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ERICBATTERYCHARGERChargerTroubleshooting

EXTERNALCHARGERTROUBLESHOOTINGINDICATORS

Ifafaultoccurs,countthenumberofredashes(onthechargerordash)betweenpausesandrefertothetablebelow:

EXTERNALCHARGERTROUBLESHOOTINGGUIDE

CHECKSTATUS

INDICATORLIGHT

STATUS

EXPLANATION

POSSIBLECAUSES

(checkinordershown)

SOLUTIONS

1.ACcordconnection

UnplugandinspectACcord.Reconnectand

attempttochargeagain.

2.ACpowersupply

wasshutoff

VerifyACpowerispresentandchargeagain.SeeAC

PowerandContinuityTestofACCircuitonpage15-22.

3.ACcircuitbreaker

istripped

ResetACcircuitbreakerandchargeagain.

4.ImproperACoutlet

voltage

TestACoutletvoltageandcorrectifnecessary.SeeAC

PowerandContinuityTestofACCircuitonpage15-22.

OFF

ACpowerto

chargerisNOT

present.

5.FailedACplugorcord

Replacecord.SeeACPowerandContinuityTest

ofACCircuitonpage15-22.

TABLECONTINUEDONNEXTPAGE

2018OnwardMaintenanceandServiceManualPage15-17

Table of Contents5
SECTION 1 - Safety17
Safety Details17
General Warnings18
Disabling the Vehicle19
Disconnecting the Battery- Gasoline Vehicles19
Connecting the Battery- Gasoline Vehicles19
Disconnecting the Batteries - Electric Vehicles20
Connecting the Batteries - Electric Vehicles20
Recycling Lead-Acid Batteries21
International Safety Symbols on Batteries21
SECTION 2 - Vehicle Specifications23
Vehicle Specifications - Electric and Subaru EX4023
E.r.I.C. Battery Charger Specifications25
SECTION 3 - General Information27
Model Identification27
Storage - Electric Vehicle28
Preparing the Electric Vehicle for Extended Storage28
Returning the Stored Electric Vehicle to Service29
Storage - Gasoline Vehicle30
Preparing the Gasoline Vehicle for Extended Storage30
Returning the Stored Gasoline Vehicle to Service31
SECTION 4 - Body and Trim33
Cleaning the Vehicle33
Seat33
Front and Rear Body Repair34
Stress Lines or Streaks34
Minor Impact Damage/Deformations34
Minor Scratches and Surface Blemishes35
Gouges, Punctures, Tears, Large Scratches, and Abrasions35
Front Body35
Front Body Removal35
Front Body Installation35
Front Bumper37
Front Bumper Removal37
Front Bumper Installation37
Headlights38
Headlight Removal38
Headlight Installation38
Underbody Bracket39
Underbody Bracket Removal39
Underbody Bracket Installation39
Instrument Panel40
Instrument Panel Removal40
Instrument Panel Installation40
Floor Mat and Retainers41
Floor Mat Retainer Removal41
Floor Mat Retainer Installation41
Kick Plate and Charger Receptacle Bezel - Electric Vehicles42
Kick Plate and Charger Receptacle Bezel Removal42
Kick Plate and Charger Receptacle Bezel Installation42
Kick Plate - EFI Gasoline Vehicles43
Kick Plate Removal43
Kick Plate Installation43
Seat Bottom44
Rear Body - Two-Passenger Vehicles44
Universal Accessory Mounting44
Seat Back and Structural Accessory Module (SAM)45
Rear Body Components (Two-Passenger)46
Rear Body - Four-Passenger Vehicles49
Seat Backs49
Seat Support50
Fold down Seat51
Rear Body Components (Four-Passenger)55
Canopy - Two-Passenger57
Two-Passenger Canopy Removal57
Two-Passenger Canopy Installation59
Canopy - Four-Passenger60
Four-Passenger Canopy Removal60
Four-Passenger Canopy Installation60
SECTION 5 - Accelerator and Brake Pedal Group63
Pedal Group - Electric Vehicle63
Pedal Group Removal63
Mcor65
Pedal Group Installation65
Pedal Group - Gasoline Vehicle66
Pedal Group Removal66
Throttle Position Sensor67
Pedal Group Installation68
Debris Shields68
Accelerator Pedal Removal68
Accelerator Pedal Installation68
Brake Pedal Removal69
Brake Pedal Installation69
SECTION 6 - Wheel Brake Assemblies71
