie locking pin (4). Lower and remove the floor jack under the transaxle.
  • Page 151 REAR SUSPENSION Leaf Springs (Four-Passenger) Figure 9-9 Remove the cable end (3) from the brake lever. Remove the brake cable from the shock mount bracket (4). Remove the nut (5), cup washer (6), and rubber bushing (7) from the bottom stem of the shock absorber (Figure 9-10, Page 9-9).

  • Page 152: Leaf Spring Installation (Four-Passenger)

    Leaf Springs (Four-Passenger) REAR SUSPENSION Remove the nut (15) and bolt (16) from the front of the leaf spring and remove the leaf spring. Examine the bushings (17) and sleeves (18) in the spring eyes. 15.1. If the bushings or sleeves are worn or have damage, replace them. LEAF SPRING INSTALLATION (FOUR-PASSENGER) CAUTION •...

  • Page 153: Leaf Springs (Four-Passenger - Heavy Duty With Panhard)

    Leaf Springs (Four-Passenger - Heavy Duty REAR SUSPENSION With Panhard) Figure 9-12 Install the cable end (2) onto the brake lever. Install the clevis pin (3) and the bow tie locking pin (4). Lower and remove the floor jack under the transaxle. Install the tire and wheel assembly.
  • Page 154 Leaf Springs (Four-Passenger - Heavy Duty With Panhard) REAR SUSPENSION Figure 9-13 Remove the cable end (3) from the brake lever. Remove the brake cable from the shock mount bracket (4). Remove the nut (5), cup washer (6), and rubber bushings (7) from the lower mounting stem of the shock absorber (Figure 9-14).

  • Page 155: Leaf Spring Installation (Four-Passenger - Heavy Duty With Panhard)

    Leaf Springs (Four-Passenger - Heavy Duty REAR SUSPENSION With Panhard) Inspect the bushings (16) and sleeves (17) in the spring eyes and replace them if they are worn or damaged. LEAF SPRING INSTALLATION (FOUR-PASSENGER - HEAVY DUTY WITH PANHARD) CAUTION •...
  • Page 156 Leaf Springs (Four-Passenger - Heavy Duty With Panhard) REAR SUSPENSION Install the brake cable onto the shock mount bracket (1) (Figure 9-16). Figure 9-16 Install the cable end (2) onto the brake lever. Install the clevis pin (3) and the bow tie locking pin (4). Lower and remove the floor jack under the transaxle.

  • Page 157: Section 10 - Vehicle Maintenance

    Use the following checklist in conjunction with the Daily Pre-Operation and Safety Checklist as a guide to inspect the vehicle and check daily for proper operation. Any problems should be corrected by a Club Car distributor/dealer or a trained technician.

  • Page 158: Maintenance

    Any vehicle not functioning correctly should be removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service. WARNING •...

  • Page 159: Maintenance Service Schedules

    VEHICLE MAINTENANCE Maintenance Service Schedules WARNING • 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.
  • Page 160 Maintenance Service Schedules VEHICLE MAINTENANCE MAINTENANCE SERVICE SCHEDULE INTERVAL DESCRIPTION Brake system: • Examine the brake shoes. Replace as necessary. • Lubricate the brake system. See the Periodic Lubrication Schedule. • Examine the brake cables. Replace as necessary. • Examine the brake cable equalizer adjustment. Adjust as necessary. 50 hours / 6 months Examine the electrical wiring and connections for tightness and damage.

  • Page 161: Periodic Lubrication Schedules

    VEHICLE MAINTENANCE Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE LUBRICATION INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Charger receptacle WD-40 ® Brake system. See Brake Assembly 50 hours / 6 months Dry Moly Lube, white lithium grease NLGI #2 Cleaning. Front suspension (two fittings) Chassis Lube - EP NLGI Grade 2 22 fl-oz (0.67 L) SAE 30 WT.

  • Page 162: Cleaning The Dynamic Braking Resistor

    Cleaning The Dynamic Braking Resistor VEHICLE MAINTENANCE CLEANING THE DYNAMIC BRAKING RESISTOR WARNING • The dynamic braking resistor becomes hot when it is on and can cause a fire, property damage, or serious personal injury. Do not touch. Before cleaning the dynamic braking resistor, make sure that it is cool.

  • Page 163: Section 11 - Ccdt

    SECTION 11 — CCDT OVERVIEW CCDT The CCDT is the diagnostic tool used for vehicles with a lithium-ion battery. The CCDT can be used for: • Software updates for all electronic control units (ECUs) • Read and clear diagnostic fault codes •...

  • Page 164: Diagnostic Cable

    The CCDT-APP is an Android app that runs on Android OS version 5.0 or above. CCDT-APP Installation The CCDT-APP is available in Google Play Store. Search for Club Car diagnostics tool or CCDT in the play store. The CCDT-APP will request permissions to install (based on the Android settings). Page 11-2...

  • Page 165: Connect The Dongle To The Vehicle

    CCDT Connect The Dongle To The Vehicle All Android versions above 5.0 support the CCDT-APP. CONNECT THE DONGLE TO THE VEHICLE Connect the diagnostic cable to the dongle. Remove the dust cap on the diagnostic receptacle. Figure 11-3 Diagnostic Receptacle Align the diagnostic cable connector with the diagnostic receptacle.

  • Page 166: Ccdt-App Screens

    Select the correct device to connect. If the device is not in the list, tap CLUB CAR DEVICES to restart the scan. NOTE: After repeated scanning, if the device is not in the list, push the button on top of the dongle to put it in discovery mode.
  • Page 167 CCDT CCDT-APP Screens G-008998-000019 Figure 11-5 Connection Screen While the device is being connected, a pairing confirmation prompt will display. To pair with the diagnostic tool, tap OK. G-008998-000002 Figure 11-6 Pairing Confirmation Screen Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 11-5...

  • Page 168: Home Screen

    CCDT-APP Screens CCDT HOME SCREEN When the vehicle is connected, the home screen will display. To open a screen, tap the desired screen icon. G-008998-000018 Figure 11-7 Home Screen SCREEN LAYOUT Callout Number Descrpition CCDT Device ID Menu option to get the CCDT app and dongle software version Quick navigation pane - Navigate to desired screen without going back to the home screen G-008998-000004 Figure 11-8 Screen Layout...

  • Page 169: Car System Screen

    CCDT CCDT-APP Screens CAR SYSTEM SCREEN The car system screen displays a system level overview of the vehicle. The car system screen has five tabs: • CAR DETAILS - Vehicle functional data • ABOUT - Vehicle and Electronic Control Unit (ECU) identification data •...

  • Page 170: Bms Screen

    CCDT-APP Screens CCDT BMS SCREEN The BMS screen displays the battery management system (BMS) data. The BMS screen has three tabs: • BATTERY DETAILS - BMS functional data • ABOUT - Battery and cell monitoring system hardware and software versions •...

  • Page 171: Vcm Screen

    CCDT CCDT-APP Screens VCM SCREEN The VCM screen displays the vehicle control module (VCM) data. The VCM screen has four tabs: • VCM - VCM functional data • ABOUT - VCM hardware, software versions, and identification data • SIGNALS INPUT - Status of inputs signals to the VCM •...

  • Page 172: Mcu Screen

    CCDT-APP Screens CCDT MCU SCREEN The MCU screen displays the motor control unit (MCU) data. The MCU screen has three tabs: • MCU - MCU functional data • ABOUT - MCU hardware, software versions, and identification data • USAGE - MCU usage history related details G-008998-000005 Figure 11-12 MCU Screen Page 11-10...

  • Page 173: Custom View Screen

    CCDT CCDT-APP Screens CUSTOM VIEW SCREEN The custom view screen lets the user customize the list of parameters to be monitored. G-008998-000015 Figure 11-13 Custom View Screen Add A Parameter Tap the search option. Enter the parameter name or partial parameter name. Select the desired parameter and drag to the middle of the screen.

  • Page 174: Settings Screen

    Tap the SAVE button. Enable The High Speed Option The high speed option requires a high speed code. Contact Club Car for the high speed code. To change the maximum speed to a higher setting, the high speed option must be enabled.
  • Page 175 CCDT CCDT-APP Screens To enable the high speed option: Go to the settings screen. Go to the HIGH SPEED ENABLE tab. Tap on the Unlock High Speed Code box (Figure 11-15, Page 11-13). G-008998-000023 Figure 11-15 High Speed Enable Enter the high speed code. Tap the VALIDATE button.
  • Page 176 CCDT-APP Screens CCDT G-008998-000020 Figure 11-16 Car Time Set the car time and date. Scroll down and tap SET. Tap the SAVE button. Finalize Settings Finalization is the final step in the “first time” configuration of VCM. Finalization should be performed in factory (making of Car) or in the field (replacement VCM).

  • Page 177: Faults Screen

    CCDT CCDT-APP Screens FAULTS SCREEN The faults screen displays the most recent 16 active faults. Tap ACTIVE FAULT to display the faults. NOTE: The screen will refresh automatically. Tap CLEAR FAULT to clear the faults. See the Vehicle Fault Code Table for more information about the faults. G-008998-000022 Figure 11-17 Faults Screen GRAPH SCREEN...
  • Page 178 CCDT-APP Screens CCDT G-008998-000012 Figure 11-18 Graphs Screen Add A Parameter Tap the search option. Enter the parameter name or partial parameter name. Select the desired parameter. Tap the SUBSCRIBE button. Log A Parameter Add the desired parameter. Tap the START/STOP button. Tap OK in the prompt message.

  • Page 179: Software Update Screen

    CCDT CCDT-APP Screens Load A Log File Tap the LOAD GRAPH button. Select the log file. G-008998-000026 Figure 11-19 Load Graph Tap the OK button. SOFTWARE UPDATE SCREEN The software update screen lets the user update the software for the BMS, MCU, VCM, and CCDT. The dongle can store up to two software files.
  • Page 180 CCDT-APP Screens CCDT G-008998-000011 Figure 11-20 Software Update Screen Update Software Files Update Process: • The CCDT-APP sends the software file information to the dongle. • The CCDT-APP sends the software file to the dongle. NOTE: If the software file is stored in the dongle, this step will be skipped. If the dongle does not have the file stored, the update will take longer.

