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Club Car Precedent 2016 Manuals
Manuals and User Guides for Club Car Precedent 2016. We have
1
Club Car Precedent 2016 manual available for free PDF download: Maintenance And Service Manual
Club Car Precedent 2016 Maintenance And Service Manual (440 pages)
Electric Vehicle with ERIC Charging System Gasoline Vehicle with Subaru EX40 Engine
Brand:
Club Car
| Category:
Golf Cars
| Size: 24.2 MB
Table of Contents
Table of Contents
5
SECTION 1 - Safety
17
Safety Details
17
General Warnings
18
Disabling the Vehicle
19
Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles
19
Side-Post Battery: Connecting the Battery-Gasoline Vehicles
19
Top-Post Battery: Disconnecting the Battery- Gasoline Vehicles
20
Top-Post Battery: Connecting the Battery- Gasoline Vehicles
20
Disconnecting the Batteries - Electric Vehicles
21
Connecting the Batteries - Electric Vehicles
21
Recycling Lead-Acid Batteries
22
International Safety Symbols on Batteries
22
SECTION 2 - Vehicle Specifications
23
Vehicle Specifications - Electric and Subaru EX40
23
E.r.I.C. Battery Charger Specifications
26
SECTION 3 - General Information
27
Model Identification
27
Safety Committee
28
Storage - Electric Vehicle
29
Preparing the Electric Vehicle for Extended Storage
29
Returning the Stored Electric Vehicle to Service
30
Storage - Gasoline Vehicle
31
Preparing the Gasoline Vehicle for Extended Storage
31
Returning the Stored Gasoline Vehicle to Service
32
SECTION 4 - Body and Trim
33
Cleaning the Vehicle
33
Seat
33
Front and Rear Body Repair
34
Stress Lines or Streaks
34
Minor Impact Damage/Deformations
34
Minor Scratches and Surface Blemishes
35
Gouges, Punctures, Tears, Large Scratches, and Abrasions
35
Front Body
35
Front Body Removal
35
Front Body Installation
35
Front Bumper
37
Headlight Adjustment
38
Aiming the Headlight Beam
38
Instrument Panel
39
Instrument Panel Removal
39
Instrument Panel Installation
39
Floor Mat and Retainers
40
Floor Mat Retainer Removal
40
Floor Mat Retainer Installation
40
Kick Plate and Charger Receptacle Bezel - Electric Vehicles
41
Kick Plate and Charger Receptacle Bezel Removal
41
Kick Plate and Charger Receptacle Bezel Installation
41
Kick Plate - EFI Gasoline Vehicles
42
Kick Plate Removal
42
Kick Plate Installation
42
Seat Bottom
43
Rear Body - Two-Passenger Vehicles
43
Universal Accessory Mounting
43
Seat Back and Structural Accessory Module (SAM)
44
Rear Body Components (Two-Passenger)
45
Rear Body - Four-Passenger Vehicles
48
Seat Backs
48
Seat Support
49
Foot Deck
50
Rear Body Components (Four-Passenger)
51
Canopy - Two-Passenger
52
Two-Passenger Canopy Removal
52
Two-Passenger Canopy Installation
54
Canopy - Four-Passenger
55
Four-Passenger Canopy Removal
55
Four-Passenger Canopy Installation
55
Canopy (Monsoon Version) - Four-Passenger
57
Monsoon Canopy Removal
57
Monsoon Canopy Installation
57
SECTION 5 - Accelerator and Brake Pedal Group
61
Pedal Group - Electric Vehicle
61
Pedal Group Removal
61
Mcor
63
Pedal Group Installation
63
Pedal Group - Gasoline Vehicle
64
Pedal Group Removal
64
Throttle Position Sensor
65
Pedal Group Installation
66
Debris Shields
66
Accelerator Pedal Removal
66
Accelerator Pedal Installation
66
Brake Pedal Removal
67
Brake Pedal Installation
67
SECTION 6 - Wheel Brake Assemblies
69
General Information
69
Brake Shoe Removal
71
Brake Assembly Cleaning
73
Brake Shoe Installation
75
Brake Cable Equalizer Adjustment
78
Brake Cluster Removal and Installation
79
Brake Cluster Removal
79
Brake Cluster Installation
79
Brake Cable Removal and Installation
81
Brake Cable Removal
81
Brake Cable Installation
82
SECTION 7 - Steering and Front Suspension
83
General Information
83
Steering Wheel
83
Steering Wheel Removal
83
Steering Wheel Installation
84
Steering Column
84
Steering Column Removal
84
Steering Column Installation
85
Rack and Pinion
86
Rack and Pinion Inspection
86
Rack and Pinion Removal
87
Rack and Pinion Installation
87
Front Suspension
88
Lubrication
88
Wheel Alignment
88
Front Suspension Components
90
Tie Rod End Removal
90
Tie Rod Installation
