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Carryall 300 2018
Club Car Carryall 300 2018 Manuals
Manuals and User Guides for Club Car Carryall 300 2018. We have
1
Club Car Carryall 300 2018 manual available for free PDF download: Maintenance And Service Manual
Club Car Carryall 300 2018 Maintenance And Service Manual (456 pages)
Gasoline Vehicle with Subaru EX40 Engine Electric Vehicle with ERIC Charging System
Brand:
Club Car
| Category:
Golf Cars
| Size: 36.63 MB
Table of Contents
Table of Contents
5
SECTION 1 - Safety
17
Safety Details
17
Personal Safety
17
Machine Safety
17
Information
17
General Warnings
17
Disabling the Vehicle
19
Disconnecting the Battery- Gasoline Vehicles
19
Connecting the Battery- Gasoline Vehicles
19
Disconnecting the Batteries - Electric Vehicles
20
Connecting the Batteries - Electric Vehicles
20
Recycling Lead-Acid Batteries
20
International Safety Symbols on Batteries
21
SECTION 2 - Vehicle Specifications
24
Vehicle Specifications
24
E.r.I.C. Battery Charger Specifications
25
Vehicle Specifications - Gasoline Vehicles
26
SECTION 3 - General Information
29
Model Identification
29
Storage - Electric Vehicles
30
Preparing the Electric Vehicle for Extended Storage
30
Returning the Stored Electric Vehicle to Service
31
Storage - Gasoline Vehicles
32
Preparing the Gasoline Vehicle for Extended Storage
32
Returning the Stored Gasoline Vehicle to Service
33
SECTION 4 - Body and Trim
35
Cleaning the Vehicle
35
Seat Cleaning
35
Front Body Repair
36
Light Scratches
36
Abrasions and Haze
36
Large Scratches and Abrasions
36
Touch-Up Paint Color Chart
36
Front Body
37
Heavy Duty Bumper Removal
37
Heavy Duty Bumper Installation
37
Cowl Removal
39
Cowl Installation
39
Grille Removal
40
Grille Installation
41
Front Bumper and Side Fender Removal
43
Front Bumper and Side Fender Installation
43
Instrument Panel Removal
44
Instrument Panel Installation
44
Dash Removal
45
Dash Installation
45
Tilt Bed
47
Tilt Bed Removal
48
Tilt Bed Installation
48
Bed Latch Assembly Removal
49
Bed Latch Assembly Installation
49
Rear Fenders and Tailskirt
51
Rear Fender and Tailskirt Removal
51
Rear Fender and Tailskirt Installation
52
Floor Mat
52
Floor Mat Removal
52
Floor Mat Installation
52
SECTION 5 - Accelerator and Brake Pedal Group
53
Brake Pedal and Park Brake (Gas and Electric Vehicles)
53
Brake Pedal Removal (Gas and Electric Vehicles)
53
Brake Pedal Installation (Gas and Electric Vehicles)
53
Park Brake Removal (Gas and Electric Vehicles)
56
Park Brake Installation (Gas and Electric Vehicles)
56
Accelerator Pedal - Gasoline Vehicles
57
Accelerator Pedal Removal - Gasoline Vehicles
57
Accelerator Pedal Installation - Gasoline Vehicles
59
Accelerator Pedal - Electric Vehicles
60
Accelerator Pedal Removal - Electric Vehicles
60
Accelerator Pedal Installation - Electric Vehicles
62
Pedal Group Adjustment - Gasoline Vehicles
62
Pedal Group Adjustment - Electric Vehicles
67
SECTION 6 - Wheel Brake Assemblies
73
General Information
73
Brake Shoe Removal
75
Brake Assembly Cleaning
77
Brake Shoe Installation
79
Brake Adjustment
81
Brake Assembly Removal and Installation
82
Brake Assembly Removal
82
Brake Assembly Installation
82
Brake Cable Removal and Installation
83
Brake Cable Removal
83
Brake Cable Installation
83
SECTION 7 - Steering and Front Suspension
85
General Information
85
Steering Wheel
85
Steering Wheel Removal
85
Steering Wheel Installation
86
Steering Column
87
Steering Column Removal
87
Steering Column Disassembly
87
Steering Column Assembly
87
Steering Column Installation
89
Steering Adjustment
90
Rack and Pinion
91
Rack and Pinion Inspection
91
Rack and Pinion Removal - Maintenance-Free Ball Joints