  • Page 181: Vehicle Settings Update / Write Screen

    CCDT CCDT-APP Screens DOWNLOAD IMAGE STARTED The software file transfer to the dongle started. PACKETS UPGRADING The software file transfer to the dongle is in progress. PACKET TRANSFER COMPLETED WAIT FOR The dongle is updating the electronic control unit (ECU). COMPLETION STATUS SOFTWARE UPGRADE WAS SUCCESSFUL The software update was successful.
  • Page 182 CCDT-APP Screens CCDT Parameter Table PARAMETER DESCRIPTION OPTIONS Factory: Up to 14.80 mph Maximum Speed Vehicle maximum speed setting High Speed Option: Up to 19.20 mph • Soft • Normal Pedal Up Speed of deceleration • Firm Wheel RPM to MPH Tire size setting See Tire Size Table on page 11-21.
  • Page 183 CCDT CCDT-APP Screens Tire Size Table TIRE SIZE WHEEL RPM TO MPH SETTING 18 x 8.5 - 8 19.65 215/40 - 12 18.20 205/55 - 10 18.20 205/50 - 10 18.60 22 x 10 - 10 16.08 23 x 10 - 12 15.19 23 x 10 - 14 15.19...

  • Page 184: Setup A Replacement Vcm

    Setup A Replacement VCM CCDT Tap the OFFPEAK CHARGING MODE drop down menu and change to: (Figure 11-22, Page 11-22) – VDU: Off peak charging is controlled through Visage. – VCM: Enables the vehicle control module (VCM) to control off peak charging. G-008998-000021 Figure 11-22 Off Peak Charging Tap the OFFPEAK CHARGE START TIME box.

  • Page 185: Troubleshooting

    CCDT Troubleshooting Configure the vehicle to the factory or desired configuration. Go to the settings screen. Go to the FINALIZE SETTING tab. Input the vehicle serial number. Tap on the FINALIZE button. TROUBLESHOOTING SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Make sure that the diagnostic cable is Dongle does not have power.
  • Page 186 Troubleshooting CCDT Pagination Page Page 11-24 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 187: Section 12 - Electrical System Troubleshooting

    SECTION 12 — ELECTRICAL SYSTEM TROUBLESHOOTING WARNING Electrical System Troubleshooting • Shorting of battery terminals can cause personal injury or death. – Remove plate from vehicle completely. GENERAL INFORMATION CONTROLLER AREA NETWORK (CAN) Lithium-ion vehicles use Controller Area Network (CAN). Standard electrical vehicles use a conventional system that uses separate wires to control individual electrical components.
  • Page 188 General Information ELECTRICAL SYSTEM TROUBLESHOOTING Figure 12-1 Main CAN bus - without VDU Page 12-2 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 189: Battery Management System (Bms)

    ELECTRICAL SYSTEM TROUBLESHOOTING General Information Figure 12-2 Main CAN bus - with VDU BATTERY MANAGEMENT SYSTEM (BMS) The BMS is an electronic system that: Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 12-3...

  • Page 190: Contactor

    General Information ELECTRICAL SYSTEM TROUBLESHOOTING • Monitors and controls the charging and discharging of the battery • Protects the battery from operating outside its safe operating area • Monitors the state of the battery • Reports data to the vehicle control system The BMS is located inside the battery case.

  • Page 191: Diode, Fuse, And Relay Locations

    ELECTRICAL SYSTEM TROUBLESHOOTING Diode, Fuse, and Relay Locations Figure 12-3 Accessories DIODE, FUSE, AND RELAY LOCATIONS Description Callout Number 10A High Voltage Interlock Fuse - Red fuse holder 80A Dynamic Braking Fuse - See Dynamic Braking Fuse Replacement 1st Generation Main Harness: 30A/80V ATO Charger Fuse - Stowed in the side of the battery box 2nd and 3rd Generation Main Harness: 20A Fast Acting Charger Fuse - Stowed in the side of the battery box Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 12-5...

  • Page 192: Fuse Block Cover

    Diode, Fuse, and Relay Locations ELECTRICAL SYSTEM TROUBLESHOOTING 10A DC to DC Converter Fuse - Stowed in the side of the battery box Fuse Block - See Fuse Block Table Figure 12-4 Diode, Fuse, and Relay Locations FUSE BLOCK COVER Fuse Block Cover Removal Figure 12-5 Fuse Block Cover Pull up on the yellow tabs (1) (Figure 12-5, Page 12-6).

  • Page 193: Fuse Block Tables

    ELECTRICAL SYSTEM TROUBLESHOOTING Diode, Fuse, and Relay Locations FUSE BLOCK TABLES The fuse block contains diodes, fuses, and relays. The fuse block is located under the seat. NOTE: If a diode is removed, make sure that the diode is installed in the correct position. Main Harness Differences: •...
  • Page 194 Diode, Fuse, and Relay Locations ELECTRICAL SYSTEM TROUBLESHOOTING 3rd Generation Harness Fuse Block (Figure 12-7) COMPONENT DESCRIPTION 1A Diode – VCM Ignition Sense 1A Diode - Interlock 3A Diode - BMS 12V Output 5A Fuse - Diagnostic Receptacle 5A DIAG 10A HORN 10A Fuse - Horn 15A ACC...

  • Page 195: Fuses

    ELECTRICAL SYSTEM TROUBLESHOOTING Fuses FUSES ATO AND MINI ATM FUSE INSPECTION Disable the vehicle. Remove the fuse. Examine the fuse. Good Fuse Blown Fuse CHARGER FAST ACTING FUSE TEST Disable the vehicle. Pull the fuse holder (1) apart (Figure 12-8, Page 12-9). Figure 12-8 Charger Fast Acting Fuse Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 12-9...

  • Page 196: Dynamic Braking Resistor (Dbr) Fuse

    Fuses ELECTRICAL SYSTEM TROUBLESHOOTING Remove the fuse (2). Test for continuity between the ends of the fuse (3). 4.1. If there is continuity, the fuse is good. 4.2. If there is no continuity, replace the fuse. Install the fuse. Install the fuse cover. DYNAMIC BRAKING RESISTOR (DBR) FUSE Dynamic Braking Resistor (DBR) Fuse Test Disable the vehicle.

  • Page 197: Ground Locations

    ELECTRICAL SYSTEM TROUBLESHOOTING Ground Locations Figure 12-10 Dynamic Braking Fuse Remove the bolt (3) on the motor control unit (MCU) B+ terminal. Remove the 80A dynamic braking fuse (4). Dynamic Braking Resistor (DBR) Fuse Installation Install the 80A dynamic braking fuse (4) on the motor control unit (MCU) B+ terminal and dynamic braking solenoid terminal (Figure 12-10, Page 12-11).

  • Page 198: Vehicle Fault Codes

    Vehicle Fault Codes ELECTRICAL SYSTEM TROUBLESHOOTING VEHICLE FAULT CODES DASH DISPLAY MESSAGES In the event of a fault, a message will display on the dash display. Use the CCDT to access the fault codes. MESSAGE Column: The message that will display on the dash display. RESPONSE LEVEL Column: Response level number.
  • Page 199 ELECTRICAL SYSTEM TROUBLESHOOTING Vehicle Fault Codes Severe Fault Applicable to VCM software versions 1.2.3 and earlier. The vehicle will: SEVFLT • Open all contactors • When possible, all components except display unit will shutdown • Log the event Display Fault Applicable to VCM software versions 1.3 and later.

  • Page 200: Vehicle Fault Code Table

    SOLUTION Column: Procedure for clearing the fault code. CODE LEVEL CLEAR DESCRIPTION SOLUTION Key Cycle Cell Over Voltage - Power Derating Contact Club Car. Key Cycle Cell Over Voltage - Power Off Contact Club Car. Auto Cell Under Voltage - Power Derating Contact Club Car. Key Cycle Cell Under Voltage - Power Off Contact Club Car.
  • Page 201 Clear the fault code. Technician Contactor A failure If the fault code activates again, the battery may need to be replaced. Contact Club Car. Clear the fault code. Technician Contactor B failure If the fault code activates again, the battery may need to be replaced.
  • Page 202 Clear the fault code. Auto Possible Cause: If the fault code activates again, the battery may need to be replaced. Contact Club Car. • Internal fault Check for water under the pedal assembly where the brake switch wires are located.
  • Page 203 Auto MCU main contactor in fault state If there is no other MCU fault active, contact Club Car. Auto MCU under voltage Contact Club Car. Key Cycle MCU severe under voltage Contact Club Car. Auto MCU over voltage Contact Club Car.
  • Page 204 Vehicle Fault Codes ELECTRICAL SYSTEM TROUBLESHOOTING MCU phase current too high Inspect the motor phase wires (W, V, U). Possible Cause: Replace as necessary. Key Cycle • Motor phase wiring damaged See Stator Winding Test Procedure. • Internal motor damage If the motor is good, replace the MCU.
  • Page 205 Replace the MCU. Possible Cause: • Internal motor control unit (MCU) failure Interlock Charger overcurrent Contact Club Car. Make sure the 3-pin and 2-pin connectors are correctly connected to the vehicle charger Loss of CAN messages from Charger receptacle. Make sure that the wires are correctly installed...
  • Page 206 Possible Cause: Key Cycle If no non-approved loads/accessories are • Motor control unit (MCU) and BMS current found, contact Club Car. measurements are more than 20A difference Charger Interlock fault while moving Possible Cause: Key Cycle See Charger Interlock Test Procedure.
  • Page 207 Auto Test the key switch. • Key is detected in RUN position without ACC signal Key Cycle MCU received BMS emergency message Contact Club Car. User display CAN Communication fault Possible Cause: Inspect the dash display wiring and connections. Auto •...
  • Page 208 BMS internal CAN communication fault Clear the fault code. Key Cycle Possible Cause: If the fault code activates again, the battery may need to be replaced. Contact Club Car. • Internal failure Battery SOC low (0% User) Auto Charge the battery.

  • Page 209: Basic Troubleshooting Guide

    ELECTRICAL SYSTEM TROUBLESHOOTING Vehicle Fault Codes MCU parameter change Make sure that the MCU and VCM software is the latest version. Key Cycle Possible Cause: If all of the software is the latest, contact Club Car. • Vehicle not configured MCU parameter out of range Make sure that the MCU and VCM software is the latest version.
  • Page 210 Vehicle Fault Codes ELECTRICAL SYSTEM TROUBLESHOOTING SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Incorrectly wired Check the vehicle wiring. Vehicle operates, but motor braking function does not Motor speed sensor disconnected or failed See the motor speed sensor test procedure. Forward/Neutral/Reverse switch incorrectly See the Forward/Neutral/Reverse switch test wired procedure.