90
Leaf Spring Removal
91
Leaf Spring Installation
91
Kingpin and Steering Spindle Removal
91
Kingpin and Steering Spindle Installation
92
Control Arm Removal
92
Control Arm Installation
93
Shock Absorber Removal
93
Shock Absorber Installation
93
Front Wheel Bearings and Hubs
96
Front Wheel Free Play Inspection
96
Front Hub Removal
96
Hub Installation
96
SECTION 8 - Wheels and Tires
99
General Information
99
Wheels
99
Wheel Removal
99
Wheel Installation
99
Tires
100
Tire Removal
100
Tire Repair
100
Tire Installation
101
SECTION 9 - Rear Suspension
103
General Information
103
Shock Absorbers
103
Shock Absorber Removal and Inspection
103
Shock Absorber Installation
103
Leaf Springs (Two-Passenger Vehicles)
104
Leaf Spring Removal (Two-Passenger Vehicles)
104
Leaf Spring Installation (Two-Passenger Vehicles)
105
Leaf Springs (Four-Passenger Vehicles)
107
Leaf Spring Removal (Four-Passenger Vehicles)
107
Leaf Spring Installation (Four-Passenger Vehicles)
109
SECTION 10 - Periodic Maintenance
111
General Information
111
Pre-Operation and Daily Safety Checklist
111
Performance Inspection
112
Maintenance
113
Periodic Service Schedules
114
Periodic Lubrication Schedules
118
SECTION 11 - Controller Diagnostic Tool (CDT)
121
General Information
122
Features
122
Plugging the CDT into the Vehicle
123
Introductory Display
123
Quick Reference Guide - Excel with ERIC Charging System
124
System Info
125
Model Number
125
Serial Number
125
Hardware Version
125
Protocol Version
125
Param Block Version
125
MFG Date Code
125
OS Version
125
SM Version
125
VCL App Version
125
Parameters
126
Settings
126
Amp Hours
128
Access Codes
128
Vehicle ID
129
Monitor Menu
129
Batt Voltage
130
Min I
130
Signed Battery Current
130
BDI Percent
130
Speed
130
Throttle
130
Temperature
130
Arm Current
130
Field Current
130
Armature PWM
131
Field PWM
131
Speed Pulses
131
Foot Input
131
Key Input
131
Forward Input
131
Reverse Input
131
Mode Switch Input
131
Charger Inhibit
131
Main Cont Driver
131
Password Tries (OEM Access Level Only)
132
Odometer
132
BDI Info
132
Battery Monitor
132
Charging Totals
132
Amp Hours Display
133
Lin
133
Vehicle Speeds
133
Pedal Counters
133
Fault Counters
133
Fault Count Odometers
133
Diagnostics Menu
134
Present Errors Folder
134
Fault History Folder
134
Causes of Faults
135
Fault Recovery
137
Fault Descriptions
138
Incorrect Password (OEM Access Level Only)
138
Max Password Tries (OEM Access Level Only)
138
Throttle Fault
138
Low Battery Voltage (Undervoltage)
138
Overvoltage
138
Thermal Cutback
139
Anti-Tamper Fault
139
Hpd
139
Main Drvr Overcurrent
139
Lockout Fault
139
Low SOC
139
Main Welded
140
High Speed Walkaway
140
Speed Sensor
140
Main Driver on
140
Main Coil Open
140
Main Dropout (1 or 2)
141
Motor Stall
141
Main Driver off
141
Current Sense Fault
141
M- Shorted
141
FLD (Field) Missing
142
HW Failsafe
142
Fault History
142
Clear Fault History
142
Programming
142
Cloning
143
Favorites
143
HHP Settings
143
Plot & Log
145
Plot
145
Log
145
CDT Troubleshooting
146
Connection Tests
147
SECTION 12 - Excel System Troubleshooting: with ERIC Charging
151
General Information
151
Accessories
151
Charge Indicator Light
151
Attributes of the Excel System
151
Key Differences: Excel with ERIC Charging System Vs. Powerdrive Chargers
152
Features
152
Wiring Diagrams
154
Troubleshooting
161
Troubleshooting the Vehicle with the CDT
161
Troubleshooting Guide 1
161
Troubleshooting Guide 2
164
Test Procedures
167
Testing Basics
167
SECTION 13 - Electrical Components: Electric Vehicle with ERIC Charging
189
Key Switch
189
Testing the Key Switch
189
Key Switch Removal
189
Key Switch Installation
189
Charge Indicator Light
190
Testing the Charge Indicator Light
190
Charge Indicator Light Removal
190
Charge Indicator Light Installation
190
Forward/Reverse Rocker Switch
191
Testing the Forward/Reverse Rocker Switch
191
Forward/Reverse Rocker Switch Removal
191
Forward/Reverse Rocker Switch Installation
192
Electronics Module Cover
193
Electronics Module Cover Removal
193
Electronics Module Cover Installation
193
Tow/Run Switch
194
Testing the Tow/Run Switch
