Page 1 2016 Precedent Golf Car Maintenance and Service Manual Electric Vehicle with ERIC Charging System Gasoline Vehicle with Subaru EX40 Engine Manual Number 105334701 Edition Code 0515F1015E...
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 Deionizer Filter Replacement Cartridge (non-SPWS) CC PN AM10975 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 Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles..............1-3 Side-Post Battery: Connecting the Battery-Gasoline Vehicles ............... 1-3 Top-Post Battery: Disconnecting the Battery- Gasoline Vehicles ..............1-4 Top-Post Battery: Connecting the Battery- Gasoline Vehicles ...............
Page 6 Seat Back and Structural Accessory Module (SAM) ................... 4-12 Rear Body Components (Two-Passenger)....................4-13 Rear Body – Four-Passenger Vehicles......................4-16 Seat Backs.............................. 4-16 Seat Support ............................4-17 Foot Deck ............................... 4-18 Rear Body Components (Four-Passenger) ....................4-19 Canopy – Two-Passenger ..........................4-20 Two-Passenger Canopy Removal ......................
Page 7 Tie Rod End Removal ..........................7-8 Tie Rod Installation ............................ 7-8 Leaf Spring Removal ..........................7-9 Leaf Spring Installation..........................7-9 Kingpin and Steering Spindle Removal ....................... 7-9 Kingpin and Steering Spindle Installation....................7-10 Control Arm Removal..........................7-10 Control Arm Installation ..........................7-11 Shock Absorber Removal..........................7-11 Shock Absorber Installation ........................7-11 Front Wheel Bearings and Hubs ........................
Page 8 SM Version ..............................11-5 VCL App Version ............................11-5 Parameters ..............................11-6 Settings ..............................11-6 Amp Hours...............................11-8 Access Codes ............................11-8 Vehicle ID ..............................11-9 Monitor Menu ...............................11-9 Batt Voltage............................11-10 V min I ..............................11-10 Signed Battery Current..........................11-10 BDI Percent............................11-10 Speed ..............................11-10 Throttle ..............................
Page 9 Current Sense Fault..........................11-21 M– Shorted ............................11-21 FLD (Field) Missing..........................11-22 HW Failsafe ............................11-22 Fault History............................11-22 Clear Fault History ..........................11-22 Programming ............................. 11-22 Cloning ..............................11-23 Favorites..............................11-23 HHP Settings ............................. 11-23 Plot & Log ..............................11-25 Plot................................
Page 10 Speed Controller ............................13-11 Testing the Solid State Speed Controller ....................13-11 Speed Controller Removal ........................13-11 Speed Controller Installation........................13-11 Solenoid..............................13-12 Testing the Solenoid ..........................13-12 Solenoid Removal ..........................13-12 Solenoid Installation..........................13-13 Charger Receptacle ............................13-13 Testing the Charger Receptacle.......................13-13 Charger Receptacle Inspection........................13-13 Charger Receptacle Removal........................13-13 Charger Receptacle Installation .......................13-14 SECTION 14 —...
Page 11 Incoming AC Service ..........................15-13 Terminal Block Cover ..........................15-14 Resetting Power – External Charger ......................15-14 Resetting Power – Onboard Charger .......................15-14 Charger Troubleshooting Indicators ......................15-15 Test Procedures ............................15-17 External Charger Repairs ..........................15-20 Terminal Block Cover Removal ........................15-20 Terminal Block Cover Installation ......................15-21 DC Cord and Strain Relief Removal ......................15-21 DC Cord and Strain Relief Installation ......................15-21 Handle Removal .............................15-21...
Page 12 Electrical System ............................18-13 Test Procedures ............................18-14 Testing Basics ............................18-14 SECTION 19 — Electrical Components – Subaru EX40 ..................19-1 Starter/Generator............................19-1 Starter/Generator Removal ........................19-1 Disassembly of the Starter/Generator to Service the Brushes ..............19-1 Brush Inspection and Replacement......................19-2 Brush Spring Inspection and Replacement ....................
Page 13 Hour Meter..............................19-30 Testing the Hour Meter..........................19-30 Hour Meter Removal..........................19-30 Hour Meter Installation ..........................19-30 Oil Level Sensor ............................19-31 Oil Level Sensor Removal ........................19-31 Oil Level Sensor Installation ........................19-31 Battery ...............................19-32 General Information – Side-Post Battery ....................19-33 General Information – Top-Post Battery....................19-33 Testing the Battery ..........................19-33 Preventive Maintenance –...
Page 14 Engine Control Linkages ..........................21-6 General Information ..........................21-6 Ground Speed............................21-7 Governor Cable ............................21-7 Accelerator Cable ............................ 21-8 Closed Throttle or Idle Adjustment – Pedal-Start Vehicles .................21-10 How to Measure Ground Speed.......................21-10 Engine RPM Adjustment ......................... 21-11 Air Intake System ............................21-12 General Information ..........................21-12 Air Filter ..............................21-12 Air Intake System Removal ........................21-13...
Page 15 SECTION 24 — Transaxle, Fuji ED65 (for Subaru EX40) ................... 24-1 General Information ............................. 24-1 Shifter Lever............................24-1 Neutral Lockout ............................24-1 Governor System............................. 24-2 Transaxle Service ............................ 24-2 Lubrication .............................. 24-2 Tools Required For This Section ....................... 24-3 Rear Hubs..............................24-4 Rear Hub Removal ..........................
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: Top-Post Battery: Disconnecting The Battery- Gasoline Vehicles
General Warnings SAFETY (–) (–) (Viewed from driver side of vehicle) 1. Remove negative battery cable. (Viewed from driver side of vehicle) 2. Remove positive battery cable. 1. Place TOW/RUN Switch in TOW before disconnecting or connecting Connect battery cables in reverse order. battery cables.
Page 21: Disconnecting The Batteries - Electric Vehicles
SAFETY General Warnings (–) (Viewed from driver side of vehicle) 1. Remove positive terminal cover. 2. Remove negative battery cable. 3. Remove positive battery cable. Connect battery cables in reverse order. 3167 Figure 1-3 Top-Battery: Battery Cable Removal-Gasoline Vehicles DISCONNECTING THE BATTERIES – ELECTRIC VEHICLES Disable the vehicle.
Page 22: 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 23: Section 2 - Vehicle Specifications
SECTION 2 — VEHICLE SPECIFICATIONS VEHICLE SPECIFICATIONS – ELECTRIC AND SUBARU EX40 Vehicle Specifications TWO- TWO- FOUR- FOUR- PASSENGER PASSENGER PASSENGER PASSENGER SPECIFICATIONS ELECTRIC GASOLINE ELECTRIC GASOLINE VEHICLE VEHICLE VEHICLE VEHICLE POWER SOURCE Drive motor: Direct drive, 48 volts DC, shunt-wound, ●...
Page 24 Vehicle Specifications – Electric and Subaru EX40 VEHICLE SPECIFICATIONS TWO- TWO- FOUR- FOUR- PASSENGER PASSENGER PASSENGER PASSENGER SPECIFICATIONS ELECTRIC GASOLINE ELECTRIC GASOLINE VEHICLE VEHICLE VEHICLE VEHICLE Brakes: Dual rear wheel self-adjusting brakes with cast iron drums and single brake pedal with ●...
Page 25 VEHICLE SPECIFICATIONS Vehicle Specifications – Electric and Subaru EX40 TWO- TWO- FOUR- FOUR- PASSENGER PASSENGER PASSENGER PASSENGER SPECIFICATIONS ELECTRIC GASOLINE ELECTRIC GASOLINE VEHICLE VEHICLE VEHICLE VEHICLE NOISE AND VIBRATION Drive-by noise level to operator 68.5 dBA 75.5 dBA 68.5 dBA 75.5 dBA Test method: EN 12053:2001 Uncertainty: 2 dBA...
Page 26: E.r.i.c. Battery Charger Specifications
E.R.I.C. Battery Charger Specifications VEHICLE 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 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: Safety Committee
• Where golf cars should be driven. • Ensuring that proper warnings of driving hazards are displayed and visible. See below for list of signs available from Club Car Service Parts Department. • Who should and who should not drive golf cars.
Page 29: Storage - Electric Vehicle
GENERAL INFORMATION Storage – Electric Vehicle 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 30: Returning The Stored Electric Vehicle To Service
Storage – Electric Vehicle GENERAL INFORMATION Store vehicle in a cool, dry place. This will minimize battery self-discharge. Adjust tires to recommended tire pressure. Perform semiannual periodic lubrication. Thoroughly clean front body, rear body, seats, battery compartment, and underside of vehicle. Do not engage the park brake.
Page 31: Storage - Gasoline Vehicle
GENERAL INFORMATION Storage – Gasoline Vehicle 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 32: Returning The Stored Gasoline Vehicle To Service
Storage – Gasoline Vehicle GENERAL INFORMATION Adjust tires to recommended tire pressure. See Vehicle Specifications – Electric and Subaru EX40 on page 2-1. Perform semiannual periodic lubrication. See Periodic Lubrication Schedules on page 10-8. Thoroughly clean front body, rear body, seats, engine compartment, and underside of vehicle. Do not engage the park brake.
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 2016 Precedent Golf Car Maintenance and Service Manual...
