Club car Onward 2018 Manual

2018Onward

Maintenanceand

ServiceManual

ElectricVehiclewithERICChargingSystem

GasolineVehiclewithSubaruEX40Engine

Manual Number 105344203

Edition Code C

FOREWORD

ClubCarvehiclesaredesignedandbuilttoprovidetheultimateinperformanceefciency;however,proper

maintenanceandrepairareessentialforachievingmaximumservicelifeandcontinuedsafeandreliableoperation.

ThismanualprovidesdetailedinformationforthemaintenanceandrepairoftheOnwardelectricandgasoline-powered

vehicles,andshouldbethoroughlyreviewedpriortoservicingthevehicle.Theproceduresprovidedhereinmustbe

properlyimplemented,andtheDANGER,WARNING,andCAUTIONstatementsmustbeheeded.

Thismanualwaswrittenforthetrainedtechnicianwhoalreadypossessesknowledgeandskillsinelectricaland

mechanicalrepair.Ifthetechniciandoesnothavesuchknowledgeandskills,attemptedserviceorrepairstothe

vehiclemayrenderthevehicleunsafe.Forthisreason,ClubCaradvisesthatallrepairsand/orservicebeperformed

byanauthorizedClubCardistributor/dealerrepresentativeorbyaClubCarfactory-trainedtechnician.

ItisthepolicyofClubCartoassistitsdistributorsanddealersincontinuallyupdatingtheirserviceknowledgeand

facilitiessotheycanprovidepromptandefcientserviceforvehicleowners.Regionaltechnicalrepresentatives,

vehicleserviceseminars,periodicservicebulletins,maintenanceandservicemanuals,andotherservicepublications

alsorepresentClubCar’scontinuingcommitmenttocustomersupport.

ClubCaroffersafulllineoftrainingandcontinuingeducationclassesfortechnicianswhowanttolearnmoreabout

ourproducts.Formoreinformation,contactyourlocaldealerorClubCar'sTechnicalServicesdepartmentfora

listofupcomingclasses.

Thismanualcoversallaspectsoftypicalvehicleservice;however,uniquesituationssometimesoccurwhenservicinga

vehicle.Ifitappearsthataservicequestionisnotansweredinthismanual,pleasecontactyournearestauthorized

ClubCardealerordistributorforassistance.

TondyourlocalauthorizedClubCardealer,visitwww.clubcardealer.com,call1-800-ClubCar(258–2227),orscan

thisQuickResponse(QR)codetobetakentotheClubCardealerlocator.RefertoFigure1.DownloadaQRcode

readersuchasRedLaserorBarcodeScannertoyourcellphoneortablet.

Ifyouwouldprefertowritetous,directyourletterto:ClubCarLLC,Attention:MarketingServices,P .O.Box204658,

Augusta,Georgia30917-4658USA.

DealerLocatorQRCode

ClubCarisaregisteredtrademarkofClubCar,LLC

ThismanualeffectiveJune,2018

2018OnwardMaintenanceandServiceManualPagei

FOREWORD

TECHNICALPUBLICATIONCUSTOMERSATISFACTIONONLINESURVEY

Letyourvoicebeheard!

PleaseparticipateintheTechnicalPublicationcustomersatisfactiononlinesurvey.

Thissurveytakeslessthanveminutestocompleteandyourresponseswillhelpexaminecurrentperformance

andidentifyareasforfutureimprovement.

Ourtoppriorityistoprovidetimely,accurate,anduserfriendlymanuals.

Theonlinesurveycanbefoundathttp://bit.ly/1w9uFMhorusingtheQRCodebelow.

OnlineSurveyQRCode

WARNING

•ReadSafetyonpage1-1beforeattemptinganyserviceonthevehicle.

•Beforeservicingvehicle,readcompletesection(s)andanyreferencedinformationthatmaybe

relevanttotheserviceorrepairtobeperformed.

MAINTENANCEITEMS

BatteryTerminalProtectorSpray

CCPN1014305

DryMolyLube

CCPN1012151

ChassisLube

EPNLGIGrade2(commerciallyavailable)

EngineAirFilter(404cc)

CCPN102558201

SparkPlugO.H.C.(404cc)

CCPN47539956001

NOTE:Thismanualrepresentsthemostcurrentinformationatthetimeofpublication.ClubCariscontinuallyworking

tofurtherimproveitsvehiclesandotherproducts.Theseimprovementsmayaffectservicingprocedures.

Anymodicationand/orsignicantchangeinspecicationsorprocedureswillbeforwardedtoallClubCar

dealersandwill,whenapplicable,appearinfutureeditionsofthismanual.

ClubCarreservestherighttochangespecicationsanddesignsatanytimewithoutnoticeandwithoutthe

obligationofmakingchangestounitspreviouslysold.

Therearenowarrantiesexpressedorimpliedinthismanual.Seethelimitedwarrantyfoundinthevehicle

Owner’sManual.

CONTENTS

SECTION1—Safety.........................................................................................................................................1-1

SafetyDetails................................................................................................................................................1-1

GeneralWarnings..........................................................................................................................................1-2

DisablingtheVehicle..................................................................................................................................1-3

DisconnectingtheBattery-GasolineVehicles..............................................................................................1-3

ConnectingtheBattery-GasolineVehicles..................................................................................................1-3

DisconnectingtheBatteries–ElectricVehicles............................................................................................1-4

ConnectingtheBatteries–ElectricVehicles................................................................................................1-4

RecyclingLead-AcidBatteries....................................................................................................................1-5

Internationalsafetysymbolsonbatteries.....................................................................................................1-5

SECTION2—VehicleSpecications..................................................................................................................2-1

VehicleSpecications–ElectricandSubaruEX40..........................................................................................2-1

E.R.I.C.BatteryChargerSpecications...........................................................................................................2-3

SECTION3—GeneralInformation.....................................................................................................................3-1

ModelIdentication........................................................................................................................................3-1

Storage–ElectricVehicle...............................................................................................................................3-2

PreparingtheElectricVehicleforExtendedStorage.....................................................................................3-2

ReturningtheStoredElectricVehicletoService..........................................................................................3-3

Storage–GasolineVehicle............................................................................................................................3-4

PreparingtheGasolineVehicleforExtendedStorage.................................................................................3-4

ReturningtheStoredGasolineVehicletoService........................................................................................3-5

SECTION4—BodyandTrim............................................................................................................................4-1

CleaningtheVehicle......................................................................................................................................4-1