General Information71
Brake Shoe Removal73
Brake Assembly Cleaning74
Brake Shoe Installation76
Brake Cable Equalizer Adjustment79
Brake Cluster Removal and Installation80
Brake Cluster Removal80
Brake Cluster Installation81
Brake Cable Removal and Installation83
Brake Cable Removal83
Brake Cable Installation84
SECTION 7 - Steering and Front Suspension85
General Information85
Steering Wheel85
Steering Wheel Removal85
Steering Wheel Installation86
Steering Column86
Steering Column Removal86
Steering Column Installation87
Rack and Pinion88
Rack and Pinion Inspection88
Rack and Pinion Removal89
Rack and Pinion Installation89
Front Suspension90
Lubrication90
Non-Lifted Suspension Wheel Alignment90
Lifted Suspension Wheel Alignment92
Non-Lifted Front Suspension Components95
Non-Lifted Tie Rod End Removal95
Non-Lifted Tie Rod Installation95
Non-Lifted Leaf Spring Removal95
Non-Lifted Leaf Spring Installation96
Non-Lifted Kingpin and Steering Spindle Removal96
Non-Lifted Kingpin and Steering Spindle Installation96
Non-Lifted Control Arm Removal97
Non-Lifted Control Arm Installation97
Non-Lifted Shock Absorber Removal97
Non-Lifted Shock Absorber Installation97
Lifted Front Suspension Components100
Lifted Tie Rod End Removal100
Lifted Tie Rod Installation100
Lifted Leaf Spring Assembly Removal102
Lifted Leaf Spring Assembly Installation102
Lifted Spindle Removal104
Lifted Spindle Installation105
Lifted Control Arm Removal106
Lifted Control Arm Installation107
Lifted Shock Absorber Removal108
Lifted Shock Absorber Installation109
Front Wheel Bearings and Hubs110
Front Wheel Free Play Inspection110
Front Hub Removal110
Front Hub Installation110
SECTION 8 - Wheels and Tires113
General Information113
Wheels113
Wheel Removal113
Wheel Installation113
Tires114
Tire Removal114
Tire Repair114
Tire Installation115
SECTION 9 - Rear Suspension117
General Information117
Panhard and Bracket117
Panhard and Bracket Removal117
Panhard and Bracket Installation117
Shock Absorbers118
Shock Absorber Removal and Inspection118
Shock Absorber Installation118
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 Maintenance135
General Information135
Pre-Operation and Daily Safety Checklist135
Performance Inspection136
Maintenance137
Periodic Service Schedules138
Periodic Lubrication Schedules142
SECTION 11 - Controller Diagnostic Tool (CDT)147
General Information148
Features148
Plugging the CDT into the Vehicle149
Introductory Display149
Quick Reference Guide - Excel with ERIC Charging System150
System Info151
Model Number151
Serial Number151
Hardware Version151
Protocol Version151
Param Block Version151
MFG Date Code151
OS Version151
SM Version151
VCL App Version151
Parameters152
Settings152
Amp Hours154
Access Codes154
Vehicle ID155
Monitor Menu155
Batt Voltage156
Min I156
Signed Battery Current156
BDI Percent156
Speed156
Throttle156
Temperature156
Arm Current156
Field Current156
Armature PWM157
Field PWM157
Speed Pulses157
Foot Input157
Key Input157
Forward Input157
Reverse Input157
Mode Switch Input157
Charger Inhibit157
Main Cont Driver157
Password Tries (OEM Access Level Only)158
Odometer158
BDI Info158
Battery Monitor158
Charging Totals158
Amp Hours Display159
Lin159
Vehicle Speeds159
Pedal Counters159
Fault Counters159
Fault Count Odometers159
Diagnostics Menu160
Present Errors Folder160
Fault History Folder160
Causes of Faults161
Fault Recovery163
Fault Descriptions164
Incorrect Password (OEM Access Level Only)164
Max Password Tries (OEM Access Level Only)164
Throttle Fault164
Low Battery Voltage (Undervoltage)164
Overvoltage164
Thermal Cutback165
Anti-Tamper Fault165
Hpd165
