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Club Car Onward 2018 Manuals
Manuals and User Guides for Club Car Onward 2018. We have
1
Club Car Onward 2018 manual available for free PDF download: Maintenance And Service Manual
Club Car Onward 2018 Maintenance And Service Manual (472 pages)
Brand:
Club Car
| Category:
Golf Cars
| Size: 32.82 MB
Table of Contents
Table of Contents
5
SECTION 1 - Safety
17
Safety Details
17
General Warnings
18
Disabling the Vehicle
19
Disconnecting the Battery- Gasoline Vehicles
19
Connecting the Battery- Gasoline Vehicles
19
Disconnecting the Batteries - Electric Vehicles
20
Connecting the Batteries - Electric Vehicles
20
Recycling Lead-Acid Batteries
21
International Safety Symbols on Batteries
21
SECTION 2 - Vehicle Specifications
23
Vehicle Specifications - Electric and Subaru EX40
23
E.r.I.C. Battery Charger Specifications
25
SECTION 3 - General Information
27
Model Identification
27
Storage - Electric Vehicle
28
Preparing the Electric Vehicle for Extended Storage
28
Returning the Stored Electric Vehicle to Service
29
Storage - Gasoline Vehicle
30
Preparing the Gasoline Vehicle for Extended Storage
30
Returning the Stored Gasoline Vehicle to Service
31
SECTION 4 - Body and Trim
33
Cleaning the Vehicle
33
Seat
33
Front and Rear Body Repair
34
Stress Lines or Streaks
34
Minor Impact Damage/Deformations
34
Minor Scratches and Surface Blemishes
35
Gouges, Punctures, Tears, Large Scratches, and Abrasions
35
Front Body
35
Front Body Removal
35
Front Body Installation
35
Front Bumper
37
Front Bumper Removal
37
Front Bumper Installation
37
Headlights
38
Headlight Removal
38
Headlight Installation
38
Underbody Bracket
39
Underbody Bracket Removal
39
Underbody Bracket Installation
39
Instrument Panel
40
Instrument Panel Removal
40
Instrument Panel Installation
40
Floor Mat and Retainers
41
Floor Mat Retainer Removal
41
Floor Mat Retainer Installation
41
Kick Plate and Charger Receptacle Bezel - Electric Vehicles
42
Kick Plate and Charger Receptacle Bezel Removal
42
Kick Plate and Charger Receptacle Bezel Installation
42
Kick Plate - EFI Gasoline Vehicles
43
Kick Plate Removal
43
Kick Plate Installation
43
Seat Bottom
44
Rear Body - Two-Passenger Vehicles
44
Universal Accessory Mounting
44
Seat Back and Structural Accessory Module (SAM)
45
Rear Body Components (Two-Passenger)
46
Rear Body - Four-Passenger Vehicles
49
Seat Backs
49
Seat Support
50
Fold down Seat
51
Rear Body Components (Four-Passenger)
55
Canopy - Two-Passenger
57
Two-Passenger Canopy Removal
57
Two-Passenger Canopy Installation
59
Canopy - Four-Passenger
60
Four-Passenger Canopy Removal
60
Four-Passenger Canopy Installation
60
SECTION 5 - Accelerator and Brake Pedal Group
63
Pedal Group - Electric Vehicle
63
Pedal Group Removal
63
Mcor
65
Pedal Group Installation
65
Pedal Group - Gasoline Vehicle
66
Pedal Group Removal
66
Throttle Position Sensor
67
Pedal Group Installation
68
Debris Shields
68
Accelerator Pedal Removal
68
Accelerator Pedal Installation
68
Brake Pedal Removal
69
Brake Pedal Installation
69
SECTION 6 - Wheel Brake Assemblies
71
General Information
71
Brake Shoe Removal
73
Brake Assembly Cleaning
74
Brake Shoe Installation
76
Brake Cable Equalizer Adjustment
79
Brake Cluster Removal and Installation
80
Brake Cluster Removal
80
Brake Cluster Installation
81
Brake Cable Removal and Installation
83
Brake Cable Removal
83
Brake Cable Installation
84
SECTION 7 - Steering and Front Suspension
85
General Information
85
Steering Wheel
85
Steering Wheel Removal
85
Steering Wheel Installation
86
Steering Column
86
Steering Column Removal
86
Steering Column Installation
87
Rack and Pinion
88
Rack and Pinion Inspection
88
Rack and Pinion Removal
89
Rack and Pinion Installation
