Club Car Onward 2018 Maintenance And Service Manual

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2018 Onward

Maintenance and

Service Manual

Electric Vehicle with ERIC Charging System

Gasoline Vehicle with Subaru EX40 Engine

Manual Number 105344203

Edition Code C

Table of Contents

Troubleshooting

Summary of Contents for Club Car Onward 2018

Page 1 2018 Onward Maintenance and Service Manual Electric Vehicle with ERIC Charging System Gasoline Vehicle with Subaru EX40 Engine Manual Number 105344203 Edition Code C...
Page 3 To find your local authorized Club Car dealer, visit www.clubcardealer.com, call 1-800-ClubCar (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 Spark Plug O.H.C. (404 cc) CC PN 47539956001 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: Table Of Contents
CONTENTS SECTION 1 — Safety............................1-1 Safety Details ..............................1-1 General Warnings............................1-2 Disabling the Vehicle..........................1-3 Disconnecting the Battery- Gasoline Vehicles ....................1-3 Connecting the Battery- Gasoline Vehicles ....................1-3 Disconnecting the Batteries – Electric Vehicles .................... 1-4 Connecting the Batteries – Electric Vehicles ....................1-4 Recycling Lead-Acid Batteries ........................
Page 6 Seat Bottom ..............................4-12 Rear Body – Two-Passenger Vehicles......................4-12 Universal Accessory Mounting........................4-12 Seat Back and Structural Accessory Module (SAM) ................... 4-13 Rear Body Components (Two-Passenger)....................4-14 Rear Body – Four-Passenger Vehicles......................4-17 Seat Backs.............................. 4-17 Seat Support ............................4-18 Fold Down Seat............................
Page 7 Non-Lifted Front Suspension Components .....................7-11 Non-Lifted Tie Rod End Removal.......................7-11 Non-Lifted Tie Rod Installation........................7-11 Non-Lifted Leaf Spring Removal ........................7-11 Non-Lifted Leaf Spring Installation ......................7-12 Non-Lifted Kingpin and Steering Spindle Removal ..................7-12 Non-Lifted Kingpin and Steering Spindle Installation .................. 7-12 Non-Lifted Control Arm Removal ......................
Page 8 ................................10-1 Performance Inspection ........................... 10-2 Maintenance ............................... 10-3 Periodic Service Schedules .......................... 10-4 Periodic Lubrication Schedules........................10-8 SECTION 11 — Controller Diagnostic Tool (CDT) ....................11-1 General Information ............................11-2 Features ..............................11-2 Plugging the CDT into the Vehicle........................11-3 Introductory Display ..........................11-3 Quick Reference Guide –...
Page 9 Fault Recovery ............................11-17 Fault Descriptions............................11-18 Incorrect Password (OEM Access Level Only) ..................11-18 Max Password Tries (OEM Access Level Only) ..................11-18 Throttle Fault ............................11-18 Low Battery Voltage (Undervoltage) ......................11-18 Overvoltage............................11-18 Thermal Cutback ............................ 11-19 Anti-Tamper Fault ...........................
Page 10 USB Port..............................13-3 USB Port Removal........................... 13-3 USB Port Installation ..........................13-4 Forward/Reverse Rocker Switch........................13-4 Testing the Forward/Reverse Rocker Switch....................13-4 Forward/Reverse Rocker Switch Removal....................13-4 Forward/Reverse Rocker Switch Installation ....................13-5 Electronics Module Cover..........................13-6 Electronics Module Cover Removal ......................13-6 Electronics Module Cover Installation......................
Page 11 SECTION 15 — ERIC Battery Charger......................15-1 General Information ............................. 15-2 USB Service Port............................. 15-3 UL and CSA Listing ..........................15-3 CE Compliance ............................15-3 Plug and Receptacle..........................15-3 Charger Power Connection Fuse ......................15-4 Charger Interlock ............................. 15-4 AC Input Voltage Detection ........................15-4 Thermal Cutback .............................
Page 12 Motor Assembly............................16-13 Motor Installation ............................16-15 SECTION 17 — Transaxle: Electric Vehicle ....................... 17-1 Lubrication ..............................17-1 Axle Bearing and Shaft ..........................17-1 Axle Shaft ............................... 17-1 Axle Bearing............................17-4 Transaxle Removal ............................17-5 Transaxle Disassembly, Inspection, and Assembly..................17-7 Transaxle Disassembly and Inspection...................... 17-7 Transaxle Assembly..........................
Page 13 Neutral Lockout Limit Switch Removal .....................19-20 Neutral Lockout Limit Switch Installation....................19-20 Solenoid..............................19-21 Testing the Solenoid ..........................19-21 Solenoid Removal ..........................19-21 Solenoid Installation..........................19-21 Fuse ................................19-22 Fuse Removal ............................19-22 Fuse Installation .............................19-22 Accelerator Pedal Limit Switch ........................19-23 Testing the Accelerator Pedal Limit Switch ....................19-23 Kill Limit Switch ............................19-23 Testing the Kill Limit Switch ........................19-23 Reverse Warning Buzzer..........................19-23...
Page 14 Oil Level Sensor Removal ........................20-12 Oil Level Sensor Installation ........................20-12 Ignition Coil ..............................20-13 Testing the Ignition Coil ...........................20-13 Ignition Coil Removal ..........................20-13 Ignition Coil Installation ...........................20-13 Snubber ..............................20-14 Snubber Removal...........................20-14 Snubber Installation ..........................20-14 SECTION 21 — Fuel System – Subaru EX40 ....................21-1 General Information .............................
Page 15 Drive Belt ..............................23-3 Drive Belt Removal ..........................23-3 Drive Belt Installation ..........................23-3 Drive Clutch ..............................23-4 Drive Clutch Removal ..........................23-5 Drive Clutch Cleaning and Inspection......................23-6 Drive Clutch Disassembly......................... 23-6 Inspection of Drive Clutch Parts........................ 23-9 Drive Clutch Assembly ..........................23-10 Drive Clutch Installation ..........................
Page 17: Section 1 - Safety
SECTION 1 — SAFETY SAFETY DETAILS Safety WARNING • This owner’s manual should be read completely before attempting to drive or service the vehicle. Failure to follow the instructions in this manual could result in property damage, severe personal injury, or death. It is important to note that some vital statements throughout this manual and on the decals affixed to the vehicle are preceded by the words DANGER, WARNING, or CAUTION.
Page 18: General Warnings
• The vehicle will not provide protection from lightning, flying objects, or other storm-related hazards. If caught in a storm while driving a Club Car vehicle, exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location.
Page 19: Disabling The Vehicle
SAFETY General Warnings WARNING • Use insulated tools when working near batteries or electrical connections. Use extreme caution to avoid shorting of components or wiring. Electric vehicles only: • Place Tow/Run switch in the TOW position before disconnecting or connecting the batteries. Failure to heed this warning could result in a battery explosion or severe personal injury.
Page 20: Disconnecting The Batteries - Electric Vehicles
General Warnings SAFETY (Viewed from driver side of vehicle) (Viewed from driver side of vehicle) 1. Remove positive terminal cover. 1. Place TOW/RUN Switch in TOW before disconnecting or connecting 2. Remove negative battery cable. battery cables. 3. Remove positive battery cable. 2.
Page 21: Recycling Lead-Acid Batteries
Responsibility for environmental protection must be shared, not only by the manufacturers of the batteries, but by people who use the batteries as well. Please contact your nearest Club Car dealer or distributor for information on how to properly recycle your batteries. 1403...
Page 22 General Warnings SAFETY Pagination Page Page 1-6 2018 Onward Maintenance and Service Manual...
Page 23: Section 2 - Vehicle Specifications
SECTION 2 — VEHICLE SPECIFICATIONS VEHICLE SPECIFICATIONS – ELECTRIC AND SUBARU EX40 Vehicle Specifications TWO- FOUR- FOUR- SPECIFICATIONS PASSENGER PASSENGER PASSENGER NON–LIFTED NON-LIFTED LIFTED POWER SOURCE - ELECTRIC VEHICLE Drive motor: Direct drive, 48 volts DC, shunt-wound, 3.1 hp ● ●...
Page 24 Vehicle Specifications – Electric and Subaru EX40 VEHICLE SPECIFICATIONS TWO- FOUR- FOUR- SPECIFICATIONS PASSENGER PASSENGER PASSENGER NON–LIFTED NON-LIFTED LIFTED Overall height (with canopy) 71 in. (180.3 cm) 71 in. (180.3 cm) 80.5 in. (204.4 cm) Overall height (at steering wheel) 48.75 in.
Page 25: E.r.i.c. Battery Charger Specifications
VEHICLE SPECIFICATIONS E.R.I.C. Battery Charger Specifications E.R.I.C. BATTERY CHARGER SPECIFICATIONS E.R.I.C. BATTERY CHARGER SPECIFICATIONS MODEL NUMBER IC650-048-CC AC INPUT AC voltage 100 to 240 VAC Frequency 50 / 60 Hz POWER CONSUMPTION Maximum AC input current (amps) DC OUTPUT Rated DC voltage (VDC) Maximum DC voltage (VDC) Maximum DC output current (amps) 13.5...
Page 26 E.R.I.C. Battery Charger Specifications VEHICLE SPECIFICATIONS Pagination Page Page 2-4 2018 Onward Maintenance and Service Manual...
Page 27: Section 3 - General Information
• See General Warnings on page 1-2. Important features unique to the different models covered in this manual are highlighted. Club Car, LLC recommends the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s).
Page 28: Storage - Electric Vehicle
Storage – Electric Vehicle GENERAL INFORMATION STORAGE – ELECTRIC VEHICLE See General Warnings on page 1-2. WARNING • Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse switch in the NEUTRAL position during storage. Place Tow/Run switch in the TOW position. This is to prevent unintentionally starting the vehicle or a fire hazard.
Page 29: Returning The Stored Electric Vehicle To Service
GENERAL INFORMATION Storage – Electric Vehicle Thoroughly clean front body, rear body, seats, battery compartment, and underside of vehicle. Do not engage the park brake. Chock the wheels to prevent the vehicle from rolling. NOTE: It is recommended that the vehicles be plugged in and the electrolyte level maintained throughout the storage period.
Page 30: Storage - Gasoline Vehicle
Storage – Gasoline Vehicle GENERAL INFORMATION STORAGE – GASOLINE VEHICLE See General Warnings on page 1-2. DANGER • Do not attempt to drain fuel when the engine is hot or while it is running. • Be sure to clean up any spilled gasoline before operating the vehicle. •...
Page 31: Returning The Stored Gasoline Vehicle To Service
GENERAL INFORMATION Storage – Gasoline Vehicle Thoroughly clean front body, rear body, seats, engine compartment, and underside of vehicle. Do not engage the park brake. Chock the wheels to prevent the vehicle from rolling. RETURNING THE STORED GASOLINE VEHICLE TO SERVICE Restore the fuel systems to operation.
Page 32 Storage – Gasoline Vehicle GENERAL INFORMATION Pagination Page Page 3-6 2018 Onward Maintenance and Service Manual...
Page 33: Section 4 - Body And Trim
A garden hose at normal residential water pressure is adequate. Club Car does not recommend any type of pressure washing or steam cleaning. Such a process (especially if the vehicle has a Surlyn ®...
Page 34: Front And Rear Body Repair
Front and Rear Body Repair BODY AND TRIM More Difficult Stains: Perform previous procedure using full-strength bleach, or allow bleach to puddle on affected area for approximately 30 minutes. Rinse with a water dampened cloth to remove any remaining bleach concentration.
Page 35: Minor Scratches And Surface Blemishes
BODY AND TRIM Front Body MINOR SCRATCHES AND SURFACE BLEMISHES For minor scratches or blemishes in the Surlyn ® body that do not penetrate the finish: Thoroughly clean the affected area using a strong, non-abrasive detergent and hot water, then clean with Ultra-Kleen ®...
Page 36 Front Body BODY AND TRIM Figure 4-1 Front Body Page 4-4 2018 Onward Maintenance and Service Manual...
Page 37: Front Bumper
BODY AND TRIM Front Bumper FRONT BUMPER FRONT BUMPER REMOVAL Remove the screw (1) (Figure 4-2, Page 4-5). Remove the nuts (2) and bolts (3). Remove the front bumper (4) FRONT BUMPER INSTALLATION Put the front bumper (4) on the frame rails (Figure 4-2, Page 4-5). Install the bolts (3) and nuts (2).
Page 38: Headlights
Headlights BODY AND TRIM HEADLIGHTS The headlights are not adjustable. HEADLIGHT REMOVAL Disconnect the headlight harness. Remove the front cowl (1) (Figure 4-3, Page 4-6). See Front Body Removal on page 4-3. Remove the screws (2). Remove the headlight (3). HEADLIGHT INSTALLATION Install the headlight (3) (Figure 4-3, Page 4-6).
Page 39: Underbody Bracket
BODY AND TRIM Underbody Bracket UNDERBODY BRACKET UNDERBODY BRACKET REMOVAL Remove the two screws (2) (Figure 4-4, Page 4-7). Remove the underbody bracket (1). UNDERBODY BRACKET INSTALLATION Put the underbody bracket (1) into position on the vehicle (Figure 4-4, Page 4-7). Install the two screws (2).
Page 40: Instrument Panel
Instrument Panel BODY AND TRIM INSTRUMENT PANEL See General Warnings on page 1-2. INSTRUMENT PANEL REMOVAL Remove two screws (1) at sides and one screw (2) on top of instrument panel (3) (Figure 4-5, Page 4-8). Tilt instrument panel up to release it from the dash assembly (4). Disconnect the electrical connector on the passenger side of the instrument panel (3) and remove the panel.
Page 41: Floor Mat And Retainers
BODY AND TRIM Floor Mat and Retainers FLOOR MAT AND RETAINERS See General Warnings on page 1-2. The floor mat retainers secure the floor mat to the vehicle and also provide a clean appearance to the side of the vehicle. Normally, if only the floor mat (3) needs to be removed, the screws (2) must be removed to allow the floor mat to be slid from beneath the retainers (1) (Figure 4-6, Page 4-9).
Page 42: Kick Plate And Charger Receptacle Bezel - Electric Vehicles
Kick Plate and Charger Receptacle Bezel – Electric Vehicles BODY AND TRIM KICK PLATE AND CHARGER RECEPTACLE BEZEL – ELECTRIC VEHICLES See General Warnings on page 1-2. KICK PLATE AND CHARGER RECEPTACLE BEZEL REMOVAL If charger bezel (4) requires removal, use charger bezel tool (P/N 102562401) to remove bezel from the kick plate (Figure 4-7, Page 4-10).
Page 43: Kick Plate - Efi Gasoline Vehicles
BODY AND TRIM Kick Plate – EFI Gasoline Vehicles KICK PLATE – EFI GASOLINE VEHICLES See General Warnings on page 1-2. KICK PLATE REMOVAL Remove floor mat. See Floor Mat and Retainers on page 4-9. Remove three screws (1) and washers (2) that hold the kick plate (3) to the vehicle (Figure 4-8, Page 4-11). Remove the two front screws (4) that hold the beauty panel to the vehicle.
Page 44: Seat Bottom
Seat Bottom BODY AND TRIM SEAT BOTTOM The seat bottom (1) is secured to the vehicle with two hinges (2) (Figure 4-9, Page 4-12) that hook into slots in the body. When replacing the hinges (2), tighten screws (3) to 75 lb·in (8.5 N·m). When replacing hip restraints (4), tighten screws (5) to 65 lb·in (7.3 N·m).
Page 45: Seat Back And Structural Accessory Module (Sam)
BODY AND TRIM Rear Body – Two-Passenger Vehicles Figure 4-10 Universal Accessory Mounting SEAT BACK AND STRUCTURAL ACCESSORY MODULE (SAM) SAM Removal If the vehicle has a canopy, the rear upright supports must be removed from the SAM. Remove four bolts (4) to release the SAM (3) from the vehicle (Figure 4-11, Page 4-14). SAM Installation Position the SAM (3) over its mounting holes and secure with four screws (4).
Page 46: Rear Body Components (Two-Passenger)
Rear Body – Two-Passenger Vehicles BODY AND TRIM 2653 Figure 4-11 Seat Back, Bag Rack and SAM REAR BODY COMPONENTS (TWO-PASSENGER) Rear Beauty Panel Removal Remove SAM. See SAM Removal on page 4-13. Page 4-14 2018 Onward Maintenance and Service Manual...
Page 47 BODY AND TRIM Rear Body – Two-Passenger Vehicles Remove one screw (3) from each canopy support bracket (1 and 2) (Figure 4-12, Page 4-16). Remove canopy supports. Remove four screws (13) attaching the rear beauty panel (12). Electric vehicles: Remove the Forward/Reverse switch housing. See Forward/Reverse Rocker Switch Removal on page 13-4.
Page 48 Rear Body – Two-Passenger Vehicles BODY AND TRIM Figure 4-12 Rear Body Components (Two Passenger Vehicles) Page 4-16 2018 Onward Maintenance and Service Manual...
Page 49: Rear Body - Four-Passenger Vehicles
BODY AND TRIM Rear Body – Four-Passenger Vehicles REAR BODY – FOUR-PASSENGER VEHICLES See General Warnings on page 1-2. SEAT BACKS Seat Back Removal Remove screws (1 or 2) securing seat back (3 or 4) to seat support and remove the seat backs (Figure 4-13, Page 4-17).
Page 50: Seat Support
Rear Body – Four-Passenger Vehicles BODY AND TRIM SEAT SUPPORT Seat Support Removal Remove the seat backs. See Seat Back Removal on page 4-17. Remove the fold down seat. See Fold Down Seat Removal on page 4-19. Remove the screws (1) (Figure 4-14, Page 4-18). Remove the seat supports (2) from the vehicle.
Page 51: Fold Down Seat
BODY AND TRIM Rear Body – Four-Passenger Vehicles FOLD DOWN SEAT Fold Down Seat Removal Remove the nuts (2) (Figure 4-15, Page 4-19). Remove the nuts (3). Remove the fold down seat (1). Figure 4-15 Fold Down Seat Removal/Installation (Four-Passenger Vehicles) Fold Down Seat Dissassembly Remove the nuts (1) from the arm rests (2) (Figure 4-16, Page 4-20).
Page 52 Rear Body – Four-Passenger Vehicles BODY AND TRIM Tighten the nuts (1) to 78 lb·in (8.8 N·m) (Figure 4-16, Page 4-20). Tighten the bolts (4 and 18) to 102 lb·in (11.5 N·m) (Figure 4-17, Page 4-21) and (Figure 4-18, Page 4-22). Tighten the nuts (19) to 150 lb·in (16.9 N·m) (Figure 4-18, Page 4-22).
Page 53 BODY AND TRIM Rear Body – Four-Passenger Vehicles Figure 4-17 Fold Down Seat Disassembly/Assembly (Four-Passenger Vehicles) - Seat Base 2018 Onward Maintenance and Service Manual Page 4-21...
Page 54 Rear Body – Four-Passenger Vehicles BODY AND TRIM Figure 4-18 Fold Down Seat Disassembly/Assembly (Four-Passenger Vehicles) - Grab Bar Fold Down Seat Installation Put the fold down seat (1) into position on the vehicle (Figure 4-15, Page 4-19). Install the nuts (2). Tighten the nuts to 150 lb·in (17 N·m) Page 4-22 2018 Onward Maintenance and Service Manual...
Page 55: Rear Body Components (Four-Passenger)
BODY AND TRIM Rear Body – Four-Passenger Vehicles Install the nuts (3). Tighten the nuts to 40 lb·in (4.5 N·m). REAR BODY COMPONENTS (FOUR-PASSENGER) Rear Beauty Panel Removal Remove seat support. See Seat Support Removal on page 4-18. Remove the fold down seat assembly Fold Down Seat Removal. Remove four screws (13) attaching the rear beauty panel (12) (Figure 4-19, Page 4-24).
