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Carryall 550 2019
Club Car Carryall 550 2019 Manuals
Manuals and User Guides for Club Car Carryall 550 2019. We have
1
Club Car Carryall 550 2019 manual available for free PDF download: Maintenance And Service Manual
Club Car Carryall 550 2019 Maintenance And Service Manual (584 pages)
Gasoline Vehicle with Kohler ECH440 Engine Electric Vehicle with QuiQ Charger
Brand:
Club Car
| Category:
Golf Cars
| Size: 61.62 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
Disable the Vehicle
19
Disconnect the Battery- Gasoline Vehicles
20
Connect the Battery- Gasoline Vehicles
20
Disconnect the Batteries - Electric Vehicles
21
Connect the Batteries - Electric Vehicles
21
Recycling Lead-Acid Batteries
21
International Safety Symbols on Batteries
22
SECTION 2 - Vehicle Specifications
24
Vehicle Specifications
24
Quiq Battery Charger Specifications
25
Vehicle Specifications - Gasoline Vehicles
26
SECTION 3 - General Information
29
Carryall 550 Wheels
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
Front Body
38
Brushguard Removal
38
Brushguard Installation
38
Cowl Removal
39
Cowl Installation
39
Grille Removal
40
Grille Installation
42
Front Bumper and Side Fender Removal
42
Front Bumper and Side Fender Installation
42
Instrument Panel Removal
43
Instrument Panel Installation
43
Dash Removal
44
Dash Installation
44
Tilt Bed
46
Tilt Bed Removal
46
Tilt Bed Installation
46
Bed Latch Assembly Removal
48
Bed Latch Assembly Installation
48
Rear Fenders and Tailskirt
50
Rear Fender and Tailskirt Removal
50
Rear Fender and Tailskirt Installation
50
Rear Triangle Reflector
52
Rear Triangle Reflector Removal
52
Rear Triangle Reflector Installation
52
Electric Bed Lift
53
Electric Bed Lift Removal
53
Electric Bed Lift Installation
54
Floor Mat
56
Floor Mat Removal
56
Floor Mat Installation
56
Trailer Hitch
56
Trailer Hitch Removal
56
Trailer Hitch Installation
56
SECTION 5 - Accelerator and Brake Pedal Group
57
Brake Pedal and Park Brake (Gas and Electric Vehicles)
57
Brake Pedal Removal (Gas and Electric Vehicles)
57
Brake Pedal Installation (Gas and Electric Vehicles)
57
Park Brake Removal (Gas and Electric Vehicles)
60
Park Brake Installation (Gas and Electric Vehicles)
60
Accelerator Pedal - Gasoline Vehicles
61
Accelerator Pedal Removal - Gasoline Vehicles
61
Accelerator Pedal Installation - Gasoline Vehicles
62
Accelerator Pedal - Electric Vehicles
63
Accelerator Pedal Removal - Electric Vehicles
63
Accelerator Pedal Installation - Electric Vehicles
66
Pedal Group Adjustment - Gasoline Vehicles
66
Pedal Group Adjustment - Electric Vehicles
72
SECTION 6 - Wheel Brake Assemblies
77
General Information
77
Brake Shoe Removal
77
Brake Assembly Cleaning
79
Brake Shoe Installation
82
Brake Adjustment
83
Brake Cluster Adjustment
84
Brake Cable Equalization
86
Final Brake Cluster Adjustment
87
Test Drive Vehicle
87
Brake Cluster Removal and Installation
88
Front Brake Cluster Removal
88
Front Brake Cluster Installation
88
Rear Brake Cluster Removal
90
Rear Brake Cluster Installation
90
Front Brake Cables
91
Front Brake Cable Removal
92
Front Brake Cable Installation
92
Rear Brake Cables
93
Rear Brake Cable Removal
94
Rear Brake Cable Installation
94
SECTION 7 - Steering and Front Suspension
95
General Information
95
Steering Wheel
95
Steering Wheel Removal
95
Steering Wheel Installation
96
Steering Column
97
Steering Column Removal
98
Steering Column Disassembly
98
Steering Column Assembly
98
Steering Column Installation
99
Steering Adjustment
100
Rack and Pinion
101
Rack and Pinion Inspection
101
Rack and Pinion Removal - Maintenance-Free Ball Joints
101
Rack and Pinion Disassembly