Seat..........................................................................................................................................................4-1

FrontandRearBodyRepair...........................................................................................................................4-2

StressLinesorStreaks..............................................................................................................................4-2

MinorImpactDamage/Deformations...........................................................................................................4-2

MinorScratchesandSurfaceBlemishes.....................................................................................................4-3

Gouges,Punctures,Tears,LargeScratches,andAbrasions.........................................................................4-3

FrontBody....................................................................................................................................................4-3

FrontBodyRemoval..................................................................................................................................4-3

FrontBodyInstallation...............................................................................................................................4-3

FrontBumper................................................................................................................................................4-5

FrontBumperRemoval..............................................................................................................................4-5

FrontBumperInstallation...........................................................................................................................4-5

Headlights.....................................................................................................................................................4-6

HeadlightRemoval....................................................................................................................................4-6

HeadlightInstallation..................................................................................................................................4-6

UnderbodyBracket........................................................................................................................................4-7

UnderbodyBracketRemoval......................................................................................................................4-7

UnderbodyBracketInstallation...................................................................................................................4-7

InstrumentPanel...........................................................................................................................................4-8

InstrumentPanelRemoval.........................................................................................................................4-8

InstrumentPanelInstallation......................................................................................................................4-8

FloorMatandRetainers.................................................................................................................................4-9

FloorMatRetainerRemoval.......................................................................................................................4-9

FloorMatRetainerInstallation....................................................................................................................4-9

KickPlateandChargerReceptacleBezel–ElectricVehicles.........................................................................4-10

KickPlateandChargerReceptacleBezelRemoval...................................................................................4-10

KickPlateandChargerReceptacleBezelInstallation.................................................................................4-10

KickPlate–EFIGasolineVehicles................................................................................................................4-11

KickPlateRemoval...................................................................................................................................4-11

KickPlateInstallation................................................................................................................................4-11

2018OnwardMaintenanceandServiceManualPageiii

SeatBottom................................................................................................................................................4-12

RearBody–Two-PassengerVehicles...........................................................................................................4-12

UniversalAccessoryMounting..................................................................................................................4-12

SeatBackandStructuralAccessoryModule(SAM)...................................................................................4-13

RearBodyComponents(Two-Passenger).................................................................................................4-14

RearBody–Four-PassengerVehicles..........................................................................................................4-17

SeatBacks..............................................................................................................................................4-17

SeatSupport...........................................................................................................................................4-18

FoldDownSeat.......................................................................................................................................4-19

RearBodyComponents(Four-Passenger)................................................................................................4-23

Canopy–Two-Passenger............................................................................................................................4-25

Two-PassengerCanopyRemoval.............................................................................................................4-25

Two-PassengerCanopyInstallation..........................................................................................................4-27

Canopy–Four-Passenger...........................................................................................................................4-28

Four-PassengerCanopyRemoval............................................................................................................4-28

Four-PassengerCanopyInstallation.........................................................................................................4-28

SECTION5—AcceleratorandBrakePedalGroup.............................................................................................5-1

PedalGroup–ElectricVehicle.......................................................................................................................5-1

PedalGroupRemoval................................................................................................................................5-1

MCOR......................................................................................................................................................5-3

PedalGroupInstallation.............................................................................................................................5-3

PedalGroup–GasolineVehicle.....................................................................................................................5-4

PedalGroupRemoval................................................................................................................................5-4

ThrottlePositionSensor.............................................................................................................................5-5

PedalGroupInstallation.............................................................................................................................5-6

DebrisShields...............................................................................................................................................5-6

AcceleratorPedalRemoval............................................................................................................................5-6

AcceleratorPedalInstallation.........................................................................................................................5-6

BrakePedalRemoval....................................................................................................................................5-7

BrakePedalInstallation.................................................................................................................................5-7

SECTION6—WheelBrakeAssemblies.............................................................................................................6-1

GeneralInformation.......................................................................................................................................6-1

BrakeShoeRemoval.....................................................................................................................................6-1

BrakeAssemblyCleaning..............................................................................................................................6-4

BrakeShoeInstallation..................................................................................................................................6-6

BrakeCableEqualizerAdjustment..................................................................................................................6-9

BrakeClusterRemovalandInstallation.........................................................................................................6-10

BrakeClusterRemoval............................................................................................................................6-10

BrakeClusterInstallation..........................................................................................................................6-11

BrakeCableRemovalandInstallation...........................................................................................................6-13

BrakeCableRemoval..............................................................................................................................6-13

BrakeCableInstallation...........................................................................................................................6-14

SECTION7—SteeringandFrontSuspension....................................................................................................7-1

GeneralInformation.......................................................................................................................................7-1

SteeringWheel..............................................................................................................................................7-1

SteeringWheelRemoval............................................................................................................................7-1

SteeringWheelInstallation.........................................................................................................................7-2

SteeringColumn............................................................................................................................................7-2

SteeringColumnRemoval..........................................................................................................................7-2

SteeringColumnInstallation.......................................................................................................................7-3

RackandPinion............................................................................................................................................7-4

RackandPinionInspection........................................................................................................................7-4

RackandPinionRemoval..........................................................................................................................7-5

RackandPinionInstallation.......................................................................................................................7-5

FrontSuspension..........................................................................................................................................7-6

Lubrication................................................................................................................................................7-6

Non-LiftedSuspensionWheelAlignment.....................................................................................................7-6

LiftedSuspensionWheelAlignment............................................................................................................7-8

Pageiv2018OnwardMaintenanceandServiceManual

Non-LiftedFrontSuspensionComponents.....................................................................................................7-11

Non-LiftedTieRodEndRemoval...............................................................................................................7-11

Non-LiftedTieRodInstallation...................................................................................................................7-11

Non-LiftedLeafSpringRemoval................................................................................................................7-11

Non-LiftedLeafSpringInstallation............................................................................................................7-12

Non-LiftedKingpinandSteeringSpindleRemoval.....................................................................................7-12

Non-LiftedKingpinandSteeringSpindleInstallation..................................................................................7-12

Non-LiftedControlArmRemoval..............................................................................................................7-13

Non-LiftedControlArmInstallation............................................................................................................7-13

Non-LiftedShockAbsorberRemoval........................................................................................................7-13

Non-LiftedShockAbsorberInstallation......................................................................................................7-13

LiftedFrontSuspensionComponents...........................................................................................................7-16

LiftedTieRodEndRemoval.....................................................................................................................7-16