Page 56 Rear Body – Four-Passenger Vehicles BODY AND TRIM Figure 4-19 Rear Body Components (Four Passenger Vehicles) Page 4-24 2018 Onward Maintenance and Service Manual...
Page 57: Canopy - Two-Passenger
BODY AND TRIM Canopy – Two-Passenger CANOPY – TWO-PASSENGER See General Warnings on page 1-2. CAUTION • To prevent damage to the canopy, do not remove the canopy supports from the vehicle without first removing the canopy. TWO-PASSENGER CANOPY REMOVAL Remove the nuts (1), washer (2), and bolts (3) from the canopy (4) and each front canopy support (5) (Figure 4-20, Page 4-25) and (Figure 4-21, Page 4-26).
Page 58 Canopy – Two-Passenger BODY AND TRIM Figure 4-21 Two-Passenger Canopy Front Supports Figure 4-22 Two-Passenger Canopy Rear Supports Page 4-26 2018 Onward Maintenance and Service Manual...
Page 59: Two-Passenger Canopy Installation
BODY AND TRIM Canopy – Two-Passenger TWO-PASSENGER CANOPY INSTALLATION Install the front canopy supports. 1.1. Ensure the front supports are properly oriented to the correct side of the vehicle. The lower profile of each support follows the profile of the vehicle. If the supports are placed on the wrong side of the vehicle, they will not follow the vehicle’s profile.
Page 60: Canopy - Four-Passenger
Canopy – Four-Passenger BODY AND TRIM CANOPY – FOUR-PASSENGER See General Warnings on page 1-2. CAUTION • To prevent damage to the canopy, do not remove the canopy supports (1 and 6) from the vehicle without first removing the canopy (9) . FOUR-PASSENGER CANOPY REMOVAL Remove the nuts (1 and 6), washers (2 and 7), and bolts (3 and 8) from the front canopy supports (Figure 4-23, Page 4-29).
Page 61 BODY AND TRIM Canopy – Four-Passenger Figure 4-23 Four-Passenger Canopy 2018 Onward Maintenance and Service Manual Page 4-29...
Page 62 Canopy – Four-Passenger BODY AND TRIM Figure 4-24 Four-Passenger Canopy Support Page 4-30 2018 Onward Maintenance and Service Manual...
Page 63: Section 5 - Accelerator And Brake Pedal Group
SECTION 5 — ACCELERATOR AND BRAKE PEDAL GROUP DANGER Accelerator and Brake Pedal Group • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. PEDAL GROUP – ELECTRIC VEHICLE See General Warnings on page 1-2. PEDAL GROUP REMOVAL Disconnect the batteries and discharge the controller.
Page 64 Pedal Group – Electric Vehicle ACCELERATOR AND BRAKE PEDAL GROUP 2518 Figure 5-2 Pedal Group – Electric Vehicle Page 5-2 2018 Onward Maintenance and Service Manual...
Page 65: Mcor
ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group – Electric Vehicle MCOR The pedal group for the electric vehicle includes a Motor Controller Output Regulator (MCOR) mounted on the side of the pedal group. The MCOR detects the position of the GO pedal and sends a corresponding voltage to the motor controller.
Page 66: Pedal Group - Gasoline Vehicle
Pedal Group – Gasoline Vehicle ACCELERATOR AND BRAKE PEDAL GROUP PEDAL GROUP – GASOLINE VEHICLE See General Warnings on page 1-2. PEDAL GROUP REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery- Gasoline Vehicles on page 1-3. Remove screws (1). Pull floor mat retainer (3) away from the vehicle (Figure 5-3, Page 5-4). Pull floor mat (2) over the pedal group to gain access to the pedal group hardware.
Page 67: Throttle Position Sensor
ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group – Gasoline Vehicle 2518a Figure 5-4 Pedal Group – Gasoline Vehicle THROTTLE POSITION SENSOR The pedal group for the vehicle includes a throttle position sensor mounted on the side of the accelerator pedal assembly.
Page 68: Pedal Group Installation
Debris Shields ACCELERATOR AND BRAKE PEDAL GROUP PEDAL GROUP INSTALLATION Connect the end of the accelerator cable to the pedal group (Figure 5-4, Page 5-5). See following CAUTION. CAUTION • Make sure the accelerator cable is properly seated to the pedal group. Connect the wire harness (12) to the throttle position sensor (Figure 5-4, Page 5-5).
Page 69: Brake Pedal Removal
ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal Removal Electric Vehicle: Install the MCOR. See MCOR Installation on page 13-8. Install pedal group in vehicle. See Pedal Group Installation on page 5-3. See Pedal Group Installation on page 5-6. BRAKE PEDAL REMOVAL Remove pedal group from vehicle.
Page 70 Brake Pedal Installation ACCELERATOR AND BRAKE PEDAL GROUP Figure 5-5 Accelerator Pedal Assembly and Brake Pedal Assembly Page 5-8 2018 Onward Maintenance and Service Manual...
Page 71: Section 6 - Wheel Brake Assemblies
SECTION 6 — WHEEL BRAKE ASSEMBLIES DANGER Wheel Brake Assemblies • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. Asbestos Dust Warning • Some aftermarket brake shoes contain asbestos fiber, and asbestos dust is created when these brake mechanisms are handled.
Page 72 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES 1400-18100-10220 Figure 6-1 Loosen Turnbuckle Figure 6-2 Shoe Retainer Pins Remove brake drums and badly worn brake shoes. 7.1. On the back of each brake cluster assembly, locate the heads of two brake shoe retainer pins. It may be necessary to remove sealant material around the head of each pin.
Page 73: Brake Shoe Removal
WHEEL BRAKE ASSEMBLIES Brake Shoe Removal 1400-18100-10222 1400-17700-10225 Figure 6-3 Remove Shoe Retainer Clip Figure 6-4 Remove Brake Shoes 1. Slide 2732 2733 Figure 6-5 Remove Adjuster Wheel Figure 6-6 Lubricate Slide 2018 Onward Maintenance and Service Manual Page 6-3...
Page 74: Brake Assembly Cleaning
Brake Assembly Cleaning WHEEL BRAKE ASSEMBLIES BRAKE ASSEMBLY CLEANING See General Warnings on page 1-2. See also Asbestos Dust Warning on page 6-1. Carefully clean the brake backing plate and all of its mechanical components. Remove the rubber boot from backing plate and wipe with a clean damp cloth. Lubricate the slide (1) with dry moly lubricant (P/N 1012151) (Figure 6-6, Page 6-3).
Page 75 WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning 2735 2736 Figure 6-9 Apply Grease To Brake Adjuster Figure 6-10 Install Adjuster Wheel, Trailing Shoe 2018 Onward Maintenance and Service Manual Page 6-5...
Page 76: Brake Shoe Installation
Brake Shoe Installation WHEEL BRAKE ASSEMBLIES BRAKE SHOE INSTALLATION See General Warnings on page 1-2. See also Asbestos Dust Warning on page 6-1. Turn the adjusting wheel screw so that the shoe slot is vertical, then position the trailing shoe in the slots in the shoe mounting block and adjuster assembly (Figure 6-10, Page 6-5).
Page 77 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation Figure 6-13 Install Leading Shoe Figure 6-14 Check Shoe Positions Place a flatblade screwdriver under the adjusting arm (1) and raise the arm off of the adjusting wheel (2). While holding the arm (1) up, turn the wheel (2) upward until it stops (Figure 6-15, Page 6-7). Remove the screwdriver. Figure 6-15 Set Adjusting Wheel For electric vehicles: Install the axle shaft.
Page 78 Brake Shoe Installation WHEEL BRAKE ASSEMBLIES Figure 6-16 Equalizer Adjustment Page 6-8 2018 Onward Maintenance and Service Manual...
Page 79: Brake Cable Equalizer Adjustment
WHEEL BRAKE ASSEMBLIES Brake Cable Equalizer Adjustment BRAKE CABLE EQUALIZER ADJUSTMENT See General Warnings on page 1-2. See also Asbestos Dust Warning on page 6-1. After maintenance on the brake system is complete, lower the vehicle onto the floor. With the brake pedal in the full up or at rest position, adjust the turnbuckle (1) until the proper brake tension is achieved (Figure 6-16, Page 6-8).
Page 80: Brake Cluster Removal And Installation
Brake Cluster Removal and Installation WHEEL BRAKE ASSEMBLIES BRAKE CLUSTER REMOVAL AND INSTALLATION See General Warnings on page 1-2. See also Asbestos Dust Warning on page 6-1. BRAKE CLUSTER REMOVAL Electric Vehicle: Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4.
Page 81: Brake Cluster Installation
WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation 2731 Figure 6-17 Self-adjusting Wheel Brake Assembly BRAKE CLUSTER INSTALLATION Install in reverse order of disassembly. Use new bow tie locking pins when installing brake cables. CAUTION • Before installing axle shaft, clean any residual oil from the exposed end of the axle tube and from the oil seal area.
Page 82 Brake Cluster Removal and Installation WHEEL BRAKE ASSEMBLIES For gasoline vehicles: Install the wheel hub assembly. See Rear Hub Installation, Section 24, Page 24-4. Tighten lug nuts on rear wheels, using a crisscross pattern, to 55 lb·ft (74.6 N·m). See Wheel Installation on page 8-1.
Page 83: Brake Cable Removal And Installation
WHEEL BRAKE ASSEMBLIES Brake Cable Removal and Installation BRAKE CABLE REMOVAL AND INSTALLATION See General Warnings on page 1-2. See also Asbestos Dust Warning on page 6-1. BRAKE CABLE REMOVAL Electric Vehicle: Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4.
Page 84: Brake Cable Installation
Brake Cable Removal and Installation WHEEL BRAKE ASSEMBLIES Figure 6-19 Disconnect Cables at Rear Brakes Figure 6-20 Brake Cable Mounting Tab 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.
Page 85: Section 7 - Steering And Front Suspension
SECTION 7 — STEERING AND FRONT SUSPENSION DANGER Steering and Front Suspension • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION Steering is controlled through a rack and pinion steering assembly that is connected by a steering column to a steering wheel.
Page 86: Steering Wheel Installation
Steering Column STEERING AND FRONT SUSPENSION Figure 7-1 Steering Wheel Removal Figure 7-2 Steering Wheel Puller STEERING WHEEL INSTALLATION NOTE: To minimize corrosion and to make future removal of the steering wheel easier, apply a small amount of oil or anti-seize compound to steering shaft before installing the steering wheel.
Page 87: Steering Column Installation
STEERING AND FRONT SUSPENSION Steering Column 2622 Figure 7-3 Steering Column STEERING COLUMN INSTALLATION For ease of assembly and to prevent corrosion, apply a light coat of anti-seize or lubricating compound to the splined stud (13) extending from the steering gear. Insert the end of the steering column (9) with the universal joint through the front underbody.
Page 88: Rack And Pinion
Rack and Pinion STEERING AND FRONT SUSPENSION RACK AND PINION See General Warnings on page 1-2. CAUTION • Front impacts that bend tie rods and/or drag links can possibly damage internal steering gear components. See Rack and Pinion Inspection on page 7-4. The manufacturer recommends inspecting the rack and pinion and replacing if damaged.
Page 89: Rack And Pinion Removal
STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION REMOVAL Electric Vehicle: Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4. Gasoline Vehicle: Disconnect battery and spark plug wire(s). See Disconnecting the Battery- Gasoline Vehicles on page 1-3.
Page 90: Front Suspension
Front Suspension STEERING AND FRONT SUSPENSION FRONT SUSPENSION See General Warnings on page 1-2. 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 10-8. CAUTION •...
Page 91 STEERING AND FRONT SUSPENSION Front Suspension Figure 7-5 Check Camber Figure 7-6 Adjust Camber Toe-in Adjustment On a level surface, roll the vehicle forward, then stop. Make sure the front wheels are pointed straight ahead. Do not turn the steering wheel again during this procedure. On each front tire, mark (as closely as possible) the center of the tread face that is oriented toward the rear of the vehicle.
Page 92: Lifted Suspension Wheel Alignment
Front Suspension STEERING AND FRONT SUSPENSION 6.2. Rotate both of the drag links equally. To increase the toe-in, rotate both drag links counterclockwise. To decrease the toe-in, rotate both drag links clockwise. Maintain an equal distance from the ball joint to the end of the threads on each drag link (Figure 7-9, Page 7-8).
Page 93 STEERING AND FRONT SUSPENSION Front Suspension Figure 7-10 Check Camber Figure 7-11 Adjust to Zero Camber Adjust the bottom rod end (3) in the appropriate direction and secure with the jam nuts. Snug hardware but do not torque until alignment is complete (Figure 7-11, Page 7-9). Make sure both ends of the spindles are correctly centered on the swivel ball of the rod ends (Figure 7-12, Page 7-9) and (Figure 7-13, Page 7-9).
Page 94 Front Suspension STEERING AND FRONT SUSPENSION Measure the distance between the marks on the face of the front facing surfaces of the tires, and then roll the vehicle forward one and a half wheel revolutions until the marks appear on the rear facing surfaces of the tires at about the same height from the floor.
Page 95: Non-Lifted Front Suspension Components
STEERING AND FRONT SUSPENSION Non-Lifted Front Suspension Components Tighten the jams nuts on the bottom rod ends (3) to 81 ft·lb (110 N·m) (Figure 7-11, Page 7-9). NON-LIFTED FRONT SUSPENSION COMPONENTS See General Warnings on page 1-2. NON-LIFTED TIE ROD END REMOVAL Electric Vehicle: Disconnect the batteries and discharge the controller.
Page 96: Non-Lifted Leaf Spring Installation
Non-Lifted Front Suspension Components STEERING AND FRONT SUSPENSION Remove the bolts (8) from the bottom of each kingpin (7) (Figure 7-18, Page 7-15). Remove the four bolts (17) and bottom spring plate (16). Remove leaf spring (13). Check the condition of the urethane bushings (15) and steel sleeves (14). Replace any that are worn or damaged. NON-LIFTED LEAF SPRING INSTALLATION Install urethane bushings (15) and steel sleeves (14) into leaf spring eyes (Figure 7-18, Page 7-15).
Page 97: Non-Lifted Control Arm Removal
STEERING AND FRONT SUSPENSION Non-Lifted Front Suspension Components Install the steering spindle on the kingpin. Place upper clevis over the kingpin threads and install nut (1). Tighten the nut to 70 lb·ft (95 N·m). Attach the tie rod ends (12) to the spindle tabs, then install and tighten the nuts (14) to 70 lb·ft (95 N·m) (Figure 7-17, Page 7-14).
Page 98 Non-Lifted Front Suspension Components STEERING AND FRONT SUSPENSION 1311 Figure 7-17 Non-Lifted Upper Front Suspension Assembly Page 7-14 2018 Onward Maintenance and Service Manual...
Page 99 STEERING AND FRONT SUSPENSION Non-Lifted Front Suspension Components 1312 Figure 7-18 Non-Lifted Lower Front Suspension Assembly 2018 Onward Maintenance and Service Manual Page 7-15...
Page 100: Lifted Front Suspension Components
Lifted Front Suspension Components STEERING AND FRONT SUSPENSION LIFTED FRONT SUSPENSION COMPONENTS See General Warnings on page 1-2. LIFTED TIE ROD END REMOVAL Electric Vehicle: Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4. Gasoline Vehicle: Disconnect battery and spark plug wire(s).
Page 101 STEERING AND FRONT SUSPENSION Lifted Front Suspension Components Figure 7-19 Lifted Suspension Tie Rod / Control Arm 2018 Onward Maintenance and Service Manual Page 7-17...
Page 102: Lifted Leaf Spring Assembly Removal
Lifted Front Suspension Components STEERING AND FRONT SUSPENSION LIFTED LEAF SPRING ASSEMBLY REMOVAL Electric Vehicle: Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4. Gasoline Vehicle: Disconnect battery and spark plug wire(s). See Disconnecting the Battery- Gasoline Vehicles on page 1-3.
Page 103 STEERING AND FRONT SUSPENSION Lifted Front Suspension Components Figure 7-20 Front Leaf Spring Assembly 2018 Onward Maintenance and Service Manual Page 7-19...
Page 104: Lifted Spindle Removal
Lifted Front Suspension Components STEERING AND FRONT SUSPENSION Figure 7-21 Front Leaf Spring / Spindle Arm LIFTED SPINDLE REMOVAL Electric Vehicle: Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4. Gasoline Vehicle: Disconnect battery and spark plug wire(s). See Disconnecting the Battery- Gasoline Vehicles on page 1-3.
Page 105: Lifted Spindle Installation
STEERING AND FRONT SUSPENSION Lifted Front Suspension Components Remove the front hub. See Front Hub Removal on page 7-26. Remove the tie rod ends from the spindle (1) (Figure 7-22, Page 7-22). Remove the bolt (2) and the tapered washer (3) from the bottom of the spindle. Remove the bolt (4) and the tapered washer (5) from the top of the spindle.
Page 106: Lifted Control Arm Removal
Lifted Front Suspension Components STEERING AND FRONT SUSPENSION Figure 7-22 Lifted Vehicle Steering Spindle LIFTED CONTROL ARM REMOVAL Electric Vehicle: Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4. Gasoline Vehicle: Disconnect battery and spark plug wire(s). See Disconnecting the Battery- Gasoline Vehicles on page 1-3.
Page 107: Lifted Control Arm Installation
STEERING AND FRONT SUSPENSION Lifted Front Suspension Components Remove the wheel. Remove bolts (1) and move rack and pinion (2) to allow clearance for the bolt (3) (Figure 7-23, Page 7-23) and (Figure 7-24, Page 7-24). Remove the bolt (4) and tapered washer (5) from the top of the spindle (6) (Figure 7-24, Page 7-24). Remove the nut (7) and bolt (8).
Page 108: Lifted Shock Absorber Removal
Lifted Front Suspension Components STEERING AND FRONT SUSPENSION Figure 7-24 Lifted Suspension Control Arm LIFTED SHOCK ABSORBER REMOVAL Inspect the shock absorbers for fluid leakage at the point where the shaft enters the shock absorber body. Leaking shock absorbers should be replaced. Remove the upper bolt (1) (Figure 7-25, Page 7-25).
Page 109: Lifted Shock Absorber Installation
STEERING AND FRONT SUSPENSION Lifted Front Suspension Components LIFTED SHOCK ABSORBER INSTALLATION NOTE: When installing shock absorbers, make sure front shocks have identical part numbers. Install the shock absorber by reversing the removal procedure. Tighten the upper bolt to 29 lb·ft (39 N·m). Tighten the lower bolt to 29 lb·ft (39 N·m).
Page 110: Front Wheel Bearings And Hubs
Front Wheel Bearings and Hubs STEERING AND FRONT SUSPENSION FRONT WHEEL BEARINGS AND HUBS See General Warnings on page 1-2. 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. FRONT WHEEL FREE PLAY INSPECTION Electric Vehicle: Disconnect the batteries and discharge the controller.
Page 111 STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs Figure 7-26 Front Wheel Hub 2018 Onward Maintenance and Service Manual Page 7-27...
Page 112 Front Wheel Bearings and Hubs STEERING AND FRONT SUSPENSION Pagination Page Page 7-28 2018 Onward Maintenance and Service Manual...
Page 113: Section 8 - Wheels And Tires
SECTION 8 — WHEELS AND TIRES DANGER Wheels and Tires • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care. •...
Page 114: Tires
Tires WHEELS AND TIRES TIRES See General Warnings on page 1-2. TIRE REMOVAL NOTE: Tire must be removed or installed from the valve stem side of the rim. Remove the tire and wheel assembly from the vehicle as instructed above. Remove the valve cap and valve core and allow air to escape from the tire.