Main Drvr Overcurrent165
Lockout Fault165
Low SOC165
Main Welded166
High Speed Walkaway166
Speed Sensor166
Main Driver on166
Main Coil Open166
Main Dropout (1 or 2)167
Motor Stall167
Main Driver off167
Current Sense Fault167
M- Shorted167
FLD (Field) Missing168
HW Failsafe168
Fault History168
Clear Fault History168
Programming168
Cloning169
Favorites169
HHP Settings169
Plot & Log171
Plot171
Log171
CDT Troubleshooting172
Connection Tests173
SECTION 12 - Excel System Troubleshooting177
General Information177
Accessories177
Charge Indicator Light177
Attributes of the Excel System177
Excel with ERIC Charging System178
Features178
Wiring Diagrams180
Instrument Panel Light Harness - with ERIC Charging188
Troubleshooting188
Troubleshooting the Vehicle with the CDT189
Troubleshooting Guide 1189
Troubleshooting Guide 2192
Test Procedures195
Testing Basics195
SECTION 13 - Electrical Components: Electric Vehicle217
Key Switch217
Testing the Key Switch217
Key Switch Removal217
Key Switch Installation217
Charge Indicator Light218
Testing the Charge Indicator Light218
Charge Indicator Light Removal218
Charge Indicator Light Installation218
USB Port219
USB Port Removal219
USB Port Installation220
Forward/Reverse Rocker Switch220
Testing the Forward/Reverse Rocker Switch220
Forward/Reverse Rocker Switch Removal220
Forward/Reverse Rocker Switch Installation221
Electronics Module Cover222
Electronics Module Cover Removal222
Electronics Module Cover Installation222
Tow/Run Switch223
Testing the Tow/Run Switch223
Tow/Run Switch Removal223
Tow/Run Switch Installation223
Motor Controller Output Regulator (MCOR)224
Testing the MCOR224
MCOR Removal224
MCOR Installation224
Reverse Buzzer225
Testing the Reverse Buzzer225
Reverse Buzzer Removal225
Reverse Buzzer Installation225
Electronics Module226
Electronics Module Removal226
Electronics Module Installation227
Speed Controller228
Testing the Solid State Speed Controller228
Speed Controller Removal228
Speed Controller Installation228
Solenoid229
Testing the Solenoid229
Solenoid Removal229
Solenoid Installation230
Charger Receptacle230
Testing the Charger Receptacle230
Charger Receptacle Inspection230
Charger Receptacle Removal230
Charger Receptacle Installation231
SECTION 14 - Batteries: Electric Vehicle233
General Information233
Battery Testing Basics - 8 Volt234
Observation234
Measuring Voltage of Battery Set234
Battery Cell Numbering234
Battery Testing - 8 Volt235
Battery Regrouping235
Battery Replacement237
Battery Care238
Water Quality238
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-Discharge241
Electrolyte Level241
Vibration Damage242
Single Point Watering System (SPWS)242
Initial Maintenance of the SPWS242
Watering Batteries with the SPWS242
Battery Storage243
Deep-Discharge243
Early Excessive Discharging243
SECTION 15 - ERIC Battery Charger245
General Information246
USB Service Port247
UL and CSA Listing247
CE Compliance247
Plug and Receptacle247
Charger Power Connection Fuse248
Charger Interlock248
AC Input Voltage Detection248
Thermal Cutback248
Charge Indicator Light248
External Charger Status Indicators249
Onboard Charger Status Indicators249
Long-Term Storage251
External Charger Mounting252
AC Power Connection253
The Charge Circuit254
Charger Operation255
Charging Batteries255
Charger Maintenance258
USB Service Port Cleaning and Care258
Charger Troubleshooting259
Numbering Vehicles and Chargers259
USB Service Port259
Incoming AC Service259
Terminal Block Cover260
Resetting Power - External Charger260
Resetting Power - Onboard Charger260
External Charger Troubleshooting Indicators261
Onboard Charger Fault Codes263