LiftedTieRodInstallation.........................................................................................................................7-16

LiftedLeafSpringAssemblyRemoval.......................................................................................................7-18

LiftedLeafSpringAssemblyInstallation....................................................................................................7-18

LiftedSpindleRemoval............................................................................................................................7-20

LiftedSpindleInstallation.........................................................................................................................7-21

LiftedControlArmRemoval......................................................................................................................7-22

LiftedControlArmInstallation...................................................................................................................7-23

LiftedShockAbsorberRemoval................................................................................................................7-24

LiftedShockAbsorberInstallation.............................................................................................................7-25

FrontWheelBearingsandHubs...................................................................................................................7-26

FrontWheelFreePlayInspection.............................................................................................................7-26

FrontHubRemoval..................................................................................................................................7-26

FrontHubInstallation...............................................................................................................................7-26

SECTION8—WheelsandTires........................................................................................................................8-1

GeneralInformation.......................................................................................................................................8-1

Wheels.........................................................................................................................................................8-1

WheelRemoval.........................................................................................................................................8-1

WheelInstallation......................................................................................................................................8-1

Tires.............................................................................................................................................................8-2

TireRemoval.............................................................................................................................................8-2

TireRepair................................................................................................................................................8-2

TireInstallation..........................................................................................................................................8-3

SECTION9—RearSuspension........................................................................................................................9-1

GeneralInformation.......................................................................................................................................9-1

PanhardandBracket.....................................................................................................................................9-1

PanhardandBracketRemoval...................................................................................................................9-1

PanhardandBracketInstallation................................................................................................................9-1

ShockAbsorbers...........................................................................................................................................9-2

ShockAbsorberRemovalandInspection....................................................................................................9-2

ShockAbsorberInstallation........................................................................................................................9-2

LeafSprings(Two-PassengerVehicle)............................................................................................................9-3

LeafSpringRemoval(Two-PassengerElectricVehicle)................................................................................9-3

LeafSpringInstallation(Two-PassengerElectricVehicle).............................................................................9-6

LeafSpringRemoval(Two-PassengerGasolineVehicle).............................................................................9-6

LeafSpringInstallation(Two-PassengerGasolineVehicle)...........................................................................9-8

LeafSprings(Four-PassengerVehicle)...........................................................................................................9-9

LeafSpringRemoval(Non-LiftedFour-PassengerElectricVehicle)...............................................................9-9

LeafSpringInstallation(Non-LiftedFour-PassengerElectricVehicle)..........................................................9-12

LeafSpringRemoval(Four-PassengerGasolineVehicle)...........................................................................9-12

LeafSpringInstallation(Four-PassengerGasolineVehicle)........................................................................9-14

LeafSpringRemoval(LiftedFour-PassengerVehicle)................................................................................9-15

LeafSpringInstallation(LiftedFour-PassengerVehicle).............................................................................9-17

SECTION10—PeriodicMaintenance..............................................................................................................10-1

GeneralInformation.....................................................................................................................................10-1

Pre-OperationandDailySafetyChecklist......................................................................................................10-1

2018OnwardMaintenanceandServiceManualPagev

..............................................................................................................................................................10-1

PerformanceInspection...........................................................................................................................10-2

Maintenance...............................................................................................................................................10-3

PeriodicServiceSchedules..........................................................................................................................10-4

PeriodicLubricationSchedules.....................................................................................................................10-8

SECTION11—ControllerDiagnosticT ool(CDT)...............................................................................................11-1

GeneralInformation......................................................................................................................................11-2

Features..................................................................................................................................................11-2

PluggingtheCDTintotheVehicle..................................................................................................................11-3

IntroductoryDisplay..................................................................................................................................11-3

QuickReferenceGuide–ExcelwithERICChargingSystem...........................................................................11-4

SystemInfo..................................................................................................................................................11-5

ModelNumber..........................................................................................................................................11-5

SerialNumber..........................................................................................................................................11-5

HardwareVersion.....................................................................................................................................11-5

ProtocolVersion.......................................................................................................................................11-5

ParamBlockVersion.................................................................................................................................11-5

MFGDateCode.......................................................................................................................................11-5

OSVersion...............................................................................................................................................11-5

SMVersion..............................................................................................................................................11-5

VCLAppVersion......................................................................................................................................11-5

Parameters..................................................................................................................................................11-6

Settings...................................................................................................................................................11-6

AmpHours...............................................................................................................................................11-8

AccessCodes..........................................................................................................................................11-8

VehicleID................................................................................................................................................11-9

MonitorMenu...............................................................................................................................................11-9

BattVoltage............................................................................................................................................11-10

VminI...................................................................................................................................................11-10

SignedBatteryCurrent............................................................................................................................11-10

BDIPercent............................................................................................................................................11-10

Speed....................................................................................................................................................11-10

Throttle..................................................................................................................................................11-10

Temperature...........................................................................................................................................11-10

ArmCurrent...........................................................................................................................................11-10

FieldCurrent..........................................................................................................................................11-10

ArmaturePWM.......................................................................................................................................11-11

FieldPWM.............................................................................................................................................11-11

SpeedPulses.........................................................................................................................................11-11

FootInput..............................................................................................................................................11-11

KeyInput...............................................................................................................................................11-11

ForwardInput.........................................................................................................................................11-11

ReverseInput.........................................................................................................................................11-11

ModeSwitchInput..................................................................................................................................11-11

ChargerInhibit........................................................................................................................................11-11

MainContDriver....................................................................................................................................11-11

LEDDriver.............................................................................................................................................11-11

PasswordTries(OEMAccessLevelOnly)................................................................................................11-12

Odometer...............................................................................................................................................11-12

BDIInfo.................................................................................................................................................11-12

BatteryMonitor.......................................................................................................................................11-12

ChargingTotals......................................................................................................................................11-12

AmpHoursDisplay.................................................................................................................................11-13

LIN........................................................................................................................................................11-13

VehicleSpeeds.......................................................................................................................................11-13

PedalCounters.......................................................................................................................................11-13

FaultCounters........................................................................................................................................11-13

FaultCountOdometers...........................................................................................................................11-13

DiagnosticsMenu.......................................................................................................................................11-14

PresentErrorsFolder..............................................................................................................................11-14

FaultHistoryFolder................................................................................................................................11-14

CausesofFaults....................................................................................................................................11-15

Pagevi2018OnwardMaintenanceandServiceManual

FaultRecovery.......................................................................................................................................11-17

FaultDescriptions.......................................................................................................................................11-18