91
Rack and Pinion Disassembly
92
Rack and Pinion Assembly
94
Rack and Pinion Installation - Maintenance-Free Ball Joints
97
Tie Rod and Drag Link
98
Tie Rod and Drag Link Removal - Maintenance-Free Ball Joints
98
Tie Rod and Drag Link Installation - Maintenance-Free Ball Joints
98
Front Suspension
99
Lubrication
99
Wheel Alignment
99
Front Suspension Components
101
Leaf Spring Removal
101
Leaf Spring Installation
101
Kingpin and Steering Spindle Removal - Maintenance-Free Ball Joints
101
Kingpin and Steering Spindle Installation - Maintenance-Free Ball Joints
104
Delta A-Plate Removal
104
Delta A-Plate Installation
104
Shock Absorber Removal
104
Shock Absorber Installation
104
Front Wheel Bearings and Hubs
105
Front Wheel Free Play Inspection
105
Front Hub Removal
105
Front Hub Installation
105
SECTION 8 - Wheels and Tires
107
General Information
107
Wheels
107
Wheel Removal
107
Wheel Installation
107
Tires
108
Tire Removal
108
Tire Repair
108
Tire Installation
109
SECTION 9 - Rear Suspension
111
General Information
111
Shock Absorbers
111
Shock Absorber Inspection and Removal
111
Shock Absorber Installation
112
Multi-Leaf Springs
112
Multi- Leaf Spring Removal
112
Multi-Leaf Spring Installation
115
Jounce Bumpers
115
Jounce Bumper Removal
115
Jounce Bumper Installation
115
SECTION 10 - Periodic Maintenance
117
General Information
117
Pre-Operation and Daily Safety Checklist
117
Performance Inspection
118
Maintenance
119
Periodic Service Schedules
120
Periodic Lubrication Schedules
123
SECTION 11 - Controller Diagnostic Tool (CDT)
125
General Information
126
Features
126
Plugging the CDT into the Vehicle
127
Introductory Display
127
Quick Reference Guide - Excel with ERIC Charging System
128
System Info
129
Model Number
129
Serial Number
129
Hardware Version
129
Protocol Version
129
Param Block Version
129
MFG Date Code
129
OS Version
129
SM Version
129
VCL App Version
129
Settings
130
Amp Hours
132
Access Codes
132
Vehicle ID
133
Monitor Menu
133
Batt Voltage
134
Min I
134
Signed Battery Current
134
BDI Percent
134
Speed
134
Throttle
134
Temperature
134
Arm Current
134
Field Current
134
Armature PWM
134
Field PWM
135
Speed Pulses
135
Foot Input
135
Key Input
135
Forward Input
135
Reverse Input
135
Mode Switch Input
135
Charger Inhibit
135
Main Cont Driver
135
LED Driver
135
Odometer
136
BDI Info
136
Battery Monitor
136
Charging Totals
136
Amp Hours Display
137
Lin
137
Vehicle Speeds
137
Pedal Counters
137
Fault Counters
137
Fault Count Odometers
137
Diagnostics Menu
138
Present Errors Folder
138
Fault History Folder
138
Causes of Faults
139
Fault Recovery
141
Fault Descriptions
142
Incorrect Password (OEM Access Level Only)
142
Max Password Tries (OEM Access Level Only)
142
Throttle Fault
142
Low Battery Voltage (Undervoltage)
142
Overvoltage
142
Thermal Cutback
143
Anti-Tamper Fault
143
Hpd
143
Main Drvr Overcurrent
143
Lockout Fault
143
Low SOC
143
Main Welded
144
High Speed Walkaway
144
Speed Sensor
144
Main Driver on
144
Main Coil Open
144
Main Dropout (1 or 2)
145
Motor Stall
145
Main Driver off
145
Current Sense Fault
145
M- Shorted
145
FLD (Field) Missing
146
HW Failsafe
146
Fault History
146
Clear Fault History
146
Programming
146
Cloning
147
Favorites
147
HHP Settings
147
Plot & Log
149
Plot
149
Log
149
CDT Troubleshooting
150
Connection Tests
151
SECTION 12 - Excel System Troubleshooting: with ERIC Charging
155
General Information
155
Accessories
155
Charge Indicator Light
155
Attributes of the Excel System
155
Key Differences: Excel with ERIC Charging System Vs. Powerdrive Chargers
156
Features
156
Wiring Diagrams
158
Troubleshooting
163
Troubleshooting the Vehicle with the CDT