102
Rack and Pinion Assembly
104
Rack and Pinion Installation - Maintenance-Free Ball Joints
107
Tie Rod and Drag Link
108
Tie Rod and Drag Link Removal - Maintenance-Free Ball Joints
108
Tie Rod and Drag Link Installation - Maintenance-Free Ball Joints
108
Front Suspension
109
Lubrication
109
Wheel Alignment
109
Front Suspension Components
111
Leaf Spring Removal
111
Leaf Spring Installation
111
Kingpin and Steering Spindle Removal - Maintenance-Free Ball Joints
111
Kingpin and Steering Spindle Installation - Maintenance-Free Ball Joints
114
Delta A-Plate Removal
114
Delta A-Plate Installation
114
Shock Absorber Removal
114
Shock Absorber Installation
114
Front Wheel Bearings and Hubs
115
Front Wheel Free Play Inspection
115
Front Hub and Wheel Bearings Removal
115
Front Hub and Wheel Bearings Installation
116
SECTION 8 - Wheels and Tires
117
General Information
117
Wheels
117
Wheel Removal
117
Wheel Installation
117
Tires
118
Tire Removal
118
Tire Repair
118
Tire Installation
119
SECTION 9 - Rear Suspension
121
General Information
121
Shock Absorbers
121
Shock Absorber Inspection and Removal
121
Shock Absorber Installation
122
Multi-Leaf Springs
122
Multi-Leaf Spring Removal
122
Multi-Leaf Spring Installation
123
SECTION 10 - Periodic Maintenance
125
General Information
125
Pre-Operation and Daily Safety Checklist
125
Performance Inspection
125
Maintenance
127
Periodic Service Schedules
128
Periodic Lubrication Schedules
131
Air Filter
133
Air Filter Removal
133
Air Filter Installation
133
Engine Oil
134
Engine Oil Viscosity
134
Engine Oil Level Inspection
134
Engine Oil Replacement
135
Add Engine Oil
138
Refuel
139
Lift the Vehicle
140
Lift the Front of the Vehicle
140
Lift the Rear of the Vehicle
141
Lower the Front of the Vehicle
142
Lower the Rear of the Vehicle
143
Spark Plug
144
Spark Plug Removal
144
Spark Plug Inspection
145
Spark Plug Gap
145
Spark Plug Installation
146
Valve Clearance Check and Adjustment
146
SECTION 11 - Controller Diagnostic Tool (CDT)
147
General Information
148
Features
148
Plugging the CDT into the Vehicle
148
Introductory Display
149
Quick Reference Guide - IQ Plus with Quiq Charger
150
System Info
151
Model Number
151
Serial Number
151
Hardware Version
151
Protocol Version
151
Param Block Version
151
MFG Date Code
151
OS Version
151
SM Version
151
VCL App Version
151
Settings
152
Amp Hours
155
Access Codes
155
Vehicle ID
155
Monitor Menu
156
Speed in
156
Throttle
157
Batt Voltage
157
Heatsink Temp
157
Mode
157
Arm Current
157
Field Current
157
Arm PWM
157
Field PWM
157
Foot Input
157
Key Input
157
Reverse Input
158
Mode Switch
158
WK Away Relay
158
Main Cont
158
Password Tries (OEM Access Level Only)
158
Cir BRKR Open
158
THRTL Fault
158
Undervoltage
158
Overvoltage
158
Temp Cutback
158
Relay Welded
159
SPD Sensor
159
Main DRV on
159
Open Armature
169
Incorrect Password (OEM Access Level Only)
169
Fault History
169
Clearing Fault History
169
Programming
170
Cloning
170
Favorites
170
HHP Settings
171
Plot & Log
172
Plot
172
Log
172
CDT Troubleshooting
173
Connection Tests
174
SECTION 12 - Electric Vehicle - Electrical System Troubleshooting
177
General Information
177
Accessories
177
Charge Indicator Light
177
Key Differences: IQ Plus with Quiq Charger Vs. IQ Plus Charger
177
Features
178
Sonic Weld, Diode, and 10K Ohm Resistor Locations
180
Troubleshooting
181
Troubleshooting the Vehicle with the CDT
181
Troubleshooting Guide 1
182
Troubleshooting Guide 2
185
Test Procedures
187
Testing Basics
187
SECTION 13 - Electric Vehicle - Electrical Components
219
Key Switch
219
Testing the Key Switch
219
Key Switch Removal
219
Key Switch Installation
219