IncorrectPassword(OEMAccessLevelOnly)..........................................................................................11-18

MaxPasswordTries(OEMAccessLevelOnly)........................................................................................11-18

ThrottleFault..........................................................................................................................................11-18

LowBatteryVoltage(Undervoltage).........................................................................................................11-18

Overvoltage............................................................................................................................................11-18

ThermalCutback....................................................................................................................................11-19

Anti-TamperFault...................................................................................................................................11-19

HPD......................................................................................................................................................11-19

MainDrvrOverCurrent............................................................................................................................11-19

LockoutFault.........................................................................................................................................11-19

LowSOC...............................................................................................................................................11-19

MainWelded..........................................................................................................................................11-20

HighSpeedWalkAway............................................................................................................................11-20

Speedsensor.........................................................................................................................................11-20

MainDriverOn.......................................................................................................................................11-20

MainCoilOpen.......................................................................................................................................11-20

MainDropout(1or2)..............................................................................................................................11-21

MotorStall..............................................................................................................................................11-21

MainDriverOff.......................................................................................................................................11-21

CurrentSenseFault................................................................................................................................11-21

M–Shorted............................................................................................................................................11-21

FLD(Field)Missing.................................................................................................................................11-22

HWFailsafe...........................................................................................................................................11-22

FaultHistory...........................................................................................................................................11-22

ClearFaultHistory..................................................................................................................................11-22

Programming.............................................................................................................................................11-22

Cloning..................................................................................................................................................11-23

Favorites....................................................................................................................................................11-23

HHPSettings.............................................................................................................................................11-23

Plot&Log..................................................................................................................................................11-25

Plot........................................................................................................................................................11-25

Log........................................................................................................................................................11-25

CDTTroubleshooting..................................................................................................................................11-26

ConnectionTests........................................................................................................................................11-27

SECTION12—ExcelSystemTroubleshooting.................................................................................................12-1

GeneralInformation.....................................................................................................................................12-1

Accessories.............................................................................................................................................12-1

ChargeIndicatorLight..............................................................................................................................12-1

AttributesoftheExcelSystem..................................................................................................................12-1

ExcelwithERICChargingSystem............................................................................................................12-2

Features.................................................................................................................................................12-2

WiringDiagrams..........................................................................................................................................12-4

InstrumentPanelLightHarness–withERICCharging..............................................................................12-12

Troubleshooting..........................................................................................................................................12-12

TroubleshootingtheVehiclewiththeCDT................................................................................................12-13

TroubleshootingGuide1.........................................................................................................................12-13

TroubleshootingGuide2.........................................................................................................................12-16

TestProcedures.........................................................................................................................................12-19

TestingBasics........................................................................................................................................12-19

SECTION13—ElectricalComponents:ElectricVehicle....................................................................................13-1

KeySwitch..................................................................................................................................................13-1

TestingtheKeySwitch.............................................................................................................................13-1

KeySwitchRemoval................................................................................................................................13-1

KeySwitchInstallation.............................................................................................................................13-1

ChargeIndicatorLight..................................................................................................................................13-2

TestingtheChargeIndicatorLight.............................................................................................................13-2

ChargeIndicatorLightRemoval................................................................................................................13-2

ChargeIndicatorLightInstallation.............................................................................................................13-2

2018OnwardMaintenanceandServiceManualPagevii

USBPort.....................................................................................................................................................13-3

USBPortRemoval...................................................................................................................................13-3

USBPortInstallation...............................................................................................................................13-4

Forward/ReverseRockerSwitch...................................................................................................................13-4

TestingtheForward/ReverseRockerSwitch..............................................................................................13-4

Forward/ReverseRockerSwitchRemoval.................................................................................................13-4

Forward/ReverseRockerSwitchInstallation..............................................................................................13-5

ElectronicsModuleCover.............................................................................................................................13-6

ElectronicsModuleCoverRemoval..........................................................................................................13-6

ElectronicsModuleCoverInstallation........................................................................................................13-6

Tow/RunSwitch...........................................................................................................................................13-7

TestingtheTow/RunSwitch......................................................................................................................13-7

Tow/RunSwitchRemoval.........................................................................................................................13-7

Tow/RunSwitchInstallation......................................................................................................................13-7

MotorControllerOutputRegulator(MCOR)...................................................................................................13-8

TestingtheMCOR...................................................................................................................................13-8

MCORRemoval......................................................................................................................................13-8

MCORInstallation...................................................................................................................................13-8

ReverseBuzzer...........................................................................................................................................13-9

TestingtheReverseBuzzer......................................................................................................................13-9

ReverseBuzzerRemoval.........................................................................................................................13-9

ReverseBuzzerInstallation......................................................................................................................13-9

ElectronicsModule.....................................................................................................................................13-10

ElectronicsModuleRemoval...................................................................................................................13-10

ElectronicsModuleInstallation................................................................................................................13-11

SpeedController........................................................................................................................................13-12

TestingtheSolidStateSpeedController..................................................................................................13-12

SpeedControllerRemoval......................................................................................................................13-12

SpeedControllerInstallation....................................................................................................................13-12

Solenoid.....................................................................................................................................................13-13

TestingtheSolenoid...............................................................................................................................13-13

SolenoidRemoval..................................................................................................................................13-13

SolenoidInstallation................................................................................................................................13-14

ChargerReceptacle....................................................................................................................................13-14

TestingtheChargerReceptacle...............................................................................................................13-14

ChargerReceptacleInspection................................................................................................................13-14

ChargerReceptacleRemoval..................................................................................................................13-14

ChargerReceptacleInstallation...............................................................................................................13-15

SECTION14—Batteries:ElectricVehicle........................................................................................................14-1

GeneralInformation.....................................................................................................................................14-1

BatteryTestingBasics–8Volt......................................................................................................................14-2

Observation.............................................................................................................................................14-2

MeasuringVoltageofBatterySet..............................................................................................................14-2

BatteryCellNumbering............................................................................................................................14-2

BatteryTesting–8Volt................................................................................................................................14-3

BatteryRegrouping......................................................................................................................................14-3

BatteryReplacement...................................................................................................................................14-5

BatteryCare................................................................................................................................................14-6

WaterQuality..........................................................................................................................................14-6

BatteryCare–VehiclesEquippedwiththeOptionalSingle-PointWateringSystem(SPWS).........................14-7

BatteryCare–VehiclesWithouttheSingle-PointWateringSystem(SPWS)................................................14-8