Page 37: Front Bumper
BODY AND TRIM Front Bumper FRONT BUMPER The underbody bracket (1) connects the front suspension to the front underbody (Figure 4-2, Page 4-5). Each bracket is secured in place by two taptite screws (2) tightened to 13 ft·lb (17.6 N·m). The front bumper (3) is attached to the vehicle frame rails by nuts (5) and bolts (4).
Page 38: Headlight Adjustment
Headlight Adjustment BODY AND TRIM HEADLIGHT ADJUSTMENT Headlights are available as an accessory on this vehicle. To raise or lower the headlight beam, washers can be added to the mounting hardware between the headlight and the bumper assembly. See General Warnings on page 1-2. AIMING THE HEADLIGHT BEAM Park the vehicle on a level surface 5 feet away from, and facing a vertical surface such as a garage door or wall.
Page 39: Instrument Panel
BODY AND TRIM Instrument Panel 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 4-4, Page 4-7). 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 40: Floor Mat And Retainers
Floor Mat and Retainers BODY AND TRIM 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 4-5, Page 4-8).
Page 41: Kick Plate And Charger Receptacle Bezel - Electric Vehicles
Kick Plate and Charger Receptacle Bezel BODY AND TRIM – Electric Vehicles 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 4-6, Page 4-9).
Page 42: Kick Plate - Efi Gasoline Vehicles
Kick Plate – EFI Gasoline Vehicles BODY AND TRIM 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 4-8. Remove three screws (1) that hold the kick plate (2) to the vehicle (Figure 4-7, Page 4-10). Remove the two front screws (3) that hold the beauty panel to the vehicle.
Page 43: Seat Bottom
BODY AND TRIM Seat Bottom SEAT BOTTOM The seat bottom (1) is secured to the vehicle with two hinges (2) (Figure 4-8, Page 4-11) that hook into slots in the body. When replacing the hinges (2), tighten screws (3) to 75 in·lb (8.5 N·m). When replacing hip restraints (4), tighten screws (5) to 65 in·lb (7.3 N·m).
Page 44: Seat Back And Structural Accessory Module (Sam)
Rear Body – Two-Passenger Vehicles BODY AND TRIM Figure 4-9 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 4-10, Page 4-13). SAM Installation Position the SAM (3) over its mounting holes and secure with four screws (4).
Page 45: Rear Body Components (Two-Passenger)
BODY AND TRIM Rear Body – Two-Passenger Vehicles 2653 Figure 4-10 Seat Back, Bag Rack and SAM REAR BODY COMPONENTS (TWO-PASSENGER) Rear Beauty Panel Removal Remove SAM. See SAM Removal on page 4-12. 2016 Precedent Golf Car Maintenance and Service Manual Page 4-13...
Page 46 Rear Body – Two-Passenger Vehicles BODY AND TRIM Remove one screw (3) from each canopy support bracket (1 and 2) (Figure 4-11, Page 4-15). Remove canopy supports. Remove four screws (13) attaching the rear beauty panel (12). Remove two screws (14) and remove Forward/Reverse switch housing (15) from vehicle. Disconnect electrical wires from the Forward/Reverse switch (16).
Page 47 BODY AND TRIM Rear Body – Two-Passenger Vehicles * Two-Passenger Vehicles Only 2656 Figure 4-11 Rear Body Components 2016 Precedent Golf Car Maintenance and Service Manual Page 4-15...
Page 48: Rear Body - Four-Passenger Vehicles
Rear Body – Four-Passenger Vehicles BODY AND TRIM REAR BODY – FOUR-PASSENGER VEHICLES See General Warnings on page 1-2. SEAT BACKS Seat Back Removal Remove screws (9 or 13) securing seat back (8 or 11) to seat support and remove the seat back (Figure 4-12, Page 4-16).
Page 49: Seat Support
BODY AND TRIM Rear Body – Four-Passenger Vehicles SEAT SUPPORT Seat Support Removal Remove screws (11 and 14) securing the rear hip restraints (6) and remove the hip restraints from the vehicle (Figure 4-13, Page 4-18). Remove the screws (5) and bolts (4) from the seat supports (3) and remove the seat supports from the vehicle. Seat Support Installation Install in the reverse order of removal.
Page 50: Foot Deck
Rear Body – Four-Passenger Vehicles BODY AND TRIM TYPICAL 4 PLACES REAR BEAUTY PANEL NOT SHOWN FOR CLARITY TYPICAL 4 PLACES 2658 Figure 4-13 Seat Supports (Four-Passenger Vehicles) FOOT DECK Foot Deck Removal Remove screws (11 and 14) securing the rear hip restraints (6) and remove the hip restraints from the vehicle (Figure 4-13, Page 4-18).
Page 51: Rear Body Components (Four-Passenger)
BODY AND TRIM Rear Body – Four-Passenger Vehicles TYPICAL 10 PLACES TYPICAL 6 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES 2659 Figure 4-14 Foot Deck (Four-Passenger Vehicles) REAR BODY COMPONENTS (FOUR-PASSENGER) Rear Beauty Panel Removal Remove seat support. See Seat Support Removal on page 4-17. Remove four screws (13) attaching the rear beauty panel (12) (Figure 4-11, Page 4-15).
Page 52: Canopy - Two-Passenger
Canopy – Two-Passenger BODY AND TRIM Rear Underbody Removal Remove four screws (5) attaching the rear underbody (4) to vehicle (Figure 4-11, Page 4-15). Lift the rear edge of the rear underbody (4) until the front portion slides out from beneath the front underbody. Remove the rear underbody from the vehicle.
Page 53 BODY AND TRIM Canopy – Two-Passenger 2378 Figure 4-15 Precedent Two-Passenger Canopy 2016 Precedent Golf Car Maintenance and Service Manual Page 4-21...
Page 54: Two-Passenger Canopy Installation
Canopy – Two-Passenger BODY AND TRIM 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 as shown (Figure 4-15, Page 4-21). 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 55: Canopy - Four-Passenger
BODY AND TRIM Canopy – Four-Passenger 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) (Figure 4-16, Page 4-24). FOUR-PASSENGER CANOPY REMOVAL Remove the two nuts (12), two bolts (11), and spacers (10) from the canopy (9), and each front canopy support (1) (Figure 4-16, Page 4-24).
Page 56 Canopy – Four-Passenger BODY AND TRIM Figure 4-16 Precedent Four-Passenger Canopy Page 4-24 2016 Precedent Golf Car Maintenance and Service Manual...
Page 57: Canopy (Monsoon Version) - Four-Passenger
BODY AND TRIM Canopy (Monsoon Version) – Four-Passenger CANOPY (MONSOON VERSION) – FOUR-PASSENGER See General Warnings on page 1-2. CAUTION • To prevent damage to the canopy, do not remove the canopy supports (1, 2, 8 and 9) from the vehicle without first removing the canopy (13) (Figure 4-19, Page 4-28).
Page 58 Canopy (Monsoon Version) – Four-Passenger BODY AND TRIM K-00834 Figure 4-17 Secure Rear Drain Struts to Seat Supports Attach the front struts. 2.1. Ensure the front struts are properly oriented to the correct side of the vehicle as shown (Figure 4-18). The lower profile of each support follows the profile of the vehicle.
Page 59 BODY AND TRIM Canopy (Monsoon Version) – Four-Passenger K-00504 Figure 4-18 Properly Orient the Front Supports With the aid of an assistant, position the canopy (13) to the top of the front struts (8 and 9) and rear drain struts (1 and 2). Secure the front canopy brackets (under the canopy) (14) to the front struts (8 and 9) with four grey M6x1 x 45 hex head bolts (15), eight rubber faced conical washers (20), and four M6 flanged nylon lock nuts (17).
Page 60 Canopy (Monsoon Version) – Four-Passenger BODY AND TRIM K-00835 Figure 4-19 Secure Canopy Page 4-28 2016 Precedent Golf Car Maintenance and Service Manual...
Page 61: 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 62 Pedal Group – Electric Vehicle ACCELERATOR AND BRAKE PEDAL GROUP 2518 Figure 5-2 Pedal Group – Electric Vehicle Page 5-2 2016 Precedent Golf Car Maintenance and Service Manual...
Page 63: Mcor
ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group – Electric Vehicle MCOR The pedal group for the Precedent 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 64: 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 Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline Vehicles on page 1-4.
Page 65: 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 Precedent vehicle includes a throttle position sensor mounted on the side of the accelerator pedal assembly.
Page 66: 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 67: Brake Pedal Removal
ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal Removal Install debris shields (4 and 5). Electric Vehicle: Install the MCOR. See MCOR Installation on page 13-7. Install pedal group in vehicle. See Pedal Group Installation on page 5-3. See Pedal Group Installation on page 5-6.
Page 68 Brake Pedal Installation ACCELERATOR AND BRAKE PEDAL GROUP 000487-002 Figure 5-5 Accelerator Pedal Assembly and Brake Pedal Assembly Page 5-8 2016 Precedent Golf Car Maintenance and Service Manual...
Page 69: 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 70 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 71: Brake Shoe Removal
WHEEL BRAKE ASSEMBLIES Brake Shoe Removal 2731 Figure 6-3 Self-adjusting Wheel Brake Assembly Grasp both brake shoes and pull them, together with the springs, out of the brake assembly as shown (Figure 6-5, Page 6-4). Remove adjuster wheel (1) with two washers (2 and 3) from the backing plate (Figure 6-6, Page 6-4). 2016 Precedent Golf Car Maintenance and Service Manual Page 6-3...