163
Troubleshooting Guide 1
163
Troubleshooting Guide 2
166
Test Procedures
169
Testing Basics
169
SECTION 13 - Electrical Components: Electric Vehicles
193
Key Switch
193
Testing the Key Switch
193
Key Switch Removal
193
Key Switch Installation
193
Forward/Reverse Rocker Switch
194
Testing the Forward/Reverse Rocker Switch
194
Forward/Reverse Rocker Switch Removal
194
Forward/Reverse Rocker Switch Installation
194
Run/Tow Switch
195
Testing the Run/Tow Switch
195
Run/Tow Switch Removal
195
Run/Tow Switch Installation
195
Motor Controller Output Regulator (MCOR)
196
Testing the MCOR
196
MCOR Removal
196
MCOR Installation
196
Reverse Buzzer
197
Reverse Buzzer Removal
197
Reverse Buzzer Installation
197
Solenoid
198
Testing the Solenoid
198
Solenoid Removal
198
Solenoid Installation
198
Speed Controller
199
Testing the Solid State Speed Controller
199
Speed Controller Removal
199
Speed Controller Installation
200
Charger Receptacle
201
Testing the Charger Receptacle
201
Charger Receptacle Inspection
201
Charger Receptacle Removal
201
Charger Receptacle Installation
202
Charge Indicator Light
202
Testing the Charge Indicator Light
202
Charge Indicator Light Removal
202
Charge Indicator Light Installation
202
DC/DC Converter
202
DC/DC Converter Removal
202
DC/DC Converter Installation
203
Fuse Block
203
Fuse Block Removal
203
Fuse Block Installation
203
Headlight Switch
204
Headlight Switch Removal
204
Headlight Switch Installation
204
Headlights
204
Headlight Bezel Removal
204
Headlight Bezel Installation
204
Headlight Bulb Removal (Halogen)
205
Headlight Bulb Installation (Halogen)
205
Headlight Bulb Removal (LED)
205
Headlight Bulb Installation (LED)
205
SECTION 14 - Batteries: Electric Vehicle with ERIC Charging
207
General Information
207
Battery Testing Basics - 8 Volt
208
Observation
208
Measuring Voltage of Battery Set
208
Battery Cell Numbering
208
Battery Testing - 8 Volt
209
Battery Regrouping
209
Battery Replacement
211
Battery Care
212
Water Quality
212
Deionizer
213
Battery Care - Vehicles Equipped with the Single-Point Watering System (SPWS)
214
Battery Care - Vehicles Without the Single-Point Watering System (SPWS)
215
Self-Discharge
216
Electrolyte Level
216
Vibration Damage
217
Single Point Watering System (SPWS)
217
Initial Maintenance of the SPWS
218
Watering Batteries with the SPWS
218
Battery Storage
220
Fleet Rotation
220
Deep-Discharge
220
Early Excessive Discharging
220
SECTION 15 - Battery Charger: for ERIC Charging System
221
General Information
222
USB Service Port
223
UL and CSA Listing
223
CE Compliance
223
Plug and Receptacle
223
Charger Power Connection Fuse
223
Charger Interlock
223
AC Input Voltage Detection
224
Thermal Cutback
224
Charge Indicator Light
224
External Charger Status Indicators
224
Onboard Charger Status Indicators
225
Long-Term Storage
226
External Charger Mounting
227
AC Power Connection
228
The Charge Circuit
229
Charger Operation
230
Charging Batteries
230
Charger Maintenance
233
USB Service Port Cleaning and Care
233
Charger Troubleshooting
234
Numbering Vehicles and Chargers
234
USB Service Port
234
Incoming AC Service
234
Terminal Block Cover
235
Resetting Power - External Charger
235
Resetting Power - Onboard Charger
235
External Charger Troubleshooting Indicators
236
Onboard Charger Fault Codes
238
Test Procedures
240
External Charger Repairs
243
Terminal Block Cover Removal
243
Terminal Block Cover Installation
244
DC Cord and Strain Relief Removal
244
DC Cord and Strain Relief Installation
244
Handle Removal
244
Handle Installation
245
Foot Removal
245
Foot Installation
245
SECTION 16 - Motor (Model EJ8-4001A): Electric Vehicle