Self-Discharge.........................................................................................................................................14-9

ElectrolyteLevel......................................................................................................................................14-9

VibrationDamage...................................................................................................................................14-10

SinglePointWateringSystem(SPWS).........................................................................................................14-10

InitialMaintenanceoftheSPWS..............................................................................................................14-10

WateringBatterieswiththeSPWS...........................................................................................................14-10

BatteryStorage..........................................................................................................................................14-11

Deep-Discharge.........................................................................................................................................14-11

EarlyExcessiveDischarging.......................................................................................................................14-11

Pageviii2018OnwardMaintenanceandServiceManual

SECTION15—ERICBatteryCharger..............................................................................................................15-1

GeneralInformation.....................................................................................................................................15-2

USBServicePort.....................................................................................................................................15-3

ULandCSAListing.................................................................................................................................15-3

CECompliance.......................................................................................................................................15-3

PlugandReceptacle................................................................................................................................15-3

ChargerPowerConnectionFuse..............................................................................................................15-4

ChargerInterlock.....................................................................................................................................15-4

ACInputVoltageDetection......................................................................................................................15-4

ThermalCutback.....................................................................................................................................15-4

ChargeIndicatorLight..............................................................................................................................15-4

ExternalChargerStatusIndicators............................................................................................................15-5

OnboardChargerStatusIndicators...........................................................................................................15-5

Long-termStorage...................................................................................................................................15-7

ExternalChargerMounting...........................................................................................................................15-8

ACPowerConnection..................................................................................................................................15-9

TheChargeCircuit......................................................................................................................................15-10

ChargerOperation......................................................................................................................................15-11

ChargingBatteries..................................................................................................................................15-11

ChargerMaintenance.................................................................................................................................15-14

USBServicePortCleaningandCare.......................................................................................................15-14

ChargerTroubleshooting.............................................................................................................................15-15

NumberingVehiclesandChargers...........................................................................................................15-15

USBServicePort....................................................................................................................................15-15

IncomingACService..............................................................................................................................15-15

TerminalBlockCover..............................................................................................................................15-16

ResettingPower–ExternalCharger........................................................................................................15-16

ResettingPower–OnboardCharger.......................................................................................................15-16

ExternalChargerTroubleshootingIndicators............................................................................................15-17

OnboardChargerFaultCodes.................................................................................................................15-19

TestProcedures.........................................................................................................................................15-21

ExternalChargerRepairs............................................................................................................................15-24

TerminalBlockCoverRemoval................................................................................................................15-24

TerminalBlockCoverInstallation.............................................................................................................15-25

DCCordandStrainReliefRemoval.........................................................................................................15-25

DCCordandStrainReliefInstallation......................................................................................................15-25

HandleRemoval.....................................................................................................................................15-25

HandleInstallation..................................................................................................................................15-26

FootRemoval.........................................................................................................................................15-26

FootInstallation......................................................................................................................................15-26

OnboardChargerRepairs...........................................................................................................................15-27

OnboardChargerRemoval.....................................................................................................................15-27

OnboardChargerInstallation...................................................................................................................15-28

TerminalBlockCoverRemoval................................................................................................................15-28

TerminalBlockCoverInstallation.............................................................................................................15-28

DCCordandStrainReliefRemoval.........................................................................................................15-29

DCCordandStrainReliefInstallation......................................................................................................15-29

DCChargingHarnessRemoval...............................................................................................................15-29

DCChargingHarnessInstallation............................................................................................................15-30

SECTION16—Motor(ModelEJ8-4001A):ElectricVehicle................................................................................16-1

GeneralInformation.....................................................................................................................................16-1

ExternalMotorTesting.................................................................................................................................16-1

Motor..........................................................................................................................................................16-4

MotorRemoval........................................................................................................................................16-4

MotorDisassembly..................................................................................................................................16-5

MotorComponentTestingandInspection......................................................................................................16-8

ArmatureInspectionandTesting...............................................................................................................16-8

MotorFrameandFieldWindingsInspection.............................................................................................16-10

MotorBrush,Spring,andTerminalInsulatorInspection.............................................................................16-10

ReconditioningtheMotor............................................................................................................................16-13

MotorSpecications...............................................................................................................................16-13

2018OnwardMaintenanceandServiceManualPageix

MotorAssembly..........................................................................................................................................16-13

MotorInstallation........................................................................................................................................16-15

SECTION17—Transaxle:ElectricVehicle.......................................................................................................17-1

Lubrication..................................................................................................................................................17-1

AxleBearingandShaft................................................................................................................................17-1

AxleShaft...............................................................................................................................................17-1

AxleBearing............................................................................................................................................17-4

TransaxleRemoval......................................................................................................................................17-5

TransaxleDisassembly,Inspection,andAssembly.........................................................................................17-7

TransaxleDisassemblyandInspection......................................................................................................17-7

TransaxleAssembly.................................................................................................................................17-9

TransaxleInstallation..................................................................................................................................17-10

SECTION18—TroubleshootingandElectricalSystem–SubaruEX40..............................................................18-1

GeneralInformation.....................................................................................................................................18-1

Accessories.............................................................................................................................................18-1

LowOilWarningLight..............................................................................................................................18-1

GroundLocations....................................................................................................................................18-1

FeaturesoftheElectronicFuelInjection(EFI)System...............................................................................18-2

TroubleshootingGuide.................................................................................................................................18-2

ECUErrorCodes(DisplayedbytheLowOilWarningLight).......................................................................18-2

GasolinePowertrain................................................................................................................................18-4

WiringDiagrams..........................................................................................................................................18-8

InstrumentPanelLightHarness...............................................................................................................18-15

ElectricalSystem........................................................................................................................................18-16

TestProcedures.........................................................................................................................................18-17

TestingBasics........................................................................................................................................18-17

SECTION19—ElectricalComponents–SubaruEX40.....................................................................................19-1

Starter/Generator.........................................................................................................................................19-1

Starter/GeneratorRemoval......................................................................................................................19-1

DisassemblyoftheStarter/GeneratortoServicetheBrushes.....................................................................19-1

BrushInspectionandReplacement...........................................................................................................19-2

BrushSpringInspectionandReplacement................................................................................................19-2

Starter/GeneratorAssembly.....................................................................................................................19-3

DisassemblyoftheStarter/GeneratortoServicetheArmature/Commutator................................................19-4

BearingCleaningandInspection..............................................................................................................19-5

BearingRemoval.....................................................................................................................................19-6