Page 72 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES 1400-18100-10222 1400-17700-10225 Figure 6-4 Remove Shoe Retainer Clip Figure 6-5 Remove Brake Shoes 1. Slide 2732 2733 Figure 6-6 Remove Adjuster Wheel Figure 6-7 Lubricate Slide Page 6-4 2016 Precedent Golf Car Maintenance and Service Manual...
Page 73: Brake Assembly Cleaning
WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning 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 6-7, Page 6-4).
Page 74 Brake Assembly Cleaning WHEEL BRAKE ASSEMBLIES 2735 2736 Figure 6-10 Apply Grease To Brake Adjuster Figure 6-11 Install Adjuster Wheel, Trailing Shoe Page 6-6 2016 Precedent Golf Car Maintenance and Service Manual...
Page 75: Brake Shoe Installation
WHEEL BRAKE ASSEMBLIES Brake Shoe Installation 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 6-11, Page 6-6).
Page 76 Brake Shoe Installation WHEEL BRAKE ASSEMBLIES Figure 6-14 Install Leading Shoe Figure 6-15 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 6-16, Page 6-8). Remove the screwdriver. Figure 6-16 Set Adjusting Wheel For electric vehicles: Install the axle shaft.
Page 77 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation Figure 6-17 Equalizer Adjustment 2016 Precedent Golf Car Maintenance and Service Manual Page 6-9...
Page 78: Brake Cable Equalizer Adjustment
Brake Cable Equalizer Adjustment WHEEL BRAKE ASSEMBLIES 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 6-17, Page 6-9).
Page 79: Brake Cluster Removal And Installation
WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation 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 1-5.
Page 80 Brake Cluster Removal and Installation WHEEL BRAKE ASSEMBLIES Tighten lug nuts on rear wheels, using a crisscross pattern, to 55 ft·lb (74.6 N·m). See Wheel Installation on page 8-1. Adjust the brakes. See Brake Cable Equalizer Adjustment on page 6-10. Page 6-12 2016 Precedent Golf Car Maintenance and Service Manual...
Page 81: 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 1-5.
Page 82: 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 83: 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 84: Steering Wheel Installation
Steering Column STEERING AND FRONT SUSPENSION 2519 2520 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 85: 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 extending from the steering gear. Insert the end of the steering column with the universal joint through the front underbody.
Page 86: 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 87: 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 1-5. Gasoline Vehicle: Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-3.
Page 88: 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 89 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 90: Front Suspension Components
Front Suspension Components STEERING AND FRONT SUSPENSION 6.1. Loosen the jam nuts on both ends of each drag link (Figure 7-8, Page 7-7). 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.
Page 91: Leaf Spring Removal
STEERING AND FRONT SUSPENSION Front Suspension Components WARNING • The tie rod ends must be threaded into the rod at least 5/16 of an inch (8 mm). Failure to thread deep enough may cause tie rod ends to separate from the rod during adjustment or while being operated, possibly resulting in loss of vehicle control and severe personal injury.
Page 92: Kingpin And Steering Spindle Installation
Front Suspension Components STEERING AND FRONT SUSPENSION Gasoline Vehicle: Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline Vehicles on page 1-4. Remove the front hub. See Front Hub Removal on page 7-14. Remove retaining nuts (14), then remove tie rod ends (12) from the tabs on the spindles (Figure 7-10, Page 7-12).
Page 93: Control Arm Installation
STEERING AND FRONT SUSPENSION Front Suspension Components Remove the control arm (6). Inspect the bushings (7) and sleeves (8 and 9) in the control arm and replace them if necessary. CONTROL ARM INSTALLATION Install the control arm in reverse order of removal. Tighten the control arm bolts (11 and 19) to 30 ft·lb (41 N·m) (Figure 7-10, Page 7-12).
Page 94 Front Suspension Components STEERING AND FRONT SUSPENSION 1311 Figure 7-10 Upper Front Suspension Assembly Page 7-12 2016 Precedent Golf Car Maintenance and Service Manual...
Page 95 STEERING AND FRONT SUSPENSION Front Suspension Components 1312 Figure 7-11 Lower Front Suspension Assembly 2016 Precedent Golf Car Maintenance and Service Manual Page 7-13...
Page 96: 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 97 STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs Figure 7-12 Front Wheel Hub 2016 Precedent Golf Car Maintenance and Service Manual Page 7-15...
Page 98 Front Wheel Bearings and Hubs STEERING AND FRONT SUSPENSION Pagination Page Page 7-16 2016 Precedent Golf Car Maintenance and Service Manual...
Page 99: 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 100: 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 101: 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 102 Tires WHEELS AND TIRES Figure 8-2 Inflate Tire Page 8-4 2016 Precedent Golf Car Maintenance and Service Manual...
Page 103: 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 104: Leaf Springs (Two-Passenger Vehicles)
Leaf Springs (Two-Passenger Vehicles) REAR SUSPENSION LEAF SPRINGS (TWO-PASSENGER VEHICLES) See General Warnings on page 1-2. LEAF SPRING REMOVAL (TWO-PASSENGER VEHICLES) Electric Vehicle: Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-5. Gasoline Vehicle: Disconnect battery and spark plug wire(s).
Page 105: Leaf Spring Installation (Two-Passenger Vehicles)
REAR SUSPENSION Leaf Springs (Two-Passenger Vehicles) Figure 9-1 Support Vehicle on Jack Stands Figure 9-2 Disconnect Brake Cable LEAF SPRING INSTALLATION (TWO-PASSENGER VEHICLES) 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 106 Leaf Springs (Two-Passenger Vehicles) REAR SUSPENSION 2689 Figure 9-3 Rear Suspension Assembly and Mounting (Two-Passenger Vehicles) Page 9-4 2016 Precedent Golf Car Maintenance and Service Manual...
Page 107: Leaf Springs (Four-Passenger Vehicles)
REAR SUSPENSION Leaf Springs (Four-Passenger Vehicles) LEAF SPRINGS (FOUR-PASSENGER VEHICLES) See General Warnings on page 1-2. LEAF SPRING REMOVAL (FOUR-PASSENGER VEHICLES) Electric Vehicle: Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-5. Gasoline Vehicle: Disconnect battery and spark plug wire(s).
Page 108 Leaf Springs (Four-Passenger Vehicles) REAR SUSPENSION 2690 Figure 9-4 Rear Suspension Assembly and Mounting (Four-Passenger Vehicles) Page 9-6 2016 Precedent Golf Car Maintenance and Service Manual...
Page 109: Leaf Spring Installation (Four-Passenger Vehicles)
REAR SUSPENSION Leaf Springs (Four-Passenger Vehicles) LEAF SPRING INSTALLATION (FOUR-PASSENGER VEHICLES) 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 110 Leaf Springs (Four-Passenger Vehicles) REAR SUSPENSION Pagination Page Page 9-8 2016 Precedent Golf Car Maintenance and Service Manual...
Page 111: 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 112: 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 113: Maintenance
When the pedal is released it should return to the original position. All Club Car vehicles operate at reduced speed in reverse.
Page 114: Periodic Service Schedules
Periodic Service Schedules PERIODIC MAINTENANCE WARNING • Frame ground – Do not allow tools or other metal objects to contact frame when disconnecting batteries or other electrical wiring. Never allow a positive wire to touch the vehicle frame, engine, or other metal component. PERIODIC SERVICE SCHEDULES WARNING •...
Page 115 PERIODIC MAINTENANCE Periodic Service Schedules PERIODIC SERVICE SCHEDULE – ELECTRIC VEHICLES REGULAR INTERVAL SERVICE For vehicles newly equipped with the SPWS, Initial (one-time) inspection by owner or Batteries (For vehicles newly equipped with manually check battery electrolyte levels of trained technician after six weeks of use the Single Point Watering System) all cells to verify correct valve operation.
Page 116 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 117 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 118: Periodic Lubrication Schedules
Periodic Lubrication Schedules PERIODIC MAINTENANCE PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE – 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 (CC P/N 1012151), white hours of operation or 100 service manual.
Page 119 PERIODIC MAINTENANCE Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULE – SUBARU EX40 GASOLINE VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Shifter cable pivots Dry Moly Lube (CC P/N 1012151) Semiannually by owner or trained technician (every 50 Brake system, per maintenance and Dry Moly Lube (CC P/N 1012151), white hours of operation or every service manual.
Page 120 Periodic Lubrication Schedules PERIODIC MAINTENANCE Pagination Page Page 10-10 2016 Precedent Golf Car Maintenance and Service Manual...
Page 121: 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 122: 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 123: 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 124: 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 125: 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 126: 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 127 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 128: 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 129: 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 13-11.
Page 130: 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 131: 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 132: 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 133: 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 134: 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 135: 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 136 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 137: 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 138: 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 139: 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 140: 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 with ERIC Charging MAIN WELDED If the speed controller detects that the solenoid contacts are welded closed, a main welded fault is detected.