247
General Information
247
External Motor Testing
247
Motor Removal
250
Motor Disassembly
252
Motor Component Testing and Inspection
254
Armature Inspection and Testing
254
Motor Frame and Field Windings Inspection
256
Motor Brush, Spring, and Terminal Insulator Inspection
256
Reconditioning the Motor
259
Motor Specifications
259
Motor Assembly
259
Motor Installation
261
SECTION 17 - Transaxle (Type G): Electric Vehicles
265
Lubrication
265
Axle Bearing and Shaft
265
Axle Shaft
265
Axle Bearing
268
Transaxle
269
Transaxle Removal
269
Transaxle Disassembly, Inspection, and Assembly
272
Transaxle Disassembly and Inspection
272
Transaxle Assembly
274
Transaxle Installation
276
SECTION 18 - Troubleshooting and Electrical System: Pedal-Start Gas Vehicle
277
General Information
277
Accessories
277
Low Oil Warning Light
277
Ground Locations
277
Features of the Electronic Fuel Injection (EFI) System
278
Troubleshooting Guide
278
ECU Error Codes (Displayed by the Low Oil Warning Light)
278
Gasoline Powertrain
280
Wiring Diagrams
284
Electrical System
289
Test Procedures
290
Testing Basics
290
SECTION 19 - Troubleshooting and Electrical System: Key-Start Gas Vehicle
321
General Information
321
Wiring Diagrams
322
Test Procedures
326
SECTION 20 - Electrical Components: Pedal-Start Gas Vehicle
333
Starter/Generator
333
Starter/Generator Removal
333
Disassembly of the Starter/Generator to Service the Brushes
333
Brush Inspection and Replacement
334
Brush Spring Inspection and Replacement
334
Starter/Generator Assembly
335
Disassembly of the Starter/Generator to Service the Armature/Commutator
336
Bearing Cleaning and Inspection
337
Bearing Removal
338
Field Coil Assembly
338
Visual Inspection of Armature
338
Commutator Cleaning and Inspection
339
Armature Ground Test
340
Visual Inspection of Field Coils
341
Starter/Generator Rework
341
Starter/Generator Assembly
341
Starter/Generator Installation
344
Belt Tension Adjustment for EFI Engines
345
Voltage Regulator
347
Voltage Regulator Removal
347
Voltage Regulator Installation
348
Engine Control Unit (ECU)
349
Engine Control Unit Removal
349
Engine Control Unit Installation
349
Key Switch
350
Key Switch Removal
350
Key Switch Installation
350
Maintenance/Operate Switch
351
Maintenance/Operate Switch Removal
351
Maintenance/Operate Switch Installation
351
Neutral Lockout Limit Switch
351
Neutral Lockout Limit Switch Removal
351
Neutral Lockout Limit Switch Installation
351
Solenoid
352
Solenoid Removal
352
Solenoid Installation
352
Fuse
352
Fuse Removal
353
Fuse Installation
353
Kill Limit Switch
354
Kill Limit Switch Removal
354
Kill Limit Switch Installation
354
Reverse Warning Buzzer
355
Reverse Warning Buzzer Removal
355
Reverse Warning Buzzer Installation
355
Reverse Buzzer Limit Switch
357
Reverse Buzzer Limit Switch Removal
358
Reverse Buzzer Limit Switch Installation
358
Low Oil Warning Light
359
Low Oil Warning Light Removal
359
Low Oil Warning Light Installation
359
Fuel Gauge/Hour Meter
359
General Information
359
Fuel Gauge/Hour Meter Removal
359
Fuel Gauge/Hour Meter Installation
360
Fuel Level Sending Unit
360
Oil Level Sensor
360
Oil Level Sensor Removal
360
Oil Level Sensor Installation
360
Voltage Limiter
360
Voltage Limiter Removal
361
Voltage Limiter Installation
361
Headlight Switch
362
Headlight Switch Removal
362
Headlight Switch Installation
362
Headlights
362
Headlight Bezel Removal
362
Headlight Bezel Installation
362
Headlight Bulb Removal (Halogen)
363
Headlight Bulb Installation (Halogen)
363
Headlight Bulb Removal (LED)
363
Headlight Bulb Installation (LED)
363
Battery
365
General Information
365
Testing the Battery
365