  • Page 211: Main Can Bus Test Procedure

    ELECTRICAL SYSTEM TROUBLESHOOTING Main CAN bus Test Procedure MAIN CAN BUS TEST PROCEDURE If the dash display shows asterisk (*) symbols, the main CAN bus has a short. Before the procedure: Disable the vehicle. Disconnect the DC charger cord from the vehicle. Remove the high voltage interlock fuse (HVIL).
  • Page 212 Main CAN bus Test Procedure ELECTRICAL SYSTEM TROUBLESHOOTING Wire Color Description White CAN Hi Blue CAN Low If the resistance is approximately 60 ohms, the CAN bus is good. See Dash Display Test Procedure to test the CAN bus circuit on the IP harness. NOTE: The dash display is also on the main CAN bus.
  • Page 213 ELECTRICAL SYSTEM TROUBLESHOOTING Main CAN bus Test Procedure Disconnect the DC charger cord is from the vehicle. Remove the high voltage interlock fuse (HVIL). Remove the D3 diode. Test procedure: Set a multimeter to measure resistance. Disconnect the dash display connector (1) from the dash display (2) (Figure 12-12, Page 12-27). Figure 12-12 Dash Display Connector Measure the resistance across pins 3 and 4 on the main harness IP connector.
  • Page 214 Main CAN bus Test Procedure ELECTRICAL SYSTEM TROUBLESHOOTING 3.2.1. The dash display has failed. Before connecting the new dash display to the vehicle, do the following steps. 3.2.2. Check for continuity between the CAN bus and 58V. Replace the harness as necessary. 3.2.3.
  • Page 215 ELECTRICAL SYSTEM TROUBLESHOOTING Main CAN bus Test Procedure Figure 12-14 VCM 81–Pin Connector Measure the resistance across pins 3 and 4 on the main harness IP connector. 8.1. If the resistance is less 40 ohms, connect the VCM 81-pin connector. Go to step 9. 8.2.
  • Page 216 If the resistance is less than 40 ohms, go to step 16. 15.2. If the resistance is approximately 60 ohms: 15.2.1. Contact Club Car Technical Support. 15.2.2. Check for continuity between the CAN bus and 58V. Replace the harness as necessary. 15.2.3.
  • Page 217 ELECTRICAL SYSTEM TROUBLESHOOTING Main CAN bus Test Procedure 17.1.1. The MCU has failed. Before connecting the new MCU to the vehicle, do the following steps. 17.1.2. Check for continuity between the CAN bus and 58V. Replace the harness as necessary. 17.1.3.
  • Page 218 Main CAN bus Test Procedure ELECTRICAL SYSTEM TROUBLESHOOTING TEST PROCEDURE 2 – 120 Ohm Resistor Test Before the procedure: Disable the vehicle. Disconnect the DC charger cord is from the vehicle. Remove the high voltage interlock fuse (HVIL). Remove the D3 diode. Test Procedure: Without VDU: Check for continuity between pin 3 of the main harness IP connector and pin 4 of the VDU strut connector.

  • Page 219: Electrical Component Test Procedures

    ELECTRICAL SYSTEM TROUBLESHOOTING Electrical Component Test Procedures Check for continuity between pin 3 of the main harness IP connector and pin 23 of the MCU 35-pin connector. Check for continuity between pin 4 of the main harness IP connector and pin 35 of the MCU 35-pin connector. 3.1.

  • Page 220: Testing Basics

    Electrical Component Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING TESTING BASICS • To use the CCDT, the Main CAN bus and VCM must be operational. • Battery Power Voltage (BPV) will be referenced throughout the test procedures. • When testing controller functions, the Run/Tow-Stow switch must be in the RUN position. The TOW/STOW position removes power to the controller.
  • Page 221 ELECTRICAL SYSTEM TROUBLESHOOTING Electrical Component Test Procedures Put the black (-) probe in the socket (4) connected to the black wire and blue wire. Wire Color Description Yellow CAN High Positive (+) Brown Interlock Black wire and Blue wire Negative (-) Put the red (+) probe in the socket (3) connected to the brown wire.

  • Page 222: Dash Display Test Procedure

    Electrical Component Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING DASH DISPLAY TEST PROCEDURE If the dash display shows astrecks (*), there is a CAN communication error. If the dash display shows nothing, there is a possible 12V supply issue. Disable the vehicle. Connect the CCDT.
  • Page 223 ELECTRICAL SYSTEM TROUBLESHOOTING Electrical Component Test Procedures Disconnect the DBR connector. While moving the wires back and forth, measure the resistance of the DBR. 7.1. If the resistance is 0.9 ohms, go to step 8. 7.2. If the resistance is not 0.9 ohms, replace the DBR. Test the DBR fuse.

  • Page 224: Forward/Neutral/Reverse Switch (Fnr) Test Procedure

    Electrical Component Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING FORWARD/NEUTRAL/REVERSE SWITCH (FNR) TEST PROCEDURE Disable the vehicle. Set the Run/Tow-Stow switch to TOW-STOW. Connect the CCDT to the vehicle. Go to the CAR screen. Go to the CAR DETAILS tab. Set the Forward/Neutral/Reverse control (FNR) to F. Repeat this step for N and R positions. 6.1.

  • Page 225: Key Switch Test Procedure

    ELECTRICAL SYSTEM TROUBLESHOOTING Electrical Component Test Procedures KEY SWITCH TEST PROCEDURE NOTE: This is a continuity and voltage test. Disable the vehicle. Connect the CCDT to the vehicle. Go to the CAR screen. Go to the CAR DETAILS tab. Set the key switch to OFF. Repeat this step for ACC and ON positions. 5.1.
  • Page 226 Electrical Component Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING Turn the key switch to OFF. Terminal Wire Color Description Black Ground Blue/White 5V VCM Input Key Switch Wake Up to BMS Figure 12-20 Key Switch – If there is continuity between any of the terminals, replace the key switch. –...

  • Page 227: Main Solenoid Test Procedure

    ELECTRICAL SYSTEM TROUBLESHOOTING Electrical Component Test Procedures MAIN SOLENOID TEST PROCEDURE Disable the vehicle. Connect the CCDT to the vehicle. Go to the CUSTOM VIEW screen. G-008998-000015 Figure 12-21 Custom View Screen Add the following to the screen: – Battery InstOutput Voltage –...
  • Page 228 Electrical Component Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING Turn the key switch to ON. G-008998-000031 Figure 12-22 Key ON – The main contactor should be Closed. – MCU Main Power Voltage should increase to Battery InstPack Voltage. – Battery InstOutput Voltage should increase to Battery InstPack Voltage. NOTE: If the vehicle has not operated for an extended period, the Battery InstOutput Voltage will increase shortly after the MCU Main Power Voltage increases.

  • Page 229: Mcor Accelerator Position Test Procedure

    ELECTRICAL SYSTEM TROUBLESHOOTING Electrical Component Test Procedures Turn the key switch to OFF. G-008998-000028 Figure 12-23 Key OFF Wait up to 30 seconds, then the main contactor should be Open. – Battery InstOutput Voltage should be less than 10V. – The MCU Main Power Voltage should slowly decrease to approximately 15V - 22V. –...
  • Page 230 Electrical Component Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING With the pedal up, Input APP %ADC should be 0%. Slowly push the accelerator pedal. The Input APP %ADC should indicate a steady, slow increase from 0% to 100%. 6.1. If the Input APP %ADC indicates a steady, slow increase from 0% to 100%, go to step 7. 6.2.
  • Page 231 ELECTRICAL SYSTEM TROUBLESHOOTING Electrical Component Test Procedures Put the red (+) probe in pin 1 of the MCOR 3-pin connector. Wire Color Description White 5V VCM Input Purple/White Signal Ground Yellow Input Signal Figure 12-25 MCOR 3-Pin Connector 13.1. If the voltage is approximately 5V, go to step 14. 13.2.

  • Page 232: Mcor Limit Switch Test Procedure

    Electrical Component Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING Connect the MCOR 3-pin connector to the MCOR. Set the multimeter to measure voltage. Put the black (-) probe on the nearest ground point. Put a red (+) probe with insulation-piercing probe on the yellow wire close to the MCOR 3-pin connector. The voltage should be 0.
  • Page 233 ELECTRICAL SYSTEM TROUBLESHOOTING Electrical Component Test Procedures Put the red (+) probe in pin 1 of the MCOR 2-pin connector. Wire Color Description Light Green 5V VCM Input Black Ground Figure 12-28 MCOR 2-Pin Connector 11.1. If the voltage is approximately 5V, go to step 12. 11.2.

  • Page 234: Multi-Purpose Buzzer Test Procedure

    Electrical Component Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING MULTI-PURPOSE BUZZER TEST PROCEDURE NOTE: This is a voltage test. Disable the vehicle. Remove the HVIL fuse. Remove the instrument panel. Disconnect the orange/white and black wires from the multi-purpose buzzer. Turn the key switch to OFF. Set the multimeter to measure voltage.

  • Page 235: Run/Tow-Stow Test Procedure

    ELECTRICAL SYSTEM TROUBLESHOOTING Electrical Component Test Procedures RUN/TOW-STOW TEST PROCEDURE NOTE: This is a voltage test. Disable the vehicle. Connect the CCDT to the vehicle. Go to the VCM screen. Go to the SIGNALSINPUT tab. Make sure that Inputs Switch Run Tow matches the Run/Tow-Stow switch position (TOW/STOW - On / RUN - Off). 5.1.

  • Page 236: Solenoid Activating Coil Test Procedure

    Electrical Component Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING SOLENOID ACTIVATING COIL TEST PROCEDURE This procedure is for the main solenoid and dynamic braking resistor (DBR) solenoid. NOTE: This is a resistance test. Disable the vehicle. Remove the high voltage interlock fuse (HVIL). Remove the controller shield.

  • Page 237: Main Harness Connector Pinouts

    ELECTRICAL SYSTEM TROUBLESHOOTING Main Harness Connector Pinouts MAIN HARNESS CONNECTOR PINOUTS This section shows the pinouts for connectors on the main harness. Pins not in the table are not used. AUXILIARY CAN CONNECTOR Wire Color Description Blue Main CAN bus Low White Main CAN bus High Black...

  • Page 238: Charger Receptacle 3-Pin Connector

    Main Harness Connector Pinouts ELECTRICAL SYSTEM TROUBLESHOOTING Blue/White 58V Main Power to DC to DC Brown Charger Interlock White HVIL Return Blue HVIL Signal Blue Main CAN bus Low White Main CAN bus High CHARGER RECEPTACLE 3-PIN CONNECTOR Wire Color Description Battery (+) Black...

  • Page 239: Dbr Blue Connector

    ELECTRICAL SYSTEM TROUBLESHOOTING Main Harness Connector Pinouts DBR BLUE CONNECTOR Wire Color Description White To DBR Solenoid Black B (-) on MCU DBR TEMPERATURE SWITCH CONNECTOR Wire Color Description Brown To DBR Solenoid Brown/White To MCU Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 12-53...