194
Tow/Run Switch Removal
194
Tow/Run Switch Installation
194
Motor Controller Output Regulator (MCOR)
195
Testing the MCOR
195
MCOR Removal
195
MCOR Installation
195
Reverse Buzzer
196
Testing the Reverse Buzzer
196
Reverse Buzzer Removal
196
Reverse Buzzer Installation
196
Electronics Module
197
Electronics Module Removal
197
Electronics Module Installation
198
Speed Controller
199
Testing the Solid State Speed Controller
199
Speed Controller Removal
199
Speed Controller Installation
199
Solenoid
200
Testing the Solenoid
200
Solenoid Removal
200
Solenoid Installation
201
Charger Receptacle
201
Testing the Charger Receptacle
201
Charger Receptacle Inspection
201
Charger Receptacle Removal
201
Charger Receptacle Installation
202
SECTION 14 - Batteries: Electric Vehicle with ERIC Charging
203
General Information
203
Battery Testing Basics - 8 Volt
204
Observation
204
Measuring Voltage of Battery Set
204
Battery Cell Numbering
204
Battery Testing - 8 Volt
205
Battery Regrouping
205
Battery Replacement
207
Battery Care
208
Water Quality
208
Deionizer
209
Battery Care - Vehicles Equipped with the Single-Point Watering System
210
Battery Care - Vehicles Without the Single-Point Watering System
211
Self-Discharge
212
Electrolyte Level
212
Vibration Damage
213
Single Point Watering System (SPWS)
213
Initial Maintenance of the SPWS
213
Watering Batteries with the SPWS
213
Battery Storage
215
Fleet Rotation
215
Deep-Discharge
216
Early Excessive Discharging
216
SECTION 15 - Battery Charger: for ERIC Charging System
217
General Information
218
USB Service Port
219
UL and CSA Listing
219
CE Compliance
219
Plug and Receptacle
219
Charger Power Connection Fuse
220
Charger Interlock
220
AC Input Voltage Detection
220
Thermal Cutback
220
Charge Indicator Light
220
Charger Status Indicators
220
Long-Term Storage
221
External Charger Mounting
222
AC Power Connection
223
The Charge Circuit
224
Charger Operation
225
Charging Batteries
225
Charger Maintenance
228
USB Service Port Cleaning and Care
228
Charger Troubleshooting
229
Numbering Vehicles and Chargers
229
USB Service Port
229
Incoming AC Service
229
Terminal Block Cover
230
Resetting Power - External Charger
230
Resetting Power - Onboard Charger
230
Charger Troubleshooting Indicators
231
Test Procedures
233
External Charger Repairs
236
Terminal Block Cover Removal
236
Terminal Block Cover Installation
237
DC Cord and Strain Relief Removal
237
DC Cord and Strain Relief Installation
237
Handle Removal
237
Handle Installation
238
Foot Removal
238
Foot Installation
238
Onboard Charger Repairs
239
Onboard Charger Removal
239
Onboard Charger Installation
240
Terminal Block Cover Removal
240
Terminal Block Cover Installation
240
DC Cord and Strain Relief Removal
241
DC Cord and Strain Relief Installation
241
DC Charging Harness Removal
241
DC Charging Harness Installation
242
SECTION 16 - Motor (Model EJ8-4001A): Electric Vehicle
243
General Information
243
External Motor Testing
243
Motor
246
Motor Removal
246
Motor Disassembly
247
Motor Component Testing and Inspection
250
Armature Inspection and Testing
250
Motor Frame and Field Windings Inspection
252
Motor Brush, Spring, and Terminal Insulator Inspection
252
Reconditioning the Motor
255
Motor Specifications
255
Motor Assembly
255
Motor Installation
257
SECTION 17 - Transaxle: Electric Vehicle
261
Lubrication
261
Axle Bearing and Shaft
261
Axle Shaft
261
Axle Bearing
264
Transaxle Removal
265
Transaxle Disassembly, Inspection, and Assembly
267
Transaxle Disassembly and Inspection
267
Transaxle Assembly
269
Transaxle Installation
270
SECTION 18 - Troubleshooting and Electrical System - Subaru EX40
273
General Information
273
Accessories
273
Low Oil Warning Light
273
Ground Locations
273
Features of the Electronic Fuel Injection (EFI) System
274
Troubleshooting Guide
274
ECU Error Codes (Displayed by the Low Oil Warning Light)
274
Gasoline Powertrain
276
Wiring Diagrams
280
Electrical System
285
Test Procedures
286
Testing Basics
286
SECTION 19 - Electrical Components - Subaru EX40
315
Starter/Generator
315
Starter/Generator Removal