Page 115: Tire Installation
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 on page 8-2.
Page 116 Tires WHEELS AND TIRES Figure 8-2 Inflate Tire Page 8-4 2018 Onward Maintenance and Service Manual...
Page 117: Section 9 - Rear Suspension
SECTION 9 — REAR SUSPENSION DANGER Rear Suspension • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. 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.
Page 118: Shock Absorbers
Shock Absorbers REAR SUSPENSION Figure 9-1 Panhard and Bracket SHOCK ABSORBERS See General Warnings on page 1-2. SHOCK ABSORBER REMOVAL AND INSPECTION Check shock absorbers (7) for damage or fluid leakage at the point where the shaft enters the shock absorber body.
Page 119: Leaf Springs (Two-Passenger Vehicle)
REAR SUSPENSION Leaf Springs (Two-Passenger Vehicle) LEAF SPRINGS (TWO-PASSENGER VEHICLE) See General Warnings on page 1-2. LEAF SPRING REMOVAL (TWO-PASSENGER ELECTRIC VEHICLE) Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4. Loosen, but do not remove, lug nuts on tire and wheel assembly on the side from which the spring is to be removed.
Page 120 Leaf Springs (Two-Passenger Vehicle) REAR SUSPENSION Inspect the bushings (4) and sleeves (3) in the spring eyes and replace them if they are worn or damaged. Page 9-4 2018 Onward Maintenance and Service Manual...
Page 121 REAR SUSPENSION Leaf Springs (Two-Passenger Vehicle) 2689 Figure 9-4 Rear Suspension: Two-Passenger Electric Vehicle 2018 Onward Maintenance and Service Manual Page 9-5...
Page 122: Leaf Spring Installation (Two-Passenger Electric Vehicle)
Leaf Springs (Two-Passenger Vehicle) REAR SUSPENSION LEAF SPRING INSTALLATION (TWO-PASSENGER ELECTRIC VEHICLE) To install the springs, reverse the removal procedure. See following CAUTION. CAUTION • When positioning the spring on the transaxle, be sure to insert the locating bolt on the spring in the locating hole in the transaxle saddle.
Page 123 REAR SUSPENSION Leaf Springs (Two-Passenger Vehicle) Figure 9-5 Support Vehicle on Jack Stands Figure 9-6 Disconnect Brake Cable Remove the nut (5), cup washer (6), and rubber bushings (7) from the lower mounting stem of the shock absorber (Figure 9-7, Page 9-8). Remove the nuts (8) and the U-bolts (9) securing the leaf spring (10) to the transaxle.
Page 124: Leaf Spring Installation (Two-Passenger Gasoline Vehicle)
Leaf Springs (Two-Passenger Vehicle) REAR SUSPENSION Figure 9-7 Rear Suspension: Two-Passenger Non-Lifted Gasoline LEAF SPRING INSTALLATION (TWO-PASSENGER GASOLINE VEHICLE) To install the springs, reverse the removal procedure. See following CAUTION. Page 9-8 2018 Onward Maintenance and Service Manual...
Page 125: Leaf Springs (Four-Passenger Vehicle)
REAR SUSPENSION Leaf Springs (Four-Passenger Vehicle) 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. Tighten the nuts (8) on the U-bolts (9) to 45 lb·ft (60 N·m) (Figure 9-7, Page 9-8). Tighten the nuts (13 and 14) on spring mounting bolts (12 and 15) to 18.5 lb·ft (25 N·m) (Figure 9-7, Page 9-8).
Page 126 Leaf Springs (Four-Passenger Vehicle) REAR SUSPENSION Figure 9-8 Support Vehicle on Jack Stands Figure 9-9 Disconnect Brake Cable Remove the nut (5), cup washer (9), and rubber bushings (10) from the lower mounting stem of the shock absorber (Figure 9-10, Page 9-11). Remove the nuts (13) and the U-bolts (11) securing the spring and jounce bumper to the transaxle.
Page 127 REAR SUSPENSION Leaf Springs (Four-Passenger Vehicle) 2690 Figure 9-10 Rear Suspension: Non-Lifted Four-Passenger Electric Vehicle 2018 Onward Maintenance and Service Manual Page 9-11...
Page 128: Leaf Spring Installation (Non-Lifted Four-Passenger Electric Vehicle)
Leaf Springs (Four-Passenger Vehicle) REAR SUSPENSION LEAF SPRING INSTALLATION (NON-LIFTED FOUR-PASSENGER ELECTRIC VEHICLE) To install the springs, reverse the removal procedure. See following CAUTION. CAUTION • When positioning the spring on the transaxle, be sure to insert the locating bolt on the spring in the locating hole in the transaxle saddle.
Page 129 REAR SUSPENSION Leaf Springs (Four-Passenger Vehicle) Figure 9-11 Support Vehicle on Jack Stands Figure 9-12 Disconnect Brake Cable Remove the nut (5), cup washer (6), and rubber bushings (7) from the lower mounting stem of the shock absorber (Figure 9-13, Page 9-14). Remove the nuts (8) and the U-bolts (9) securing the leaf spring (10) to the transaxle.
Page 130: Leaf Spring Installation (Four-Passenger Gasoline Vehicle)
Leaf Springs (Four-Passenger Vehicle) REAR SUSPENSION Figure 9-13 Rear Suspension: Four-Passenger Non-Lifted Gasoline LEAF SPRING INSTALLATION (FOUR-PASSENGER GASOLINE VEHICLE) To install the springs, reverse the removal procedure. See following CAUTION. Page 9-14 2018 Onward Maintenance and Service Manual...
Page 131: Leaf Spring Removal (Lifted Four-Passenger Vehicle)
REAR SUSPENSION Leaf Springs (Four-Passenger Vehicle) 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. Tighten the nuts (8) on the U-bolts (9) to 45 lb·ft (60 N·m) (Figure 9-13, Page 9-14). Tighten the nuts (13 and 14) on spring mounting bolts (12 and 15) to 18.5 lb·ft (25 N·m) (Figure 9-13, Page 9-14).
Page 132 Leaf Springs (Four-Passenger Vehicle) REAR SUSPENSION Figure 9-14 Support Vehicle on Jack Stands Figure 9-15 Disconnect Brake Cable Remove the nut (5), cup washer (6), and rubber bushings (7) from the lower mounting stem of the shock absorber (Figure 9-16, Page 9-17). Remove the nuts (8) and the U-bolts (9) securing the leaf spring (10) and jounce bumper bracket (11) to the transaxle.
Page 133: Leaf Spring Installation (Lifted Four-Passenger Vehicle)
REAR SUSPENSION Leaf Springs (Four-Passenger Vehicle) Figure 9-16 Rear Suspension: Lifted Four-Passenger Vehicle LEAF SPRING INSTALLATION (LIFTED FOUR-PASSENGER VEHICLE) To install the springs, reverse the removal procedure. See following CAUTION. 2018 Onward Maintenance and Service Manual Page 9-17...
Page 134 Leaf Springs (Four-Passenger Vehicle) REAR SUSPENSION 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. Tighten the nuts (8) on the U-bolts (9) to 45 lb·ft (60 N·m) and tighten nuts (13 and 14) on spring mounting bolts (12 and 15) to 18.5 lb·ft (25 N·m) (Figure 9-16, Page 9-17).
Page 135: Section 10 - Periodic Maintenance
Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service. PRE-OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new vehicle(s), you should become familiar with its controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery.
Page 136: Performance Inspection
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 137: Maintenance
When the pedal is released it should return to the original position. All Club Car vehicles operate at reduced speed in reverse.
Page 138: Periodic Service Schedules
Periodic Service Schedules PERIODIC MAINTENANCE WARNING • Hot! Do not attempt to service hot engine or exhaust system. Failure to heed this warning could result in severe burns. • To avoid unintentionally starting the vehicle, disconnect battery and spark plug wire(s). See Disconnecting the Battery- Gasoline Vehicles on page 1-3.
Page 139 PERIODIC MAINTENANCE Periodic Service Schedules PERIODIC SERVICE SCHEDULE – ELECTRIC VEHICLES REGULAR INTERVAL SERVICE Monthly service by owner or trained Batteries (For vehicles equipped with the technician Single-Point Watering System). Water monthly Water the batteries. Observe that water flow or according to the established watering occurs and no water overflows from any cell.
Page 140 Periodic Service Schedules PERIODIC MAINTENANCE PERIODIC SERVICE SCHEDULE – SUBARU EX40 GASOLINE VEHICLES REGULAR INTERVAL SERVICE See Pre-Operation and Daily Safety Pre-Operation and Daily Safety Checklist Checklist on page 10-1. Daily service by owner Performance Inspection See Performance Inspection on page 10-2. Check engine oil level;...
Page 141 PERIODIC MAINTENANCE Periodic Service Schedules PERIODIC SERVICE SCHEDULE – SUBARU EX40 GASOLINE VEHICLES REGULAR INTERVAL SERVICE Check for leaks around gaskets, fill plugs, etc. Engine Inspect, clean and regap spark plug; replace if necessary. Check air filter element; replace if necessary. Engine air intake system Check clamps for tightness;...
Page 142: Periodic Lubrication Schedules
Periodic Lubrication Schedules PERIODIC MAINTENANCE PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE – NON-LIFTED ELECTRIC VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Charger receptacle WD-40 ® Semiannually by owner or Brake system, per maintenance and trained technician (every 50 Dry Moly Lube, white lithium grease NLGI #2 service manual.
Page 143 PERIODIC MAINTENANCE Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULE – NON-LIFTED SUBARU EX40 GASOLINE VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Shifter cable pivots Dry Moly Lube Semiannually by owner or Brake system, per maintenance and trained technician (every 50 Dry Moly Lube, white lithium grease NLGI #2 service manual.
Page 144 Periodic Lubrication Schedules PERIODIC MAINTENANCE PERIODIC LUBRICATION SCHEDULE – LIFTED ELECTRIC VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Charger receptacle WD-40 ® Semiannually by owner or trained technician (every 50 Brake system, per maintenance and Dry Moly Lube, white lithium grease NLGI #2 hours of operation) service manual.
Page 145 PERIODIC MAINTENANCE Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULE – LIFTED SUBARU EX40 GASOLINE VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Shifter cable pivots Dry Moly Lube Semiannually by owner or trained technician (every 50 Brake system, per maintenance and Dry Moly Lube, white lithium grease NLGI #2 hours of operation) service manual.
Page 146 Periodic Lubrication Schedules PERIODIC MAINTENANCE Pagination Page Page 10-12 2018 Onward Maintenance and Service Manual...
Page 147: Section 11 - Controller Diagnostic Tool (Cdt)
SECTION 11 — CONTROLLER DIAGNOSTIC TOOL (CDT) DANGER Controller Diagnostic Tool (CDT) • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. NOTE: The information presented in this section addresses the following: • The Controller Diagnostic Tool (CDT) handheld programmer which replaced the IQDM series 2 handset. •...
Page 148: General Information
General Information CONTROLLER DIAGNOSTIC TOOL (CDT) GENERAL INFORMATION The CDT is used to adjust and save parameter settings of the controller, monitor real-time data, and perform diagnostics and troubleshooting of the electric vehicle. FEATURES • Batteries: Two AA batteries provide power for the CDT’s real-time clock and they allow for use of the CDT when not connected to a vehicle.
Page 149: Plugging The Cdt Into The Vehicle
CONTROLLER DIAGNOSTIC TOOL (CDT) Plugging the CDT into the Vehicle PLUGGING THE CDT INTO THE VEHICLE Figure 11-2 Communication Port Under Instrument Panel Connect one end of the cable to the port located on the bottom of the CDT. Connect the cable adaptor to the CDT cable. Find the communication port on the vehicle (Figure 11-2, Page 11-3).
Page 150: Quick Reference Guide - Excel With Eric Charging System
Quick Reference Guide – Excel with ERIC Charging System CONTROLLER DIAGNOSTIC TOOL (CDT) QUICK REFERENCE GUIDE – EXCEL WITH ERIC CHARGING SYSTEM OPERATION: Change screen contrast for better viewing by selecting the following: HPP Settings, Backlight Preset Favorites: Select a frequently viewed screen, press “Add to” softkey, highlight “Favorites”, press “Select” softkey. CONTROLLER FAULTS: Anti Tamper: If car is not equipped with Visage, make sure Control Main Driver Off: Replace controller.
Page 151: System Info
CONTROLLER DIAGNOSTIC TOOL (CDT) System Info SYSTEM INFO The System Info menu is accessed by using the arrow keys to highlight System Info and pressing the Select softkey to activate the menu. The System Info selection displays information pertaining to the controller. The information provided from this menu selection includes: MODEL NUMBER Displays the model number of the controller.
Page 152: Parameters
Parameters CONTROLLER DIAGNOSTIC TOOL (CDT) PARAMETERS The Parameters menu is accessed by using the arrow keys to highlight Parameters and pressing the Select softkey to activate the menu. The Parameters menu is where you can view and modify the settings of the controller's adjustable parameters. Navigate through this complex menu using the arrow keys, +/- keys, and softkeys.
Page 153 CONTROLLER DIAGNOSTIC TOOL (CDT) Parameters When going down an incline with the accelerator pedal partially pressed, the motor braking function will activate to assist the operator in maintaining a speed less than the top speed setting. For example, if the vehicle is going down an incline with the accelerator pedal pressed half way, the motor braking function will activate to assist the operator in maintaining a speed approximately half of the speed setting defined in the Program Menu.
Page 154: Amp Hours
Parameters CONTROLLER DIAGNOSTIC TOOL (CDT) Anti-Tamper The anti-tamper setting defines maximum speed if the Anti-Tamper fault is triggered (e.g. controller is disconnected from the Guardian or Visage system). These speeds can only be activated if the Control Mode option is set to 1 (Guardian/Visage) and are intended to be a deterrent.
Page 155: Vehicle Id
15 mph (24.1 km/h). For more information on this feature, contact your local Club Car distributor or dealer. NOTE: If controller is replaced, the information below must be entered into the new controller. See Speed Controller Installation, Section 13, Page 13-12.
Page 156: Batt Voltage
Monitor Menu CONTROLLER DIAGNOSTIC TOOL (CDT) Since the Monitor menu is updated while the vehicle is in operation, the trained technician has the ability to monitor the status of several components in conditions or locations where a problem with vehicle performance has been reported.
Page 157: Armature Pwm
CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu ARMATURE PWM Displays motor armature PWM (pulse width modulation). The range of pulse width modulation is 0% to 100%. When the vehicle is operating at full speed, the pulse width modulation should be at 100%. FIELD PWM Displays motor field PWM (pulse width modulation).
Page 158: Password Tries (Oem Access Level Only)
“private speed mode”. In the event that “private speed mode” is locked out, the controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 11-8.
Page 159: Amp Hours Display
CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu AMP HOURS DISPLAY Signed Battery Current While driving the vehicle, this displays either the current being pulled out of the batteries or the current being returned to the batteries during regenerative motor braking. It has a range from negative (–) 300 amps to positive (+) 300 amps. Amp Hours Displays total accumulated amp hours removed from batteries since initial vehicle start-up.
Page 160: Diagnostics Menu
Diagnostics Menu CONTROLLER DIAGNOSTIC TOOL (CDT) DIAGNOSTICS MENU CAUTION • A failed motor will damage the controller. Always inspect the motor before replacing the controller. See External Motor Testing, Section 16, Page 16-1. NOTE: The software is subject to frequent updates, and this manual may span many versions. Be aware that some faults listed in this manual may not display in the CDT, indicating older software.
Page 161: Causes Of Faults
CONTROLLER DIAGNOSTIC TOOL (CDT) Diagnostics Menu CAUSES OF FAULTS Some common causes of faults are: • Loose, broken, or disconnected wires or connectors • Failed components • Improper adjustment or installation of electrical or mechanical components (examples: brake adjustment, improper MCOR installation) •...
Page 162 Diagnostics Menu CONTROLLER DIAGNOSTIC TOOL (CDT) CONTROLLER FAULT CONTROLLER RESPONSE VEHICLE RESPONSE HW FAILSAFE A, B, C Vehicle comes to a stop THROTTLE FAULT A, C Vehicle comes to a stop SPEED SENSOR Vehicle runs at slow speed MAIN WELDED Vehicle runs at slow speed MAIN DRIVER ON A, B...
Page 163: Fault Recovery
CONTROLLER DIAGNOSTIC TOOL (CDT) Diagnostics Menu FAULT RECOVERY When a fault is detected by the controller, the controller will attempt to recover from the fault and resume normal operation. In the case of an intermittent problem, such as a loose wiring connection, the controller may be able to recover and operate normally for a while, but the problem should be repaired before placing the vehicle in service.
Page 164: Fault Descriptions
The max password tries fault is declared when the incorrect password fault has been declared several times. In the event that the max password tries fault is indicated, the speed controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 11-8. See also Password Tries (OEM Access Level Only) on page 11-12.
Page 165: Thermal Cutback
CONTROLLER DIAGNOSTIC TOOL (CDT) Fault Descriptions THERMAL CUTBACK If the controller heatsink temperature is found to be in excess of 185 °F (±9) (85 °C (±5)) or below –13 °F (±9) (–25 °C (±5)), the thermal cutback fault is detected. What it means: Heatsink temperature rises above 185 °F (85 °C).
Page 166: Main Welded
Fault Descriptions CONTROLLER DIAGNOSTIC TOOL (CDT) What it means: This is a symptom, not a cause. The controller records the number of times this occurs. What to do: Charge batteries. If fault occurs more frequently than normal, test battery pack. Section 14 — Batteries: Electric Vehicle MAIN WELDED If the speed controller detects that the solenoid contacts are welded closed, a main welded fault is detected.
Page 167: Main Dropout (1 Or 2)
CONTROLLER DIAGNOSTIC TOOL (CDT) Fault Descriptions large solenoids should read 180 to 190 ohms; small solenoids 200 to 250 ohms), a broken blue/white wire at the 16-pin controller plug or its terminal is loose in the 16-pin plug. MAIN DROPOUT (1 OR 2) If the controller detects that the solenoid contacts have opened while the vehicle is in operation, a main dropout fault is detected.
Page 168: Fld (Field) Missing
Programming CONTROLLER DIAGNOSTIC TOOL (CDT) FLD (FIELD) MISSING If the speed controller is operating at a duty cycle of greater than 90% (almost full speed) and the field current is less than 3 amps, a field missing fault is detected by the speed controller. CAUTION •...
Page 169: Cloning
CONTROLLER DIAGNOSTIC TOOL (CDT) Favorites CLONING Use the “Restore .cpf File” function to clone a controller with a saved .cpf file stored in the CDT. If using an OEM-level CDT, after you highlight a stored .cpf file and choose “Restore,” a pop-up window will ask whether you want to enable Advanced Cloning (“Yes”/“No”) using the softkeys.
Page 170 HHP Settings CONTROLLER DIAGNOSTIC TOOL (CDT) MENU ITEM DESCRIPTIONS Keytone You can choose between several tones to sound each time you press a key, or you can turn the keytone Off for silent programmer operation. Auto Poweroff (battery) You can set the idle time before the programmer will automatically power off when it is powered by its own batteries (i.e., when the control system is not running, or when the programmer is not connected to the control system).
Page 171: Plot & Log
CONTROLLER DIAGNOSTIC TOOL (CDT) Plot & Log PLOT & LOG The Plot & Log menu selection allows the user, with the Plot program, to plot real-time variables on the CDT display screen; or, with the Log program, to create a log file of variable values to view later in a spreadsheet program on a PC. The first step is to add the desired items to the Plot Variable List or the Log Variable List.