89
Front Suspension
90
Lubrication
90
Non-Lifted Suspension Wheel Alignment
90
Lifted Suspension Wheel Alignment
92
Non-Lifted Front Suspension Components
95
Non-Lifted Tie Rod End Removal
95
Non-Lifted Tie Rod Installation
95
Non-Lifted Leaf Spring Removal
95
Non-Lifted Leaf Spring Installation
96
Non-Lifted Kingpin and Steering Spindle Removal
96
Non-Lifted Kingpin and Steering Spindle Installation
96
Non-Lifted Control Arm Removal
97
Non-Lifted Control Arm Installation
97
Non-Lifted Shock Absorber Removal
97
Non-Lifted Shock Absorber Installation
97
Lifted Front Suspension Components
100
Lifted Tie Rod End Removal
100
Lifted Tie Rod Installation
100
Lifted Leaf Spring Assembly Removal
102
Lifted Leaf Spring Assembly Installation
102
Lifted Spindle Removal
104
Lifted Spindle Installation
105
Lifted Control Arm Removal
106
Lifted Control Arm Installation
107
Lifted Shock Absorber Removal
108
Lifted Shock Absorber Installation
109
Front Wheel Bearings and Hubs
110
Front Wheel Free Play Inspection
110
Front Hub Removal
110
Front Hub Installation
110
SECTION 8 - Wheels and Tires
113
General Information
113
Wheels
113
Wheel Removal
113
Wheel Installation
113
Tires
114
Tire Removal
114
Tire Repair
114
Tire Installation
115
SECTION 9 - Rear Suspension
117
General Information
117
Panhard and Bracket
117
Panhard and Bracket Removal
117
Panhard and Bracket Installation
117
Shock Absorbers
118
Shock Absorber Removal and Inspection
118
Shock Absorber Installation
118
Leaf Springs (Two-Passenger Vehicle)
119
Leaf Spring Removal (Two-Passenger Electric Vehicle)
119
Leaf Spring Installation (Two-Passenger Electric Vehicle)
122
Leaf Spring Removal (Two-Passenger Gasoline Vehicle)
122
Leaf Spring Installation (Two-Passenger Gasoline Vehicle)
124
Leaf Springs (Four-Passenger Vehicle)
125
Leaf Spring Removal (Non-Lifted Four-Passenger Electric Vehicle)
125
Leaf Spring Installation (Non-Lifted Four-Passenger Electric Vehicle)
128
Leaf Spring Removal (Four-Passenger Gasoline Vehicle)
128
Leaf Spring Installation (Four-Passenger Gasoline Vehicle)
130
Leaf Spring Removal (Lifted Four-Passenger Vehicle)
131
Leaf Spring Installation (Lifted Four-Passenger Vehicle)
133
SECTION 10 - Periodic Maintenance
135
General Information
135
Pre-Operation and Daily Safety Checklist
135
Performance Inspection
136
Maintenance
137
Periodic Service Schedules
138
Periodic Lubrication Schedules
142
SECTION 11 - Controller Diagnostic Tool (CDT)
147
General Information
148
Features
148
Plugging the CDT into the Vehicle
149
Introductory Display
149
Quick Reference Guide - Excel with ERIC Charging System
150
System Info
151
Model Number
151
Serial Number
151
Hardware Version
151
Protocol Version
151
Param Block Version
151
MFG Date Code
151
OS Version
151
SM Version
151
VCL App Version
151
Parameters
152
Settings
152
Amp Hours
154
Access Codes
154
Vehicle ID
155
Monitor Menu
155
Batt Voltage
156
Min I
156
Signed Battery Current
156
BDI Percent
156
Speed
156
Throttle
156
Temperature
156
Arm Current
156
Field Current
156
Armature PWM
157
Field PWM
157
Speed Pulses
157
Foot Input
157
Key Input
157
Forward Input
157
Reverse Input
157
Mode Switch Input
157
Charger Inhibit
157
Main Cont Driver
157
Password Tries (OEM Access Level Only)
158
Odometer
158
BDI Info
158
Battery Monitor
158
Charging Totals
158
Amp Hours Display
159
Lin
159
Vehicle Speeds
159
Pedal Counters
159
Fault Counters
159
Fault Count Odometers
159
Diagnostics Menu
160
Present Errors Folder
160
Fault History Folder
160
Causes of Faults
161
Fault Recovery
163
Fault Descriptions
164
Incorrect Password (OEM Access Level Only)
164
Max Password Tries (OEM Access Level Only)
164
Throttle Fault
164
Low Battery Voltage (Undervoltage)
164
Overvoltage
164