  • Page 240: Dc-Dc 3-Pin Connector

    Main Harness Connector Pinouts ELECTRICAL SYSTEM TROUBLESHOOTING DC-DC 3-PIN CONNECTOR Wire Color Description 58V Input Black Ground Blue/White 58V BMS Enable DC-DC 2-PIN CONNECTOR Wire Color Description Black Ground 12V (+) Output Page 12-54 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 241: Forward Lighting Connector

    ELECTRICAL SYSTEM TROUBLESHOOTING Main Harness Connector Pinouts FORWARD LIGHTING CONNECTOR Wire Color Description Blue Left Headlight from VCM Yellow/Light Green Left Daytime Run Light from VCM Green/Yellow Front Left Turn Signal from VCM Black Ground Gray Logo Light from VCM Light Blue Right Headlight from VCM Light Green/Red...

  • Page 242: Lighting Control Connector

    Main Harness Connector Pinouts ELECTRICAL SYSTEM TROUBLESHOOTING Green Dash Display On/Off White Main CAN bus High Blue Main CAN bus Low To 5A Diagnostic Receptacle Fuse Black Ground Key Switch Wake Blue/White Key Switch 5V VCM Input Orange/White Multi-purpose Buzzer from VCM LIGHTING CONTROL CONNECTOR Wire Color Description...

  • Page 243: Mcor 3-Pin Connector

    ELECTRICAL SYSTEM TROUBLESHOOTING Main Harness Connector Pinouts MCOR 3-PIN CONNECTOR Wire Color Description White 5V VCM Input Purple/White Ground Yellow Input Signal to VCM MCOR 2-PIN CONNECTOR Wire Color Description Light Green 5V VCM Input Black Ground Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 12-57...

  • Page 244: Mcu 35-Pin Connector

    Main Harness Connector Pinouts ELECTRICAL SYSTEM TROUBLESHOOTING MCU 35-PIN CONNECTOR Wire Color Description Orange/Blue 58V Power Brown/White DBR Driver Coil Purple/White 5V Driver to Main Solenoid Black Ground 5V Output to Motor Temperature Sensor Light Blue 5V DBR Coil Return Yellow Main CAN Terminal High White...

  • Page 245: Motor Speed Sensor Connector

    ELECTRICAL SYSTEM TROUBLESHOOTING Main Harness Connector Pinouts MOTOR SPEED SENSOR CONNECTOR Wire Color Description 5V from MCU Green Position Feedback B Position Feedback A Black Ground MOTOR TEMPERATURE SENSOR CONNECTOR Wire Color Description 5V from MCU Black Ground Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 12-59...

  • Page 246: Left Taillight Connector

    Main Harness Connector Pinouts ELECTRICAL SYSTEM TROUBLESHOOTING LEFT TAILLIGHT CONNECTOR Wire Color Description Black Ground White 12V Turn Signal from VCM Brown 12V Taillight from VCM RIGHT TAILLIGHT CONNECTOR Wire Color Description Black Ground Yellow 12V Turn Signal from VCM Brown 12V Taillight from VCM Page 12-60...

  • Page 247: Vcm 81-Pin Connector

    ELECTRICAL SYSTEM TROUBLESHOOTING Main Harness Connector Pinouts VCM 81-PIN CONNECTOR Wire Color Description 12V Battery (+) Black Ground 12V Battery (+)) Black Ground Black Ground Brown 5V to Forward on FNR Pink 5V to Run/Tow Switch Light Green 5V to MCOR 2-Pin Connector White/Light Green 5V to Light Switch Gray/Black...

  • Page 248: Vcm 40-Pin Connector

    Main Harness Connector Pinouts ELECTRICAL SYSTEM TROUBLESHOOTING Purple/White Ground Blue Main CAN bus Low VCM 40-PIN CONNECTOR Wire Color Description Pink 5V Driver to Auxiliary CAN Connector Orange/White 1A Multi-purpose buzzer Red/Black ACC Relay Coil on Fuse Block Black Ground to Front Lighting Connector Brown 12V to Taillights White...

  • Page 249: Vdu Strut Connector

    ELECTRICAL SYSTEM TROUBLESHOOTING Main Harness Connector Pinouts VDU STRUT CONNECTOR Wire Color Description Black Ground Yellow/Black 58V Power Blue Main CAN bus Low White Main CAN bus High Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 12-63...

  • Page 250: Visage Harness Connector Pinouts

    Visage Harness Connector Pinouts ELECTRICAL SYSTEM TROUBLESHOOTING VISAGE HARNESS CONNECTOR PINOUTS This section shows the pinouts for connectors on the main harness. Pins not in the table are not used. 14-PIN CONNECTOR Wire Color Description White Main CAN bus High Gray Left Speaker Positive (+) Gray/Black...

  • Page 251: Section 13 - Electrical Components

    SECTION 13 — ELECTRICAL COMPONENTS DASH DISPLAY Electrical Components The dash display operates when the key switch is set to ACC, ON, or when the battery is charging. The backlight will dim when the headlight switch is on. The dash display is on the main CAN bus system. DASH DISPLAY REMOVAL Disable the vehicle.

  • Page 252: Headlight Switch

    Headlight Switch ELECTRICAL COMPONENTS HEADLIGHT SWITCH HEADLIGHT SWITCH REMOVAL Disable the vehicle. Set the Run/Tow-Stow switch to TOW/STOW. Remove the high voltage interlock fuse (HVIL). Remove the instrument panel. Disconnect the wires from the headlight switch. Loosen the set screw (1) (Figure 13-2, Page 13-2). Figure 13-2 Headlight Switch Remove the threaded knob (2).

  • Page 253: Key Switch

    ELECTRICAL COMPONENTS Key Switch KEY SWITCH KEY SWITCH REMOVAL Disable the vehicle. Set the Run/Tow-Stow switch to TOW/STOW. Remove the high voltage interlock fuse (HVIL). Remove the instrument panel. Make a note of the wire connections. Disconnect the wires from the key switch. Push on the retaining tabs and remove the key switch cap (1) (Figure 13-3, Page 13-3).

  • Page 254: Multi-Purpose Buzzer

    Multi-Purpose Buzzer ELECTRICAL COMPONENTS MULTI-PURPOSE BUZZER MULTI-PURPOSE BUZZER REMOVAL Disable the vehicle. Set the Run/Tow-Stow switch to TOW/STOW. Remove the high voltage interlock fuse (HVIL). Remove the instrument panel. Disconnect the wires from the multi-purpose buzzer. Remove the screws (1) (Figure 13-4, Page 13-4). Figure 13-4 Multi-Purpose Buzzer Remove the multi-purpose buzzer (2).

  • Page 255: Hazard Light Switch

    ELECTRICAL COMPONENTS Hazard Light Switch HAZARD LIGHT SWITCH HAZARD LIGHT SWITCH REMOVAL Disable the vehicle. Set the Run/Tow-Stow switch to TOW/STOW. Remove the high voltage interlock fuse (HVIL). Remove the instrument panel. Disconnect the hazard switch wires (1) from the hazard light switch (2) (Figure 13-5, Page 13-5). Figure 13-5 Hazard Light Switch Push the lock tabs (3) on both sides and remove the hazard light switch.

  • Page 256: Usb Receptacle

    USB Receptacle ELECTRICAL COMPONENTS USB RECEPTACLE The 5-volt, 2.1 amp USB receptacle supplies electricity to power and charge portable devices. The USB receptacle is not for movement of data. The USB receptacle will only operate when a shielded USB cord is connected. When the USB receptacle is not in use, remove the shielded USB cord to prevent battery drain.

  • Page 257: Forward/Neutral/Reverse Switch (Fnr)

    ELECTRICAL COMPONENTS Forward/Neutral/Reverse Switch (FNR) FORWARD/NEUTRAL/REVERSE SWITCH (FNR) FORWARD/NEUTRAL/REVERSE SWITCH (FNR) REMOVAL Disable the vehicle. Set the Run/Tow-Stow switch to TOW/STOW. Remove the high voltage interlock fuse (HVIL). Remove the screws (1) (Figure 13-7, Page 13-7). Figure 13-7 FNR Switch Removal Push in on the locking tabs (2) and remove the rocker switch (3).

  • Page 258: Forward/Neutral/Reverse Switch (Fnr) Installation

    Forward/Neutral/Reverse Switch (FNR) ELECTRICAL COMPONENTS FORWARD/NEUTRAL/REVERSE SWITCH (FNR) INSTALLATION Put the wires (4) through the housing (Figure 13-8, Page 13-8). Figure 13-8 FNR Switch Installation Make sure that the rocker switch terminals are towards the front of the vehicle. Connect the blue wire to T1. See graphic detail A. Connect the orange wire to T2.

  • Page 259: Motor Controller Output Regulator (Mcor)

    ELECTRICAL COMPONENTS Motor Controller Output Regulator (MCOR) MOTOR CONTROLLER OUTPUT REGULATOR (MCOR) The pedal group includes a Motor Controller Output Regulator (MCOR) mounted on the side of the pedal group. The MCOR detects the position of the accelerator pedal and sends a corresponding voltage to the motor controller. MCOR REMOVAL Disable the vehicle.

  • Page 260: Mcor Installation

    Motor Controller Output Regulator (MCOR) ELECTRICAL COMPONENTS MCOR INSTALLATION Install the MCOR (3) onto the accelerator pedal (Figure 13-10, Page 13-10). NOTE: Rotate the pedal back and forth if necessary to align the D-shaped end of shaft with the MCOR. Figure 13-10 MCOR Installation Make sure that the two tabs (2) engage.

  • Page 261: Vehicle Control Module (Vcm)

    ELECTRICAL COMPONENTS Vehicle Control Module (VCM) VEHICLE CONTROL MODULE (VCM) The VCM serves as the vehicle brain and the controller for all powered accessories. VEHICLE CONTROL MODULE (VCM) REMOVAL Disable the vehicle. Set the Run/Tow-Stow switch to TOW/STOW. Remove the high voltage interlock fuse (HVIL). Release the electrical connector levers (1) (Figure 13-11, Page 13-11).

  • Page 262: Vehicle Control Module (Vcm) Mount Removal

    Vehicle Control Module (VCM) ELECTRICAL COMPONENTS Figure 13-12 Vehicle Control Module (VCM) Installation Make sure that the four tabs (3) lock. Connect the electrical connectors (2). Engage the electrical connector levers (1). Install the high voltage interlock fuse (HVIL). Set the Run/Tow-Stow switch to RUN. If a new VCM was installed, use the CCDT to: 7.1.