Page 172: Cdt Troubleshooting
CDT Troubleshooting CONTROLLER DIAGNOSTIC TOOL (CDT) CDT TROUBLESHOOTING In the event that the handset does not function as described in this manual, the following troubleshooting guide should be studied and the referenced test procedures should be performed to troubleshoot the handset. TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES...
Page 173: Connection Tests
CONTROLLER DIAGNOSTIC TOOL (CDT) Connection Tests TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Disconnect the CDT cord from the vehicle. Handset malfunction Wait a few seconds and reconnect the handset to the vehicle Vehicle batteries – loose terminals or corrosion Section 14 —...
Page 174 Connection Tests CONTROLLER DIAGNOSTIC TOOL (CDT) The multimeter should indicate continuity on only one pin. If any other reading is obtained, the adaptor must be replaced. Repeat the procedure three more times, each time with the red (+) probe inserted into a different terminal on the end of the adaptor with the square plug.
Page 175 CONTROLLER DIAGNOSTIC TOOL (CDT) Connection Tests 4.3.2. Connect the handset cord to the handset. 4.3.3. Connect the other end of the handset cord (without the adapter) (4) to the four-pin connector of the controller (2) (Figure 11-4, Page 11-29). 4.3.4. Connect the vehicle batteries, positive (+) cable first.
Page 176 Connection Tests CONTROLLER DIAGNOSTIC TOOL (CDT) Pagination Page Page 11-30 2018 Onward Maintenance and Service Manual...
Page 177: Section 12 - Excel System Troubleshooting
SECTION 12 — EXCEL SYSTEM TROUBLESHOOTING DANGER Excel System Troubleshooting • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. • Shorting of battery terminals can cause personal injury or death. – Do not place component mounting plate directly on top of batteries when removing or installing plate.
Page 178: Excel With Eric Charging System
General Information EXCEL SYSTEM TROUBLESHOOTING • The Excel accelerator pedal has more control of downhill speed. • The programmed speed of the Excel vehicle can now range from 5 to 19.2 mph (8 to 30.8 kph) with fine adjustments in 0.1 mph (0.16 kph) increments. •...
Page 179 EXCEL SYSTEM TROUBLESHOOTING General Information • Motor Braking: When going down an incline with the accelerator pedal partially pressed, the motor braking function will activate to assist the operator in maintaining a speed less than the speed setting. For example, if the vehicle is going down an incline with the accelerator pedal pressed half way, the motor braking function will activate to assist the operator in maintaining a speed approximately half of the speed setting defined in the Program Menu.
Page 180: Wiring Diagrams
Wiring Diagrams EXCEL SYSTEM TROUBLESHOOTING WIRING DIAGRAMS WD1040232_DGM_B-LA Figure 12-1 Main Harness – Excel System with ERIC Charging Page 12-4 2018 Onward Maintenance and Service Manual...
Page 181 EXCEL SYSTEM TROUBLESHOOTING Wiring Diagrams WD1040232_DGM_B-RA Figure 12-2 Main Harness – Excel System with ERIC Charging (Continued) 2018 Onward Maintenance and Service Manual Page 12-5...
Page 182 Wiring Diagrams EXCEL SYSTEM TROUBLESHOOTING WD1039915_DGM_C1 Figure 12-3 Instrument Panel Dash Harness – with ERIC Charging Page 12-6 2018 Onward Maintenance and Service Manual...
Page 183 EXCEL SYSTEM TROUBLESHOOTING Wiring Diagrams Figure 12-4 Light Harness – with ERIC Charging 2018 Onward Maintenance and Service Manual Page 12-7...
Page 184 Wiring Diagrams EXCEL SYSTEM TROUBLESHOOTING Figure 12-5 Instrument Panel Light Harness – with ERIC Charging Page 12-8 2018 Onward Maintenance and Service Manual...
Page 185 EXCEL SYSTEM TROUBLESHOOTING Wiring Diagrams Figure 12-6 Instrument Panel Light Harness – with ERIC Charging (Continued) 2018 Onward Maintenance and Service Manual Page 12-9...
Page 186 Wiring Diagrams EXCEL SYSTEM TROUBLESHOOTING WD_6x8V_Batteries_ERIC_Charging Figure 12-7 Battery Wiring Diagram – with ERIC Charging Page 12-10 2018 Onward Maintenance and Service Manual...
Page 187 EXCEL SYSTEM TROUBLESHOOTING Wiring Diagrams 2783 Figure 12-8 Sonic Weld and 10k Ohm Resistor Locations (Approximate) 2018 Onward Maintenance and Service Manual Page 12-11...
Page 188: Instrument Panel Light Harness - With Eric Charging
Troubleshooting EXCEL SYSTEM TROUBLESHOOTING INSTRUMENT PANEL LIGHT HARNESS – WITH ERIC CHARGING Lighting Connector Pinout (Left and Right) Refer to the instrument panel light harness diagram (Figure 12-5, Page 12-8). DESCRIPTION Head Light Accent/Logo Light Turn Signal Ground Visage Strut Harness Connector Pinout Refer to the instrument panel light harness diagram (Figure 12-6, Page 12-9).
Page 189: Troubleshooting The Vehicle With The Cdt
TROUBLESHOOTING THE VEHICLE WITH THE CDT Club Car recommends the use of the CDT handset for troubleshooting vehicles equipped with the Excel electrical system. Troubleshooting Guide 1 is to be used in conjunction with the CDT handset. See Controller Diagnostic Tool (CDT) on page 11-1 for operating instructions.
Page 190 Troubleshooting EXCEL SYSTEM TROUBLESHOOTING TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected two-pin connector at Repair and/or connect the two-pin connector the MCOR or broken wire to the MCOR Monitor Menu – FOOT INPUT menu item Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector indicates that the MCOR internal limit switch is speed controller or broken wire...
Page 191 EXCEL SYSTEM TROUBLESHOOTING Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Armature drive FETs (field-effect transistors) Replace the speed controller. See Speed inside speed controller have failed Controller Removal on page 13-12. Disconnect the batteries and allow the Diagnostic Menu – HW FAILSAFE (Hardware speed controller capacitors to discharge.
Page 192: Troubleshooting Guide 2
Troubleshooting EXCEL SYSTEM TROUBLESHOOTING TROUBLESHOOTING GUIDE 2 In the event that the vehicle is not functioning properly after completing Troubleshooting Guide 1, use Troubleshooting Guide 2. If an CDT handset is unavailable, use Troubleshooting Guide 2. Page 12-16 2018 Onward Maintenance and Service Manual...
Page 193 EXCEL SYSTEM TROUBLESHOOTING Troubleshooting TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Batteries – batteries discharged Charge batteries Check vehicle wiring. See Wiring Diagrams Batteries – battery connections on page 12-4. Battery charger is connected to the vehicle Disconnect the battery charger from the –...
Page 194 Troubleshooting EXCEL SYSTEM TROUBLESHOOTING TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Procedure 12 – Motor Speed Sensor on Speed sensor disconnected or failed page 12-32 To change the programmed top speed of the Incorrect speed setting vehicle, an CDT handset must be used Check vehicle wiring.
Page 195: Test Procedures
EXCEL SYSTEM TROUBLESHOOTING Test Procedures TEST PROCEDURES Using the following procedures, the entire electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
Page 196 Test Procedures EXCEL SYSTEM TROUBLESHOOTING CAUTION • Be careful not to damage the wire or terminal when back-probing. • When testing voltage, the batteries must remain connected. • When testing voltage, unless specifically directed to do otherwise in a procedure, connect the black (–) probe of the multimeter to the negative post of battery no.
Page 197 EXCEL SYSTEM TROUBLESHOOTING Test Procedures Access the Monitor menu and select BATT VOLTAGE by using the SCROLL DISPLAY buttons. The CDT should indicate at least 48 volts. See following NOTE. If not, check for loose battery connections or a battery installed in reverse polarity.
Page 198 Test Procedures EXCEL SYSTEM TROUBLESHOOTING (Viewed from driver side of vehicle) 1. RED probe to battery no. 1 (+). 2. BLACK probe to battery no. 6 (-). 2500-30100-10411 Figure 12-10 Battery Discharge Test Turn the discharge machine on and record the voltage reading of battery pack while under load. A fully charged set of batteries in good condition should read between 46 and 49 volts while under load.
Page 199 EXCEL SYSTEM TROUBLESHOOTING Test Procedures If the CDT display screen begins to work, proceed to step 5; otherwise, perform the following procedure, Tow/Run Switch Test without the CDT Handset. With the CDT still connected to vehicle, place Tow/Run Switch in TOW position. If the CDT display screen goes blank, the Tow/Run switch and connecting wires are operating correctly.
Page 200 Test Procedures EXCEL SYSTEM TROUBLESHOOTING 3.3. If the red wire side does not show BPV, replace fuse. 3.4. If the pink wire side does not show BPV, make sure Tow/Run switch in the RUN position. If it is in RUN, inspect Tow/Run switch, red-to-pink wire spade connector near the solenoid, and sonic welds 5 and 8.
Page 201 EXCEL SYSTEM TROUBLESHOOTING Test Procedures Pin 6 Green Wire: Access the controller by removing the access panel in the rear body. See following NOTE. NOTE: The easiest way to test the key switch and MCOR Limit Switch is to check the pin 6 green wire in the 16-pin connector.
Page 202 Test Procedures EXCEL SYSTEM TROUBLESHOOTING 3.2. Place the Forward/Reverse switch in the FORWARD position. The CDT should indicate that FORWARD INPUT is ON. If the CDT indicates any other reading, check vehicle wiring. See Wiring Diagrams on page 12-4. Also check the 16-pin connector at the speed controller. See Test Procedure 15 – 16-Pin Connector on page 12-35.
Page 203 EXCEL SYSTEM TROUBLESHOOTING Test Procedures TEST PROCEDURE 7 – Solenoid Activating Coil See General Warnings on page 1-2. NOTE: This is a resistance test. Be aware that one of two different solenoids may be found on the vehicle. Visually, the production solenoid is smaller than the service replacement.
Page 204 Test Procedures EXCEL SYSTEM TROUBLESHOOTING Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. TEST PROCEDURE 9 – Solenoid Continuity See General Warnings on page 1-2. Solenoid Continuity Test with the CDT Handset If necessary, see Testing Basics on page 12-19.
Page 205 EXCEL SYSTEM TROUBLESHOOTING Test Procedures Place the Tow/Run switch in the RUN position, turn the key switch to the ON position, place the Forward/Reverse rocker switch in the FORWARD position, and press the accelerator pedal. The rear tire should rotate and the multimeter should show a change in resistance.
Page 206 Test Procedures EXCEL SYSTEM TROUBLESHOOTING If the meter does not indicate continuity, check and repair related connections, Tow/Run switch and wiring. If necessary, replace affected wire harness, charger receptacle or Tow/Run switch. When finished, install 15-amp fuse and fuse cover. TEST PROCEDURE 11 –...
Page 207 EXCEL SYSTEM TROUBLESHOOTING Test Procedures WARNING • The key switch should be placed in the OFF position and left in the OFF position for the duration of this test. With the batteries connected, place Tow/Run switch in RUN. Using a multimeter set to 200 volts DC, place red (+) probe on battery no.
Page 208 Test Procedures EXCEL SYSTEM TROUBLESHOOTING TEST PROCEDURE 12 – Motor Speed Sensor See General Warnings on page 1-2. Motor Speed Sensor Test without any Tool CAUTION • Perform the following procedure only on a level surface. To avoid injury or property damage, ensure that the path of the vehicle is clear before pushing vehicle.
Page 209 EXCEL SYSTEM TROUBLESHOOTING Test Procedures 4.1. With Tow/Run switch in the RUN position and using a multimeter set to 20 volts DC, place the black (–) probe on the battery no. 6 (6 x 8-Volt battery set) negative post and place red (+) probe on red wire terminal socket in three-pin connector.
Page 210 Test Procedures EXCEL SYSTEM TROUBLESHOOTING As the accelerator pedal is pressed, the voltage reading should increase from approximately 5 volts RMS when the MCOR limit switch closes, to approximately 48 volts RMS with the accelerator pedal fully pressed. See following NOTE. NOTE: Voltage can vary depending on controller speed setting as well as which zone a Guardian equipped vehicle is located.
Page 211 EXCEL SYSTEM TROUBLESHOOTING Test Procedures TEST PROCEDURE 15 – 16-Pin Connector See General Warnings on page 1-2. Pin 1 – White Pin 5 – Light Blue Pin 9 – Gray Pin 13 – White/Black Pin 2 – Yellow Pin 6 – Green Pin 10 –...
Page 212 Test Procedures EXCEL SYSTEM TROUBLESHOOTING If 16-pin must be disconnected: Keep the 16-pin connector disconnected from the controller. With Tow/Run switch in the TOW position, reconnect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. Place the Tow/Run switch in the RUN position and then check the appropriate wires. If 16-pin must be connected: Disconnect the batteries and discharge the controller.
Page 213 EXCEL SYSTEM TROUBLESHOOTING Test Procedures PERFORM TEST WITH 16-PIN CONTROLLER INPUTS CONNECTED TO CONTROLLER? (IF TEST PROCEDURE YES, BACK-PROBE TO TEST) FORWARD INPUT BPV from Forward/Reverse switch in FWD Pin 8 – Brown (Key switch either ON or OFF) B+ INPUT Pin 9 –...
Page 214 Test Procedures EXCEL SYSTEM TROUBLESHOOTING If necessary, see Testing Basics on page 12-19. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4. Remove the instrument panel. See Key Switch Removal, Section 13, Page 13-1. Disconnect the orange/white and pink wires from the reverse buzzer.
Page 215 EXCEL SYSTEM TROUBLESHOOTING Test Procedures – Condition of the 9-pin connector behind instrument panel. – Condition of the yellow/green wire terminal in the instrument panel wire harness. – Continuity of the wires in the wire harnesses. If no problems exist in the above items, replace the charge indicator light. TEST PROCEDURE 18 –...
Page 216 Test Procedures EXCEL SYSTEM TROUBLESHOOTING Pagination Page Page 12-40 2018 Onward Maintenance and Service Manual...
Page 217: Section 13 - Electrical Components: Electric Vehicle
SECTION 13 — ELECTRICAL COMPONENTS: ELECTRIC VEHICLE DANGER Electrical Components: Electric Vehicle • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. KEY SWITCH See General Warnings on page 1-2. TESTING THE KEY SWITCH See the appropriate troubleshooting section for the type of electrical system used in the vehicle. See Test Procedure 5 –...
Page 218: Charge Indicator Light
ELECTRICAL COMPONENTS: ELECTRIC Charge Indicator Light VEHICLE Figure 13-1 Instrument Panel Removal Figure 13-2 Key Switch CHARGE INDICATOR LIGHT See General Warnings on page 1-2. TESTING THE CHARGE INDICATOR LIGHT See Test Procedure 17 – Charge Indicator Light on page 12-38. CHARGE INDICATOR LIGHT REMOVAL Disconnect the batteries and discharge the controller.
Page 219: Usb Port
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE USB Port 2787 Figure 13-3 Charge Indicator Light USB PORT The 5–volt 3 amp USB port (Figure 13-4) provides electricity to power and recharge portable devices. The USB port is not designed for the transfer of data. Figure 13-4 USB Port USB PORT REMOVAL Remove the instrument panel to access the USB port wires and lock tabs (Figure 13-5, Page 13-4).
Page 220: Usb Port Installation
ELECTRICAL COMPONENTS: ELECTRIC Forward/Reverse Rocker Switch VEHICLE Figure 13-5 USB Port Removal (Electric) Figure 13-6 USB Port Installation (Electric) USB PORT INSTALLATION Put the USB port wires into the dash. Push the USB port into the dash. Connect the red instrument panel wire to the red USB port wire (1) (Figure 13-6, Page 13-4). Connect the black instrument panel wire to the black USB port wire (2).
Page 221: Forward/Reverse Rocker Switch Installation
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE Forward/Reverse Rocker Switch Figure 13-7 Forward/Reverse Rocker Switch FORWARD/REVERSE ROCKER SWITCH INSTALLATION Route the three wires through bezel. Connect the blue (4), orange (5) and brown (6) wires to the rocker switch (3), exactly as shown in (Figure 13-7, Page 13-5). Orient the rocker switch (3) so the terminals are towards the front of the housing (1).
Page 222: Electronics Module Cover
ELECTRICAL COMPONENTS: ELECTRIC Electronics Module Cover VEHICLE ELECTRONICS MODULE COVER See General Warnings on page 1-2. The electronics module cover needs to be removed to gain access to the speed controller, Tow/Run switch, and solenoid. ELECTRONICS MODULE COVER REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4.
Page 223: Tow/Run Switch
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE Tow/Run Switch Figure 13-8 Access and Remove Electronics Module Cover TOW/RUN SWITCH See General Warnings on page 1-2. TESTING THE TOW/RUN SWITCH See Test Procedure 3 – Tow/Run Switch on page 12-22. TOW/RUN SWITCH REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4.
Page 224: Motor Controller Output Regulator (Mcor)
ELECTRICAL COMPONENTS: ELECTRIC Motor Controller Output Regulator (MCOR) VEHICLE Figure 13-9 Tow/Run Switch MOTOR CONTROLLER OUTPUT REGULATOR (MCOR) See General Warnings on page 1-2. TESTING THE MCOR See Test Procedure 11 – MCOR Voltage on page 12-30 and Test Procedure 5 – Key Switch and MCOR Limit Switch Circuit on page 12-24.
Page 225: Reverse Buzzer
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE Reverse Buzzer REVERSE BUZZER See General Warnings on page 1-2. TESTING THE REVERSE BUZZER See 12-37. REVERSE BUZZER REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4. Remove instrument panel.
Page 226: Electronics Module
ELECTRICAL COMPONENTS: ELECTRIC Electronics Module VEHICLE ELECTRONICS MODULE See General Warnings on page 1-2. While it is not necessary to remove the electronics module from the vehicle, access to individual components may be easier with the module removed. ELECTRONICS MODULE REMOVAL Disconnect the batteries and discharge the controller (1).
Page 227: Electronics Module Installation
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE Electronics Module 2771 Figure 13-11 Controller and Solenoid Removal ELECTRONICS MODULE INSTALLATION Return electronics module (3) to its location in vehicle but leave it tilted forward. Complete connections to the controller (1), the Tow/Run switch (5) and the solenoid (4) per the electrical schematics.
Page 228: Speed Controller
ELECTRICAL COMPONENTS: ELECTRIC Speed Controller VEHICLE Set electronics module in place and secure with bolt (2) (Figure 13-11, Page 13-11). Tighten bolt to 40 lb·in (4.5 N·m). Install the batteries and battery cables in their original locations. See Battery Replacement on page 14-5. Place the Tow/Run switch (5) in the TOW position and connect the batteries.
Page 229: Solenoid
Select Program, Vehicle ID, Vehicle Date of Manufacture and enter the number on the model year and week from the vehicle serial number. 7.7. Select Information, Software Version and verify the value is 13 or higher. If not, contact a Club Car Technical Representative. 7.8.
Page 230: Solenoid Installation
ELECTRICAL COMPONENTS: ELECTRIC Charger Receptacle VEHICLE Disconnect the heavy gauge wires from the solenoid (4) by removing the nuts (7) and washers (10) (Figure 13-11, Page 13-11). Disconnect the spade connectors from the solenoid (4). Slide solenoid (4) up to disengage the mounting tabs and remove from mounting plate. SOLENOID INSTALLATION Slide solenoid (4) into mounting plate (Figure 13-11, Page 13-11).
Page 231: Charger Receptacle Installation
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE Charger Receptacle CHARGER RECEPTACLE INSTALLATION Insert the wires through the hole in the bucket. Insert receptacle (2) into bucket. Install the three screws (1) that secure the receptacle to the bucket. Tighten screws to 16 lb·in (1.8 N·m). Connect 10-gauge red wire to solenoid.