Thermal Cutback
165
Anti-Tamper Fault
165
Hpd
165
Main Drvr Overcurrent
165
Lockout Fault
165
Low SOC
165
Main Welded
166
High Speed Walkaway
166
Speed Sensor
166
Main Driver on
166
Main Coil Open
166
Main Dropout (1 or 2)
167
Motor Stall
167
Main Driver off
167
Current Sense Fault
167
M- Shorted
167
FLD (Field) Missing
168
HW Failsafe
168
Fault History
168
Clear Fault History
168
Programming
168
Cloning
169
Favorites
169
HHP Settings
169
Plot & Log
171
Plot
171
Log
171
CDT Troubleshooting
172
Connection Tests
173
SECTION 12 - Excel System Troubleshooting
177
General Information
177
Accessories
177
Charge Indicator Light
177
Attributes of the Excel System
177
Excel with ERIC Charging System
178
Features
178
Wiring Diagrams
180
Instrument Panel Light Harness - with ERIC Charging
188
Troubleshooting
188
Troubleshooting the Vehicle with the CDT
189
Troubleshooting Guide 1
189
Troubleshooting Guide 2
192
Test Procedures
195
Testing Basics
195
SECTION 13 - Electrical Components: Electric Vehicle
217
Key Switch
217
Testing the Key Switch
217
Key Switch Removal
217
Key Switch Installation
217
Charge Indicator Light
218
Testing the Charge Indicator Light
218
Charge Indicator Light Removal
218
Charge Indicator Light Installation
218
USB Port
219
USB Port Removal
219
USB Port Installation
220
Forward/Reverse Rocker Switch
220
Testing the Forward/Reverse Rocker Switch
220
Forward/Reverse Rocker Switch Removal
220
Forward/Reverse Rocker Switch Installation
221
Electronics Module Cover
222
Electronics Module Cover Removal
222
Electronics Module Cover Installation
222
Tow/Run Switch
223
Testing the Tow/Run Switch
223
Tow/Run Switch Removal
223
Tow/Run Switch Installation
223
Motor Controller Output Regulator (MCOR)
224
Testing the MCOR
224
MCOR Removal
224
MCOR Installation
224
Reverse Buzzer
225
Testing the Reverse Buzzer
225
Reverse Buzzer Removal
225
Reverse Buzzer Installation
225
Electronics Module
226
Electronics Module Removal
226
Electronics Module Installation
227
Speed Controller
228
Testing the Solid State Speed Controller
228
Speed Controller Removal
228
Speed Controller Installation
228
Solenoid
229
Testing the Solenoid
229
Solenoid Removal
229
Solenoid Installation
230
Charger Receptacle
230
Testing the Charger Receptacle
230
Charger Receptacle Inspection
230
Charger Receptacle Removal
230
Charger Receptacle Installation
231
SECTION 14 - Batteries: Electric Vehicle
233
General Information
233
Battery Testing Basics - 8 Volt
234
Observation
234
Measuring Voltage of Battery Set
234
Battery Cell Numbering
234
Battery Testing - 8 Volt
235
Battery Regrouping
235
Battery Replacement
237
Battery Care
238
Water Quality
238
Battery Care - Vehicles Equipped with the Optional Single-Point Watering System (SPWS)
239
Battery Care - Vehicles Without the Single-Point Watering System (SPWS)
240
Self-Discharge
241
Electrolyte Level
241
Vibration Damage
242
Single Point Watering System (SPWS)
242
Initial Maintenance of the SPWS
242
Watering Batteries with the SPWS
242
Battery Storage
243
Deep-Discharge
243
Early Excessive Discharging
243
SECTION 15 - ERIC Battery Charger
245
General Information
246
USB Service Port
247
UL and CSA Listing
247
CE Compliance
247
Plug and Receptacle
247
Charger Power Connection Fuse
248
Charger Interlock
248
AC Input Voltage Detection
248
Thermal Cutback
248
Charge Indicator Light
248
External Charger Status Indicators
249
Onboard Charger Status Indicators
249
Long-Term Storage
251
External Charger Mounting
252
AC Power Connection
253
The Charge Circuit
254
Charger Operation
255
Charging Batteries
255
Charger Maintenance
258
USB Service Port Cleaning and Care
258
Charger Troubleshooting
259
Numbering Vehicles and Chargers
259
USB Service Port
259
Incoming AC Service