  • Page 263: Controller Shield

    ELECTRICAL COMPONENTS Controller Shield Figure 13-14 Vehicle Control Module (VCM) Mount Installation Make sure that the tabs (1) lock. CONTROLLER SHIELD The electronics module cover needs to be removed to gain access to the motor control unit (MCU) and solenoids, Run/Tow-Stow switch, and solenoids.

  • Page 264: Controller Shield Installation

    Run/Tow-Stow Switch ELECTRICAL COMPONENTS Figure 13-15 Controller Shield Release the top four tabs (3) and remove the electronics module cover. CONTROLLER SHIELD INSTALLATION CAUTION • Exposure to water may damage electronic components. – Do not operate vehicle without this cover properly installed. –...

  • Page 265: Run/Tow-Stow Switch Removal

    ELECTRICAL COMPONENTS Run/Tow-Stow Switch Vehicle operation in RUN: • Connected to a battery charger. • The battery will charge to 100%. Vehicle operation in TOW/STOW: • Connected to a battery charger. • If the state of charge (SOC) is above 50%, the battery will slowly self-discharge to 50%. –...
  • Page 266 Run/Tow-Stow Switch ELECTRICAL COMPONENTS Connect the black wire (2). Install the high voltage interlock fuse (HVIL). Set the Run/Tow-Stow switch to RUN. Page 13-16 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 267: Motor Control Unit (Mcu)

    ELECTRICAL COMPONENTS Motor Control Unit (MCU) MOTOR CONTROL UNIT (MCU) MOTOR CONTROL UNIT (MCU) REMOVAL Disable the vehicle. Set the Run/Tow-Stow switch to TOW/STOW. Remove the high voltage interlock fuse (HVIL). Remove the access panel. Remove the controller shield. Make a note of the wire connections. Remove the screws (1) and wires from the motor control unit (MCU) (2) (Figure 13-17, Page 13-17).

  • Page 268: Motor Control Unit (Mcu) Installation

    Motor Control Unit (MCU) ELECTRICAL COMPONENTS MOTOR CONTROL UNIT (MCU) INSTALLATION Install the motor control unit (MCU) (2) with the screws (4). Tighten the screws to 115 lb·in (13 N·m) (Figure 13-18, Page 13-18). Figure 13-18 Connect the CAN connector (3). Install the wires with the screws (1).

  • Page 269: Main Solenoid

    ELECTRICAL COMPONENTS Main Solenoid MAIN SOLENOID MAIN SOLENOID REMOVAL Disable the vehicle. Set the Run/Tow-Stow switch to TOW/STOW. Remove the high voltage interlock fuse (HVIL). Remove the access panel. Remove the controller shield. Remove the nuts (1) and washers (2) (Figure 13-19, Page 13-19). Figure 13-19 Main Solenoid Removal Remove the wires from the main solenoid posts (3 and 4).

  • Page 270: Main Solenoid Installation

    Main Solenoid ELECTRICAL COMPONENTS MAIN SOLENOID INSTALLATION Install the main solenoid (8) with the screws (7) (Figure 13-20, Page 13-20). Tighten the screws to 115 lb·in (13 N·m). Figure 13-20 Main Solenoid Installation Connect the 20 gauge light blue wire to the left terminal (5). Connect the 20 gauge purple/white wire to the right terminal (6).

  • Page 271: Dynamic Braking Solenoid

    ELECTRICAL COMPONENTS Dynamic Braking Solenoid DYNAMIC BRAKING SOLENOID DYNAMIC BRAKING SOLENOID REMOVAL Disable the vehicle. Set the Run/Tow-Stow switch to TOW/STOW. Remove the high voltage interlock fuse (HVIL). Remove the access panel. Remove the controller shield. Remove the nuts (1) and washers (2) (Figure 13-21, Page 13-21). Figure 13-21 Dynamic Braking Solenoid Removal Remove the wires from the dynamic braking solenoid posts (3 and 4).

  • Page 272: Dynamic Braking Solenoid Installation

    Dynamic Braking Solenoid ELECTRICAL COMPONENTS DYNAMIC BRAKING SOLENOID INSTALLATION Install the hooks (9) into the mounting plate (Figure 13-22, Page 13-22). Figure 13-22 Dynamic Braking Solenoid Installation Push the bottom of the dynamic braking solenoid (7) until the tab (8) engages. Connect the 20 gauge light blue wire to the left terminal (5).

  • Page 273: Dynamic Braking Resistor

    ELECTRICAL COMPONENTS Dynamic Braking Resistor DYNAMIC BRAKING RESISTOR The dynamic braking resistor (DBR) is a resistor that is switched into the power circuit to dissipate regenerative electrical energy from the motor during high state-of-charge (SOC) conditions. DYNAMIC BRAKING RESISTOR REMOVAL Disable the vehicle.

  • Page 274: Charger Receptacle

    Charger Receptacle ELECTRICAL COMPONENTS CHARGER RECEPTACLE 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 receptacle show signs of corrosion or the plug is difficult to insert or remove, the receptacle contacts and plug terminals should be cleaned with a good electrical contact cleaner or lightly sprayed with WD-40 ®...

  • Page 275: Charger Receptacle Installation

    ELECTRICAL COMPONENTS Charger Receptacle CHARGER RECEPTACLE INSTALLATION Put the wires through the hole in the bucket. Install the charger receptacle (3) in the bucket (Figure 13-25, Page 13-25). Figure 13-25 Charger Receptacle Installation Install the screws (2). Tighten the screws to 16 lb·in (1.8 N·m). CAUTION •...

  • Page 276: Dc To Dc Converter

    DC to DC Converter ELECTRICAL COMPONENTS DC TO DC CONVERTER DC TO DC CONVERTER REMOVAL Disable the vehicle. Set the Run/Tow-Stow switch to TOW/STOW. Remove the high voltage interlock fuse (HVIL). Disconnect the electrical connectors (1) (Figure 13-26, Page 13-26). Figure 13-26 DC To DC Converter Remove the nuts (2).

  • Page 277: Visage Display Unit (Vdu)

    ELECTRICAL COMPONENTS Visage Display Unit (VDU) VISAGE DISPLAY UNIT (VDU) The VDU is powered by 58V. Power Management: If the battery charger is connected to AC power and the vehicle, the VDU and vehicle will stay on indefinitely. If the battery charger is connected to the vehicle with no AC power: •...
  • Page 278 Visage Display Unit (VDU) ELECTRICAL COMPONENTS Pagination Page Page 13-28 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 279: Section 14 - Battery

    SECTION 14 — BATTERY WARNING Battery • Wear safety glasses or approved eye protection when servicing the vehicle or battery charger. • Use insulated tools when working near the battery or electrical connections. Use extreme caution to avoid shorting of components or wiring. •...

  • Page 280: Terminal Cover

    Terminal Cover BATTERY TERMINAL COVER TERMINAL COVER REMOVAL Disable the vehicle. Set the Run/Tow-Stow switch to TOW/STOW. Remove the high voltage interlock fuse (HVIL). Remove the nuts (1) (Figure 14-1, Page 14-2). Figure 14-1 Terminal Cover Removal Remove the terminal cover (2). TERMINAL COVER INSTALLATION CAUTION •...

  • Page 281: Battery Removal

    BATTERY Battery Removal Figure 14-2 Wire Routing Install the terminal cover (2) onto the battery (Figure 14-3, Page 14-3). Figure 14-3 Terminal Cover Installation Make sure that the wires are not between the terminal cover and the battery. Install the nuts (1). Tighten the nuts to 79.6 lb·in (9 N·m) Install the high voltage interlock fuse (HVIL).
  • Page 282 Battery Removal BATTERY Figure 14-4 Terminal Cover Remove the terminal cover (2). Measure the voltage across the main B+ (3) and B- (4) terminals (Figure 14-5, Page 14-4). Make sure the voltage is 0. 6.1. If there is voltage, contacts within the battery management system (BMS) have fused. Replace the battery. Figure 14-5 19 Pin Connector, B+, and B- Loosen the locking collar (5).
  • Page 283 BATTERY Battery Removal Figure 14-6 B+ and B- Remove the B+ (7) and B- (8) wires from the battery posts. Release the electrical connector levers (9) (Figure 13-11, Page 13-11). Figure 14-7 Vehicle Control Module (VCM) and Battery Disconnect the electrical connectors (10). Remove and discard the nuts (11).

  • Page 284: Battery Installation

    Battery Installation BATTERY CAUTION • The battery weighs approximately 110 lbs (50 kg). Use two people to lift the battery. Use two people to lift and remove the battery from the vehicle. BATTERY INSTALLATION WARNING • Wear steel-toe shoes when replacing the battery. NOTE: Use new hardware to install the battery.
  • Page 285 BATTERY Battery Installation Figure 14-9 Vehicle Control Module (VCM) and Battery Installation Connect the electrical connectors (3). Engage the electrical connector levers (4). Install the new spacers (5). Tighten the spacers to 15 lb·ft (20 N·m). Install the B+ (6) and B- (7) wires onto the battery posts (Figure 14-10, Page 14-7). Figure 14-10 B+ and B- Installation Make sure that the wires are routed correctly.
  • Page 286 Battery Installation BATTERY Hold the allen wrench and tighten the nuts to 15 lb·ft (20 N·m). CAUTION • Incorrect removal and installation of the 19-pin connector can cause 19-pin connector damage. Do not twist, bend, or move the 19 pin connector side to side. Make sure that the 19 pin connector aligns with the plug.

  • Page 287: Battery Support Removal

    BATTERY Battery Support Removal Figure 14-13 Terminal Cover Installation Install the nuts (12). Tighten the nuts to 80 lb·in (9 N·m) Install the high voltage interlock fuse (HVIL). Set the Run/Tow-Stow switch to RUN. If a new battery was installed, use the CCDT to: 22.1.

  • Page 288: Battery Support Installation

    Battery Support Installation BATTERY Figure 14-14 Battery Support Removal Remove the battery support (3). BATTERY SUPPORT INSTALLATION Install the new retention hooks (2) into the battery bucket (4) (Figure 14-15, Page 14-10). Figure 14-15 Battery Support Installation Install battery support (3) onto the retention hooks. Install the new nuts (1) by hand.

  • Page 289: Section 15 - Battery Charger

    SECTION 15 — BATTERY CHARGER WARNING Battery Charger • Only trained technicians should repair or service the charger. Contact your nearest Club Car distributor/dealer. • This vehicle is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the vehicle by a person responsible for their safety.