Page 232 ELECTRICAL COMPONENTS: ELECTRIC Charger Receptacle VEHICLE Pagination Page Page 13-16 2018 Onward Maintenance and Service Manual...
Page 233: Section 14 - Batteries: Electric Vehicle
SECTION 14 — BATTERIES: ELECTRIC VEHICLE DANGER Batteries: Electric Vehicle • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area.
Page 234: Battery Testing Basics - 8 Volt
Battery Testing Basics – 8 Volt BATTERIES: ELECTRIC VEHICLE BATTERY TESTING BASICS – 8 VOLT See General Warnings on page 1-2. OBSERVATION Inspect the battery compartment for the following items: • Rusted, corroded, or broken battery posts • Rusted, corroded, loose or broken wires •...
Page 235: Battery Testing - 8 Volt
Regrouping is now Club Car’s standard battery replacement method. Regrouping is the practice of placing batteries of similar condition together in one vehicle. For example, if there was an issue with the batteries in two cars and the battery test indicated three failed batteries in each car, after removing the failed batteries, there will be six good batteries remaining.
Page 236 Battery Regrouping BATTERIES: ELECTRIC VEHICLE 3104 Figure 14-2 Battery Regrouping Process Flow Page 14-4 2018 Onward Maintenance and Service Manual...
Page 237: Battery Replacement
BATTERIES: ELECTRIC VEHICLE Battery Replacement BATTERY REPLACEMENT See General Warnings on page 1-2. WARNING • Wear steel-toe shoes when replacing batteries. • To prevent electrolyte leakage from the battery vents, batteries must be kept in an upright position. Tipping a battery beyond a 45° angle in any direction can allow a small amount of electrolyte to leak out the vent hole.
Page 238: Battery Care
See General Warnings on page 1-2. WATER QUALITY Water purity is the most important factor in the performance and life span of the vehicle batteries. Club Car is, therefore, placing increased importance on battery water quality. Outlined below are four battery watering procedures, grouped into two categories: Preferred and Alternate methods.
Page 239: Battery Care - Vehicles Equipped With The Optional Single-Point Watering System (Spws)
BATTERIES: ELECTRIC VEHICLE Battery Care ALLOWABLE CONTENT (PARTS IMPURITY EFFECTS OF IMPURITY PER MILLION) Increased self-discharge, lower Copper on-charge voltage Increased self-discharge, lower Iron on-charge voltage Magnesium 40.0 Reduced life Nickel None allowed Intense lowering of on-charge voltage Nitrates 10.0 Increased sulfation of negative plate Nitrites Plate corrosion, loss of capacity, reduced life...
Page 240: Battery Care - Vehicles Without The Single-Point Watering System (Spws)
• Do not overfill the batteries. NOTE: A battery watering gun or bottle is available from your authorized Club Car dealer. The battery hold-downs should be tight enough so that the batteries do not move while the vehicle is in motion, but not so tight as to crack or buckle the battery case.
Page 241: Self-Discharge
BATTERIES: ELECTRIC VEHICLE Battery Care After use, charge the batteries. The batteries should never be left discharged any longer than absolutely necessary (do not leave discharged overnight). SELF-DISCHARGE Contaminants on dirty batteries can provide a path for a small current draw that can slowly discharge batteries, thus wasting valuable energy.
Page 242: Vibration Damage
• Water the batteries only AFTER charging. • Use water that meets the quality standards shown on page 14-6. Bottled distilled water, with hand pump, Club Car Part Number 104006101, is recommended for private consumer applications. INITIAL MAINTENANCE OF THE SPWS After six weeks of operation, remove the valves from the batteries and manually check the battery water level to ensure that the SPWS is not leaving any cells dry.
Page 243: Battery Storage
BATTERIES: ELECTRIC VEHICLE Battery Storage BATTERY STORAGE DEEP-DISCHARGE Never discharge batteries to the point the vehicle will no longer operate. This will considerably shorten the cycle life of the batteries, and may permanently damage the batteries. It is possible the batteries will not accept a charge if they are completely discharged.
Page 244 Early Excessive Discharging BATTERIES: ELECTRIC VEHICLE Pagination Page Page 14-12 2018 Onward Maintenance and Service Manual...
Page 245: Section 15 - Eric Battery Charger
2%. Make sure proper ventilation is used when charging batteries. WARNING • Only trained technicians should repair or service the charger. Contact your nearest Club Car distributor/dealer. • This appliance 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 appliance by a person responsible for their safety.
Page 246: General Information
Club Car only recommends OEM replacement batteries. Contact your authorized Club Car dealer/distributor with any questions about battery and charger compatibility or algorithm updates.
Page 247: Usb Service Port
USB SERVICE PORT The ERIC charger has a USB port for use by Club Car authorized technicians for data transfer, reconfiguration, and updates. Keep the USB port cover in place when the port is not in use. See USB Service Port Cleaning and Care on page 15-14.
Page 248: Charger Power Connection Fuse
General Information ERIC BATTERY CHARGER cleaner or light coating of WD-40 ® brand spray lubricant. The plug should then be inserted and removed several times to ensure ease of insertion, ease of removal, and good electrical contact. DANGER • To prevent fire, immediately replace battery charger DC cord plug and receptacle if the following conditions exist: –...
Page 249: External Charger Status Indicators
ERIC BATTERY CHARGER General Information Charging Confirmation • The light will flash three times and the reverse buzzer simultaneously will sound three times to indicate a battery charging session has begun. See following NOTE. NOTE: The number of flashes and beeps can vary depending on the Beep Option setting. See Beep Option, Section 11, Page 11-8.
Page 250 General Information ERIC BATTERY CHARGER LIGHT STATUS STATUS EXPLANATION Solid red Charger fault. See the display panel for details. Flashing orange External error condition - caution. See the display panel for details. Flashing green USB port is active. Solid green Safe to remove the USB flash drive.
Page 251: Long-Term Storage
ERIC BATTERY CHARGER General Information LONG-TERM STORAGE High-frequency chargers are designed to be left connected with AC power to the charger during off-season or long-term storage. 2018 Onward Maintenance and Service Manual Page 15-7...
Page 252: External Charger Mounting
External Charger Mounting ERIC BATTERY CHARGER EXTERNAL CHARGER MOUNTING WARNING • Make sure the charger is securely mounted. Do not hang the charger by its handle. • Place all cords so they will not be stepped on, tripped over, or otherwise subjected to damage or stress. CAUTION •...
Page 253: Ac Power Connection
NOTE: Make sure that the AC cord provided with your charger has the proper AC plug for your location. If it does not, contact your Club Car representative to obtain the proper cord or plug. 2018 Onward Maintenance and Service Manual...
Page 254: The Charge Circuit
The Charge Circuit ERIC BATTERY CHARGER Two of these high-frequency chargers can be used on a dedicated 15 or 20 ampere, single-phase branch circuit. This high-frequency charger caps current draw at 6 amps and will operate at full power if the voltage is within the 100 to 240 VAC and 50 to 60 Hz ranges.
Page 255: Charger Operation
ERIC BATTERY CHARGER Charger Operation Onboard Charger: The charge circuit consists of the charger receptacle, interlock wire, controller, solenoid and battery pack (Figure 15-7, Page 15-11). 2789 Figure 15-7 Charge Circuit – Onboard High-Frequency Charger CHARGER OPERATION CHARGING BATTERIES See Dangers and Warnings beginning on page 15-1. WARNING •...
Page 256 Vehicles should be restricted to 40 to 50 amp hours of discharge between charges until the batteries have been properly seasoned (50 to 70 charge cycles). For maximum battery life, Club Car recommends that electric vehicles always be recharged after 40 to 50 amp hours of discharge or each night in order to avoid deeply discharging the batteries.
Page 257 If the charger does not seem to be operating properly, or if the batteries seem weak, see Charger Troubleshooting on page 15-15. If troubleshooting does not solve the issue, contact your local Club Car distributor/dealer. Figure 15-8 Correct Insertion of External Charger DC Plug...
Page 258: Charger Maintenance
Charger Maintenance ERIC BATTERY CHARGER CHARGER MAINTENANCE See General Warnings on page 1-2. 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.
Page 259: Charger Troubleshooting
ERIC BATTERY CHARGER Charger Troubleshooting CHARGER TROUBLESHOOTING See General Warnings on page 1-2. 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 •...
Page 260: Terminal Block Cover
When the blue AC status indicator light comes on, reconnect the DC cord under the rear-facing seat. If the triangular status indicator light comes on, contact your Club Car dealer. If the light does not come back on, attempt to charge the vehicle as usual.
Page 261: External Charger Troubleshooting Indicators
ERIC BATTERY CHARGER Charger Troubleshooting EXTERNAL 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: EXTERNAL CHARGER TROUBLESHOOTING GUIDE CHECK STATUS STATUS POSSIBLE CAUSES STATUS SOLUTIONS INDICATOR LIGHT...
Page 262 Charger Troubleshooting ERIC BATTERY CHARGER EXTERNAL CHARGER TROUBLESHOOTING GUIDE 1. Erroneous event (an unknown variable; Reset charger power. See Resetting Power – External something occurred to Charger on page 15-16. Reconnect DC cord to vehicle. the charger or vehicle that If status goes away, continue using charger.
Page 263: Onboard Charger Fault Codes
ERIC BATTERY CHARGER Charger Troubleshooting ONBOARD CHARGER FAULT CODES The “E” and “F” codes will appear in the display panel followed by three numbers and a period to indicate the different conditions. ONBOARD CHARGER FAULT CODES FAULT CODE DESCRIPTION SOLUTIONS F-0-0-1 F-0-0-2 F-0-0-3...
Page 264 Charger Troubleshooting ERIC BATTERY CHARGER ONBOARD CHARGER FAULT CODES Possible causes: Poor battery health, discharged battery, battery not connected correctly, and/or high parasitic loads on the battery while it is charging. • Replace the battery pack. E-0-0-7 Battery amp hour limit reached •...
Page 265: Test Procedures
ERIC BATTERY CHARGER Test Procedures ONBOARD CHARGER FAULT CODES There has been a problem connecting or disconnect- ing the USB flash drive. • Disconnect and reconnect the USB flash drive. E-0-1-7 USB error • If the problem persists, remove AC and battery for E-0-2-7 minimum 30 seconds and retry charger.
Page 266 Test Procedures ERIC BATTERY CHARGER 3.1. Verify that the 10-gauge red wire from the charger receptacle is connected to the large post of solenoid with 6-gauge red wire (Figure 15-6, Page 15-10). 3.2. Verify that the 10-gauge black wire from the charger receptacle is connected to the B- terminal of controller. 3.3.
Page 267 ERIC BATTERY CHARGER Test Procedures With a multimeter set to 500 volts AC, check incoming AC voltage. Insert multimeter test probes into AC wall outlet; voltage should be between 85 and 270 volts. See AC Input Voltage Detection on page 15-4. If proper voltage is not present, have building wiring checked by a licensed electrical contractor.
Page 268: External Charger Repairs
External Charger Repairs ERIC BATTERY CHARGER EXTERNAL CHARGER REPAIRS See General Warnings on page 1-2. WARNING • Knowledge of battery charger wiring and component terminology is required before attempting any repair (Figure 15-6, Page 15-10). • Prior to servicing the charger, disconnect the DC plug from the vehicle charger receptacle and the AC cord from the AC outlet.
Page 269: Terminal Block Cover Installation
ERIC BATTERY CHARGER External Charger Repairs 2791 Figure 15-11 Terminal Block Cover Mounting Tabs TERMINAL BLOCK COVER INSTALLATION WARNING • The terminal block cover (3) on the DC terminal block (4) must be installed properly to comply with UL code. This cover prevents water exposure and prevents a short across the DC terminals. Align cover (3) with terminal block (4) and push onto block until tabs lock into place.
Page 270: Handle Installation
External Charger Repairs ERIC BATTERY CHARGER HANDLE INSTALLATION Place handle (9) onto charger and seat it onto mounting bosses of charger. See following NOTE. NOTE: The handle (9) features locating tabs to aid installation. Secure handle (9) to charger with two torx screws (8). Tighten screws (8) to 39.8 lb·in (4.5 N·m). FOOT REMOVAL Disconnect DC cord (1) from vehicle.
Page 271: Onboard Charger Repairs
ERIC BATTERY CHARGER Onboard Charger Repairs ONBOARD CHARGER REPAIRS WARNING • Knowledge of battery charger wiring and component terminology is required before attempting any repair (Figure 15-7, Page 15-11). • Prior to servicing the charger, disconnect the DC plug from the vehicle charger receptacle and the AC cord from the AC outlet.
Page 272: Onboard Charger Installation
Onboard Charger Repairs ERIC BATTERY CHARGER Disconnect AC cord reel lead (3) from onboard charger (4). Retain sleeve (5). Disconnect DC charging harness (6) from onboard charger DC cord (7). Disconnect 14-pin plug (8) from onboard charger (4). Remove two torx screws (9) securing DC cord connector (7) to seat bottom (2). Retain insulator (10). Remove two torx screws (11) securing charger shield (12) to onboard charger (4).
Page 273: Dc Cord And Strain Relief Removal
ERIC BATTERY CHARGER Onboard Charger Repairs 2793 Figure 15-13 Terminal Block Cover, DC Cord and Strain Relief – Onboard Charger DC CORD AND STRAIN RELIEF REMOVAL Disconnect AC cord from AC outlet. Disconnect DC cord (1) at connector mounted under seat (Figure 15-13, Page 15-29). Remove terminal block cover.
Page 274: Dc Charging Harness Installation
Onboard Charger Repairs ERIC BATTERY CHARGER Lift rear-facing seat bottom and support in the raised position. Disconnect DC charging harness from onboard charger DC cord. Disconnect 14-pin plug from onboard charger. Remove access panel and electronics module cover. See Electronics Module Cover Removal, Section 13, Page 13-6.
Page 275: Section 16 - Motor (Model Ej8-4001A): Electric Vehicle
The vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. The shunt-wound motor is designed for use in Excel System vehicles. 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 276 MOTOR (MODEL EJ8-4001A): ELECTRIC External Motor Testing VEHICLE MOTOR TERMINALS CONTINUITY TEST RESULT A1 to A2 Continuity F1 to F2 A1 to F1 No Continuity A1 to F2 A2 to F1 No Continuity A2 to F2 A1 to Ground No Continuity A2 to Ground F1 to Ground No Continuity...
Page 277 MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE External Motor Testing TEST PROCEDURE 3 – Field Circuit Open See General Warnings on page 1-2. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Disconnect wires from the F1 and F2 terminals on the motor using two wrenches to prevent posts from turning. Set a multimeter to 200 ohms and place the red (+) probe on the F1 terminal and the black (–) probe on the F2 terminal.
Page 278: Motor
MOTOR (MODEL EJ8-4001A): ELECTRIC Motor VEHICLE MOTOR See General Warnings on page 1-2. MOTOR REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Disconnect wires from the terminals on the motor using two wrenches to prevent posts from turning. Label the wires to ensure proper reconnection.
Page 279: Motor Disassembly
MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Motor Figure 16-3 Lower Axle Remove the bolts and lock washers that secure the motor to the transaxle (Figure 16-24, Page 16-17). See following CAUTION. CAUTION • Do not position fingers under motor when sliding motor off of the input shaft in step 9. Fingers may get pinched when motor disengages.
Page 280 MOTOR (MODEL EJ8-4001A): ELECTRIC Motor VEHICLE 2.1. Remove the two screws (25) that secure the speed sensor (10) to the end cap (11) (Figure 16-15, Page 16-12). 2.2. Remove the screw securing the magnet to the armature shaft (Figure 16-4, Page 16-5). 2.3.
Page 281 MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Motor CAUTION • Removing the armature from the end cap requires two people: one to operate the press, and another to hold the armature. Failure to heed this CAUTION could result in personal injury and/or damage to the armature resulting from an unsupported armature falling after it becomes disengaged from the end cap bearing.
Page 282: Motor Component Testing And Inspection
MOTOR (MODEL EJ8-4001A): ELECTRIC Motor Component Testing and Inspection VEHICLE Figure 16-10 Brush Rigging Figure 16-11 Bearing Retaining Ring MOTOR COMPONENT TESTING AND INSPECTION See General Warnings on page 1-2. ARMATURE INSPECTION AND TESTING Remove the motor from the vehicle. See Motor Removal on page 16-4. Remove the end cap and armature by performing steps 1 through 7 of Motor Disassembly on page 16-5.
Page 283 MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Motor Component Testing and Inspection CAUTION • Do not use emery cloth to polish the commutator. Particles of emery are conductive and may short-circuit the commutator bars. Do not use oil or lubricants on the commutator or brushes. NOTE: Oil on the commutator may indicate a faulty transaxle input shaft oil seal.
Page 284: Motor Frame And Field Windings Inspection
MOTOR (MODEL EJ8-4001A): ELECTRIC Motor Component Testing and Inspection VEHICLE MOTOR FRAME AND FIELD WINDINGS INSPECTION Remove the motor from the vehicle. See Motor Removal on page 16-4. Remove the and cap and armature by performing steps 1 through 7 of Motor Disassembly on page 16-5. Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings.
Page 285 MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Motor Component Testing and Inspection Bearing Inspection NOTE: Replacement of the end cap bearing is highly-recommended if the end cap is removed from the motor. The following procedure is provided as a guideline for determining general bearing failure. Remove the motor from the vehicle.
Page 286 MOTOR (MODEL EJ8-4001A): ELECTRIC Motor Component Testing and Inspection VEHICLE 2613 Figure 16-15 Electric Motor (EJ8-4001A) Page 16-12 2018 Onward Maintenance and Service Manual...
Page 287: Reconditioning The Motor
MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Reconditioning the Motor RECONDITIONING THE MOTOR See General Warnings on page 1-2. Motor reconditioning must be performed by a qualified motor repair technician. The use of proper tools and procedures is absolutely essential for successful motor reconditioning. MOTOR SPECIFICATIONS Any rework must be performed by a qualified technician.
Page 288 MOTOR (MODEL EJ8-4001A): ELECTRIC Motor Assembly VEHICLE Figure 16-16 Brush Rigging Figure 16-17 Retracted Brushes Figure 16-18 Armature Installation Figure 16-19 Brush Setting With the brushes retracted, use an arbor press to press the armature shaft into the end cap bearing (Figure 16-18, Page 16-14).
Page 289: Motor Installation
MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Motor Installation Make sure the armature turns freely. If it does not turn freely, disassemble the motor to find the problem. MOTOR INSTALLATION See General Warnings on page 1-2. Clean the transaxle input shaft. 1.1. Spray the input shaft thoroughly with CRC ®...
Page 290 MOTOR (MODEL EJ8-4001A): ELECTRIC Motor Installation VEHICLE Install motor on transaxle. 4.1. Slide the motor coupling onto the transaxle input shaft. See following NOTE. NOTE: The coupling will push any excess grease on the input shaft along the shaft toward the transaxle. When the motor is pushed onto the input shaft, the motor housing will not bottom out against the transaxle housing (Figure 16-15, Page 16-12).
Page 291 MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Motor Installation retaining nuts. For 5/16 inch (8mm) diameter studs, tighten the nuts to 100 lb·in (11 N·m). For 1/4 inch (6.3mm) diameter studs, tighten the nuts to 45 lb·in (5.0 N·m). 4.8. Secure the white, orange, green, and blue wires with a wire tie so that none of the motor wires will scrub the motor or transaxle when the vehicle is in operation.
Page 292 MOTOR (MODEL EJ8-4001A): ELECTRIC Motor Installation VEHICLE Pagination Page Page 16-18 2018 Onward Maintenance and Service Manual...