Test Procedures265
External Charger Repairs268
Terminal Block Cover Removal268
Terminal Block Cover Installation269
DC Cord and Strain Relief Removal269
DC Cord and Strain Relief Installation269
Handle Removal269
Handle Installation270
Foot Removal270
Foot Installation270
Onboard Charger Repairs271
Onboard Charger Removal271
Onboard Charger Installation272
Terminal Block Cover Removal272
Terminal Block Cover Installation272
DC Cord and Strain Relief Removal273
DC Cord and Strain Relief Installation273
DC Charging Harness Removal273
DC Charging Harness Installation274
SECTION 16 - Motor (Model EJ8-4001A): Electric Vehicle275
General Information275
External Motor Testing275
Motor278
Motor Removal278
Motor Disassembly279
Motor Component Testing and Inspection282
Armature Inspection and Testing282
Motor Frame and Field Windings Inspection284
Motor Brush, Spring, and Terminal Insulator Inspection284
Reconditioning the Motor287
Motor Specifications287
Motor Assembly287
Motor Installation289
SECTION 17 - Transaxle: Electric Vehicle293
Lubrication293
Axle Bearing and Shaft293
Axle Shaft293
Axle Bearing296
Transaxle Removal297
Transaxle Disassembly, Inspection, and Assembly299
Transaxle Disassembly and Inspection299
Transaxle Assembly301
Transaxle Installation302
SECTION 18 - Troubleshooting and Electrical System - Subaru EX40305
General Information305
Accessories305
Low Oil Warning Light305
Ground Locations305
Features of the Electronic Fuel Injection (EFI) System306
Troubleshooting Guide306
ECU Error Codes (Displayed by the Low Oil Warning Light)306
Gasoline Powertrain308
Wiring Diagrams312
Instrument Panel Light Harness319
Electrical System320
Test Procedures321
Testing Basics321
SECTION 19 - Electrical Components - Subaru EX40349
Starter/Generator349
Starter/Generator Removal349
Disassembly of the Starter/Generator to Service the Brushes349
Brush Inspection and Replacement350
Brush Spring Inspection and Replacement350
Starter/Generator Assembly351
Disassembly of the Starter/Generator to Service the Armature/Commutator352
Bearing Cleaning and Inspection353
Bearing Removal354
Field Coil Assembly354
Visual Inspection of Armature354
Commutator Cleaning and Inspection355
Armature Ground Test356
Visual Inspection of Field Coils357
Starter/Generator Rework357
Starter/Generator Assembly357
Starter/Generator Installation360
Belt Tension Adjustment for EFI Engines361
Voltage Regulator363
Voltage Regulator Removal363
Voltage Regulator Installation364
Engine Control Unit (ECU)365
Engine Control Unit Removal365
Engine Control Unit Installation365
Key Switch366
Key Switch Removal366
Key Switch Installation367
Maintenance/Operate Switch367
Maintenance/Operate Switch Removal367
Maintenance/Operate Switch Installation367
Neutral Lockout Limit Switch368
Neutral Lockout Limit Switch Removal368
Neutral Lockout Limit Switch Installation368
Solenoid369
Testing the Solenoid369
Solenoid Removal369
Solenoid Installation369
Fuse370
Fuse Removal370
Fuse Installation370
Accelerator Pedal Limit Switch371
Testing the Accelerator Pedal Limit Switch371
Kill Limit Switch371
Testing the Kill Limit Switch371
Reverse Warning Buzzer371
Reverse Warning Buzzer Removal371
Reverse Warning Buzzer Installation372
Reverse Buzzer Limit Switch373
Reverse Buzzer Limit Switch Removal373
Reverse Buzzer Limit Switch Installation373
Low Oil Warning Light375
Low Oil Warning Light Removal375
Low Oil Warning Light Installation375
Fuel Gauge376
Fuel Gauge Removal376
Fuel Gauge Installation376
Fuel Level Sending Unit377
Hour Meter377
Testing the Hour Meter377
Hour Meter Removal377
Hour Meter Installation377