Page 141: 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 142: 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 143: 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 144 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 145: 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 146: 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 147: Connection Tests
CONTROLLER DIAGNOSTIC TOOL (CDT) Connection Tests TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Section 12 — Excel System Troubleshooting: Speed controller malfunction with ERIC Charging Disconnect the CDT cord from the vehicle. Handset malfunction Wait a few seconds and reconnect the handset to the vehicle Display screen shows jumbled or Loose connection at CDT port...
Page 148 Connection Tests CONTROLLER DIAGNOSTIC TOOL (CDT) Using a multimeter set for 200 ohms, place the red (+) probe into one of the terminals on the end of the cord with the square plug. Place the black (–) probe on each of the pins, one at a time, on the plug on the other end of the cord. The multimeter should indicate continuity on only one pin.
Page 149 CONTROLLER DIAGNOSTIC TOOL (CDT) Connection Tests Figure 11-3 Instrument Panel Assembly Removal and CDT Port Connection 3.2. Disconnect the four-pin connectors (4 and 5) and visually inspect the contacts for damage and corrosion. Inspect the CDT port, mounted under the instrument panel assembly (2). Repair and replace parts as necessary.
Page 150 Connection Tests CONTROLLER DIAGNOSTIC TOOL (CDT) Figure 11-4 CDT Connector On Controller Page 11-30 2016 Precedent Golf Car Maintenance and Service Manual...
Page 151: Section 12 - Excel System Troubleshooting: With Eric Charging
SECTION 12 — EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING DANGER Excel System Troubleshooting: with ERIC Charging • 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. –...
Page 152: Key Differences: Excel With Eric Charging System Vs. Powerdrive Chargers
EXCEL SYSTEM TROUBLESHOOTING: General Information WITH ERIC CHARGING • The Excel minimum motor braking speed has been lowered to almost zero. • Excel has higher energy output during regenerative braking due to the lowered minimum motor braking speed. • The Excel accelerator pedal has more control of downhill speed. •...
Page 153 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING General Information • Walk Away Braking: This feature prevents the vehicle from rolling away uncontrolled should the driver park on a slope and leave the vehicle without locking the park brake. The vehicle will roll at about 1 to 3 mph (1.5 to 4.8 km/h).
Page 154: Wiring Diagrams
EXCEL SYSTEM TROUBLESHOOTING: Wiring Diagrams WITH ERIC CHARGING WIRING DIAGRAMS RUN/TOW SW ITCH FORWARD/REVERS E (FNR) SW ITCH WD1040232_DGM_B-L Figure 12-1 Wiring Diagram – Excel System with ERIC Charging Page 12-4 2016 Precedent Golf Car Maintenance and Service Manual...
Page 155 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Wiring Diagrams 30 A WD1040232_DGM_B-R Figure 12-2 Wiring Diagram – Excel System with ERIC Charging (Continued) 2016 Precedent Golf Car Maintenance and Service Manual Page 12-5...
Page 156 EXCEL SYSTEM TROUBLESHOOTING: Wiring Diagrams WITH ERIC CHARGING BATTERY CHARGING OP TIONAL INDICATOR SWITCH NOTE: SOME WIRING / COMPONENTS S HOWN ARE OPTIONAL ACCESSORIES WD1039915_DGM_C1 Figure 12-3 Instrument Panel Wiring Diagram – Precedent with ERIC Charging Page 12-6 2016 Precedent Golf Car Maintenance and Service Manual...
Page 157 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Wiring Diagrams To Solenoid Lead for DC-DC Converter To B- Terminal on Controller WD_6x8V_Batteries_ERIC_Charging Figure 12-4 Battery Wiring Diagram – Precedent with ERIC Charging 2016 Precedent Golf Car Maintenance and Service Manual Page 12-7...
Page 158 EXCEL SYSTEM TROUBLESHOOTING: Wiring Diagrams WITH ERIC CHARGING USED WHEN THERE ARE LIGHTS BUT NO TURN S IGNAL. NORMALLY OPEN MOM ENTARY PUSH BU TTON FOR HORN 9-PIN #16 ORANGE CONNECT OR #16 BLUE/WHITE #16 WHITE #16 YELLOW SONIC #16 BROWN/WHITE WELD FLASHER UNIT...
Page 159 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Wiring Diagrams HEADLIGHT ASSEMBLY DC - DC HORN CONVERTER SONIC 20 AMP WELD #16 BLACK FUS E SONIC WELD #18 O RANGE DIODE #16 BLACK/WHITE #12 BLACK SON IC WELD #16 BLACK SON IC WELD CONNE CTS TO MAIN HARNESS.
Page 160 EXCEL SYSTEM TROUBLESHOOTING: Wiring Diagrams WITH ERIC CHARGING To Connected To Instument Car Device Panel Harness (i.e. Guardian 9-Pin Connector or Visage) Sonic We ld To MCOR Sonic Forward/ Reverse We ld Switch Sonic We ld 10k Ohm Resistor Sonic We ld Sonic We ld...
Page 161: Troubleshooting
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 162 EXCEL SYSTEM TROUBLESHOOTING: Troubleshooting WITH ERIC CHARGING TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected motor speed sensor Repair and/or connect the three-pin connector or broken wire to the motor speed sensor Monitor Menu – SPEED PULSES menu item indicates that speed pulses are OFF when Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector...
Page 163 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected three-pin connector at Repair and/or connect the three-pin connector the MCOR or broken wire to the MCOR Diagnostic Menu – THROTTLE FAULT fault Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector code...
Page 164: Troubleshooting Guide 2
EXCEL SYSTEM TROUBLESHOOTING: Troubleshooting WITH ERIC CHARGING 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 12-14 2016 Precedent Golf Car Maintenance and Service Manual...
Page 165 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING 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 166 EXCEL SYSTEM TROUBLESHOOTING: Troubleshooting WITH ERIC CHARGING TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Procedure 12 – Motor Speed Sensor on Speed sensor disconnected or failed page 12-30 To change the programmed top speed of the Incorrect speed setting vehicle, an CDT handset must be used Check vehicle wiring.
Page 167: Test Procedures
EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING 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 168 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING 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 169 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures installed in reverse polarity. Refer to Batteries: Electric Vehicle with ERIC Charging on page 14-1 for further details on battery testing. NOTE: The voltage displayed through the CDT shows what the controller thinks it sees. If the controller is not operating properly, it may display a different voltage from what the battery pack voltage (BPV) really is.
Page 170 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING (Viewed from driver side of vehicle) 1. RED probe to battery no. 1 (+). 2. BLACK probe to battery no. 6 (-). 2500-30100-10411 Figure 12-9 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 171 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING 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 172 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING 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 173 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING 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 174 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING 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.
Page 175 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING 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 176 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-5. 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 12-17.
Page 177 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING 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 178 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING 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 179 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING 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 180 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING 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 181 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING 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 182 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING 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.
Page 183 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING 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 –...
Page 184 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING 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 1-5. Place the Tow/Run switch in the RUN position and then check the appropriate wires.
Page 185 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING 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 186 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING If necessary, see Testing Basics on page 12-17. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-5. 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 187 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING 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 188 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING Pagination Page Page 12-38 2016 Precedent Golf Car Maintenance and Service Manual...
Page 189: Section 13 - Electrical Components: Electric Vehicle With Eric Charging
SECTION 13 — ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH ERIC CHARGING DANGER Electrical Components: Electric Vehicle with ERIC Charging • 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.
Page 190: Charge Indicator Light
ELECTRICAL COMPONENTS: ELECTRIC Charge Indicator Light VEHICLE WITH ERIC CHARGING 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 12-36. CHARGE INDICATOR LIGHT REMOVAL Disconnect the batteries and discharge the controller.
Page 191: Forward/Reverse Rocker Switch
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH ERIC CHARGING Forward/Reverse Rocker Switch 2787 Figure 13-3 Charge Indicator Light FORWARD/REVERSE ROCKER SWITCH See General Warnings on page 1-2. TESTING THE FORWARD/REVERSE ROCKER SWITCH See Test Procedure 6 – Forward/Reverse Rocker Switch on page 12-23. FORWARD/REVERSE ROCKER SWITCH REMOVAL Disconnect the batteries and discharge the controller.
Page 192: Forward/Reverse Rocker Switch Installation
ELECTRICAL COMPONENTS: ELECTRIC Forward/Reverse Rocker Switch VEHICLE WITH ERIC CHARGING Figure 13-4 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 13-4, Page 13-4). Orient the rocker switch (3) so the terminals are towards the front of the housing (1).
Page 193: Electronics Module Cover
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH ERIC CHARGING Electronics Module Cover 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.
Page 194: Tow/Run Switch
ELECTRICAL COMPONENTS: ELECTRIC Tow/Run Switch VEHICLE WITH ERIC CHARGING Figure 13-5 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 12-20. TOW/RUN SWITCH REMOVAL Disconnect the batteries and discharge the controller.
Page 195: Motor Controller Output Regulator (Mcor)
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH ERIC CHARGING Motor Controller Output Regulator (MCOR) Figure 13-6 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 12-28 and Test Procedure 5 – Key Switch and MCOR Limit Switch Circuit on page 12-22.
Page 196: Reverse Buzzer
ELECTRICAL COMPONENTS: ELECTRIC Reverse Buzzer VEHICLE WITH ERIC CHARGING REVERSE BUZZER See General Warnings on page 1-2. TESTING THE REVERSE BUZZER See 12-35. REVERSE BUZZER REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-5.