Preventive Maintenance
365
Self-Discharge
366
Vibration Damage
366
Battery Removal
367
Charging the Battery
367
Battery Installation
367
Battery Storage
368
Charging a Dead Battery
368
Ground Cables
368
SECTION 21 - Electrical Components: Key-Start Gas Vehicle
369
General Information
369
Key Switch
369
Key Switch Removal
369
Key Switch Installation
370
Maintenance/Operate Switch
371
Maintenance/ Operate Switch Removal
371
Maintenance/Operate Switch Installation
371
Solenoid
371
Solenoid Removal
371
Solenoid Installation
371
Charging Diode
372
Charging Diode Removal
374
Charging Diode Installation
374
SECTION 22 - Engine (Subaru EX40)
375
General Information
375
Before Servicing
375
Engine Rotation
375
Torque Specifications
376
Adjustments and Settings
376
Engine Oil - Gasoline Vehicle
376
Spark Plug
379
Breather
380
Valve Clearance Check and Adjustment
381
Engine Removal
382
Engine Installation
383
Flywheel
384
Flywheel Removal
384
Flywheel Installation
385
Oil Level Sensor
386
Testing the Oil Level Sensor
386
Oil Level Sensor Removal
386
Oil Level Sensor Installation
386
Ignition Coil
387
Testing the Ignition Coil
387
Ignition Coil Removal
387
Ignition Coil Installation
387
Snubber
388
Snubber Removal
388
Snubber Installation
388
SECTION 23 - Fuel System: Gasoline Vehicles
389
General Information
389
EFI System Features/Specifications
389
Relieving Fuel Pressure
390
To Relieve Fuel Pressure
390
Throttle Body
391
Throttle Body Removal
391
Throttle Body Installation
392
Engine Control Linkages
394
General Information
394
Ground Speed
395
Accelerator Rod
395
Governor Cable
397
Accelerator Cable
398
Closed Throttle or Idle Adjustment - Pedal-Start Vehicles
399
Closed Throttle or Idle Adjustment - Key-Start Vehicles
399
How to Measure Ground Speed
400
Engine RPM Adjustment
400
Air Intake System
401
Air Filter
402
Air Cleaner Removal
402
Air Cleaner Installation
402
Fuel Line
403
Fuel Line Removal
403
Fuel Line Installation
404
Fuel Pump Module
405
General Information
405
Fuel Pump Module Removal
405
Fuel Pump Module Installation
405
Fuel Tank
408
General Information
408
Fuel Tank Removal
408
Fuel Tank Disposal
409
Fuel Tank Storage
409
Fuel Tank Installation
409
Fuel Filter
410
General Information
410
Fuel Filter Removal
410
Fuel Filter Installation
411
Fueling Instructions - Gasoline Vehicle
411
SECTION 24 - Exhaust System: Gasoline Vehicles
413
Muffler
413
Muffler Removal
413
Muffler Installation
413
SECTION 25 - Clutches: Gasoline Vehicles
415
General Information
415
Troubleshooting
416
Drive Belt
417
Drive Belt Removal
417
Drive Belt Installation
417
Drive Clutch
418
Drive Clutch Removal
422
Drive Clutch Disassembly
422
Inspection of Drive Clutch Parts
423
Drive Clutch Assembly
424
Drive Clutch Installation
425
Driven Clutch
426
Driven Clutch Removal
427
Driven Clutch Disassembly
427
Driven Clutch Inspection
428
Driven Clutch Assembly
428
Driven Clutch Installation
430
SECTION 26 - Transaxle (ED65): Gasoline Vehicles
431
General Information
431
Shifter Lever
431
Neutral Lockout
431
Governor System
432
Transaxle Service
432
Lubrication
432
Tools Required for this Section
433
Rear Hubs
434
Rear Hub Removal
434
Rear Hub Installation
434
Axle Tubes, Axle Shafts and Wheel Bearings
436
Axle Tube and Axle Shaft Removal
436
Axle Tube and Axle Shaft Installation
437
Rear Wheel Bearing Removal
437
Rear Wheel Bearing Installation
437
Axle Shaft Oil Seal Removal
437
Axle Shaft Oil Seal Installation
438
Transaxle Removal
439
Transaxle Installation
443
Shifter Cable
443
Shifter Cable Removal
443
Shifter Cable Installation
444
Shifter Cable Adjustment
444
Index
445
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