Oil Level Sensor378
Oil Level Sensor Removal378
Oil Level Sensor Installation378
Battery379
General Information379
Testing the Battery379
Preventive Maintenance379
Self-Discharge380
Vibration Damage380
Battery Removal381
Charging the Battery381
Battery Installation381
Battery Storage382
Charging a Dead Battery382
Ground Cables382
SECTION 20 - Engine - Subaru EX40383
General Information383
Before Servicing383
Engine Rotation383
Torque Specifications384
Adjustments and Settings384
Engine Oil - Gasoline Vehicle384
Spark Plug387
Breather388
Valve Clearance Check and Adjustment389
Engine Removal390
Engine Installation391
Flywheel392
Flywheel Removal392
Flywheel Installation393
Oil Level Sensor394
Testing the Oil Level Sensor394
Oil Level Sensor Removal394
Oil Level Sensor Installation394
Ignition Coil395
Testing the Ignition Coil395
Ignition Coil Removal395
Ignition Coil Installation395
Snubber396
Snubber Removal396
Snubber Installation396
SECTION 21 - Fuel System - Subaru EX40397
General Information397
EFI System Features/Specifications397
Relieving Fuel Pressure398
To Relieve Fuel Pressure398
Throttle Body399
Throttle Body Removal399
Throttle Body Installation401
Engine Control Linkages402
General Information402
Ground Speed403
Governor Cable403
Accelerator Cable404
Closed Throttle or Idle Adjustment - Vehicles406
How to Measure Ground Speed406
Engine RPM Adjustment407
Air Intake System408
General Information408
Air Filter408
Air Intake System Removal409
Air Intake System Installation410
Fuel Line411
Fuel Line Removal411
Fuel Line Installation412
Fuel Pump Module413
General Information413
Fuel Pump Module Removal413
Fuel Pump Module Installation413
Fuel Tank416
General Information416
Fuel Tank Removal416
Fuel Tank Disposal417
Fuel Tank Storage417
Fuel Tank Installation417
Fuel Filter419
General Information419
Fuel Filter Removal419
Fuel Filter Installation419
Fueling Instructions - Gasoline Vehicles420
Carbon Canister421
Carbon Canister Removal421
Carbon Canister Installation422
SECTION 22 - Exhaust System - Subaru EX40423
Muffler423
Muffler Removal423
Muffler Installation423
SECTION 23 - Clutches - Subaru EX40425
General Information425
Troubleshooting425
Drive Belt427
Drive Belt Removal427
Drive Belt Installation427
Drive Clutch428
Drive Clutch Removal429
Drive Clutch Cleaning and Inspection430
Drive Clutch Disassembly430
Inspection of Drive Clutch Parts433
Drive Clutch Assembly434
Drive Clutch Installation435
Driven Clutch437
Driven Clutch Removal438
Driven Clutch Disassembly438
Driven Clutch Inspection439
Driven Clutch Assembly439
Driven Clutch Installation441
SECTION 24 - Transaxle, Fuji ED65 (for Subaru EX40)443
General Information443
Shifter Lever443
Neutral Lockout443
Governor System444
Transaxle Service444
Lubrication444
Tools Required for this Section445
Rear Hubs446
Rear Hub Removal446
Rear Hub Installation446
Axle Tubes, Axle Shafts and Wheel Bearings448
Axle Tube and Axle Shaft Removal448
Axle Tube and Axle Shaft Installation449
Rear Wheel Bearing Removal449
Rear Wheel Bearing Installation449
Axle Shaft Oil Seal Removal449
Axle Shaft Oil Seal Installation450
Transaxle Removal451
Transaxle Installation454
Forward/Reverse Handle455
Forward/Reverse Handle Removal455
Forward/Reverse Handle Installation455
Shifter Cable455
Shifter Cable Removal455
Shifter Cable Installation456
Shifter Cable Adjustment456
Index457

Brand	Club Car
Model	Onward 2018
Category	Golf Cars
Language	English

Club Car Onward 2018 Service Manual

Table of Contents

Questions and Answers:

Club Car Onward 2018 Specifications

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