Page 197: Electronics Module
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH ERIC CHARGING Electronics Module 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 198: Electronics Module Installation
ELECTRICAL COMPONENTS: ELECTRIC Electronics Module VEHICLE WITH ERIC CHARGING 2771 Figure 13-8 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 199: Speed Controller
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH ERIC CHARGING Speed Controller Set electronics module in place and secure with bolt (2) (Figure 13-8, Page 13-10). Tighten bolt to 40 in·lb (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 200: 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 201: Solenoid Installation
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH ERIC CHARGING Charger Receptacle Disconnect the heavy gauge wires from the solenoid (4) by removing the nuts (7) and washers (10) (Figure 13-8, Page 13-10). 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 13-8, Page 13-10).
Page 202: Charger Receptacle Installation
ELECTRICAL COMPONENTS: ELECTRIC Charger Receptacle VEHICLE WITH ERIC CHARGING 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 in·lb (1.8 N·m). Connect 10-gauge red wire to solenoid.
Page 203: Section 14 - Batteries: Electric Vehicle With Eric Charging
SECTION 14 — BATTERIES: ELECTRIC VEHICLE WITH ERIC CHARGING DANGER Batteries: Electric Vehicle with ERIC Charging • 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 204: Battery Testing Basics - 8 Volt
BATTERIES: ELECTRIC VEHICLE WITH Battery Testing Basics – 8 Volt ERIC CHARGING 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 •...
Page 205: 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 206 BATTERIES: ELECTRIC VEHICLE WITH Battery Regrouping ERIC CHARGING BATTERY REGROUPING PROCESS FLOW (6 volt, 8 volt, and 12 volt batteries) CAUTION: To prevent degradation of battery perform a n c e a n d life , n e ve r m ix b a tte rie s o f d iffe re n t p a rt n u m b e rs o r b r a n d s / m o d e l n u m b e r s .
Page 207: Battery Replacement
BATTERIES: ELECTRIC VEHICLE WITH ERIC CHARGING 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°...
Page 208: 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 209: Deionizer
Replace filter immediately if the red light comes ON indicating service is required. The following replacement filter is available from Club Car Service Parts: — Use filter P/N 104005901 for Deionizer Systems P/N's 105166801, 104006001, and AM10974.
Page 210: Battery Care - Vehicles Equipped With The Single-Point Watering System
BATTERIES: ELECTRIC VEHICLE WITH Battery Care ERIC CHARGING Log. Use these decals to record filter replacement activity and fleet inspection activity. For convenience, both decals have a QR code for ordering replacement filters. Seasonal Maintenance Water supplies must be drained and stored in an empty state if they will be exposed to freezing temperatures. Failure to do so can cause permanent damage.
Page 211: Battery Care - Vehicles Without The Single-Point Watering System
• Do not overfill the batteries. NOTE: A battery watering gun or bottle (CC P/N AM10818) 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 212: Self-Discharge
BATTERIES: ELECTRIC VEHICLE WITH Battery Care ERIC CHARGING 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 213: Vibration Damage
A deionizer for vehicles with SPWS, Club Car Part Number 105166801 is available from Service Parts (DC powered water quality indicator light). Replacement cartridge: 104005901. Bottled distilled water, with hand pump, Club Car Part Number 104006101, is recommended for private consumer applications.
Page 214 BATTERIES: ELECTRIC VEHICLE WITH Single Point Watering System (SPWS) ERIC CHARGING • Do not use a longer garden hose than provided with the System (20 feet), as a decrease in water pressure could overfill the batteries and damage the refill system. Before screwing the hose-end assembly (3) onto the opposite end of the water hose, check the screen filter (4) inside the end of the assembly to make sure it is clean (Figure 14-4).
Page 215: Battery Storage
BATTERIES: ELECTRIC VEHICLE WITH ERIC CHARGING Battery Storage Figure 14-6 Dust Cap Figure 14-7 Connecting Hose-end Assembly to Battery Fill Connector The red flow indicator balls should swirl, indicating that the batteries are being filled. See following CAUTION. CAUTION • If at any time water overflows from the batteries, immediately stop the refill process, disconnect the pressure regulator from the battery fill coupling, and call for service.
Page 216: Deep-Discharge
BATTERIES: ELECTRIC VEHICLE WITH Deep-Discharge ERIC CHARGING 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 217: Section 15 - Battery Charger: For Eric Charging System
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 218: General Information
IC0650-048-COMM). Do not attempt to service a battery charger that has not been properly identified. If a charger cannot be properly identified, contact your local Club Car dealer or distributor. How To Identify A Vehicle That Uses This High-Frequency Charger •...
Page 219: 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 15-12.
Page 220: Charger Power Connection Fuse
BATTERY CHARGER: FOR ERIC General Information CHARGING SYSTEM CHARGER POWER CONNECTION FUSE The charger receptacle harness has an in-line, 30-amp fuse located near the solenoid. CHARGER INTERLOCK External Charger: While the charger DC cord is plugged into the vehicle, the vehicle control circuit is locked out, preventing operation of the vehicle, as well as the possibility of consequent damage to the charger and the vehicle.
Page 221: Long-Term Storage
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM General Information Solid green Charging is complete. Battery pack is fully charged. Solid green Flashing green Charging is in progress. Battery pack has reached a high state of charge. Solid green Charging is in progress. Battery pack has NOT reached a high state of charge.
Page 222: External Charger Mounting
BATTERY CHARGER: FOR ERIC External Charger Mounting CHARGING SYSTEM 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 223: 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. 2016 Precedent Golf Car Maintenance and Service Manual...
Page 224: The Charge Circuit
BATTERY CHARGER: FOR ERIC The Charge Circuit CHARGING SYSTEM 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 225: Charger Operation
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM Charger Operation Onboard Charger: The charge circuit consists of the charger receptacle, interlock wire, controller, solenoid and battery pack (Figure 15-7, Page 15-9). FRONT OF VEHICLE Battery Pack Voltage (+) BATTERY BANK Pull-up Resistor (10k Ohm) CONTROLLER B–...
Page 226 Vehicles should be restricted to 40 to 50 amp hours of discharge (or 36 holes of golf) 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 227 If the charger does not seem to be operating properly, or if the batteries seem weak, see Charger Troubleshooting on page 15-13. 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 228: Charger Maintenance
BATTERY CHARGER: FOR ERIC Charger Maintenance CHARGING SYSTEM 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 229: Charger Troubleshooting
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM 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 230: 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 231: Charger Troubleshooting Indicators
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM Charger Troubleshooting 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: HIGH-FREQUENCY BATTERY CHARGER TROUBLESHOOTING GUIDE CHECK STATUS STATUS POSSIBLE CAUSES...
Page 232 BATTERY CHARGER: FOR ERIC Charger Troubleshooting CHARGING SYSTEM HIGH-FREQUENCY BATTERY CHARGER TROUBLESHOOTING GUIDE 1. Erroneous event (an unknown variable; Reset charger power. See Resetting Power – External something occurred to Charger on page 15-14. Reconnect DC cord to vehicle. the charger or vehicle that If status goes away, continue using charger.
Page 233: Test Procedures
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM Test Procedures TEST PROCEDURES See General Warnings on page 1-2. When the upper green light is flashing, indicating the charger is in finish charge, it is okay to begin a battery discharge test if so desired. Index of Test Procedures 1 –...
Page 234 BATTERY CHARGER: FOR ERIC Test Procedures CHARGING SYSTEM first and then stay on continuously within 10 to 20 minutes, indicating sound, fully charged batteries. See Charger Status Indicators on page 15-4. NOTE: Batteries near the end of their useful lives may not allow the battery charge current to taper and the upper half of the battery-shaped status indicator will continue to flash.
Page 235 BATTERY CHARGER: FOR ERIC CHARGING SYSTEM Test Procedures TEST PROCEDURE 7 – Charger Output Test Without a Meter: Connect DC cord and start a charge cycle. If buzzer sounds three times, then charger is functioning. Both a confirmed connection with the charger and a rise in battery pack voltage are required for buzzer to sound three times.
Page 236: External Charger Repairs
BATTERY CHARGER: FOR ERIC External Charger Repairs CHARGING SYSTEM 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 15-8). • Prior to servicing the charger, disconnect the DC plug from the vehicle charger receptacle and the AC cord from the AC outlet.
Page 237: Terminal Block Cover Installation
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM 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.
Page 238: Handle Installation
BATTERY CHARGER: FOR ERIC External Charger Repairs CHARGING SYSTEM 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 in·lb (4.5 N·m). FOOT REMOVAL Disconnect DC cord (1) from vehicle.
Page 239: Onboard Charger Repairs
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM 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 15-9). • Prior to servicing the charger, disconnect the DC plug from the vehicle charger receptacle and the AC cord from the AC outlet.
Page 240: Onboard Charger Installation
BATTERY CHARGER: FOR ERIC Onboard Charger Repairs CHARGING SYSTEM 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).
Page 241: Dc Cord And Strain Relief Removal
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM 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 15-25). Remove terminal block cover.
Page 242: Dc Charging Harness Installation
BATTERY CHARGER: FOR ERIC Onboard Charger Repairs CHARGING SYSTEM 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 13-5.