Page 293: Section 17 - Transaxle: Electric Vehicle
SECTION 17 — TRANSAXLE: ELECTRIC VEHICLE DANGER Transaxle: Electric Vehicle • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. LUBRICATION See General Warnings on page 1-2. There are two plugs located on the lower half of the transaxle housing. The upper plug (21) (as viewed when the vehicle is on a level surface) is used as a lubricant level indicator (Figure 17-5, Page 17-3).
Page 294 Axle Bearing and Shaft TRANSAXLE: ELECTRIC VEHICLE 6.2. Use a press to separate the axle oil seal (15) from the adapter ring (39) (Figure 17-3, Page 17-2). Retain the adapter ring and discard the oil seal. Inspect the axle shaft assembly to be sure the bearing and collar have not slipped and are still seated against the shoulder on the axle shaft.
Page 295 TRANSAXLE: ELECTRIC VEHICLE Axle Bearing and Shaft Figure 17-5 Transaxle – Type G 2018 Onward Maintenance and Service Manual Page 17-3...
Page 296: Axle Bearing
Axle Bearing and Shaft TRANSAXLE: ELECTRIC VEHICLE Axle Shaft and Oil Seal Installation If previously removed, install a new oil seal. 1.1. Clean seal seat in the adapter ring (39) (Figure 17-3, Page 17-2). 1.2. Place a new seal (15) in the adapter ring with the seal lip facing toward the adapter ring lip (Figure 17-3, Page 17-2).
Page 297: Transaxle Removal
TRANSAXLE: ELECTRIC VEHICLE Transaxle Removal TRANSAXLE REMOVAL See General Warnings on page 1-2. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4. Place chocks at the front wheels and slightly loosen lug nuts on both rear wheels. See WARNING “Lift only one end...”...
Page 298 Transaxle Removal TRANSAXLE: ELECTRIC VEHICLE 2700 Figure 17-8 Disconnect Shocks Figure 17-9 Shackles If a floor jack was used, pull floor jack from beneath the transaxle and allow the springs to rest on the floor. Lifted Vehicles: Remove the panhard. See Panhard and Bracket Removal on page 9-1. Remove the U-bolts attaching the transaxle to the leaf springs (Figure 17-10, Page 17-6).
Page 299: Transaxle Disassembly, Inspection, And Assembly
TRANSAXLE: ELECTRIC VEHICLE Transaxle Disassembly, Inspection, and Assembly TRANSAXLE DISASSEMBLY, INSPECTION, AND ASSEMBLY See General Warnings on page 1-2. TRANSAXLE DISASSEMBLY AND INSPECTION To detach axle tubes (14 and 35) from the transaxle housing, remove the bolts (8) (Figure 17-5, Page 17-3). Remove 11 bolts (24) that hold housing together.
Page 300 Transaxle Disassembly, Inspection, and Assembly TRANSAXLE: ELECTRIC VEHICLE Disassemble the differential gear case: 8.1. Remove the hex bolts (33) and the ring gear (32) from the differential case (Figure 17-5, Page 17-3). 8.2. Remove the ring gear. 8.3. Separate the differential gear case housing. If necessary, install two of the hex bolts (removed previously in step 8.1.) into the differential gear unit and, while holding the unit slightly above the work area, lightly tap the bolt heads (Figure 17-13, Page 17-8).
Page 301: Transaxle Assembly
TRANSAXLE: ELECTRIC VEHICLE Transaxle Disassembly, Inspection, and Assembly NOTE: Damaged or worn gears should be replaced as sets. TRANSAXLE ASSEMBLY CAUTION • Do not press against the bearing outer race. • The housing and all parts must be wiped clean and dry before reassembly. If bearings (13) were removed during disassembly, install new bearings using an arbor press (Figure 17-5, Page 17-3).
Page 302: Transaxle Installation
Transaxle Installation TRANSAXLE: ELECTRIC VEHICLE WARNING • Be sure retaining ring is properly seated in its groove. If ring is not properly installed, the axle assembly will separate from the transaxle and damage the axle assembly and other components. Loss of vehicle control could result in severe personal injury or death.
Page 303 TRANSAXLE: ELECTRIC VEHICLE Transaxle Installation 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 304 Transaxle Installation TRANSAXLE: ELECTRIC VEHICLE Pagination Page Page 17-12 2018 Onward Maintenance and Service Manual...
Page 305: Section 18 - Troubleshooting And Electrical System - Subaru Ex40
SECTION 18 — TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 DANGER Troubleshooting and Electrical System – Subaru EX40 • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION WARNING • To prevent damage to the ECU, never mix the black and gray connectors that attach to it. The black connector is tethered to the ECU mounting plate to help avoid installing it in the gray port.
Page 306: Features Of The Electronic Fuel Injection (Efi) System
TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM – SUBARU EX40 • Top of Fuel Tank: The fuel tank has a lead that connects to the main wire harness and goes to the B– battery terminal. FEATURES OF THE ELECTRONIC FUEL INJECTION (EFI) SYSTEM •...
Page 307 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Troubleshooting Guide Error Codes – ECU BLINK CODE CODE DESCRIPTION CORRECTIVE ACTION Check battery voltage. Charge/replace battery Low Battery Voltage as necessary. Check connector at ECU & Throttle module. MAP Sensor: Open or Shorted Connection If connection is made and no corrosion is present, replace ECU and Throttle Module.
Page 308: Gasoline Powertrain
TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM – SUBARU EX40 GASOLINE POWERTRAIN TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Spark plug is partially fouled or in poor Clean or replace condition Spark plug is damaged or loose Replace or tighten Incorrect spark plug gap Adjust gap Spark plug wire is damaged or loose Replace or reconnect...
Page 309 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Fuel tank is empty Section 21 — Fuel System – Subaru EX40 Fuel line or filter clogged Section 21 — Fuel System – Subaru EX40 Fouled spark plug Section 20 —...
Page 310 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM – SUBARU EX40 TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Incorrect plug Section 20 — Engine – Subaru EX40 Spark plug wire is damaged Section 20 — Engine – Subaru EX40 Unsuitable fuel, or incorrect (rich) fuel mixture Section 21 —...
Page 311 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Transmission shifter linkage is binding or is Section 24 — Transaxle, Fuji ED65 (for Subaru out of adjustment EX40) Insufficient (low) level of lubricant or wrong Section 24 —...
Page 312: Wiring Diagrams
TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM – SUBARU EX40 WIRING DIAGRAMS WD1052367_dgmE-L Figure 18-1 Main Harness for EFI Gasoline Vehicle Page 18-8 2018 Onward Maintenance and Service Manual...
Page 313 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Wiring Diagrams WD1052367_dgmE-R Figure 18-2 Main Harness for EFI Gasoline Vehicle – Continued 2018 Onward Maintenance and Service Manual Page 18-9...
Page 314 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM – SUBARU EX40 WD1050083_DGM_A Figure 18-3 Instrument Panel Control Harness Page 18-10 2018 Onward Maintenance and Service Manual...
Page 315 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Wiring Diagrams Figure 18-4 Instrument Panel Light Harness for EFI Gasoline Vehicle 2018 Onward Maintenance and Service Manual Page 18-11...
Page 316 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM – SUBARU EX40 Figure 18-5 Instrument Panel Light Harness for EFI Gasoline Vehicle — Continued Page 18-12 2018 Onward Maintenance and Service Manual...
Page 317 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Wiring Diagrams WD1050081_DGM_D Figure 18-6 Engine Harness – EFI and Engine 2018 Onward Maintenance and Service Manual Page 18-13...
Page 318 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM – SUBARU EX40 Figure 18-7 Sonic Weld and Diode Locations (Approximate) – EFI Page 18-14 2018 Onward Maintenance and Service Manual...
Page 319: Instrument Panel Light Harness
TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Wiring Diagrams INSTRUMENT PANEL LIGHT HARNESS Lighting Connector Pinout (Left and Right) Refer to the instrument panel light harness diagram (Figure 18-4, Page 18-11). DESCRIPTION Head Light Accent/Logo Light Turn Signal Ground Visage Strut Harness Connector Pinout Refer to the instrument panel light harness diagram (Figure 18-5, Page 18-12).
Page 320: Electrical System
TROUBLESHOOTING AND ELECTRICAL Electrical System SYSTEM – SUBARU EX40 ELECTRICAL SYSTEM The electrical system on the gasoline vehicle is 12 volts DC with negative (–) ground to frame, and consists of the following circuits that are easily identified: • Starter Circuit •...
Page 321: Test Procedures
TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Test Procedures TEST PROCEDURES Using the following procedures, the entire electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
Page 322 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 2 – Fuses 3 – Ground Cables 4 – EFI System (ECU and Sensors) 5 – Key Switch (Start Circuit) 6 – Key Switch (Engine Kill Circuit) 7 – Throttle Position Sensor (TPS) 8 –...
Page 323 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Test Procedures TEST PROCEDURE 1 – Battery See General Warnings on page 1-2. DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working near a battery.
Page 324 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 IF TEMPERATURE IS MINIMUM CRANKING VOLTAGE 70 °F (20 °C and above) 9.6 V 60 °F (16 °C) 9.5 V 50 °F (10 °C) 9.4 V 40 °F (4 °C) 9.3 V 30 °F (-1 °C) 9.1 V 20 °F (-7 °C)
Page 325 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Test Procedures TEST PROCEDURE 2 – Fuses See General Warnings on page 1-2. WARNING • Failure to use properly rated fuse can result in a fire hazard. NOTE: This vehicle uses three ATM-style blade fuses. A single ABC-style glass fuse is used for the Guardian/Visage 4-pin connector that is labeled “V3 circuit”...
Page 326 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 5-amp ATM Fuse Only: With the key switch in the ON position: 4.1. Probe the two, small metal contacts on the top of the fuse (Figure 18-8, Page 18-21). 4.2. Each contact should show battery voltage. 4.3.
Page 327 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Test Procedures TEST PROCEDURE 4 – EFI System (ECU and Sensors) See General Warnings on page 1-2. WARNING • This procedure involves testing voltage, resistance and continuity. If necessary, see Testing Basics on page 18-17. 2018 Onward Maintenance and Service Manual Page 18-23...
Page 328 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 18-PIN CONNECTOR (GRAY AND BLACK): A. ECU SIDE OF CONNECTOR B. WIRE ENTRY SIDE OF CONNECTOR CONNECTOR FUNCTION TEST TYPE & PROBE BETWEEN LOCATIONS TEST RESULT CONDITION I.D. COLOR Resistance: ECU Gray Pin 1 (Black/White) and ECU Approx.
Page 329 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Test Procedures 18-PIN CONNECTOR (GRAY AND BLACK): A. ECU SIDE OF CONNECTOR B. WIRE ENTRY SIDE OF CONNECTOR CONNECTOR FUNCTION TEST TYPE & PROBE BETWEEN LOCATIONS TEST RESULT CONDITION I.D. COLOR Meter should beep Key OFF Black Ignition OFF Input...
Page 330 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 TEST PROCEDURE 5 – Key Switch (Start Circuit) See General Warnings on page 1-2. NOTE: This is a voltage test. The key switch provides power and KEY INPUT to the ECU. If necessary, see Testing Basics on page 18-17.
Page 331 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Test Procedures –M WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 200 Ohm Setting 1337 Figure 18-9 Key Switch Test – Engine Kill Circuit TEST PROCEDURE 7 – Throttle Position Sensor (TPS) The throttle position sensor performs the function of two limit switches: the accelerator pedal limit switch and the kill limit switch.
Page 332 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 Kill Limit Switch Function See General Warnings on page 1-2. The black and white/black wires connect to the kill limit switch function of the throttle position sensor. This is the normally closed (NC) portion of the circuit used to ground the ignition and shut the engine off when the pedal is released. NOTE: Keep the battery connected while performing this test procedure.
Page 333 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Test Procedures TEST PROCEDURE 8 – Solenoid See General Warnings on page 1-2. NOTE: This is a resistance and voltage test. WAVETEK 1000 2000 200k 200mA 1000 --- FUSED 750V 2424 2426 Figure 18-10 Solenoid Wire Removal Figure 18-11 Solenoid Ground Test If necessary, See Testing Basics on page 18-17..
Page 334 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 TEST PROCEDURE 9 – Maintenance/Operate Switch – Vehicles See General Warnings on page 1-2. NOTE: This is a continuity test. The Maintenance/Operate Switch is also known as the Neutral Lockout Switch. If necessary, See Testing Basics on page 18-17..
Page 335 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Test Procedures TEST PROCEDURE 10 – Neutral Lockout Limit Switch – Vehicles Only See General Warnings on page 1-2. NOTE: This is a continuity test. This switch is located on the transaxle. A black/light blue wire, a red wire, and a blue wire are connected to this limit switch with a 3-pin connector.
Page 336 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 TEST PROCEDURE 11 – Starter/Generator (Generator Function) See General Warnings on page 1-2. NOTE: This is a voltage test. If necessary, See Testing Basics on page 18-17.. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position.
Page 337 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Test Procedures • When disconnecting wires from starter/generator terminals, use a second wrench on the lower nut of the terminal post to hold post steady. • Scrape a small amount of paint from starter/generator housing (ground) and use this location when testing motor terminals to electrical ground.
Page 338 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 TEST PROCEDURE 13 – Voltage Regulator See General Warnings on page 1-2. NOTE: This is a voltage test. Keep the battery connected while performing this test procedure. If necessary, See Testing Basics on page 18-17.. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position.
Page 339 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Test Procedures TEST PROCEDURE 14 – Ignition Spark See General Warnings on page 1-2. NOTE: Keep the battery connected while performing this test procedure. If necessary, See Testing Basics on page 18-17.. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position.
Page 340 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 TEST PROCEDURE 15 – Ignition Coil See General Warnings on page 1-2. NOTE: This is a resistance test. The following test procedures will properly detect a coil that has failed in most cases; however, in rare cases, some ignition coils can fail to operate at normal (warmer) operating temperatures.
Page 341 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Test Procedures TEST PROCEDURE 16 – Reverse Buzzer and Reverse Buzzer Limit Switch See General Warnings on page 1-2. NOTE: Reverse Buzzer: This is a voltage test. Reverse Buzzer Limit Switch: This is a continuity test. A reverse buzzer is mounted on the back side of the instrument panel.
Page 342 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 TEST PROCEDURE 18 – Oil Level Sensor See General Warnings on page 1-2. NOTE: Keep the battery connected while performing this test procedure. This procedure requires the oil to be drained from the engine. If necessary, See Testing Basics on page 18-17..
Page 343 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Test Procedures TEST PROCEDURE 20 – Fuel Pump See General Warnings on page 1-2. WARNING • To avoid the possibility of fire or explosion, make sure the fuel tank cap is securely in place while performing this test procedure.
Page 344 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 Probe between pin (1) and pin (2) terminals in module (Figure 18-18, Page 18-39). 4.1. The reading should be approximately 2 to 5 ohms. If the reading indicates no resistance, the fuel pump has failed and the fuel pump module must be replaced.
Page 345 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Test Procedures TEST PROCEDURE 22 – Fuel Gauge See General Warnings on page 1-2. NOTE: This is a voltage test. If necessary, See Testing Basics on page 18-17.. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.
Page 346 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 TEST PROCEDURE 23 – Hour Meter See General Warnings on page 1-2. NOTE: Keep the battery connected while performing this test procedure. Place the neutral lockout cam in the MAINTENANCE position, put the Forward/Reverse handle in the NEUTRAL position, and chock the wheels.
Page 347 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Test Procedures TEST PROCEDURE 24 – 4-Pin Connector (for Connected Car Device) See General Warnings on page 1-2. NOTE: This is a voltage and continuity test. The Connected Car Device 4-pin connector is used for Guardian/Visage and is labeled “V3 circuit” on the main wire harness.
Page 348 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 Pagination Page Page 18-44 2018 Onward Maintenance and Service Manual...
Page 349: Section 19 - Electrical Components - Subaru Ex40
SECTION 19 — ELECTRICAL COMPONENTS – SUBARU EX40 DANGER Electrical Components – Subaru EX40 • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. STARTER/GENERATOR TESTING THE STARTER/GENERATOR See Test Procedure 12 – Starter/Generator (Starter Function) on page 18-32. See Test Procedure 11 –...
Page 350: Brush Inspection And Replacement
Starter/Generator ELECTRICAL COMPONENTS – SUBARU EX40 Figure 19-2 Brush Covers and Brushes Figure 19-1 Commutator End Cover BRUSH INSPECTION AND REPLACEMENT Visually inspect brushes. Replace brushes that are cracked or severely chipped. Measure the length of each brush. Replace the brush set if a brush is less than 0.375 inch (9.5 mm) (Figure 19-3, Page 19-2).
Page 351: Starter/Generator Assembly
ELECTRICAL COMPONENTS – SUBARU EX40 Starter/Generator CAUTION • When checking brush spring tension, do not push springs beyond the point they would normally be if there were new brushes installed. Exerting excessive force or pushing brush springs beyond their normal maximum extension point will damage springs. Figure 19-4 Brush Spring Tension Test STARTER/GENERATOR ASSEMBLY Install the brushes (27) into the holders.
Page 352: Disassembly Of The Starter/Generator To Service The Armature/Commutator
Starter/Generator ELECTRICAL COMPONENTS – SUBARU EX40 Figure 19-5 Pull Brushes Away From Center of the Commutator End Cover DISASSEMBLY OF THE STARTER/GENERATOR TO SERVICE THE ARMATURE/COMMUTATOR Remove the commutator end cover to prevent damage to the brushes and armature. See Commutator End Cover on page 19-2.
Page 353: Bearing Cleaning And Inspection
ELECTRICAL COMPONENTS – SUBARU EX40 Starter/Generator 1342 Figure 19-6 Output End Cover Assembly, Armature and Housing BEARING CLEANING AND INSPECTION Using a clean cloth, wipe the carbon dust from the two bearings. Inspect bearings by spinning them by hand and checking for both axial (A) and radial (B) play (Figure 19-7, Page 19-5).
Page 354: Bearing Removal
Starter/Generator ELECTRICAL COMPONENTS – SUBARU EX40 BEARING REMOVAL Place the wedge attachment tool (P/N 1012812) between the bearing and the armature. Make sure the wedge attachment tool is supporting the inner race of the bearing. If a press is not available, secure a bearing puller (P/N 1012811) to the wedge attachment tool and pull the bearing off of the end of the armature shaft.
Page 355: Commutator Cleaning And Inspection
ELECTRICAL COMPONENTS – SUBARU EX40 Starter/Generator Figure 19-9 Field Coil Assembly COMMUTATOR CLEANING AND INSPECTION Clean the carbon dust, dirt and oil from the commutator. Visually inspect the commutator for worn, burned or glazed areas. Check for loose or raised commutator bars. Slight roughness of the commutator can be polished away with 400 grit (or finer) sandpaper.
Page 356: Armature Ground Test
Starter/Generator ELECTRICAL COMPONENTS – SUBARU EX40 1. Measure each position in two places, 90 degrees apart Figure 19-10 Inspect Commutator ARMATURE GROUND TEST CAUTION • Do not submerge armature in solvent. NOTE: Before testing, wipe the armature with a clean cloth and remove carbon dust and metal particles from between commutator bars.
Page 357: Visual Inspection Of Field Coils
ELECTRICAL COMPONENTS – SUBARU EX40 Starter/Generator WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 200 Ohms Setting 2. Commutator 3. Armature Shaft Figure 19-11 Armature Ground Test VISUAL INSPECTION OF FIELD COILS If the insulation on the field coils appears blackened or charred, the serviceability of the coils is questionable. Burned or scorched coil insulation indicates the starter/generator has overheated due to overloads or grounded or shorted coil windings.