FieldCoilAssembly.................................................................................................................................19-6

VisualInspectionofArmature...................................................................................................................19-6

CommutatorCleaningandInspection.......................................................................................................19-7

ArmatureGroundTest..............................................................................................................................19-8

VisualInspectionofFieldCoils.................................................................................................................19-9

Starter/GeneratorRework........................................................................................................................19-9

Starter/GeneratorAssembly.....................................................................................................................19-9

Starter/GeneratorInstallation...................................................................................................................19-12

BeltTensionAdjustmentforEFIEngines..................................................................................................19-13

VoltageRegulator.......................................................................................................................................19-15

VoltageRegulatorRemoval.....................................................................................................................19-15

VoltageRegulatorInstallation..................................................................................................................19-16

EngineControlUnit(ECU)..........................................................................................................................19-17

EngineControlUnitRemoval...................................................................................................................19-17

EngineControlUnitInstallation................................................................................................................19-17

KeySwitch.................................................................................................................................................19-18

KeySwitchRemoval...............................................................................................................................19-18

KeySwitchInstallation............................................................................................................................19-19

Maintenance/OperateSwitch.......................................................................................................................19-19

Maintenance/OperateSwitchRemoval.....................................................................................................19-19

Maintenance/OperateSwitchInstallation..................................................................................................19-19

NeutralLockoutLimitSwitch.......................................................................................................................19-20

Pagex2018OnwardMaintenanceandServiceManual

NeutralLockoutLimitSwitchRemoval.....................................................................................................19-20

NeutralLockoutLimitSwitchInstallation...................................................................................................19-20

Solenoid.....................................................................................................................................................19-21

TestingtheSolenoid...............................................................................................................................19-21

SolenoidRemoval..................................................................................................................................19-21

SolenoidInstallation................................................................................................................................19-21

Fuse..........................................................................................................................................................19-22

FuseRemoval........................................................................................................................................19-22

FuseInstallation.....................................................................................................................................19-22

AcceleratorPedalLimitSwitch....................................................................................................................19-23

TestingtheAcceleratorPedalLimitSwitch...............................................................................................19-23

KillLimitSwitch..........................................................................................................................................19-23

TestingtheKillLimitSwitch.....................................................................................................................19-23

ReverseWarningBuzzer.............................................................................................................................19-23

ReverseWarningBuzzerRemoval..........................................................................................................19-23

ReverseWarningBuzzerInstallation........................................................................................................19-24

ReverseBuzzerLimitSwitch.......................................................................................................................19-25

ReverseBuzzerLimitSwitchRemoval.....................................................................................................19-25

ReverseBuzzerLimitSwitchInstallation..................................................................................................19-25

LowOilWarningLight.................................................................................................................................19-27

LowOilWarningLightRemoval...............................................................................................................19-27

LowOilWarningLightInstallation............................................................................................................19-27

FuelGauge................................................................................................................................................19-28

FuelGaugeRemoval..............................................................................................................................19-28

FuelGaugeInstallation...........................................................................................................................19-28

FuelLevelSendingUnit..............................................................................................................................19-29

HourMeter.................................................................................................................................................19-29

TestingtheHourMeter............................................................................................................................19-29

HourMeterRemoval...............................................................................................................................19-29

HourMeterInstallation............................................................................................................................19-29

OilLevelSensor.........................................................................................................................................19-30

OilLevelSensorRemoval.......................................................................................................................19-30

OilLevelSensorInstallation....................................................................................................................19-30

Battery.......................................................................................................................................................19-31

GeneralInformation................................................................................................................................19-31

TestingtheBattery..................................................................................................................................19-31

PreventiveMaintenance..........................................................................................................................19-31

Self-Discharge........................................................................................................................................19-32

VibrationDamage...................................................................................................................................19-32

BatteryRemoval.....................................................................................................................................19-33

ChargingtheBattery...............................................................................................................................19-33

BatteryInstallation..................................................................................................................................19-33

BatteryStorage......................................................................................................................................19-34

ChargingaDeadBattery.........................................................................................................................19-34

GroundCables...........................................................................................................................................19-34

SECTION20—Engine–SubaruEX40............................................................................................................20-1

GeneralInformation.....................................................................................................................................20-1

BeforeServicing......................................................................................................................................20-1

EngineRotation.......................................................................................................................................20-1

TorqueSpecications...............................................................................................................................20-2

AdjustmentsandSettings.........................................................................................................................20-2

EngineOil–GasolineVehicle...................................................................................................................20-2

SparkPlug..............................................................................................................................................20-5

Breather..................................................................................................................................................20-6

ValveClearanceCheckandAdjustment....................................................................................................20-7

EngineRemoval..........................................................................................................................................20-8

EngineInstallation.......................................................................................................................................20-9

Flywheel....................................................................................................................................................20-10

FlywheelRemoval..................................................................................................................................20-10

FlywheelInstallation...............................................................................................................................20-11

OilLevelSensor.........................................................................................................................................20-12

TestingtheOilLevelSensor....................................................................................................................20-12

2018OnwardMaintenanceandServiceManualPagexi

OilLevelSensorRemoval.......................................................................................................................20-12

OilLevelSensorInstallation....................................................................................................................20-12

IgnitionCoil................................................................................................................................................20-13

TestingtheIgnitionCoil...........................................................................................................................20-13

IgnitionCoilRemoval..............................................................................................................................20-13

IgnitionCoilInstallation...........................................................................................................................20-13

Snubber.....................................................................................................................................................20-14

SnubberRemoval...................................................................................................................................20-14

SnubberInstallation................................................................................................................................20-14

SECTION21—FuelSystem–SubaruEX40....................................................................................................21-1

GeneralInformation.....................................................................................................................................21-1

EFISystemFeatures/Specications..........................................................................................................21-1

RelievingFuelPressure...............................................................................................................................21-2

ToRelieveFuelPressure.........................................................................................................................21-2

ThrottleBody...............................................................................................................................................21-3

ThrottleBodyRemoval.............................................................................................................................21-3

ThrottleBodyInstallation..........................................................................................................................21-5

EngineControlLinkages..............................................................................................................................21-6

GeneralInformation.................................................................................................................................21-6

GroundSpeed.........................................................................................................................................21-7

GovernorCable.......................................................................................................................................21-7

AcceleratorCable....................................................................................................................................21-8

ClosedThrottleorIdleAdjustment–Vehicles...........................................................................................21-10