259
Terminal Block Cover
260
Resetting Power - External Charger
260
Resetting Power - Onboard Charger
260
External Charger Troubleshooting Indicators
261
Onboard Charger Fault Codes
263
Test Procedures
265
External Charger Repairs
268
Terminal Block Cover Removal
268
Terminal Block Cover Installation
269
DC Cord and Strain Relief Removal
269
DC Cord and Strain Relief Installation
269
Handle Removal
269
Handle Installation
270
Foot Removal
270
Foot Installation
270
Onboard Charger Repairs
271
Onboard Charger Removal
271
Onboard Charger Installation
272
Terminal Block Cover Removal
272
Terminal Block Cover Installation
272
DC Cord and Strain Relief Removal
273
DC Cord and Strain Relief Installation
273
DC Charging Harness Removal
273
DC Charging Harness Installation
274
SECTION 16 - Motor (Model EJ8-4001A): Electric Vehicle
275
General Information
275
External Motor Testing
275
Motor
278
Motor Removal
278
Motor Disassembly
279
Motor Component Testing and Inspection
282
Armature Inspection and Testing
282
Motor Frame and Field Windings Inspection
284
Motor Brush, Spring, and Terminal Insulator Inspection
284
Reconditioning the Motor
287
Motor Specifications
287
Motor Assembly
287
Motor Installation
289
SECTION 17 - Transaxle: Electric Vehicle
293
Lubrication
293
Axle Bearing and Shaft
293
Axle Shaft
293
Axle Bearing
296
Transaxle Removal
297
Transaxle Disassembly, Inspection, and Assembly
299
Transaxle Disassembly and Inspection
299
Transaxle Assembly
301
Transaxle Installation
302
SECTION 18 - Troubleshooting and Electrical System - Subaru EX40
305
General Information
305
Accessories
305
Low Oil Warning Light
305
Ground Locations
305
Features of the Electronic Fuel Injection (EFI) System
306
Troubleshooting Guide
306
ECU Error Codes (Displayed by the Low Oil Warning Light)
306
Gasoline Powertrain
308
Wiring Diagrams
312
Instrument Panel Light Harness
319
Electrical System
320
Test Procedures
321
Testing Basics
321
SECTION 19 - Electrical Components - Subaru EX40
349
Starter/Generator
349
Starter/Generator Removal
349
Disassembly of the Starter/Generator to Service the Brushes
349
Brush Inspection and Replacement
350
Brush Spring Inspection and Replacement
350
Starter/Generator Assembly
351
Disassembly of the Starter/Generator to Service the Armature/Commutator
352
Bearing Cleaning and Inspection
353
Bearing Removal
354
Field Coil Assembly
354
Visual Inspection of Armature
354
Commutator Cleaning and Inspection
355
Armature Ground Test
356
Visual Inspection of Field Coils
357
Starter/Generator Rework
357
Starter/Generator Assembly
357
Starter/Generator Installation
360
Belt Tension Adjustment for EFI Engines
361
Voltage Regulator
363
Voltage Regulator Removal
363
Voltage Regulator Installation
364
Engine Control Unit (ECU)
365
Engine Control Unit Removal
365
Engine Control Unit Installation
365
Key Switch
366
Key Switch Removal
366
Key Switch Installation
367
Maintenance/Operate Switch
367
Maintenance/Operate Switch Removal
367
Maintenance/Operate Switch Installation
367
Neutral Lockout Limit Switch
368
Neutral Lockout Limit Switch Removal
368
Neutral Lockout Limit Switch Installation
368
Solenoid
369
Testing the Solenoid
369
Solenoid Removal
369
Solenoid Installation
369
Fuse
370
Fuse Removal
370
Fuse Installation
370
Accelerator Pedal Limit Switch
371
Testing the Accelerator Pedal Limit Switch
371
Kill Limit Switch
371
Testing the Kill Limit Switch
371
Reverse Warning Buzzer
371
Reverse Warning Buzzer Removal
371
Reverse Warning Buzzer Installation
372
Reverse Buzzer Limit Switch
373
Reverse Buzzer Limit Switch Removal
373
Reverse Buzzer Limit Switch Installation
373
Low Oil Warning Light
375
Low Oil Warning Light Removal
375
Low Oil Warning Light Installation
375
Fuel Gauge