Page 358 Starter/Generator ELECTRICAL COMPONENTS – SUBARU EX40 Press a new ball bearing (35) onto the output end of the armature (Figure 19-6, Page 19-5). Press a new ball bearing onto the commutator end of the armature shaft. See following CAUTION. CAUTION •...
Page 359 ELECTRICAL COMPONENTS – SUBARU EX40 Starter/Generator 90° 1. Jumper Wire 2. 1 inch (25.4 mm) Minimum Radius 3. Jumper Wire Not Allowed in this Area. 2687 Figure 19-12 A1 to F1 Terminal Jumper Wire Routing 2018 Onward Maintenance and Service Manual Page 19-11...
Page 360: Starter/Generator Installation
Starter/Generator ELECTRICAL COMPONENTS – SUBARU EX40 STARTER/GENERATOR INSTALLATION 2997 Figure 19-13 Starter/Generator Installation Install the green wire (1) from the F1 terminal to the A2 terminal on the starter/generator (Figure 19-14, Page 19-13). Install a flat washer, lock washer, and nut onto each terminal and tighten to 48 lb·in (5.4 N·m). Position the starter/generator over the mounting bracket so that the bolts will go through the starter/generator before going through the bracket.
Page 361: Belt Tension Adjustment For Efi Engines
ELECTRICAL COMPONENTS – SUBARU EX40 Starter/Generator 3033 Figure 19-14 Starter/Generator Wiring BELT TENSION ADJUSTMENT FOR EFI ENGINES NOTE: To prevent belt slipping while starting an EFI engine, follow procedure outlined below which is best performed by two people to expedite the process, but can be performed by a single individual if required. The amount a starter/generator belt is tensioned varies between a used and new belt.
Page 362 Starter/Generator ELECTRICAL COMPONENTS – SUBARU EX40 – Use combination of above methods. Mark a location on belt to repeat tension measurement each time. Use paint pen or permanent marker of light color. For Existing Belts Only: Verify current belt tension using Universal Belt Tension Gauge (OTC 6673 ®...
Page 363: Voltage Regulator
ELECTRICAL COMPONENTS – SUBARU EX40 Voltage Regulator 7.1. Tighten nut on belt tension tool 1/2 turn and check belt tension with gauge (Figure 19-15, Page 19-13). NOTE: To prevent errors in measurement caused by residual tension, ensure to loosen, then reapply, the Universal Belt Tension gauge between measurements.
Page 364: Voltage Regulator Installation
Voltage Regulator ELECTRICAL COMPONENTS – SUBARU EX40 2432 Figure 19-18 Voltage Regulator VOLTAGE REGULATOR INSTALLATION Position the voltage regulator (1) and install the mounting screw (2) (Figure 19-18, Page 19-16). Tighten screw to 23 lb·in (2.6 N·m). Connect the voltage regulator three-pin connector (3) to the wire harness. Connect battery and spark plug wire(s).
Page 365: Engine Control Unit (Ecu)
ELECTRICAL COMPONENTS – SUBARU EX40 Engine Control Unit (ECU) ENGINE CONTROL UNIT (ECU) CAUTION • The Engine Control Unit (ECU) and Throttle Body are to be purchased as one unit. They are matched pairs with matching serial numbers. Do not mix an ECU with another Throttle Body of a different serial number.
Page 366: Key Switch
Key Switch ELECTRICAL COMPONENTS – SUBARU EX40 KEY SWITCH See General Warnings on page 1-2. TESTING THE KEY SWITCH See Test Procedure 5 – Key Switch (Start Circuit) on page 18-26. See Test Procedure 6 – Key Switch (Engine Kill Circuit) on page 18-26. KEY SWITCH REMOVAL Disconnect battery and spark plug wire(s).
Page 367: Key Switch Installation
ELECTRICAL COMPONENTS – SUBARU EX40 Maintenance/Operate Switch KEY SWITCH INSTALLATION Reverse removal procedures to install key switch in the instrument panel. Connect wires to key switch. Install the instrument panel. 2.1. Connect the electrical connector (3) (Figure 19-19, Page 19-18). 2.2.
Page 368: Neutral Lockout Limit Switch
Neutral Lockout Limit Switch ELECTRICAL COMPONENTS – SUBARU EX40 NEUTRAL LOCKOUT LIMIT SWITCH See General Warnings on page 1-2. TESTING THE NEUTRAL LOCKOUT LIMIT SWITCH See Test Procedure 10 – Neutral Lockout Limit Switch – Vehicles Only on page 18-31. NEUTRAL LOCKOUT LIMIT SWITCH REMOVAL Turn the key switch OFF and remove the key.
Page 369: Solenoid
ELECTRICAL COMPONENTS – SUBARU EX40 Solenoid SOLENOID See General Warnings on page 1-2. TESTING THE SOLENOID See Test Procedure 8 – Solenoid on page 18-29. SOLENOID REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery- Gasoline Vehicles on page 1-3. Disconnect all the wires from the solenoid.
Page 370: Fuse
Fuse ELECTRICAL COMPONENTS – SUBARU EX40 FUSE See General Warnings on page 1-2. ATM-style blade fuses are located on the main wire harness in front of the battery. The ABC-style glass fuse is located on the main wire harness adjacent to the ATM-fuse holder. TESTING THE FUSE See Test Procedure 2 –...
Page 371: Accelerator Pedal Limit Switch
ELECTRICAL COMPONENTS – SUBARU EX40 Accelerator Pedal Limit Switch ACCELERATOR PEDAL LIMIT SWITCH See General Warnings on page 1-2. TESTING THE ACCELERATOR PEDAL LIMIT SWITCH See Test Procedure 7 – Throttle Position Sensor (TPS) on page 18-27. The accelerator pedal limit switch is housed inside the throttle position sensor. The throttle position sensor itself is not intended to be replaced.
Page 372: Reverse Warning Buzzer Installation
Reverse Warning Buzzer ELECTRICAL COMPONENTS – SUBARU EX40 A, Red/White wire B. Black wire Figure 19-21 Reverse Buzzer REVERSE WARNING BUZZER INSTALLATION Install the screws (3) through the buzzer bracket tabs and tighten to 3.5 lb·in (0.40 N·m) (Figure 19-21, Page 19-24).
Page 373: Reverse Buzzer Limit Switch
ELECTRICAL COMPONENTS – SUBARU EX40 Reverse Buzzer Limit Switch REVERSE BUZZER LIMIT SWITCH See General Warnings on page 1-2. TESTING THE REVERSE BUZZER LIMIT SWITCH See Test Procedure 16 – Reverse Buzzer and Reverse Buzzer Limit Switch on page 18-37. REVERSE BUZZER LIMIT SWITCH REMOVAL Disconnect battery and spark plug wire(s).
Page 374 Reverse Buzzer Limit Switch ELECTRICAL COMPONENTS – SUBARU EX40 Figure 19-22 Reverse Buzzer Limit Switch Page 19-26 2018 Onward Maintenance and Service Manual...
Page 375: Low Oil Warning Light
ELECTRICAL COMPONENTS – SUBARU EX40 Low Oil Warning Light LOW OIL WARNING LIGHT See General Warnings on page 1-2. TESTING THE LOW OIL WARNING LIGHT See Test Procedure 17 – Low Oil Warning Light (LED) on page 18-37. LOW OIL WARNING LIGHT REMOVAL Disconnect battery and spark plug wire(s).
Page 376: Fuel Gauge
Fuel Gauge ELECTRICAL COMPONENTS – SUBARU EX40 FUEL GAUGE See General Warnings on page 1-2. With the key switch in the OFF position, the fuel gauge reads empty. When the key switch is turned to ON, the fuel gauge becomes active. TESTING THE FUEL GAUGE See Test Procedure 22 –...
Page 377: Fuel Level Sending Unit
ELECTRICAL COMPONENTS – SUBARU EX40 Fuel Level Sending Unit 4.2. Position the instrument panel (2) on the dash assembly. Make sure tabs on upper edge properly engage with the corresponding slots on the dash assembly. Ensure that there are no wires exposed or pinched during positioning.
Page 378: Oil Level Sensor
Oil Level Sensor ELECTRICAL COMPONENTS – SUBARU EX40 BLACK 2438 Figure 19-25 Hour Meter Installation OIL LEVEL SENSOR See General Warnings on page 1-2. TESTING THE OIL LEVEL SENSOR See Test Procedure 18 – Oil Level Sensor on page 18-38. OIL LEVEL SENSOR REMOVAL See Oil Level Sensor Removal on page 20-12.
Page 379: Battery
ELECTRICAL COMPONENTS – SUBARU EX40 Battery BATTERY DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working on or near batteries. • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area.
Page 380: Self-Discharge
Battery ELECTRICAL COMPONENTS – SUBARU EX40 CAUTION • If battery wire terminals are damaged or corroded, replace or clean them as necessary. Failure to do so may cause them to overheat during operation and could result in a fire, property damage, or personal injury.
Page 381: Battery Removal
ELECTRICAL COMPONENTS – SUBARU EX40 Battery BATTERY REMOVAL Also see DANGER at beginning of Battery topic. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels. Disconnect battery and spark plug wire(s). See Disconnecting the Battery- Gasoline Vehicles on page 1-3. Remove the battery hold-down clamp from the battery.
Page 382: Battery Storage
Ground Cables ELECTRICAL COMPONENTS – SUBARU EX40 BATTERY STORAGE Also see DANGER at beginning of Battery topic. Keep the battery clean and free of corrosion. See Preventive Maintenance on page 19-31. The battery cables should be disconnected from the battery so the battery can be connected to the charger. The battery can be left in the vehicle.
Page 383: Section 20 - Engine - Subaru Ex40
SECTION 20 — ENGINE – SUBARU EX40 DANGER Engine – Subaru EX40 • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION See General Warnings on page 1-2. This vehicle is powered by a Subaru EX40, high-compression, chain driven, overhead cam engine. The engine offers a heavy-duty construction featuring cast iron cylinder liner for longer life, dual ball bearing crankshaft support, low oil level sensor and heavy-duty air cleaner system, to name a few characteristics.
Page 384: Torque Specifications
General Information ENGINE – SUBARU EX40 TORQUE SPECIFICATIONS ITEM SIZE TORQUE Flywheel retaining nut 80 lb·ft (110 N·m) Crankcase cover to block bolts 250 lb·in (28.3 N·m) Step Step New head and bolts: New head and bolts: 159 lb·in (18 N·m) 336 lb·in (38 N·m) Cylinder head bolts Used head and bolts:...
Page 385 ENGINE – SUBARU EX40 General Information Check oil by fully inserting the dipstick into the oil filler tube and immediately removing it. If the oil level is at or below the low level mark on the dipstick gauge, add oil until the level is between low and full levels (safe level).
Page 386 General Information ENGINE – SUBARU EX40 1. Drain pan 2. Drain plug 2667 Figure 20-2 Engine Oil Drain Plug and Pan Use a 14 mm socket or wrench to remove the drain plug, turning it counterclockwise, and allow the engine oil to drain into the pan.
Page 387: Spark Plug
ENGINE – SUBARU EX40 General Information Figure 20-3 Oil Viscosity Chart Connect battery and spark plug wire. See Connecting the Battery- Gasoline Vehicles on page 1-3. With the Forward/Reverse handle in the NEUTRAL position and the Maintenance/Operate switch in the OPERATE position, start and run the engine for a few minutes.
Page 388: Breather
General Information ENGINE – SUBARU EX40 Figure 20-4 Spark Plug Testing the Spark Plug Check the sparking ability of a cleaned and properly gapped plug on a sparking comparator if possible. Spark should be blue and strong and able to jump a 5/16-in. (8 mm) gap. Setting the Spark Gap Pass a contact point file between the electrodes to produce flat, parallel surfaces to facilitate accurate gauging.
Page 389: Valve Clearance Check And Adjustment
ENGINE – SUBARU EX40 General Information VALVE CLEARANCE CHECK AND ADJUSTMENT NOTE: Check and adjust clearance when the engine is cold. If equipped, remove air deflector from top of engine. Remove rocker cover. Turn the crankshaft until the piston is at top dead center of the compression stroke (Figure 20-5, Page 20-7). Using a feeler gauge (1), measure the clearance between the adjuster screw (3) and the top of the valve stem (Figure 20-6, Page 20-7).
Page 390: Engine Removal
Engine Removal ENGINE – SUBARU EX40 ENGINE REMOVAL Figure 20-7 EX40 Engine and Mounting Brackets CAUTION • Before removal and disassembly, clean the engine. Disconnect battery and spark plug wire(s). See Disconnecting the Battery- Gasoline Vehicles on page 1-3. Page 20-8 2018 Onward Maintenance and Service Manual...
Page 391: Engine Installation
ENGINE – SUBARU EX40 Engine Installation For some vehicles, the engine (1) can be removed by lifting it up and out of the chassis. For other vehicles, it is easier to remove the entire powertrain assembly first. If removing powertrain, see Transaxle Removal on page 24-9.
Page 392: Flywheel
Flywheel ENGINE – SUBARU EX40 CAUTION • Do not overfill with oil. Connect battery and spark plug wire(s). See Connecting the Battery- Gasoline Vehicles on page 1-3. Adjust the engine RPM setting. See Engine RPM Adjustment on page 21-11. Test-drive vehicle to ensure all systems are functional and correctly adjusted. FLYWHEEL See General Warnings on page 1-2.
Page 393: Flywheel Installation
ENGINE – SUBARU EX40 Flywheel CAUTION • The flywheel nut has right-hand threads. Turn it clockwise to tighten, or counterclockwise to loosen. • Do not damage the fan blades with the strap wrench. Do not place screwdriver or pry bar in the fan blades.
Page 394: Oil Level Sensor
Oil Level Sensor ENGINE – SUBARU EX40 OIL LEVEL SENSOR TESTING THE OIL LEVEL SENSOR See Oil Level Sensor on page 18-38. OIL LEVEL SENSOR REMOVAL Drain oil from engine. See Engine Oil – Gasoline Vehicle, Section 20, Page 20-2. Remove flywheel.
Page 395: Ignition Coil
ENGINE – SUBARU EX40 Ignition Coil IGNITION COIL See General Warnings on page 1-2. TESTING THE IGNITION COIL See Test Procedure 14 – Ignition Spark on page 18-35 and Test Procedure 15 – Ignition Coil on page 18-36. IGNITION COIL REMOVAL Remove screws (1) and fan housing (2) (Figure 20-8, Page 20-10).
Page 396: Snubber
Snubber ENGINE – SUBARU EX40 SNUBBER See General Warnings on page 1-2. NOTE: The snubber is installed on the gasoline vehicle only. SNUBBER REMOVAL Support the powertrain with a floor jack under the engine pan (1) so that the snubber (2) is raised slightly and does not rest on the vehicle frame (Figure 20-14, Page 20-14).
Page 397: Section 21 - Fuel System - Subaru Ex40
SECTION 21 — FUEL SYSTEM – SUBARU EX40 DANGER Fuel System – Subaru EX40 • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. • Fuel may be under pressure. Use extreme caution when disconnecting fuel line to prevent the spray of fuel onto hot engine.
Page 398: Relieving Fuel Pressure
Relieving Fuel Pressure FUEL SYSTEM – SUBARU EX40 1. ECU 2. Fuel Pump 3. Fuel Tank 4. Fuel Injector 5. MAP Sensor 6. Engine Temperature Sensor 7. CDI Ignition Unit 3040 Figure 21-1 EFI System Components RELIEVING FUEL PRESSURE In the event that servicing the EFI fuel system necessitates removal of the fuel delivery hose, extreme caution must be exercised.
Page 399: Throttle Body
FUEL SYSTEM – SUBARU EX40 Throttle Body THROTTLE BODY See General Warnings on page 1-2. Before suspecting the throttle body as the cause of poor engine performance, make sure the fuel and ignition systems are in proper operating condition. Check the following items: •...
Page 400 Throttle Body FUEL SYSTEM – SUBARU EX40 3041 Figure 21-2 Throttle Body – Exploded View Page 21-4 2018 Onward Maintenance and Service Manual...
Page 401: Throttle Body Installation
FUEL SYSTEM – SUBARU EX40 Throttle Body THROTTLE BODY INSTALLATION See General Warnings on page 1-2. Install throttle body (1) and its related components onto threaded studs in order as shown (Figure 21-2, Page 21-4). Install two flange nuts (7) and tighten to 53 to 71 lb·in (6 to 8 N·m). Connect fuel line (6) and vent hose (5).
Page 402: Engine Control Linkages
Engine Control Linkages FUEL SYSTEM – SUBARU EX40 ENGINE CONTROL LINKAGES See General Warnings on page 1-2. DANGER • To ensure the vehicle does not run over you while you disconnect or adjust the accelerator push rod, do the following: –...
Page 403: Ground Speed
FUEL SYSTEM – SUBARU EX40 Engine Control Linkages GROUND SPEED NOTE: If possible, the manufacturer recommends measuring ground speed when setting engine RPM. This vehicle should reach the forward ground speed specified in Section 2 – Vehicle Specifications. See How to Measure Ground Speed on page 21-10.
Page 404: Accelerator Cable
Engine Control Linkages FUEL SYSTEM – SUBARU EX40 2.4. Connect “Z” fitting of governor cable (1) to governor arm (4). Loosen adjustment screw jam nuts (6 and 10) and back off throttle stop screw (7) and power limiter screw (11) several turns (Figure 21-6, Page 21-8).
Page 405 FUEL SYSTEM – SUBARU EX40 Engine Control Linkages Accelerator Cable Installation At transaxle: 1.1. Hook spring fitting of accelerator cable (8) to governor arm (4) (Figure 21-5, Page 21-8). 1.2. Snap accelerator cable (8) into FNR/accelerator cable bracket (9). 1.3. Push dust shield (13) onto end of cable housing.
Page 406: Closed Throttle Or Idle Adjustment - Vehicles
Engine Control Linkages FUEL SYSTEM – SUBARU EX40 CLOSED THROTTLE OR IDLE ADJUSTMENT – VEHICLES When the accelerator pedal is released, the engine will stop. Therefore, it is not possible to measure or set idling speed under normal vehicle operating conditions. Set throttle valve as follows: Loosen the throttle body idle screw so that it is not touching the throttle lever (Figure 21-7, Page 21-10).
Page 407: Engine Rpm Adjustment
FUEL SYSTEM – SUBARU EX40 Engine Control Linkages ENGINE RPM ADJUSTMENT DANGER • Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. If governor is adjusted, proceed to step 2; otherwise, adjust governor. See Governor Cable Installation and Adjustment on page 21-7.
Page 408: Air Intake System
Air Intake System FUEL SYSTEM – SUBARU EX40 AIR INTAKE SYSTEM See General Warnings on page 1-2. GENERAL INFORMATION The air intake system is a simple mechanism requiring very little or no maintenance. The system consists of an air cleaner (1) and air hose (3) mounted under the seat (Figure 21-8, Page 21-12). The air cleaner draws clean, cool air from beneath the vehicle via an opening between the kick plate and the fuel bucket.
Page 409: Air Intake System Removal
• If air cleaner is extremely dirty, clean thoroughly. • Use only Club Car replacement air filters (P/N 102558201) or equivalent. The use of other air filters could result in engine damage. If the air filter is too small, the cover will seat before the filter can seal, leaving space for dirt to pass into the engine on all sides of the element.
Page 410: Air Intake System Installation
• Intake hose (3) is made from a special fire retardant neoprene material. Use of any hose that does not meet Club Car, LLC specifications could create a fire hazard. • Improper orientation of the hose clamp (5) may result in fuel tank damage (Figure 21-10, Page 21-14).
Page 411: Fuel Line
NOTE: This EFI gasoline vehicle is equipped with SAEJ30R9 fuel hose rated for high-pressure systems. Always replace the fuel line on this vehicle with approved Club Car replacement part. Do not attempt to repair, patch or splice the fuel line.