HowtoMeasureGroundSpeed...............................................................................................................21-10

EngineRPMAdjustment.........................................................................................................................21-11

AirIntakeSystem.......................................................................................................................................21-12

GeneralInformation................................................................................................................................21-12

AirFilter.................................................................................................................................................21-12

AirIntakeSystemRemoval.....................................................................................................................21-13

AirIntakeSystemInstallation...................................................................................................................21-14

FuelLine....................................................................................................................................................21-15

FuelLineRemoval..................................................................................................................................21-15

FuelLineInstallation...............................................................................................................................21-16

FuelPumpModule......................................................................................................................................21-17

GeneralInformation................................................................................................................................21-17

FuelPumpModuleRemoval...................................................................................................................21-17

FuelPumpModuleInstallation.................................................................................................................21-17

FuelTank...................................................................................................................................................21-20

GeneralInformation................................................................................................................................21-20

FuelTankRemoval.................................................................................................................................21-20

FuelTankDisposal.................................................................................................................................21-21

FuelTankStorage..................................................................................................................................21-21

FuelTankInstallation..............................................................................................................................21-21

FuelFilter...................................................................................................................................................21-23

GeneralInformation................................................................................................................................21-23

FuelFilterRemoval.................................................................................................................................21-23

FuelFilterInstallation..............................................................................................................................21-23

FuelingInstructions–GasolineVehicles......................................................................................................21-24

CarbonCanister.........................................................................................................................................21-25

CarbonCanisterRemoval.......................................................................................................................21-25

CarbonCanisterInstallation....................................................................................................................21-26

SECTION22—ExhaustSystem–SubaruEX40...............................................................................................22-1

Mufer........................................................................................................................................................22-1

MuferRemoval......................................................................................................................................22-1

MuferInstallation....................................................................................................................................22-1

SECTION23—Clutches–SubaruEX40..........................................................................................................23-1

GeneralInformation.....................................................................................................................................23-1

Troubleshooting...........................................................................................................................................23-1

Pagexii2018OnwardMaintenanceandServiceManual

DriveBelt....................................................................................................................................................23-3

DriveBeltRemoval..................................................................................................................................23-3

DriveBeltInstallation...............................................................................................................................23-3

DriveClutch................................................................................................................................................23-4

DriveClutchRemoval..............................................................................................................................23-5

DriveClutchCleaningandInspection........................................................................................................23-6

DriveClutchDisassembly.........................................................................................................................23-6

InspectionofDriveClutchParts................................................................................................................23-9

DriveClutchAssembly............................................................................................................................23-10

DriveClutchInstallation..........................................................................................................................23-11

DrivenClutch.............................................................................................................................................23-13

DrivenClutchRemoval...........................................................................................................................23-14

DrivenClutchDisassembly......................................................................................................................23-14

DrivenClutchInspection.........................................................................................................................23-15

DrivenClutchAssembly..........................................................................................................................23-15

DrivenClutchInstallation.........................................................................................................................23-17

SECTION24—Transaxle,FujiED65(forSubaruEX40)...................................................................................24-1

GeneralInformation.....................................................................................................................................24-1

ShifterLever............................................................................................................................................24-1

NeutralLockout.......................................................................................................................................24-1

GovernorSystem.....................................................................................................................................24-2

TransaxleService....................................................................................................................................24-2

Lubrication..............................................................................................................................................24-2

ToolsRequiredForThisSection...............................................................................................................24-3

RearHubs...................................................................................................................................................24-4

RearHubRemoval..................................................................................................................................24-4

RearHubInstallation...............................................................................................................................24-4

AxleTubes,AxleShaftsandWheelBearings................................................................................................24-6

AxleTubeandAxleShaftRemoval...........................................................................................................24-6

AxleTubeandAxleShaftInstallation........................................................................................................24-7

RearWheelBearingRemoval..................................................................................................................24-7

RearWheelBearingInstallation................................................................................................................24-7

AxleShaftOilSealRemoval.....................................................................................................................24-7

AxleShaftOilSealInstallation..................................................................................................................24-8

TransaxleRemoval......................................................................................................................................24-9

TransaxleInstallation..................................................................................................................................24-12

Forward/ReverseHandle............................................................................................................................24-13

Forward/ReverseHandleRemoval..........................................................................................................24-13

Forward/ReverseHandleInstallation........................................................................................................24-13

ShifterCable..............................................................................................................................................24-13

ShifterCableRemoval............................................................................................................................24-13

ShifterCableInstallation.........................................................................................................................24-14

ShifterCableAdjustment.........................................................................................................................24-14

Index..........................................................................................................................................................Index-1

2018OnwardMaintenanceandServiceManualPagexiii

SECTION1—SAFETY1

Safety

SAFETYDETAILS

WARNING

•Thisowner’smanualshouldbereadcompletelybeforeattemptingtodriveorservicethevehicle.

Failuretofollowtheinstructionsinthismanualcouldresultinpropertydamage,severepersonal

injury,ordeath.

Itisimportanttonotethatsomevitalstatementsthroughoutthismanualandonthedecalsafxedtothevehicleare

precededbythewordsDANGER,WARNING,orCAUTION.Foryourprotection,werecommendthatyoutakespecial

noticeofthesesafetyprecautions.Safetyprecautionsareessentialandmustbefollowed.

Ifanyoftheoperationorsafetydecalsonthevehiclebecomedamaged,havebeenremovedorcannotbeeasily

read,theyshouldbereplacedimmediatelytoavoidpossiblepropertydamage,personalinjury,ordeath.Contactyour

distributor/dealer.

DANGER

•ADANGERindicatesanimmediatehazardthatwillresultinseverepersonalinjuryordeath.

WARNING

•AWARNINGindicatesanimmediatehazardthatcouldresultinseverepersonalinjuryordeath.

CAUTION

•ACAUTIONwiththesafetyalertsymbolindicatesahazardorunsafepracticethatcouldresultin

minorpersonalinjury.

CAUTION

•ACAUTIONwithoutthesafetyalertsymbolindicatesapotentiallyhazardoussituationthatcould

resultinpropertydamage.

2018OnwardMaintenanceandServiceManualPage1-1

1GeneralWarningsSAFETY

GENERALWARNINGS

Thefollowingsafetystatementsmustbeheededwheneverthevehicleisbeingoperated,repaired,orserviced.

Vehiclefeatureidenticationinformationisalsoincluded.Otherspecicsafetystatementsappearthroughoutthis

manualandonthevehicle.