  • Page 290: General Information

    Do not attempt to service a battery charger that has not been properly identified. If a battery charger cannot be properly identified, contact your local Club Car dealer or distributor. The battery charger has no internal parts or components to service or repair. It only has a few external repairs that can be performed.

  • Page 291: Ic 900 Battery Charger Specifications

    BATTERY CHARGER IC 900 Battery Charger Specifications 85 to 270 VAC minimum/maximum Voltage 100 to 240 VAC maximum efficiency range Current 7.5 A maximum Frequency 50 to 60 Hz DC OUTPUT Voltage 48 VDC nominal 72 VDC maximum Current 13.5 A maximum IC 900 BATTERY CHARGER SPECIFICATIONS MANUFACTURER INFORMATION Manufacturer...

  • Page 292: Governmental And Industry Certifications

    Governmental And Industry Certifications BATTERY CHARGER GOVERNMENTAL AND INDUSTRY CERTIFICATIONS EUROPEAN CONFORMITY The battery charger is European conformity (CE) certified per EU 2014/30/EU Electromagnetic Compatibility Directive, 2014/35/EU Low Voltage Equipment Directive, 2014/65/EU Restriction of Hazardous Substances Directive, LV Directives EN 60335-1:2012 and EN 60335-2-29:2004, and EMC Directives EN 61000-3-2: 2014, EN 61000-3-3: 2013, EN 61000-6-2: 2005, EN 61000-6-4: 2007.

  • Page 293: Features

    BATTERY CHARGER Features FEATURES AC ELECTRICAL CORD AND PLUG The AC electric cord has an equipment-grounding conductor and grounding type plug. The AC plug must be connected to a correctly rated ground fault circuit interrupter (GFCI) receptacle with arc flash protection. The receptacle must be installed and grounded in accordance with the National Electrical Code, local codes, and local ordinances.
  • Page 294 Features BATTERY CHARGER (3) AC Power Indicator (7) Select Charge Profile button (4) USB Receptacle Figure 15-1 Battery Charger Interface Page 15-6 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 295: Status Indicator Lights

    BATTERY CHARGER Features STATUS INDICATOR LIGHTS LIGHT STATUS STATUS EXPLANATION Charger fault. See the display panel for details. (Constant) Orange External error condition - caution. See the display panel for details. (Flash On and Off) Green USB port is active. (Flash On and Off) Green Safe to remove the USB flash drive.

  • Page 296: Battery Charging Interlock

    Features BATTERY CHARGER Internal fault condition has caused the charging to stop. See the Battery Charger F code Fault Codes for more information. External error condition has caused the charging to stop. See the Battery Charger E code Error Codes for more information. P code The charger programming mode is active.

  • Page 297: How To Make A Strain Relief And Drip Loop

    BATTERY CHARGER Battery Charger Operation HOW TO MAKE A STRAIN RELIEF AND DRIP LOOP A strain relief and drip loop is necessary to prevent damage to the charger. The strain relief prevents tension on the AC plug. The drip loop prevents water damage to the AC plug. Connect the AC cord (1) into the AC plug (Figure 15-2, Page 15-9).
  • Page 298 Battery Charger Operation BATTERY CHARGER Connect the AC cord to the power source. CAUTION • Incorrect removal and installation of the DC cord can cause DC cord damage and vehicle charge receptacle damage. Do not twist, bend, or move the DC cord plug side to side. Do not pull on the DC cord.

  • Page 299: Charging With Onboard Charger

    BATTERY CHARGER Battery Charger Operation CHARGING WITH ONBOARD CHARGER DANGER • Charging the batteries with accessories on can cause a fire and serious personal injury. Turn off all accessories before charging the batteries. The recommended temperature range to charge the battery is from -4°F (-20°C) to 113°F (45°C). Turn the key to OFF.

  • Page 300: How To Change The Algorithm

    Battery Charger Operation BATTERY CHARGER Before vehicle operation: 4.1. Disconnect the AC cord from the power source. 4.2. Retract the AC cord. HOW TO CHANGE THE ALGORITHM Disconnect the AC cord from the battery charger. Wait 30 seconds. Push and hold the Select Charge Profile button (1) (Figure 15-5, Page 15-12). Figure 15-5 Algorithm Change While pushing the Select Charge Profile button, connect the AC cord to the battery charger.

  • Page 301: Update Battery Charger With Usb

    Battery Charger Operation UPDATE BATTERY CHARGER WITH USB Contact Club Car to obtain the required algorithm, software, and settings files for the correct battery charger and vehicle model. Copy the files to a blank USB 2.0 flash drive formatted as FAT16 or FAT32. See the instructions that were included with the file.

  • Page 302: Inspection And Maintenance

    Inspection And Maintenance BATTERY CHARGER INSPECTION AND MAINTENANCE To ensure trouble-free performance, it is very important to follow an established preventive maintenance program. Regular and consistent maintenance can prevent vehicle downtime and expensive repairs that can result from neglect. Any charger not functioning correctly should be removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions.

  • Page 303: Electrical Plugs And Receptacles

    BATTERY CHARGER Inspection And Maintenance ELECTRICAL PLUGS AND RECEPTACLES Examine electrical plugs for wear and damage before use. Immediately replace electrical plugs for: • Bent pins • Corrosion • Cracks • Loose connections • Missing pins • Worn pins CLEAN THE ELECTRICAL PLUGS AND RECEPTACLES DANGER •...

  • Page 304: Battery Charger Troubleshooting

    Battery Charger Troubleshooting BATTERY CHARGER BATTERY CHARGER TROUBLESHOOTING DANGER • Do not touch any wire or component in the battery charger while AC power is present. Failure to heed this warning will result in an electric shock. WARNING • Knowledge of battery charger wiring and component terminology is required before attempting any repair.

  • Page 305: Reset Power - External Charger

    BATTERY CHARGER Battery Charger Troubleshooting RESET POWER – EXTERNAL CHARGER Before replacing the charger, reset the charger in case the failure was caused by a temporary situation. Disconnect the DC cord from the vehicle. Disconnect the AC cord from the AC power source. When the red triangle status indicator light turns off, wait 30 seconds.

  • Page 306: Battery Charger Troubleshooting Indicators

    Battery Charger Troubleshooting BATTERY CHARGER BATTERY CHARGER TROUBLESHOOTING INDICATORS If a fault occurs, count the number of red flashes (on the charger or dash) between pauses and refer to the table below: BATTERY CHARGER TROUBLESHOOTING GUIDE STATUS INDICATOR STATUS STATUS SOLUTIONS LIGHT EXPLANATION...

  • Page 307: Battery Charger Error Codes

    Reset the battery charger power. rent If problem continues, contact Club Car. • Error in the BMS/VCM software configuration This error will automatically clear once the battery charger USB operation failed (software) power is reset.

  • Page 308: Battery Charger Fault Codes

    • A battery or some other source has been connected to the Make sure the correct battery is installed. charger that exceeds the hardware’s design limits If the problem continues, contact Club Car. • VCM/BMS issue BATTERY CHARGER FAULT CODES The “F”...

  • Page 309: Test Procedures

    BATTERY CHARGER Test Procedures TEST PROCEDURES Index of Test Procedures 1 – DC Cord and Vehicle Charge Receptacle 2 – AC Power Source 3 – AC Circuit - Continuity Test 4 – DC Circuit - Continuity Test 5 – Battery Charger Output Test TEST PROCEDURE 1 –...
  • Page 310 Test Procedures BATTERY CHARGER Set the multimeter to check Ohms. Remove the 3A diode (D3) from the fuse block (Figure 15-6, Page 15-22). Figure 15-6 Fuse Block Measure the resistance between sockets (1) and (4). 14.1. If the reading is between 110 - 130 Ohms, test passed. 14.2.
  • Page 311 BATTERY CHARGER Test Procedures Check the continuity of the DC cord wires. DC Cord Plug Wire Color Description Orange CAN High Black Negative (-) White Interlock Positive (+) CAN Connector Wire Color Description Orange CAN High Blue CAN Low TEST PROCEDURE 5 – Battery Charger Output Test Without a Meter: Connect the DC cord to the vehicle charge receptacle.

  • Page 312: External Charger Repairs

    External Charger Repairs BATTERY CHARGER EXTERNAL CHARGER REPAIRS WARNING • Knowledge of battery charger wiring and component terminology is required before attempting any repair. • Prior to servicing the charger, disconnect the DC cord from the vehicle charge receptacle and the AC cord from the AC outlet.

  • Page 313: Dc Cord Removal

    BATTERY CHARGER External Charger Repairs DC CORD REMOVAL The procedure is the same for the IC 650 and IC 900. Disconnect the DC cord from the vehicle charge receptacle. Disconnect the AC cord from the AC power source. Remove the terminal block cover. Remove the screws (1) (Figure 15-8, Page 15-25).

  • Page 314: Dc Cord Installation

    External Charger Repairs BATTERY CHARGER DC CORD INSTALLATION Attach the red DC cord wire to the positive (+) terminal (5) (Figure 15-9, Page 15-26). NOTE: The positive symbol (+) and negative symbol (–) are molded into the terminal block. Figure 15-9 Left: IC 650 / Right: IC 900 Attach the black, blue, and white DC cord wires to the negative (-) terminal (6).

  • Page 315: Handle Removal

    BATTERY CHARGER External Charger Repairs HANDLE REMOVAL Remove the screws (1) (Figure 15-11, Page 15-27). Figure 15-11 Handle Remove the handle (2). HANDLE INSTALLATION Install the handle (2) on the battery charger (Figure 15-11, Page 15-27). Install the screws (1). Tighten the screws to 39.8 lb·in (4.5 N·m). Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 15-27...

  • Page 316: Foot Removal

    External Charger Repairs BATTERY CHARGER FOOT REMOVAL Disconnect the DC cord from the vehicle charge receptacle. Disconnect the AC cord from the AC power source. If the battery charge is mounted, remove the battery charger. Squeeze the barbs (1) on the foot (2) and push the foot out of charger mounting tab (Figure 15-12, Page 15-28). Figure 15-12 Foot FOOT INSTALLATION Push the foot (2) into hole in charger mounting tab until the barbs (1) come through and secure foot in place...

  • Page 317: Onboard Charger Repairs

    BATTERY CHARGER Onboard Charger Repairs ONBOARD CHARGER REPAIRS WARNING • Knowledge of battery charger wiring and component terminology is required before attempting any repair . • Prior to servicing the charger, disconnect the DC plug from the vehicle charge receptacle and the AC cord from the AC outlet.