Page 412: Fuel Line Installation
Fuel Line FUEL SYSTEM – SUBARU EX40 1. Push fuel line onto nipple until it locks into place. 2. Push in locking clip until fully seated. 1. Pull out locking clip. 2. Push in on release tab. 3. While pushing in on release tab, pull fuel line off nipple. 3050 3051 Figure 21-11 Fuel Line Connector –...
Page 413: Fuel Pump Module
FUEL SYSTEM – SUBARU EX40 Fuel Pump Module FUEL PUMP MODULE See General Warnings on page 1-2. GENERAL INFORMATION NOTE: The fuel pump and fuel level sending unit themselves are not replaceable. If necessary, the fuel pump module must be replaced as an assembly. The fuel pump module can be disassembled to replace the fuel filter.
Page 414 Fuel Pump Module FUEL SYSTEM – SUBARU EX40 CAUTION • Ensure o-ring stays seated in place during fuel pump module installation. Install hold down ring (6) and ground wire (7) with hardware (5) and tighten in a crisscross pattern to 66 lb·in (7.5 N·m).
Page 415 FUEL SYSTEM – SUBARU EX40 Fuel Pump Module 3125a Figure 21-13 Fuel System – Exploded View 2018 Onward Maintenance and Service Manual Page 21-19...
Page 416: Fuel Tank
SAEJ30R9 1/4 in (6.3 mm) fuel vent hose and 3/16 in (4.78 mm) fuel vent hose. To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car fuel vent hoses. FUEL TANK REMOVAL Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels, and the neutral lockout switch in the MAINTENANCE position.
Page 417: Fuel Tank Disposal
SAEJ30R9 1/4 in (6.3 mm) fuel vent hose and 3/16 in (4.78 mm) fuel vent hose. To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car fuel vent hoses. Place fuel tank (10) in vehicle.
Page 418 Fuel Tank FUEL SYSTEM – SUBARU EX40 Connect fuel pump module ground wire (7) to main wire harness. See following WARNING. WARNING • Always install ground wires during reassembly. Connect fuel line (3) to fuel pump module (1). See Fuel Line Installation on page 21-16. See following DANGER.
Page 419: Fuel Filter
FUEL SYSTEM – SUBARU EX40 Fuel Filter FUEL FILTER See General Warnings on page 1-2. GENERAL INFORMATION The fuel filter is located in the fuel tank. It is part of the fuel pump module assembly and should last the life of the vehicle;...
Page 420: Fueling Instructions - Gasoline Vehicles
Fueling Instructions – Gasoline Vehicles FUEL SYSTEM – SUBARU EX40 FUELING INSTRUCTIONS – GASOLINE VEHICLES See General Warnings on page 1-2. DANGER • Turn the key switch to the OFF position before fueling. • Do not pour fuel into the fuel tank when the engine is hot or while it is running. •...
Page 421: Carbon Canister
CARBON CANISTER WARNING • If the carbon canister is damaged, only use an OEM (Club Car) replacement that is specifically designed and approved for use on this vehicle. Do not attempt to repair it. See the following canister removal procedure.
Page 422: Carbon Canister Installation
Carbon Canister FUEL SYSTEM – SUBARU EX40 Detail A: Side View 1. Clamp 2. Vent Tube (Fuel Tank to Canister) 3. Vent Tube (Canister to Engine) 4. Vent Tube (Canister to Atmosphere) 5. Carbon Canister 6. Mounting Bracket 2447 Figure 21-15 Carbon Canister, Hoses and Routing CARBON CANISTER INSTALLATION Align canister mounting tabs with slots in mounting bracket (6) and push canister (5) into bracket (Figure 21-15, Page 21-26).
Page 423: Section 22 - Exhaust System - Subaru Ex40
SECTION 22 — EXHAUST SYSTEM – SUBARU EX40 DANGER Exhaust System – Subaru EX40 • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. MUFFLER MUFFLER REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery- Gasoline Vehicles on page 1-3. If equipped, remove air deflector from top of engine.
Page 424 Muffler EXHAUST SYSTEM – SUBARU EX40 3112a Figure 22-1 Exhaust System Page 22-2 2018 Onward Maintenance and Service Manual...
Page 425: Section 23 - Clutches - Subaru Ex40
SECTION 23 — CLUTCHES – SUBARU EX40 DANGER Clutches – Subaru EX40 • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION The torque converter consists of a drive clutch, a driven clutch, and a drive belt. The drive clutch, which is mounted to the engine, is in the open position when the engine is at idle.
Page 426 Troubleshooting CLUTCHES – SUBARU EX40 If cleaning the driven clutch does not solve the problem, disassemble and thoroughly clean all parts of the drive clutch. Be sure to clean the plastic drive buttons (7) (Figure 23-3, Page 23-4). (CC P/N 101809101) (CC P/N 1014497) (CC P/N 1014508) (CC P/N 1014507)
Page 427: Drive Belt
CLUTCHES – SUBARU EX40 Drive Belt DRIVE BELT See General Warnings on page 1-2. The drive belt should be inspected semiannually for wear and (or) glazing. If it is excessively worn, frayed, or glazed, replace the belt. As the drive belt wears, the engine RPM will increase to compensate for the change in torque converter ratio. This will keep the vehicle’s maximum ground speed correct.
Page 428: Drive Clutch
Drive Clutch CLUTCHES – SUBARU EX40 DRIVE CLUTCH See General Warnings on page 1-2. 1. Screw, 3/8-24 x 5.75, Patch 10. Retainer 2. Washer, 3/8, Type A, Flat 11. Ring, Spiral Backup 3. Washer, Hard, M10 12. Bushing, Split, Drive Clutch 4.
Page 429: Drive Clutch Removal
CLUTCHES – SUBARU EX40 Drive Clutch CAUTION • Be very careful when handling the clutches. A clutch that has been dropped will not be properly balanced. If either clutch is dropped, assume that it is damaged and replace it. DRIVE CLUTCH REMOVAL Remove the drive belt as instructed.
Page 430: Drive Clutch Cleaning And Inspection
Drive Clutch CLUTCHES – SUBARU EX40 WARNING position. Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor. When not performing a test or service procedure that requires movement of the wheels, lock the brakes. Remove the drive clutch retaining bolt (1) and mounting washers (2 and 3) (Figure 23-3, Page 23-4).
Page 431 CLUTCHES – SUBARU EX40 Drive Clutch 2.1. Remove the three plugs (4) from the clutch puller attachment holes. 2.2. Thread the center bolt of the Drive Clutch Hub Puller (1) into clutch until the stop nut touches the clutch, then back the bolt out one-half turn (Figure 23-7, Page 23-7). 2.3.
Page 432 Drive Clutch CLUTCHES – SUBARU EX40 3053 Figure 23-8 Drive Button Mounting Figure 23-9 Weight Position Remove the clutch weights: 5.1. Remove the screws (1) and flat washers (2) attaching the weights (3) as shown (Figure 23-9, Page 23-8). 5.2. Pull the weight assemblies (3), with pins, from slots (4) in the clutch.
Page 433: Inspection Of Drive Clutch Parts
CLUTCHES – SUBARU EX40 Drive Clutch Figure 23-10 Primary and Secondary Weights, Wave Washer and Pin Remove the retaining ring (6) from the shaft of the fixed sheave (18) and slide the moveable sheave (13) off the shaft (Figure 23-3, Page 23-4). See following NOTE. NOTE: If the moveable sheave is removed from the hub of the fixed sheave, the spiral back-up rings (11) must be replaced with new rings (Figure 23-3, Page 23-4).
Page 434: Drive Clutch Assembly
Drive Clutch CLUTCHES – SUBARU EX40 Inspect the primary weights (8) and the hub casting for wear. If the primary weights show signs they are touching the casting, the tips of the weights have worn beyond specification and they must be replaced. Inspect the pins on the primary weights (8).
Page 435: Drive Clutch Installation
CLUTCHES – SUBARU EX40 Drive Clutch NOTE: Make sure there is at least a (minimum) gap of 0.020 in. (0.51 mm) between each end of the mounting pin and the mounting bolt. Install three drive button take-up springs. 11.1. Install each spring on right-hand side of the three button mounting posts (when looking into the interior of the clutch drive hub, and with the rib at a twelve o’clock position) as shown (Figure 23-13, Page 23-11).
Page 436 Drive Clutch CLUTCHES – SUBARU EX40 Drive the vehicle and check for proper operation. Page 23-12 2018 Onward Maintenance and Service Manual...
Page 437: Driven Clutch
CLUTCHES – SUBARU EX40 Driven Clutch DRIVEN CLUTCH See General Warnings on page 1-2. 1. Screw, 5/16-18 X 3/4 Hex-Head with Patch 7. Screw, #8-32 X 3/4, Socket-Head Cap 2. Washer, Driven Clutch 8. Button, Drive 3. Ring, Retaining 9. Sheave, Movable, Driven 4.
Page 438: Driven Clutch Removal
Driven Clutch CLUTCHES – SUBARU EX40 DRIVEN CLUTCH REMOVAL Remove the drive belt as instructed. See Drive Belt Removal on page 23-3. Remove the bolt (1) and mounting washer (2) from the transaxle input shaft (Figure 23-14, Page 23-13). Grasp the driven clutch assembly and slide it off the shaft. Leave the key (12) in the keyway.
Page 439: Driven Clutch Inspection
CLUTCHES – SUBARU EX40 Driven Clutch Figure 23-15 Remove Retaining Ring Figure 23-16 Driven Clutch Disassembly DRIVEN CLUTCH INSPECTION Inspect the cam (5) for excessive wear (Figure 23-14, Page 23-13). Replace it if necessary. Inspect the drive buttons (8) for excessive wear. Replace if necessary. To remove the drive buttons (8), remove the socket-head cap screws (7) and then the buttons.
Page 440 Driven Clutch CLUTCHES – SUBARU EX40 5.1.2. Hold the fixed sheave (3) and rotate the moveable sheave (1) one-third turn counterclockwise, then press the cam (2) onto the fixed sheave (Figure 23-17, Page 23-16). The match marks made before disassembly should now align. 5.1.3.
Page 441: Driven Clutch Installation
CLUTCHES – SUBARU EX40 Driven Clutch 5.2.6. Hold the fixed sheave of the clutch (5) and rotate the moveable sheave of the clutch one-third turn counterclockwise (Figure 23-18, Page 23-16). The match marks made before disassembly should now align. 5.2.7. Use two wrenches and hold the bolt head (1) while tightening the cam press hub (6) to press the cam onto the keyed shaft.
Page 442 Driven Clutch CLUTCHES – SUBARU EX40 Pagination Page Page 23-18 2018 Onward Maintenance and Service Manual...
Page 443: Section 24 - Transaxle, Fuji Ed65 (For Subaru Ex40)
SECTION 24 — TRANSAXLE, FUJI ED65 (FOR SUBARU EX40) DANGER Transaxle, Fuji ED65 (for Subaru EX40) • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION The vehicles addressed in this manual are equipped with heavy-duty transaxles. The transaxle utilizes internal gearing to change vehicle direction.
Page 444: Governor System
General Information TRANSAXLE, FUJI ED65 (FOR SUBARU EX40) WARNING • With the switch in the MAINTENANCE position and the engine running, the vehicle may move suddenly if the Forward/Reverse handle is shifted or accidentally bumped. To prevent this, chock the front and rear wheels and firmly set the park brake before servicing or leaving the vehicle.
Page 445: Tools Required For This Section
TRANSAXLE, FUJI ED65 (FOR SUBARU EX40) General Information 3055 Figure 24-2 Lubricant Level Plug and Drain Plug TOOLS REQUIRED FOR THIS SECTION Hydraulic floor jack (or chain hoist) Torque wrench, 3/8-in. drive 1/2-in. combination wrench Jack stands (2) (one ton capacity) 3/8-in.
Page 446: Rear Hubs
Rear Hubs TRANSAXLE, FUJI ED65 (FOR SUBARU EX40) REAR HUBS REAR HUB REMOVAL Turn the key switch to the OFF position and remove the key, and place the Forward/Reverse handle in the NEUTRAL position. Disconnect battery and spark plug wire(s). See Disconnecting the Battery- Gasoline Vehicles on page 1-3. Place chocks at the front wheels and loosen lug nuts on both rear wheels.
Page 447 TRANSAXLE, FUJI ED65 (FOR SUBARU EX40) Rear Hubs CAUTION • Do not allow anti-seize compound to contact the brake drum or shoes. Slide hub (6) onto axle shaft (Figure 24-3, Page 24-4). Install the large flat washer (5) onto the threaded portion of the axle. Install hub nut (4) and advance the nut to the large flat washer.
Page 448: Axle Tubes, Axle Shafts And Wheel Bearings
Axle Tubes, Axle Shafts and Wheel Bearings TRANSAXLE, FUJI ED65 (FOR SUBARU EX40) AXLE TUBES, AXLE SHAFTS AND WHEEL BEARINGS Removal of the transaxle is not required for servicing or replacing axle shafts, axle bearings, or axle shaft oil seals. If the transaxle is to be removed from the vehicle, do not remove the wheels, axle shafts, or axle tubes first.
Page 449: Axle Tube And Axle Shaft Installation
TRANSAXLE, FUJI ED65 (FOR SUBARU EX40) Axle Tubes, Axle Shafts and Wheel Bearings AXLE TUBE AND AXLE SHAFT INSTALLATION Clean mating surfaces of axle tube (2) flange and transaxle gearcase (4). Also clean the threads of the five axle tube mounting holes in the gearcase. See following CAUTION. CAUTION •...
Page 450: Axle Shaft Oil Seal Installation
Axle Tubes, Axle Shafts and Wheel Bearings TRANSAXLE, FUJI ED65 (FOR SUBARU EX40) Remove axle tube (2) from gearcase (4) (Figure 24-5, Page 24-6). See Axle Tube and Axle Shaft Removal on page 24-6. Pull oil seal (7) from gearcase (4). AXLE SHAFT OIL SEAL INSTALLATION Clean bore in gearcase (4) where new oil seal (7) will sit (Figure 24-5, Page 24-6).
Page 451: Transaxle Removal
TRANSAXLE, FUJI ED65 (FOR SUBARU EX40) Transaxle Removal TRANSAXLE REMOVAL See General Warnings on page 1-2. Turn the key switch to the OFF position and remove the key, and place the Forward/Reverse handle in the NEUTRAL position. Disconnect battery and spark plug wire(s). See Disconnecting the Battery- Gasoline Vehicles on page 1-3. Place chocks at the front wheels and loosen lug nuts on both rear wheels.
Page 452 Transaxle Removal TRANSAXLE, FUJI ED65 (FOR SUBARU EX40) 2700 2401 Figure 24-8 Disconnect Rear Shackles Figure 24-9 Disconnect Front of Leaf Spring Position floor jack under rear crossmember of chassis or trailer hitch mount (if equipped) (Figure 24-10, Page 24-10). See WARNING “Lift only one end of the vehicle...” in General Warnings on page 1-2. Raise vehicle just enough to relieve weight on leaf springs, then remove bolts securing leaf springs to shackles (Figure 24-8, Page 24-10).
Page 453 TRANSAXLE, FUJI ED65 (FOR SUBARU EX40) Transaxle Removal Roll powertrain out from under vehicle. Place blocks under the engine pan so they will completely support the engine and keep it level to the floor (Figure 24-12, Page 24-11). See following NOTE. NOTE: Place the blocks so they will support the engine when the transaxle is detached and moved away from the powertrain.
Page 454: Transaxle Installation
Transaxle Installation TRANSAXLE, FUJI ED65 (FOR SUBARU EX40) 3063 Figure 24-13 Transaxle Mounting Bolts TRANSAXLE INSTALLATION See General Warnings on page 1-2. Installation is reverse of removal procedure. When attaching transaxle to powertrain, initially install the eight bolts (1) finger-tight (Figure 24-13, Page 24-12). Then, tighten fasteners in the following order: 1.1.
Page 455: Forward/Reverse Handle
TRANSAXLE, FUJI ED65 (FOR SUBARU EX40) Forward/Reverse Handle FORWARD/REVERSE HANDLE FORWARD/REVERSE HANDLE REMOVAL Remove the bolt (1) from the Forward/Reverse handle (2) (Figure 24-14, Page 24-13). Remove the bolts (3) from the bezel (4). Remove the bezel. FORWARD/REVERSE HANDLE INSTALLATION Install the bezel (4) and the bolts (3).
Page 456: Shifter Cable Installation
Shifter Cable TRANSAXLE, FUJI ED65 (FOR SUBARU EX40) Press in tangs (4) anchoring shifter cable (2) to chassis and push out of mounting hole. Loosen jam nuts (1) securing shifter cable (2) to FNR/accelerator cable bracket (3) (Figure 24-16, Page 24-14). Then, remove bowtie clip (3) to disconnect shifter cable end (4) from transaxle shift lever (5).
Page 457: Index
Index Index installation ............19-33 Index storage ............19-34 AC power and circuit testing ............. 18-19 testing (ERIC charger) ........15-22 testing under load........18-19, 18-38 accelerator voltage test ............18-19 cable battery charger (ERIC) ........... 15-1 installation ............21-9 AC service, incoming ........
Page 458 INDEX audible charging indicator ........11-8 seat ..............4-1 battery type............11-8 vehicle body............4-1 code a, code b, and code c ......... 11-8 clutch (torque converter) troubleshooting....23-1 connection tests ..........11-27 clutch, drive control mode ............11-7 see drive clutch ..........23-4 deterrent demo speed.........
Page 459 INDEX removal ............24-13 handle (lever)............. 24-1 switch connector, 18-pin installation ............13-5 see test procedures........18-23 removal ............13-4 installation ............19-17 testing ............12-25 removal ............19-17 front body testing ............. 18-23 see body, front ............. 4-3 electric motor front bumper............
Page 460 INDEX installation ............4-11 removal ............. 4-11 headlight ..............4-6 kill limit switch function, engine high pedal detect ........... 12-3 testing ............. 18-28 hip restraint ............4-12 hubs hub, rear installation ............24-4 removal ............24-4 leaf spring see suspension, front and suspension, rear........9-3, 9-6, 9-9, 9-12, 9-15 low oil warning light installation ............
Page 461 INDEX installation ............13-8 see suspension, rear ..........9-1 removal ............. 13-8 rear underbody testing ........... 12-24, 12-30 installation ..........4-15, 4-23 muffler removal .............4-15, 4-23 installation ............22-1 rear wheel bearing removal ............. 22-1 see wheel bearing ..........24-7 see also exhaust system........22-1 receptacle see charger receptacle ........
Page 462 INDEX installation ............20-6 suspension, front (lifted) removal ............. 20-5 components testing ............... 20-6 control arm, installation........7-23 specifications control arm, removal ........7-22 vehicle..............2-1 leaf spring removal.......... 7-18 speed controller leaf spring, installation ........7-18 connector, 16-pin shock absorber, installation......7-25 see test procedures........
Page 463 INDEX reverse buzzer ..........18-37 reverse buzzer limit switch ........ 18-37 test procedures, CDT connection......11-27 solenoid............18-29 test procedures, charger starter/generator..........18-32 AC power and continuity test of AC circuit... 15-22 voltage regulator ..........18-34 battery condition using charger......15-22 test procedures, index of battery voltage using multimeter ......
Page 464 INDEX gasoline vehicle ..........18-2 underbody bracket ........... 4-7 universal accessory mounting......... 4-12 usb port (electric) installation ............13-4 removal ............. 13-3 Visage connector, 4-pin see test procedures......12-39, 18-43 voltage regulator installation ............19-15 removal ............19-15 testing ............. 18-34 walk away braking ..........
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