376
Fuel Gauge Removal
376
Fuel Gauge Installation
376
Fuel Level Sending Unit
377
Hour Meter
377
Testing the Hour Meter
377
Hour Meter Removal
377
Hour Meter Installation
377
Oil Level Sensor
378
Oil Level Sensor Removal
378
Oil Level Sensor Installation
378
Battery
379
General Information
379
Testing the Battery
379
Preventive Maintenance
379
Self-Discharge
380
Vibration Damage
380
Battery Removal
381
Charging the Battery
381
Battery Installation
381
Battery Storage
382
Charging a Dead Battery
382
Ground Cables
382
SECTION 20 - Engine - Subaru EX40
383
General Information
383
Before Servicing
383
Engine Rotation
383
Torque Specifications
384
Adjustments and Settings
384
Engine Oil - Gasoline Vehicle
384
Spark Plug
387
Breather
388
Valve Clearance Check and Adjustment
389
Engine Removal
390
Engine Installation
391
Flywheel
392
Flywheel Removal
392
Flywheel Installation
393
Oil Level Sensor
394
Testing the Oil Level Sensor
394
Oil Level Sensor Removal
394
Oil Level Sensor Installation
394
Ignition Coil
395
Testing the Ignition Coil
395
Ignition Coil Removal
395
Ignition Coil Installation
395
Snubber
396
Snubber Removal
396
Snubber Installation
396
SECTION 21 - Fuel System - Subaru EX40
397
General Information
397
EFI System Features/Specifications
397
Relieving Fuel Pressure
398
To Relieve Fuel Pressure
398
Throttle Body
399
Throttle Body Removal
399
Throttle Body Installation
401
Engine Control Linkages
402
General Information
402
Ground Speed
403
Governor Cable
403
Accelerator Cable
404
Closed Throttle or Idle Adjustment - Vehicles
406
How to Measure Ground Speed
406
Engine RPM Adjustment
407
Air Intake System
408
General Information
408
Air Filter
408
Air Intake System Removal
409
Air Intake System Installation
410
Fuel Line
411
Fuel Line Removal
411
Fuel Line Installation
412
Fuel Pump Module
413
General Information
413
Fuel Pump Module Removal
413
Fuel Pump Module Installation
413
Fuel Tank
416
General Information
416
Fuel Tank Removal
416
Fuel Tank Disposal
417
Fuel Tank Storage
417
Fuel Tank Installation
417
Fuel Filter
419
General Information
419
Fuel Filter Removal
419
Fuel Filter Installation
419
Fueling Instructions - Gasoline Vehicles
420
Carbon Canister
421
Carbon Canister Removal
421
Carbon Canister Installation
422
SECTION 22 - Exhaust System - Subaru EX40
423
Muffler
423
Muffler Removal
423
Muffler Installation
423
SECTION 23 - Clutches - Subaru EX40
425
General Information
425
Troubleshooting
425
Drive Belt
427
Drive Belt Removal
427
Drive Belt Installation
427
Drive Clutch
428
Drive Clutch Removal
429
Drive Clutch Cleaning and Inspection
430
Drive Clutch Disassembly
430
Inspection of Drive Clutch Parts
433
Drive Clutch Assembly
434
Drive Clutch Installation
435
Driven Clutch
437
Driven Clutch Removal
438
Driven Clutch Disassembly
438
Driven Clutch Inspection
439
Driven Clutch Assembly
439
Driven Clutch Installation
441
SECTION 24 - Transaxle, Fuji ED65 (for Subaru EX40)
443
General Information
443
Shifter Lever
443
Neutral Lockout
443
Governor System
444
Transaxle Service
444
Lubrication
444
Tools Required for this Section
445
Rear Hubs
446
Rear Hub Removal
446
Rear Hub Installation
446
Axle Tubes, Axle Shafts and Wheel Bearings
448
Axle Tube and Axle Shaft Removal
448
Axle Tube and Axle Shaft Installation
449
Rear Wheel Bearing Removal
449
Rear Wheel Bearing Installation
449
Axle Shaft Oil Seal Removal
449
Axle Shaft Oil Seal Installation
450
Transaxle Removal
451
Transaxle Installation
454
Forward/Reverse Handle
455
Forward/Reverse Handle Removal
455
Forward/Reverse Handle Installation
455
Shifter Cable
455
Shifter Cable Removal
455
Shifter Cable Installation
456
Shifter Cable Adjustment
456
Index
457
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