  • Page 318: Ac Cord Reel Removal

    Onboard Charger Repairs BATTERY CHARGER AC CORD REEL REMOVAL Disable the vehicle. Disconnect the AC cord from AC power source. Remove the high voltage interlock fuse (HVIL). Disconnect the DC cord (1) from the battery charger (Figure 15-14, Page 15-30). Figure 15-14 Disconnect From Battery Charger Remove the screws (2) (Figure 15-15, Page 15-30).

  • Page 319: Ac Cord Reel Installation

    BATTERY CHARGER Onboard Charger Repairs Figure 15-16 AC Cord Reel Removal Remove the AC cord reel (9). AC CORD REEL INSTALLATION Install the AC cord reel (9) on the cord reel plate (Figure 15-17, Page 15-31). Figure 15-17 AC Cord Reel Installation Install the bolts (8), washers (7), and nuts (6).
  • Page 320 Onboard Charger Repairs BATTERY CHARGER Figure 15-18 Cord Housing Installation Put the AC cord through the cord housing (3). Install the cord housing on the underbody. Install the screws (2). Tighten the screws to 13 lb·in (1.5 N·m). Connect the DC cord (1) to the battery charger (Figure 15-19, Page 15-32). Figure 15-19 Connect To Battery Charger Install the high voltage interlock fuse (HVIL).

  • Page 321: Terminal Block Cover Removal

    BATTERY CHARGER Onboard Charger Repairs TERMINAL BLOCK COVER REMOVAL Disconnect the AC cord from AC power source. Disconnect the DC cord from the charger harness. Push the tabs (1) in and remove the terminal block cover (2) (Figure 15-20, Page 15-33). Figure 15-20 Onboard Charger Terminal Block Cover TERMINAL BLOCK COVER INSTALLATION WARNING...

  • Page 322: Dc Cord Removal

    Onboard Charger Repairs BATTERY CHARGER DC CORD REMOVAL Disable the vehicle. Disconnect the AC cord from AC power source. Remove the high voltage interlock fuse (HVIL). Disconnect the DC cord from the onboard charger harness. Remove the terminal block cover. Remove the screws (1) (Figure 15-21, Page 15-34).

  • Page 323: Section 16 - Motor

    Motor The vehicle is equipped with a 30-volt AC motor. Club Car recommends that motors requiring major repair be sent to a qualified motor repair shop; however, there are many relatively simple tasks that can be performed by a technician with general knowledge and experience in electric motor repair.
  • Page 324 External Motor Testing MOTOR Figure 16-2 35-pin Connector 5.1. If the reading is approximately 1k to 1.7k ohms, the motor temperature sensor and wiring is good. Replace the MCU. 5.2. If the reading is not approximately 1k to 1.7k ohms, go to step 6. Use snap ring pliers to separate the motor harness clip (3) and push the speed sensor connector (4) down (Figure 16-3, Page 16-2).
  • Page 325 MOTOR External Motor Testing Figure 16-4 35-pin and 2-pin Connectors 9.1. If there is continuity, go to step 10. 9.2. If there is no continuity, repair or replace the wiring as necessary. After the wires are repaired or replaced, go to step 10. Set the multimeter to measure resistance (ohms).

  • Page 326: External Motor Testing

    External Motor Testing MOTOR Remove the high voltage interlock fuse (HVIL). Remove the rubber boots (1) (Figure 16-6, Page 16-4). Figure 16-6 Motor Wire Connections Remove the nuts (2) and lock washers (3). Remove the motor wires from the terminal block. Set a multimeter to measure resistance.

  • Page 327: Motor Removal

    MOTOR Motor Removal Connect the orange wire with the blue end to the W terminal (5). Connect the orange wire with the yellow end to the V terminal (6). Connect the orange wire with the white end to the U terminal (7). Install the lock washers (8) and nuts (9).
  • Page 328 Motor Removal MOTOR Figure 16-9 Disconnect Shocks Remove the shock absorbers from the bracket. CAUTION • If a motor wire has damage, the motor harness must be replaced. The motor harness has epoxy lined heat shrink. Do not try to cut the heat shrink. Label the motor wires.
  • Page 329 MOTOR Motor Removal Figure 16-11 Temperature Sensor and Terminal Block Connections Remove the rear lower shackle nuts (14) and bolts (15) (Figure 16-12, Page 16-7). Figure 16-12 Rear Lower Shackle Hardware Removal Position the shackles so they are clear of springs. If a chain hoist was used to raise the vehicle, lift the vehicle high enough to permit easy access and clearance for removal of the motor.

  • Page 330: Motor Installation

    Motor Installation MOTOR Figure 16-13 Motor Mounting Bolt Removal Remove the motor mounting bolt (18) and lock washer (19). Slide the motor away from the transaxle until the motor spline becomes disengaged from the input shaft, then lift motor out. MOTOR INSTALLATION Use a clean cloth and CRC ®...
  • Page 331 MOTOR Motor Installation Make sure that the chamfer (1) and end (2) are completely clean (Figure 16-15, Page 16-9). Figure 16-15 Clean Chamfer and Input Shaft End Make sure that the motor coupling (3) and new molded bumper (4) are clean (Figure 16-16, Page 16-9). Figure 16-16 Motor Coupling and New Molded Bumper Install the new molded bumper with the flat side toward the motor coupling.
  • Page 332 Motor Installation MOTOR Figure 16-17 Gap at Motor and Transaxle Loosely install the bolts (5) and lock washers (6). Do not tighten. Figure 16-18 Motor Mounting Bolts Tighten the bolts with your fingers in the sequence shown until the motor is seated on the transaxle housing (Figure 16-19, Page 16-11).
  • Page 333 MOTOR Motor Installation Figure 16-19 Tightening Sequence Tighten the bolts in the sequence shown to 100 lb·in (11.3 N·m) (Figure 16-18, Page 16-10). Tighten the bolts again to 100 lb·in (11.3 N·m). Connect the temperature sensor (7) and terminal block (8) (Figure 16-11, Page 16-7). Figure 16-20 Temperature Sensor and Terminal Block Connections Install the washers (9) (Figure 16-21, Page 16-12).
  • Page 334 Motor Installation MOTOR Figure 16-21 Motor Wire Connections Connect the orange wire with the blue nd to the W terminal (10). Connect the orange wire with the yellow end to the V terminal (11). Connect the orange wire with the white end to the U terminal (12). Install the lock washers (13) and nuts (14).
  • Page 335 MOTOR Motor Installation Figure 16-23 Brake Cable Installation Install the cables (19) onto the brake actuator arms. Install the brake cable clevis pins (20). Install the bow tie pins (21). Install the shock absorbers onto the shock mount brackets. Install the rubber bushings (22), cup washers (22), and nuts (24) (Figure 16-24, Page 16-13). Tighten the nuts until the rubber bushings expand to the same size as the cup washers.

  • Page 336: Terminal Block Removal

    Terminal Block Removal MOTOR WARNING • Make sure that the vehicle operates in the forward direction when the Forward/Reverse switch is in the FORWARD position. • Make sure that the vehicle operates in the reverse direction when the Forward/Reverse switch is in the REVERSE position.

  • Page 337: Speed Sensor Removal

    MOTOR Speed Sensor Removal Figure 16-26 Terminal Block Installation Install the wires, washers (4), and nuts (3). Tighten the nuts from 70 to 88.5 lb·in (8 to 10 N·m). Install the terminal block onto the motor. Make sure that the gasket is installed correctly. Apply Loctite®...

  • Page 338: Speed Sensor Installation

    Speed Sensor Installation MOTOR Figure 16-27 Speed Sensor Connector Removal Remove the screw (3) (Figure 16-28, Page 16-16). Figure 16-28 Speed Sensor Removal Remove the speed sensor (4). SPEED SENSOR INSTALLATION Install the speed sensor (1) on the motor (Figure 16-29, Page 16-17). Page 16-16 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...
  • Page 339 MOTOR Speed Sensor Installation Figure 16-29 Speed Sensor Installation Install the screw (2). Tighten the screw to 44 lb·in (5 N·m). Route the speed sensor wire in the motor harness connector (3) (Figure 16-30, Page 16-17). Figure 16-30 Speed Sensor Connector Installation Install the speed sensor connector (4) in the motor harness connector.
  • Page 340 Speed Sensor Installation MOTOR Pagination Page Page 16-18 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 341: Section 17 - Transaxle

    SECTION 17 — TRANSAXLE TRANSAXLE FLUID LEVEL CHECK Transaxle Disable the vehicle. Set the Run/Tow-Stow switch to TOW/STOW. Remove the top plug (1) (Figure 17-1, Page 17-1). Figure 17-1 Transaxle Fluid Level Check Make sure that the fluid level is at the bottom of the hole. If the fluid level is low, add the recommended fluid until it is level with the bottom of the hole.

  • Page 342: Transaxle Fluid Change

    Transaxle Fluid Change TRANSAXLE TRANSAXLE FLUID CHANGE Disable the vehicle. Set the Run/Tow-Stow switch to TOW/STOW. Remove the top plug (1) (Figure 17-2, Page 17-2). Figure 17-2 Transaxle Fluid Change Put a drain pan below the bottom plug (2). Remove the bottom plug. Let the fluid drain fully.

  • Page 343: Oil Seal Removal

    TRANSAXLE Axle Shaft And Oil Seal Remove the internal retaining ring (1) (Figure 17-3, Page 17-3). Figure 17-3 Axle Shaft Removal Pull the axle shaft assembly (2) straight out of the axle tube (3). OIL SEAL REMOVAL CAUTION • Do not scar or damage the inside surfaces of the tube when removing the oil seal and adapter ring. A damaged tube might have to be replaced.

  • Page 344: Axle Shaft And Bearing Inspection

    Axle Shaft And Oil Seal TRANSAXLE Figure 17-4 Oil Seal Removal Use a press to separate the oil seal from the adapter ring. Discard the oil seal. AXLE SHAFT AND BEARING INSPECTION Make sure that the bearing (1) and collar have not slipped and are still seated against the shoulder on the axle shaft (Figure 17-5, Page 17-4).

  • Page 345: Oil Seal Installation

    TRANSAXLE Axle Shaft And Oil Seal OIL SEAL INSTALLATION Special Tools Needed Transaxle Pinion Seal Tool NOTE: Refer to the Illustrated Parts Catalog for service tool part numbers. Clean seal seat in the adapter ring (2) (Figure 17-6, Page 17-5). Figure 17-6 Oil Seal Installation Use the transaxle pinion seal tool and a mallet to tap the new oil seal (1) into the adapter ring.