Forward/Reverse Rocker Switch
221
Forward/Reverse Rocker Switch Removal
221
Forward/Reverse Rocker Switch Installation
221
Run/Tow Switch
221
Run/Tow Switch Removal
222
Run/Tow Switch Installation
222
Circuit Breaker
222
Circuit Breaker Removal
222
Circuit Breaker Installation
222
Motor Controller Output Regulator (MCOR)
224
Testing the MCOR
224
MCOR Removal
224
MCOR Installation
224
Reverse Buzzer
225
Reverse Buzzer Removal
225
Reverse Buzzer Installation
225
Speed Controller Cover
225
Removing the Speed Controller Cover
225
Installing the Speed Controller Cover
225
Solenoid
225
Solenoid Removal
226
Solenoid Installation
226
Speed Controller
226
Speed Controller Removal
227
Speed Controller Installation
227
Charge Indicator Light
229
Testing the Charge Indicator Light
229
Charge Indicator Light Removal
229
Charge Indicator Light Installation
229
Headlights
230
Headlight Bezel Removal
230
Headlight Bezel Installation
230
Halogen Headlight Bulb Removal
231
Halogen Headlight Bulb Installation
231
Halogen Headlight Lens Removal
232
Halogen Headlight Lens Installation
232
LED Headlight Removal
233
LED Headlight Installation
233
Lockout Relay
233
Lockout Relay Removal
234
Lockout Relay Installation
234
Walk Away Relay
235
Walk Away Relay Removal
235
Walk Away Relay Installation
235
SECTION 14 - Electric Vehicle - Batteries
237
General Information
237
Battery Testing Basics - 6 Volt
238
Observation
238
Measuring Voltage of Battery Set
238
Battery Cell Numbering
238
Battery Testing - 6 Volt
239
Battery Regrouping
239
Battery Replacement
241
Battery Care
242
Water Quality
242
Deionizer
243
Battery Care - Vehicles Equipped with the Single-Point Watering System (SPWS)
244
Battery Care - Vehicles Without the Single-Point Watering System (SPWS)
245
Self-Discharge
246
Electrolyte Level
246
Vibration Damage
247
Single Point Watering System (SPWS)
247
Initial Maintenance of the SPWS
247
Watering Batteries with the SPWS
247
Battery Storage
249
Fleet Rotation
249
Deep-Discharge
250
Early Excessive Discharging
250
SECTION 15 - Electric Vehicle - Battery Charger
251
General Information
251
Features
251
UL and CSA Listing
251
CE Compliance
251
IP (Ingress Protection) Rating
251
How to Identify Charge Algorithm Number
252
How to Change the Algorithm
253
The Charge Circuit
253
Onboard Charger Operation
254
Charger Displays
256
AC Power Connection
258
Charging Batteries
258
Maintenance
259
Troubleshooting
260
Test Procedures
261
Charger Repairs
262
Onboard Charger Removal and Installation
262
Onboard Charger Removal
262
Onboard Charger Installation
263
SECTION 16 - Electric Vehicle - Motor
265
General Information
265
External Motor Testing
265
Motor Removal
266
Motor Disassembly
268
Motor Component Testing and Inspection
271
Armature Inspection and Testing
271
Motor Frame and Field Windings Inspection
272
Motor Brush, Spring, and Terminal Insulator Inspection
272
Reconditioning the Motor
275
Motor Specifications
275
Motor Assembly
275
Motor Installation
277
SECTION 17 - Electric Vehicle - Transaxle
281
Lubrication
281
Axle Bearing and Shaft
281
Axle Shaft
281
Axle Bearing
284
Transaxle
285
Transaxle Removal
285
Transaxle Disassembly, Inspection, and Assembly
288
Transaxle Disassembly and Inspection
288
Transaxle Assembly
290
Transaxle Installation
291
SECTION 18 - Gasoline Vehicle - Troubleshooting and Electrical System
293
General Information
293
Accessories
293
Low Oil Warning Light
293
Malfunction Indicator Light
294
Ground Locations
295
Features of the Electronic Fuel Injection (EFI) System
295
Troubleshooting Guide
295
Gasoline Powertrain
296
Electrical System
298
Test Procedures
299
Testing Basics
299
SECTION 19 - Gasoline Vehicle - Electrical Components