315
Disassembly of the Starter/Generator to Service the Brushes
315
Brush Inspection and Replacement
316
Brush Spring Inspection and Replacement
316
Starter/Generator Assembly
317
Disassembly of the Starter/Generator to Service the Armature/Commutator
318
Bearing Cleaning and Inspection
319
Bearing Removal
320
Field Coil Removal
320
Visual Inspection of Armature
320
Commutator Cleaning and Inspection
321
Armature Ground Test
322
Visual Inspection of Field Coils
323
Starter/Generator Rework
323
Starter/Generator Assembly
324
Starter/Generator Installation
325
Belt Tension Adjustment for EFI Engines with P/N 105205401 Belt
326
Belt Tension Adjustment for EFI Engines with P/N 47539338001 Belt
329
Voltage Regulator
331
Voltage Regulator Removal
331
Voltage Regulator Installation
332
Engine Control Unit (ECU)
333
Engine Control Unit Removal
333
Engine Control Unit Installation
333
Key Switch
334
Key Switch Removal
334
Key Switch Installation
334
Maintenance/Operate Switch
335
Maintenance/Operate Switch Removal
335
Maintenance/Operate Switch Installation
335
Neutral Lockout Limit Switch
336
Neutral Lockout Limit Switch Removal
336
Neutral Lockout Limit Switch Installation
336
Testing the Solenoid
337
Solenoid Removal
337
Solenoid Installation
337
Fuse
338
Fuse Removal
338
Fuse Installation
338
Accelerator Pedal Limit Switch
339
Testing the Accelerator Pedal Limit Switch
339
Kill Limit Switch
339
Testing the Kill Limit Switch
339
Reverse Warning Buzzer
339
Reverse Warning Buzzer Removal
339
Reverse Warning Buzzer Installation
340
Reverse Buzzer Limit Switch
341
Reverse Buzzer Limit Switch Removal
341
Reverse Buzzer Limit Switch Installation
341
Low Oil Warning Light
342
Low Oil Warning Light Removal
342
Low Oil Warning Light Installation
342
Fuel Gauge
343
Fuel Gauge Removal
343
Fuel Gauge Installation
343
Fuel Level Sending Unit
344
Hour Meter
344
Testing the Hour Meter
344
Hour Meter Removal
344
Hour Meter Installation
344
Oil Level Sensor
345
Oil Level Sensor Removal
345
Oil Level Sensor Installation
345
General Information - Side-Post Battery
347
General Information - Top-Post Battery
347
Testing the Battery
347
Preventive Maintenance - Side-Post Battery Only
347
Water Level - Side-Post Battery
348
Self-Discharge
348
Vibration Damage
348
Mineral Content - Side-Post Battery Only
349
Battery Removal
350
Charging the Battery
350
Battery Installation
350
Battery Storage
351
Charging a Dead Battery
351
Ground Cables
351
SECTION 20 - Engine - Subaru EX40
353
General Information
353
Before Servicing
353
Engine Rotation
353
Torque Specifications
354
Adjustments and Settings
354
Engine Oil - Gasoline Vehicle
354
Spark Plug
357
Breather
358
Valve Clearance Check and Adjustment
359
Engine Removal
360
Engine Removal to MID-2016 Model Year
360
Engine Removal from MID-2016 Model Year
362
Engine Installation
363
Engine Installation to MID-2016 Model Year
363
Engine Installation from MID-2016 Model Year
363
Flywheel
365
Flywheel Removal
365
Flywheel Installation
366
Oil Level Sensor
367
Testing the Oil Level Sensor
367
Oil Level Sensor Removal
367
Oil Level Sensor Installation
367
Ignition Coil
368
Testing the Ignition Coil
368
Ignition Coil Removal
368
Ignition Coil Installation
368
Snubber
369
Snubber Removal
369
Snubber Installation
369
SECTION 21 - Fuel System - Subaru EX40
371
General Information
371
EFI System Features/Specifications
371
Relieving Fuel Pressure
372
To Relieve Fuel Pressure
372
Throttle Body
373
Throttle Body Removal
373
Throttle Body Installation
375
Tools Required for this Section
419
Rear Hubs
420
Rear Hub Removal
420
Rear Hub Installation
420
Axle Tubes, Axle Shafts and Wheel Bearings
422
Axle Tube and Axle Shaft Removal
422
Axle Tube and Axle Shaft Installation
423
Rear Wheel Bearing Removal
423
Rear Wheel Bearing Installation
423
Axle Shaft Oil Seal Removal
423
Axle Shaft Oil Seal Installation
424
Transaxle Removal
425
Transaxle Installation
428
Shifter Cable
429
Shifter Cable Removal
429
Shifter Cable Installation
429
Shifter Cable Adjustment
430
Index
438
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