Page 243: 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 244 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 245 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 1-5. 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 246: 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 1-5. Disconnect wires from the terminals on the motor using two wrenches to prevent posts from turning. Label the wires to ensure proper reconnection.
Page 247: 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 248 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 249 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 250: 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 251 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 252: 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 253 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 254 MOTOR (MODEL EJ8-4001A): ELECTRIC Motor Component Testing and Inspection VEHICLE 2613 Figure 16-15 Electric Motor (EJ8-4001A) Page 16-12 2016 Precedent Golf Car Maintenance and Service Manual...
Page 255: 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 256 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 257: 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 258 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 259 MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Motor Installation retaining nuts. For 5/16 inch (8mm) diameter studs, tighten the nuts to 100 in·lb (11 N·m). For 1/4 inch (6.3mm) diameter studs, tighten the nuts to 45 in·lb (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 260 MOTOR (MODEL EJ8-4001A): ELECTRIC Motor Installation VEHICLE Pagination Page Page 16-18 2016 Precedent Golf Car Maintenance and Service Manual...
Page 261: 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 262 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 263 TRANSAXLE: ELECTRIC VEHICLE Axle Bearing and Shaft Figure 17-5 Transaxle – Type G 2016 Precedent Golf Car Maintenance and Service Manual Page 17-3...
Page 264: 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 265: 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 1-5. Place chocks at the front wheels and slightly loosen lug nuts on both rear wheels. See WARNING “Lift only one end...”...
Page 266 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. Remove the U-bolts attaching the transaxle to the leaf springs (Figure 17-10, Page 17-6). Carefully lift each end of the transaxle off its positioning pin (on the leaf spring) and slide the transaxle to the rear and out of the vehicle.
Page 267: 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 268 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 269: 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 270: 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 271 TRANSAXLE: ELECTRIC VEHICLE Transaxle Installation WARNING • Make sure that the vehicle operates in the reverse direction when the Forward/Reverse switch is in the REVERSE position. The reverse buzzer will sound as a warning when the Forward/Reverse switch is in REVERSE. •...
Page 272 Transaxle Installation TRANSAXLE: ELECTRIC VEHICLE Pagination Page Page 17-12 2016 Precedent Golf Car Maintenance and Service Manual...
Page 273: 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 274: 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 275 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 276: 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 277 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 278 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 279 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 280: Wiring Diagrams
TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM – SUBARU EX40 WIRING DIAGRAMS BR AKE SWIT CH TAILLIGH TS FUS E FUS EBL OCK WD1052367_dgmE-L Figure 18-1 Wiring Diagram for Precedent EFI Gasoline Vehicle Page 18-8 2016 Precedent Golf Car Maintenance and Service Manual...
Page 281 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Wiring Diagrams TR ANSA XLE LIMIT SWI T CH WD1052367_dgmE-R Figure 18-2 Wiring Diagram for Precedent EFI Gasoline Vehicle – Continued 2016 Precedent Golf Car Maintenance and Service Manual Page 18-9...
Page 282 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM – SUBARU EX40 FUEL GAUGE KEY SWITCH OIL LIGHT #18 BLUE 9-PIN CONNECTOR CONNECTS TO #18 YELLOW/WHITE MAIN HARNESS. #16 RED #16 RED #16 BLACK #18 WHITE/BLACK #18 YELLOW #18 YELLOW #18 BLUE #18 ORANGE #18 RED/WHITE REVE RS E BUZZER...
Page 283 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Wiring Diagrams MAP SENSOR W05 18 BLK_YEL PIN 1 - S ENS OR GND PIN 2 - S ENS OR S IGNAL W07 18 GRN_YEL PIN 3 - S ENS OR +5V W06 18 RED_YEL TEMPERATURE SENSOR W04 18 ORG_BLU...
Page 284 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM – SUBARU EX40 Sonic To Con nec te d We ld Car Device S onic (i.e. Gu ar dia n #1 2 We ld or Visa ge ) To Ins tume nt Sonic Pa nel Harnes s We ld 9-Pin Con nec tor #1 6...
Page 285: Electrical System
TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Electrical System 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 286: Test Procedures
TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 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 287 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Test Procedures 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 288 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 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 289 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Test Procedures Hold the hydrometer vertically, ensuring that the float is not contacting the sides of the glass tube. Hold the hydrometer at eye level and read the scale at the level of electrolyte (Figure 18-6, Page 18-17). Record the reading.
Page 290 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 does not reach 12.4 volts, or if the specific gravity of a cell is still less than 1.225 after charging, replace the battery. See following NOTE. NOTE: A fully charged battery that is in good condition should have a specific gravity of at least 1.225 in all cells, and the difference in the specific gravity of any two cells should be less than 50 points.
Page 291 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 292 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 18-19). 4.2. Each contact should show battery voltage. 4.3.
Page 293 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 18-14. 2016 Precedent Golf Car Maintenance and Service Manual Page 18-21...
Page 294 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 295 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 296 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 18-14.
Page 297 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 298 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 299 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 18-14.
Page 300 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 TEST PROCEDURE 9 – Maintenance/Operate Switch – Pedal-Start 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 18-14.
Page 301 TROUBLESHOOTING AND ELECTRICAL SYSTEM – SUBARU EX40 Test Procedures TEST PROCEDURE 10 – Neutral Lockout Limit Switch – Pedal-Start 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 302 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 18-14. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position.
Page 303 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 304 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 18-14. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position.
Page 305 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 18-14. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position.
Page 306 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 307 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 308 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 18-14.
Page 309 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 310 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 Disconnect the 5-pin connector from the top of the fuel pump module. Probe between pin (1) and pin (2) terminals in module (Figure 18-18, Page 18-37). 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 311 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 18-14. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.
Page 312 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 313 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 314 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM – SUBARU EX40 Pagination Page Page 18-42 2016 Precedent Golf Car Maintenance and Service Manual...
Page 315: 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 18-30. See Test Procedure 11 –...
Page 316: Brush Inspection And Replacement
Starter/Generator ELECTRICAL COMPONENTS – SUBARU EX40 Figure 19-1 Commutator End Cover Figure 19-2 Brush Covers and Brushes BRUSH INSPECTION AND REPLACEMENT Visually inspect brushes. Replace brushes that are cracked or severely chipped. Measure brush length. Minimum brush length is 3/8 inch (9.5 mm) (Figure 19-3, Page 19-2). Replace all four brushes as a set.
Page 317: Starter/Generator Assembly
ELECTRICAL COMPONENTS – SUBARU EX40 Starter/Generator CAUTION Figure 19-4 Brush Spring Tension Test STARTER/GENERATOR ASSEMBLY Connect the brush wires to the holders using four lock washers (26) and four screws (25), making sure the crossover leads are connected also. Tighten the screws to 31 in·lb (3.5 N·m) (Figure 19-2, Page 19-2). To prevent contact between the brushes and commutator as the commutator is installed, and possible damage to the brushes, lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover.
Page 318: 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 If the brushes are not removed, contact between the brushes and commutator as the commutator end cover is being removed or installed could damage the brushes.
Page 319: Bearing Cleaning And Inspection
ELECTRICAL COMPONENTS – SUBARU EX40 Starter/Generator Figure 19-6 Armature and Output End Cover Assembly 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). Replace the bearing if it is noisy, does not spin smoothly, or has excessive play.
Page 320: Bearing Removal
Starter/Generator ELECTRICAL COMPONENTS – SUBARU EX40 BEARING REMOVAL Place the wedge attachment tool (CC 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 (CC P/N 1012811) to the wedge attachment tool and pull the bearing off of the end of the armature shaft.
Page 321: Commutator Cleaning And Inspection
ELECTRICAL COMPONENTS – SUBARU EX40 Starter/Generator • Bruised or damaged armature core laminations • Worn armature bearing or shaft • Dirty or oily commutator 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.
Page 322: Armature Ground Test
Starter/Generator ELECTRICAL COMPONENTS – SUBARU EX40 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 323: Visual Inspection Of Field Coils
ELECTRICAL COMPONENTS – SUBARU EX40 Starter/Generator WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 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 324: Starter/Generator Assembly
Starter/Generator ELECTRICAL COMPONENTS – SUBARU EX40 STARTER/GENERATOR ASSEMBLY Place the field coil into the housing. The two insulators that look alike fit into the slots next to the F1 and F2 markings on the outside of the housing. The insulator that looks different slides into the slot next to the DF marking. After the insulators are seated in the slots, install the threaded terminals through the wire connectors and then through the insulators.
Page 325: Starter/Generator Installation
ELECTRICAL COMPONENTS – SUBARU EX40 Starter/Generator STARTER/GENERATOR INSTALLATION 2997 Figure 19-12 Starter/Generator Installation Install the green wire (1) from the F1 terminal to the A2 terminal on the starter/generator (Figure 19-13, Page 19-12). Install a flat washer, lock washer, and nut onto each terminal and tighten to 48 in·lb (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 326: Belt Tension Adjustment For Efi Engines With P/N 105205401 Belt
Starter/Generator ELECTRICAL COMPONENTS – SUBARU EX40 3033 Figure 19-13 Starter/Generator Wiring BELT TENSION ADJUSTMENT FOR EFI ENGINES WITH P/N 105205401 BELT NOTE: This tension adjustment procedure is only for belts with part number 105205401. Locate and confirm part number on belt before proceeding. For belt with part number 47539338001, see Belt Tension Adjustment for EFI Engines with P/N 47539338001 Belt on page 19-15.