DANGER

•Battery–Explosivegases!Donotsmoke.Keepsparksandamesawayfromthevehicleandservice

area.Ventilatewhenchargingoroperatingvehicleinanenclosedarea.Wearafullfaceshieldand

rubbergloveswhenworkingonornearbatteries.

•Gasoline–Flammable!Explosive!Donotsmoke.Keepsparksandamesawayfromthevehicleand

servicearea.Serviceonlyinawell-ventilatedarea.

•Donotoperateengineinanenclosedareawithoutproperventilation.Theengineproducescarbon

monoxide,whichisanodorless,deadlypoison.

•Thevehiclewillnotprovideprotectionfromlightning,yingobjects,orotherstorm-relatedhazards.If

caughtinastormwhiledrivingaClubCarvehicle,exitthevehicleandseekshelterinaccordancewith

applicablesafetyguidelinesforyourlocation.

WARNING

•Followtheproceduresexactlyasstatedinthismanual,andheedallDANGER,WARNING,and

CAUTIONstatementsinthismanualaswellasthoseonthevehicleandbatterycharger.

•Childrenrequiringachildsafetyseatmustnotrideinvehicle.

•Donotleavechildrenunattendedonvehicle.

•Priortoleavingthevehicleunattendedorservicingthevehicle,settheparkbrake,placethe

Forward/ReversehandleorswitchintheNEUTRALposition,turnthekeyswitchtotheOFFposition,

andremovethekey.Chockthewheelswhenservicingthevehicle.

•Improperuseofthevehicleorfailuretoproperlymaintainitcouldresultindecreasedvehicle

performance,severepersonalinjury,ordeath.

•Anymodicationorchangetothevehiclethataffectstheelectricalsystem,stabilityorhandling

ofthevehicle,orincreasesmaximumvehiclespeedbeyondfactoryspecications,couldresultin

severepersonalinjuryordeath.

•Checkthevehicleforproperlocationofallvehiclesafetyandoperationdecalsandmakesuretheyare

inplaceandareeasytoread.

•Onlytrainedtechniciansshouldserviceorrepairthevehicleorbatterycharger.Anyonedoingeven

simplerepairsorserviceshouldhaveknowledgeandexperienceinelectricalandmechanicalrepair.

Theappropriateinstructionsmustbeusedwhenperformingmaintenance,service,oraccessory

installation.

•Wearsafetyglassesorapprovedeyeprotectionwhenservicingthevehicleorbatterycharger.Weara

fullfaceshieldandrubbergloveswhenworkingonornearbatteries.

•Donotwearlooseclothingorjewelrysuchasrings,watches,chains,etc.,whenservicingthe

vehicleorbatterycharger.

WARNINGCONTINUEDONNEXTPAGE

Page1-22018OnwardMaintenanceandServiceManual

SAFETYGeneralWarnings1

WARNING

•Useinsulatedtoolswhenworkingnearbatteriesorelectricalconnections.Useextremecautionto

avoidshortingofcomponentsorwiring.

Electricvehiclesonly:

•PlaceTow/RunswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failureto

heedthiswarningcouldresultinabatteryexplosionorseverepersonalinjury.

•Toavoidunintentionallystartinganelectricvehicle,disconnectthebatteriesanddischargethe

controller.SeeDisconnectingtheBatteries–ElectricVehiclesonpage1-4.

Gasolinevehiclesonly:

•Toavoidunintentionallystartingagasolinevehicle,disconnectthebatteryandsparkplugwire.

SeeDisconnectingtheBattery-GasolineVehiclesonpage1-3.

•Frameground–Donotallowtoolsorothermetalobjectstocontactframewhendisconnectingbattery

cablesorotherelectricalwiring.Donotallowapositivewiretotouchthevehicleframe,engine,or

anyothermetalcomponent.

DISABLINGTHEVEHICLE

1.Settheparkbrake.

2.TurnthekeyswitchOFFandremovethekey.

3.PlacetheForward/ReversecontrolintheNEUTRALposition.

4.Inaddition,chockthewheelsifservicingorrepairingthevehicle.

DISCONNECTINGTHEBATTERY-GASOLINEVEHICLES

1.Disablethevehicle.SeeDisablingtheVehicleonpage1-3.

2.Removepositiveterminalcover.

3.Disconnectthebatterycables,negative(–)cablerst,asshown(Figure1-2).

4.Disconnectthesparkplugwire(s)fromthesparkplug(s).

CONNECTINGTHEBATTERY-GASOLINEVEHICLES

1.Connectthebatterycables,positive(+)cablerst.

2.Tightenbatteryterminalsto41lb·in(4.3N·m).

3.CoatterminalswithBatteryT erminalProtectorSpraytominimizecorrosion.

4.Attachpositiveterminalcover.

5.Connectthesparkplugwire(s)tothesparkplug(s).

2018OnwardMaintenanceandServiceManualPage1-3

1GeneralWarningsSAFETY

(Viewedfromdriversideofvehicle)

1.PlaceTOW/RUNSwitchinTOWbeforedisconnectingorconnecting

batterycables.

2.Removenegativebatterycable.

3.Removepositivebatterycable.

Connectbatterycablesinreverseorder.

(Viewedfromdriversideofvehicle)

1.Removepositiveterminalcover.

2.Removenegativebatterycable.

3.Removepositivebatterycable.

Connectbatterycablesinreverseorder.

49A

Figure1-1BatteryCableRemoval–ElectricVehicles

6x8-VoltBatteryConguration

3167

Figure1-2Top-Battery:BatteryCableRemoval-Gasoline

Vehicles

DISCONNECTINGTHEBATTERIES–ELECTRICVEHICLES

1.Disablethevehicle.SeeDisablingtheVehicleonpage1-3.

2.PlaceT ow/RunswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failuretoheed

thiswarningcouldresultinabatteryexplosionorseverepersonalinjury.

3.Disconnectthebatteries,negative(–)cablerst,asshown(Figure1-1).

4.Afterdisconnectingthebatteries,wait90secondsforthecontrollercapacitorstodischarge.

CONNECTINGTHEBATTERIES–ELECTRICVEHICLES

1.EnsuretheT ow/RunswitchisintheTOWposition.

2.Connectthebatterycables,positive(+)cablerst.

3.Tightenbatteryterminalsto110lb·in(12.4N·m).

4.CoatterminalswithBatteryT erminalProtectorSpraytominimizecorrosion.

Page1-42018OnwardMaintenanceandServiceManual

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