  • Page 346: Axle Shaft Installation

    Axle Shaft And Oil Seal TRANSAXLE AXLE SHAFT INSTALLATION Install the axle shaft (2) through the oil seal and into the axle tube (3) (Figure 17-7, Page 17-6). Be careful not to damage the seal on the inside of the axle tube hub. Figure 17-7 Axle Shaft Installation Rotate the axle shaft to align the shaft splines with the differential side gear.

  • Page 347: Transaxle Removal

    TRANSAXLE Transaxle Removal TRANSAXLE REMOVAL Special Tools Needed Brake Cable Release Tool NOTE: Refer to the Illustrated Parts Catalog for service tool part numbers. Disable the vehicle. Set the Run/Tow-Stow switch to TOW/STOW. Remove the high voltage interlock fuse (HVIL). Lift the rear of the vehicle.
  • Page 348 Transaxle Removal TRANSAXLE Remove the nut (5), cup washer (6), and rubber bushings (7) from the lower mounting stem of the shock absorbers (Figure 17-9, Page 17-8). Figure 17-9 Disconnect Shocks Remove the shock absorbers from the bracket. CAUTION • If a motor wire has damage, the motor harness must be replaced. The motor harness has epoxy lined heat shrink.
  • Page 349 TRANSAXLE Transaxle Removal Disconnect the speed sensor (12) and temperature sensor (13) (Figure 17-11, Page 17-9). Figure 17-11 Temperature Sensor and Terminal Block Connections Remove the rear lower shackle nuts (14) and bolts (15) (Figure 17-12, Page 17-9). Figure 17-12 Rear Lower Shackle Hardware Removal Position the shackles so they are clear of springs.
  • Page 350 Transaxle Removal TRANSAXLE Figure 17-13 Motor Mounting Bolt Removal Remove the motor mounting bolt (18) and lock washer (19). Slide the motor away from the transaxle until the motor spline becomes disengaged from the input shaft, then lift motor out. Page 17-10 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...
  • Page 351 TRANSAXLE Transaxle Removal If a floor jack was used, pull floor jack from beneath the transaxle and lower the leaf springs to the floor (Figure 17-14, Page 17-11). Figure 17-14 Lower Leaf Springs Remove the nuts (20) and U-bolts (21) attaching the transaxle to the leaf springs (Figure 17-15, Page 17-11). Figure 17-15 U-Bolt Removal Lift each end of the transaxle off the leaf spring positioning pin and slide the transaxle to the rear and out of the vehicle.

  • Page 352: Transaxle Disassembly

    Transaxle Disassembly TRANSAXLE TRANSAXLE DISASSEMBLY Drain the transaxle fluid. NOTE: Recycle or dispose of used oil or lubricant in accordance with local, state, and federal regulations. Remove the axle shafts. Remove the brake assemblies. Remove the bolts (1) and the axle tubes (2) (Figure 17-16, Page 17-12). Figure 17-16 Axle Tube Removal Remove the 11 bolts (3) (Figure 17-17, Page 17-12).
  • Page 353 TRANSAXLE Transaxle Disassembly Pull the driver-side gear case (4) and passenger-side gear case (5) apart. If necessary, tap lightly on the spline of the input shaft (6) (Figure 17-18, Page 17-13). CAUTION • Do not damage gears. Use extreme care when handling them. Figure 17-18 Gear Case Disassembly Lift and remove the input pinion gear (7), intermediate gear (8), and differential assembly (9) at the same time (Figure 17-19, Page 17-13).
  • Page 354 Transaxle Disassembly TRANSAXLE Figure 17-20 Input Pinion Gear Disassembly To disassemble the intermediate gear: CAUTION • Do not reuse the bearings. Replace the bearings with new bearings. 9.1. Use a bearing puller or an arbor press to remove the bearings (11 and 12) from the intermediate gear (Figure 17-21, Page 17-14).
  • Page 355 TRANSAXLE Transaxle Disassembly Figure 17-22 Ring Gear Removal 10.2. Use a press to remove the bearings (15) from the differential housing (Figure 17-23, Page 17-15). Figure 17-23 Differential Case Bearings 10.3. Remove the differential pin (16) (Figure 17-24, Page 17-16). Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual Page 17-15...

  • Page 356: Transaxle Inspection

    Transaxle Inspection TRANSAXLE Figure 17-24 Differential Pin 10.4. Remove the idler gears (17), small thrust plates (18), differential gears (19), and large thrust plates (20). TRANSAXLE INSPECTION Inspect the oil seal (1) in the driver-side gear case (2) (Figure 17-25, Page 17-16). Replace as necessary. Figure 17-25 Oil Seal Inspection Inspect all of the bearings.

  • Page 357: Transaxle Assembly

    TRANSAXLE Transaxle Assembly TRANSAXLE ASSEMBLY CAUTION • Do not press against the bearing outer race. • The housing and all parts must be wiped clean and dry before reassembly. Special Tools Needed Transaxle Pinion Seal Tool NOTE: Refer to the Illustrated Parts Catalog for service tool part numbers. To assemble the differential assembly (1): Figure 17-26 Differential Assembly 1.1.
  • Page 358 Transaxle Assembly TRANSAXLE Figure 17-27 Differential Bearing and Output Gear Installation 1.5. Install the bolts (8) and output gear (9). Tighten the bolts to 58 lb·ft (78.6 N·m). To assemble the intermediate gear (10): Figure 17-28 Intermediate Gear Assembly 2.1. Use a press to install new bearings (11 and 12).
  • Page 359 TRANSAXLE Transaxle Assembly Figure 17-29 Input Pinion Gear Assembly 3.1. Use a press to install new bearings (14). To install the oil seal (15): Figure 17-30 Oil Seal Installation 4.1. Apply grease to the lip of the new oil seal. 4.2.
  • Page 360 Transaxle Assembly TRANSAXLE Figure 17-31 Dowel Pin Installation Install the differential assembly, intermediate gear, and the input pinion gear into the driver-side gear case at the same time. Make sure that all of the bearings are seated correctly in the gear case. Rotate the input shaft to check for smooth gear operation.
  • Page 361 TRANSAXLE Transaxle Assembly Figure 17-33 Gear Case Bolt Installation Apply a thin bead of ThreeBond® 1215 liquid gasket on the gear case and axle tube mating points. Install the axle tubes (21) and bolts (22) (Figure 17-34, Page 17-21). Tighten the bolts to 37 lb·ft (50.2 N·m). Figure 17-34 Axle Tube Installation Install the brake clusters.

  • Page 362: Transaxle Installation

    Transaxle Installation TRANSAXLE TRANSAXLE INSTALLATION If using a chain hoist, lift the vehicle and put the transaxle in position on the jack stands. If using a floor jack, lower the jack stands to their lowest settings and place the transaxle in position on the jack stands.
  • Page 363 TRANSAXLE Transaxle Installation Install the bolts (6) and rear lower shackle nuts (7) (Figure 16-22, Page 16-12). Tighten the nuts to 18.5 lb·ft (25 N·m). Figure 17-37 Rear Lower Shackle Hardware Installation Install the cable housings into the shock mount brackets (8) (Figure 16-23, Page 16-13). Make sure that the cable clips are secure.
  • Page 364 Transaxle Installation TRANSAXLE Figure 17-39 Connect Shocks Install the rear wheels. Lift the vehicle and remove the jack stands. Lower the vehicle. Set the Run/Tow-Stow switch to TOW/STOW. Install the high voltage interlock fuse (HVIL). Set the Run/Tow-Stow switch to RUN. Inspect the vehicle to check for correct operation.
  • Page 365 SECTION 18 — WIRING DIAGRAMS GENERAL INFORMATION Wiring Diagrams Wire Description EXAMPLE: 18_GRN_RED • 18 = 18 gauge wire • GRN_RED = Green wire with red stripe Wire Colors NOTE: The following colors will represented as a black wire in the wiring diagrams: •...
  • Page 366 General Information WIRING DIAGRAMS GRN_WHT Green with White Stripe ORG_BLK Orange with Black Stripe ORG_WHT Orange with White Stripe PUR_WHT Purple with White Stripe RED_GRN Red with Green Stripe RED_WHT Red with White Stripe RED_YEL Red with Yellow Stripe WHT_BLK White with Black Stripe Page 18-2 Tempo, Tempo Connect, and Tempo 2+2 Maintenance and Service Manual...

  • Page 367: Section 18 - Wiring Diagrams

    Wiring Diagrams Main Harness: 47614750001 MAIN HARNESS: 47614750001...
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  • Page 369 Wiring Diagrams Main Harness: 47661455001 MAIN HARNESS: 47661455001...
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  • Page 371 Wiring Diagrams Main Harness: 47675944001 MAIN HARNESS: 47675944001...
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  • Page 373 Wiring Diagrams Instrument Panel Harness INSTRUMENT PANEL HARNESS...
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  • Page 375 Wiring Diagrams Lighting Control Harness LIGHTING CONTROL HARNESS...
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  • Page 377 Wiring Diagrams Front Lighting Harness FRONT LIGHTING HARNESS...
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  • Page 379 Wiring Diagrams Visage Wire Harness VISAGE WIRE HARNESS...
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  • Page 381 Wiring Diagrams Onboard Charger Harness ONBOARD CHARGER HARNESS...
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  • Page 383: Index

    Index Index terminal block cover installation...... 15-33 Index terminal block cover removal ......15-33 accelerator pedal ............. 5-6 operation ............15-9 installation ............5-6 external charger..........15-9 removal ............... 5-6 onboard............15-11 access panel ............4-17 test procedures ..........15-21 installation ............4-17 AC circuit - continuity test ......
  • Page 384 INDEX installation ............4-26 forward/neutral/reverse switch removal ............4-25 installation ............13-8 rear canopy support removal ............. 13-7 installation ............4-28 front body..............4-6 removal ............4-27 installation ............4-7 charger receptacle removal ............... 4-7 inspection ............13-24 front bumper............4-8 installation ............
  • Page 385 INDEX disassembly ........... 4-54 installation ............4-56 lubrication removal ............4-53 front suspension........... 7-7 rear underbody...........4-57–4-58 installation ............4-58 nstallation............4-57 removal ..........4-57–4-58 seat back, 2+2 ........... 4-43 installation ............4-44 main solenoid removal ............4-43 installation ............13-20 removal ............13-19 seat support............
  • Page 386 INDEX tie rod and drag link removal ............... 7-7 safety information ............ 1-1 tire battery international safety symbols ....... 1-5 installation ............8-5 practice safety............1-1 removal ............... 8-4 safety committee ..........1-1 repair..............8-5 safety signal words..........1-1 transaxle ............... 17-1 vehicle safety information........
  • Page 387 NOTES...
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  • Page 389 NOTES...
  • Page 390 NOTES...

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