Page 327 ELECTRICAL COMPONENTS – SUBARU EX40 Starter/Generator Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline Vehicles on page 1-4. Access engine compartment. – Remove seat and rear access panel (if equipped). –...
Page 328 Starter/Generator ELECTRICAL COMPONENTS – SUBARU EX40 A. Remove 3/8 to 1/2 inch (9.5 to 12.7 mm) 1. Before 2. After 2726 Figure 19-16 Belt Tension Tool Modification (If Necessary) Tension belt. 7.1. Tighten nut on belt tension tool 1/2 turn and check belt tension with gauge(Figure 19-14, Page 19-12). NOTE: To prevent errors in measurement caused by residual tension, ensure to loosen, then reapply, the Universal Belt Tension gauge between measurements.
Page 329: Belt Tension Adjustment For Efi Engines With P/N 47539338001 Belt
ELECTRICAL COMPONENTS – SUBARU EX40 Starter/Generator BELT TENSION ADJUSTMENT FOR EFI ENGINES WITH P/N 47539338001 BELT NOTE: This tension adjustment procedure is only for belts with part number 47539338001. Locate and confirm part number on belt before proceeding. For belt with part number 105205401, see Belt Tension Adjustment for EFI Engines with P/N 105205401 Belt on page 19-12.
Page 330 Starter/Generator ELECTRICAL COMPONENTS – SUBARU EX40 Tighten starter/generator mounting hardware (4 and 7) finger-tight (Figure 19-12, Page 19-11). Install belt tension tool (P/N 102570401). 6.1. Carefully insert pry bar between starter/generator and bracket. 6.2. Carefully lift starter up until tension tool can be installed as shown over the slotted adjustment bracket (Figure 19-15, Page 19-12).
Page 331: Voltage Regulator
ELECTRICAL COMPONENTS – SUBARU EX40 Voltage Regulator 8.3. Connect battery only. DO NOT CONNECT SPARK PLUG WIRE. See Side-Post Battery: Connecting the Battery-Gasoline Vehicles on page 1-3. See Top-Post Battery: Connecting the Battery- Gasoline Vehicles on page 1-4. See following WARNING. WARNING •...
Page 332: Voltage Regulator Installation
Voltage Regulator ELECTRICAL COMPONENTS – SUBARU EX40 2432 Figure 19-20 Voltage Regulator VOLTAGE REGULATOR INSTALLATION Position the voltage regulator (1) and install the mounting screw (2) (Figure 19-20, Page 19-18). Tighten screw to 23 in·lb (2.6 N·m). Connect the voltage regulator three-pin connector (3) to the wire harness. Connect battery and spark plug wire(s).
Page 333: 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 334: 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 18-24. See Test Procedure 6 – Key Switch (Engine Kill Circuit) on page 18-24. KEY SWITCH REMOVAL Disconnect battery and spark plug wire(s).
Page 335: Maintenance/Operate Switch
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 19-21, Page 19-20). 2.2.
Page 336: 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 – Pedal-Start Vehicles Only on page 18-29. NEUTRAL LOCKOUT LIMIT SWITCH REMOVAL Turn the key switch OFF and remove the key.
Page 337: Testing The Solenoid
ELECTRICAL COMPONENTS – SUBARU EX40 Solenoid SOLENOID See General Warnings on page 1-2. TESTING THE SOLENOID See Test Procedure 8 – Solenoid on page 18-27. SOLENOID REMOVAL Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline Vehicles on page 1-4.
Page 338: 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 339: 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 18-25. The accelerator pedal limit switch is housed inside the throttle position sensor. The throttle position sensor itself is not intended to be replaced.
Page 340: Reverse Warning Buzzer Installation
Reverse Warning Buzzer ELECTRICAL COMPONENTS – SUBARU EX40 A, Red/White wire B. Black wire Figure 19-23 Reverse Buzzer REVERSE WARNING BUZZER INSTALLATION Install the screws (3) through the buzzer bracket tabs and tighten to 3.5 in·lb (0.40 N·m) (Figure 19-23, Page 19-26).
Page 341: 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 18-35. REVERSE BUZZER LIMIT SWITCH REMOVAL Disconnect battery and spark plug wire(s).
Page 342: Low Oil Warning Light
Low Oil Warning Light ELECTRICAL COMPONENTS – SUBARU EX40 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 18-35. LOW OIL WARNING LIGHT REMOVAL Disconnect battery and spark plug wire(s).
Page 343: Fuel Gauge
ELECTRICAL COMPONENTS – SUBARU EX40 Fuel Gauge 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 344: Fuel Level Sending Unit
Fuel Level Sending Unit ELECTRICAL COMPONENTS – SUBARU EX40 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 345: Oil Level Sensor
ELECTRICAL COMPONENTS – SUBARU EX40 Oil Level Sensor BLACK 2438 Figure 19-26 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 18-36. OIL LEVEL SENSOR REMOVAL See Oil Level Sensor Removal on page 20-15.
Page 346 Battery ELECTRICAL COMPONENTS – SUBARU EX40 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 on or near batteries. • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area.
Page 347: General Information - Side-Post Battery
ELECTRICAL COMPONENTS – SUBARU EX40 Battery GENERAL INFORMATION – SIDE-POST BATTERY See preceding DANGER and WARNING statements. Gasoline vehicles may be equipped with 12-volt, side-post battery that requires infrequent watering. When changing a 12-volt battery in any gasoline-powered vehicle, the same size battery with adequate amperage ratings should be used as a replacement.
Page 348: Water Level - Side-Post Battery
Battery ELECTRICAL COMPONENTS – SUBARU EX40 WATER LEVEL – SIDE-POST BATTERY The water level should be checked semi-annually to be sure water is at its proper level (Figure 19-29, Page 19-34). Never allow the water level to fall below the tops of the plates because this will cause the exposed part of the plate to become permanently inactive.
Page 349: Mineral Content - Side-Post Battery Only
ELECTRICAL COMPONENTS – SUBARU EX40 Battery MINERAL CONTENT – SIDE-POST BATTERY ONLY For the longest battery life, distilled water should be used in the battery. However, if tap water is going to be used, contact your local water department to be sure mineral contents are below the levels listed in the following table. See following NOTE.
Page 350: Battery Removal
Battery ELECTRICAL COMPONENTS – SUBARU EX40 BATTERY REMOVAL See General Warnings on page 1-2. 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).
Page 351: Battery Storage
ELECTRICAL COMPONENTS – SUBARU EX40 Ground Cables BATTERY STORAGE See General Warnings on page 1-2. Also see DANGER at beginning of Battery topic. Keep the battery clean and free of corrosion. 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 352 Ground Cables ELECTRICAL COMPONENTS – SUBARU EX40 Pagination Page Page 19-38 2016 Precedent Golf Car Maintenance and Service Manual...
Page 353: 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 354: Torque Specifications
General Information ENGINE – SUBARU EX40 TORQUE SPECIFICATIONS ITEM SIZE TORQUE Flywheel retaining nut 80 ft·lb (110 N·m) Crankcase cover to block bolts 250 in·lb (28.3 N·m) Step Step New head and bolts: New head and bolts: 159 in·lb (18 N·m) 336 in·lb (38 N·m) Cylinder head bolts Used head and bolts:...
Page 355 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 356 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 357: Spark Plug
ENGINE – SUBARU EX40 General Information SAE 30 SAE 10W-30/ SAE 10W-40 SAE 5 W-30 Figure 20-3 Oil Viscosity Chart Connect battery and spark plug wire. See Side-Post Battery: Connecting the Battery-Gasoline Vehicles on page 1-3. See Top-Post Battery: Connecting the Battery- Gasoline Vehicles on page 1-4. 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 358: Breather
General Information ENGINE – SUBARU EX40 WARNING • Remove spark plug wire to avoid accidental start up of the engine when servicing vehicle. To avoid ignition of fuel and serious personal injury or death, never try to start the engine with plug removed from engine.
Page 359: Valve Clearance Check And Adjustment
ENGINE – SUBARU EX40 General Information Oil laden air in the crankcase passes through the reed valve and expands into the rocker chamber. In the rocker chamber most oil separates from the air and drains back to the crankcase. The air passes through a tube and vents to the intake manifold.
Page 360: Engine Removal
Engine Removal ENGINE – SUBARU EX40 ENGINE REMOVAL ENGINE REMOVAL TO MID-2016 MODEL YEAR Utility/T ransportation Orientation Precedent Orientation 3036 Figure 20-7 EX40 Engine and Mounting Brackets Page 20-8 2016 Precedent Golf Car Maintenance and Service Manual...
Page 361 ENGINE – SUBARU EX40 Engine Removal CAUTION • Before removal and disassembly, clean the engine. Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles, Section 1, Page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline Vehicles on page 1-4. For some vehicles, the engine (1) can be removed by lifting it up and out of the chassis.
Page 362: Engine Removal From Mid-2016 Model Year
Engine Removal ENGINE – SUBARU EX40 ENGINE REMOVAL FROM MID-2016 MODEL YEAR Utility/T ransportation Orientation Precedent Orientation 3036a Figure 20-8 EX40 Engine and Mounting Brackets CAUTION • Before removal and disassembly, clean the engine. Page 20-10 2016 Precedent Golf Car Maintenance and Service Manual...
Page 363: Engine Installation
ENGINE – SUBARU EX40 Engine Installation Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles, Section 1, Page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline Vehicles on page 1-4. 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.
Page 364 Engine Installation ENGINE – SUBARU EX40 If equipped, install air deflector on top of engine. Secure accelerator cable and governor cable P-clamps to engine. Tighten P-clamp bolts to 36 in·lb (4.0 N·m). Check all hardware for proper torque/tightness. Fill engine to proper level with correct type of oil. See Engine Oil – Gasoline Vehicle, Section 20, Page 20-2. CAUTION •...
Page 365: Flywheel
ENGINE – SUBARU EX40 Flywheel 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. 3037 Figure 20-9 Flywheel, Fan and Fan Housing – EX40 FLYWHEEL REMOVAL Remove screws (1) and fan housing (2) (Figure 20-9, Page 20-13).
Page 366: Flywheel Installation
Flywheel ENGINE – SUBARU EX40 CAUTION • Do not damage the fan blades with the strap wrench. Do not place screwdriver or pry bar in the fan blades. Temporarily install flywheel nut (8) onto end of crankshaft to protect threads and to prevent flywheel (4) from falling off while being pulled.
Page 367: Oil Level Sensor
ENGINE – SUBARU EX40 Oil Level Sensor OIL LEVEL SENSOR TESTING THE OIL LEVEL SENSOR See Oil Level Sensor on page 18-36. OIL LEVEL SENSOR REMOVAL Drain oil from engine. See Engine Oil – Gasoline Vehicle, Section 20, Page 20-2. Remove flywheel.
Page 368: Ignition Coil
Ignition Coil ENGINE – SUBARU EX40 IGNITION COIL See General Warnings on page 1-2. TESTING THE IGNITION COIL See Test Procedure 14 – Ignition Spark on page 18-33 and Test Procedure 15 – Ignition Coil on page 18-34. IGNITION COIL REMOVAL Remove screws (1) and fan housing (2) (Figure 20-9, Page 20-13).
Page 369: Snubber
ENGINE – SUBARU EX40 Snubber 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 20-15, Page 20-17).
Page 370 Snubber ENGINE – SUBARU EX40 Pagination Page Page 20-18 2016 Precedent Golf Car Maintenance and Service Manual...
Page 371: 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 372: 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 373: 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 374 Throttle Body FUEL SYSTEM – SUBARU EX40 3041 Figure 21-2 Throttle Body – Exploded View Page 21-4 2016 Precedent Golf Car Maintenance and Service Manual...
Page 375: 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 in·lb (6 to 8 N·m). Connect fuel line (6) and vent hose (5).
Page 376 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 377 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 378 Engine Control Linkages FUEL SYSTEM – SUBARU EX40 2.3. Push bellows back onto threaded end of cable housing. 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 379 FUEL SYSTEM – SUBARU EX40 Engine Control Linkages 4.2. Loosen jam nuts securing accelerator cable to underbody and remove accelerator cable (9) from vehicle (Figure 5-4, Page 5-5). 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.
Page 380 Engine Control Linkages FUEL SYSTEM – SUBARU EX40 CLOSED THROTTLE OR IDLE ADJUSTMENT – PEDAL-START 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 381 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 382 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 383 • 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 384 • 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 385 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 386 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 387 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 388 Fuel Pump Module FUEL SYSTEM – SUBARU EX40 NOTE: If equipped with a fuel level sending unit, carefully maneuver module so as to avoid damaging the float arm mechanism. 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 in·lb (7.5 N·m).
Page 389 FUEL SYSTEM – SUBARU EX40 Fuel Pump Module 3125a Figure 21-13 Fuel System (Precedent) – Exploded View 2016 Precedent Golf Car Maintenance and Service Manual Page 21-19...
Page 390 SAEJ30R9 1/4 in (6.3 mm) fuel vent hose (CC P/N 102865101) and 3/16 in (4.78 mm) fuel vent hose (CC P/N 1015137). To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car P/N's 102865101, 1015137, or equivalent. 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 391 3/16 in (4.78 mm) fuel vent hose (CC P/N 1015137). To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car P/N's 102865101, 1015137, or equivalent. Place fuel tank (10) in vehicle.
Page 392 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 393 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 394 Fueling Instructions – Gasoline Vehicles FUEL SYSTEM – SUBARU EX40 DANGER • Repair all fuel leaks before operating the vehicle. If no leaks are found, place the neutral lockout switch in the OPERATE position (Figure 24-1, Page 24-1). FUELING INSTRUCTIONS – GASOLINE VEHICLES See General Warnings on page 1-2.
Page 395 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 396 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 397 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 Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-3.
Page 398 Muffler EXHAUST SYSTEM – SUBARU EX40 3112 Figure 22-1 Exhaust System Page 22-2 2016 Precedent Golf Car Maintenance and Service Manual...
Page 399 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 400 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 401 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 402 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 403 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 404 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 405 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) (CC P/N 1014497) 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 406 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 407 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 408 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 409 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 410 Drive Clutch CLUTCHES – SUBARU EX40 Connect battery and spark plug wire(s). See Side-Post Battery: Connecting the Battery-Gasoline Vehicles on page 1-3. See Top-Post Battery: Connecting the Battery- Gasoline Vehicles on page 1-4. Drive the vehicle and check for proper operation. Page 23-12 2016 Precedent Golf Car Maintenance and Service Manual...
Page 411 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 412 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 413 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 414 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 415 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 416 Driven Clutch CLUTCHES – SUBARU EX40 Pagination Page Page 23-18 2016 Precedent Golf Car Maintenance and Service Manual...
Page 417 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 418 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 419: 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 420: 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 Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-3.
Page 421 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 422: 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 423: 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 424: 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 425: 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 Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-3.
Page 426 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 427 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 428: 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 429: Shifter Cable
TRANSAXLE, FUJI ED65 (FOR SUBARU EX40) Shifter Cable SHIFTER CABLE See General Warnings on page 1-2. If the Forward/Reverse shifter cable is damaged in any way, it must be replaced. SHIFTER CABLE REMOVAL NOTE: Before removing cable, note cable routing and positions of wire ties or other devices securing the cable to the vehicle.
Page 430: Shifter Cable Adjustment
Shifter Cable TRANSAXLE, FUJI ED65 (FOR SUBARU EX40) Place rear of cable (2) in FNR/accelerator cable bracket with a jam nut (1) on each side of bracket (Figure 24-15, Page 24-13). Tighten jam nuts (1) to 22 ft·lb (29.8 N·m). Hook shifter cable end (4) into transaxle shift lever (5) and secure with bowtie clip (3).
Page 431 Index Index battery Index hydrometer test ..........18-16 AC power and circuit installation ............19-36 testing (ERIC charger) ........15-18 storage ............19-37 accelerator testing ............. 18-16 cable testing under load........18-18, 18-36 installation ............21-9 voltage test ............18-17 removal ............
Page 432 INDEX removal ............. 4-20 test procedures ..........15-17 carburetor choke button bezel closed throttle or idle adjustment ....... 21-10 installation ............4-10 removal ............. 4-10 amp hours ............11-8 cleaning anti-tamper speed ..........11-8 brake assembly............ 6-5 audible charging indicator ........11-8 seat ..............
Page 433 INDEX disassembly............. 23-14 installation ............ 24-13 inspection ............23-15 removal ............24-13 installation ............23-17 handle (lever)............. 24-1 removal ............23-14 switch installation ............13-4 removal ............13-3 testing ............12-23 front body see body, front ............. 4-3 front bumper............4-5 connector, 18-pin fuel see test procedures........
Page 434 INDEX installation ..........4-9–4-10 removal ............4-9–4-10 headlight kill limit switch function, engine adjustment ............4-6 testing ............. 18-26 aiming .............. 4-6 high pedal detect ........... 12-3 hip restraint ............4-11 hubs hub, rear leaf spring installation ............24-4 see suspension, front and suspension, removal ............
Page 435 INDEX installation ............13-7 installation ..........4-14, 4-20 removal ............. 13-7 removal .............4-14, 4-20 testing ........... 12-22, 12-28 rear wheel bearing muffler see wheel bearing ..........24-7 installation ............22-1 receptacle removal ............. 22-1 see charger receptacle ........13-13 see also exhaust system........22-1 regenerative braking ..........
Page 436 INDEX removal ............. 20-5 leaf spring, installation ........7-9 testing ............... 20-6 shock absorber, installation......7-11 specifications shock absorber, removal........7-11 vehicle..............2-1 tie rod end, removal .......... 7-8 speed controller tie rod, installation ..........7-8 connector, 16-pin wheel bearings and hub, inspection....7-14 see test procedures........
Page 437 INDEX test procedures, index of testing ............. 12-20 pedal-start gasoline vehicle....... 18-14 transaxle test procedures, motor installation ............24-12 1 internal short circuits........16-2 lubrication ............24-2 2 armature circuit open ........16-2 removal ............. 24-9 3 field circuit open ..........16-3 service...............
Page 438: Index
INDEX see steering wheel ..........7-1 wiring diagram............12-4 wiring diagram – pedal-start gasoline vehicle ... 18-8 Index-8 2016 Precedent Golf Car Maintenance and Service Manual...

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