341
General Information
341
Starter/Generator
341
Starter/Generator Removal
341
Disassembly of the Starter/Generator to Service the Brushes
342
Brush Inspection and Replacement
343
Brush Spring Inspection and Replacement
343
Starter/Generator Assembly
344
Disassembly of the Starter/Generator to Service the Armature/Commutator
345
Bearing Cleaning and Inspection
346
Bearing Removal
347
Field Coil Assembly
347
Visual Inspection of Armature
347
Commutator Cleaning and Inspection
348
Armature Ground Test
349
Visual Inspection of Field Coils
350
Starter/Generator Rework
350
Starter/Generator Assembly
350
Starter/Generator Installation
353
Belt Tension Inspection for EFI Engines
354
Belt Tension Adjustment for EFI Engines
355
Belt Tension Tool Modification
358
Voltage Regulator
359
Voltage Regulator Removal
359
Voltage Regulator Installation
359
Key Switch
360
Key Switch Removal
360
Key Switch Installation
361
Maintenance/Operate Switch
362
Maintenance/Operate Switch Removal
362
Maintenance/Operate Switch Installation
362
Neutral Lockout Limit Switch
363
Neutral Lockout Limit Switch Removal
363
Neutral Lockout Limit Switch Installation
365
Solenoid
366
Solenoid Removal
366
Solenoid Installation
367
Fuse
368
Fuse Removal
369
Fuse Installation
369
Accelerator Pedal Limit Switch
370
Accelerator Pedal Limit Switch Removal
370
Accelerator Pedal Limit Switch Installation
370
Kill Limit Switch
371
Kill Limit Switch Removal
371
Kill Limit Switch Installation
371
Reverse Warning Buzzer
372
Reverse Warning Buzzer Removal
372
Reverse Warning Buzzer Installation
372
Reverse Buzzer Limit Switch
373
Reverse Buzzer Limit Switch Removal
373
Reverse Buzzer Limit Switch Installation
373
Low Oil Warning Light
374
Low Oil Warning Light Removal
374
Low Oil Warning Light Installation
374
Malfunction Indicator Light
375
Malfunction Indicator Light Removal
375
Malfunction Indicator Light Installation
375
Fuel Gauge/Hour Meter
375
General Information
375
Fuel Gauge/Hour Meter Removal
376
Fuel Gauge/Hour Meter Installation
376
Fuel Level Sending Unit
376
Voltage Limiter
377
Voltage Limiter Removal
377
Voltage Limiter Installation
377
Headlight Switch
378
Headlight Switch Removal
378
Headlight Switch Installation
378
Headlights
379
Headlight Bezel Removal
379
Headlight Bezel Installation
379
Halogen Headlight Bulb Removal
380
Halogen Headlight Bulb Installation
380
Halogen Headlight Lens Removal
381
Halogen Headlight Lens Installation
381
LED Headlight Removal
382
LED Headlight Installation
382
Battery
382
General Information
383
Preventive Maintenance
383
Self-Discharge
383
Vibration Damage
384
Battery Removal
384
Charging the Battery
384
Battery Installation
384
Battery Storage
385
Charging a Dead Battery
385
Oxygen Sensor
386
Oxygen Sensor Removal
386
Oxygen Sensor Installation
386
Ground Cables
386
Charging Dioded (Key-Start Only)
387
Charging Diode Removal
387
Charging Diode Installation
388
SECTION 20 - Gasoline Vehicle - Engine
389
General Information
389
Before Servicing
389
Louver Arm
390
Engine Removal
391
Engine Installation
394
Snubber
397
Snubber Removal
397
Snubber Installation
397
SECTION 21 - Gasoline Vehicle - Fuel System
399
General Information
399
EFI System Features/Specifications
399
Engine Control Linkages
399
General Information
400
Ground Speed
400
Accelerator Rod
400
Governor Cable
403
Accelerator Cable
405
Closed Throttle or Idle Adjustment - Pedal-Start Vehicles
408
Closed Throttle or Idle Adjustment - Key-Start Vehicles
408
How to Measure Ground Speed
408
Engine RPM Adjustment
408
Air Intake System
410
Air Cleaner Removal
411
Air Cleaner Installation
411
Relieving Fuel Pressure
412
To Relieve Fuel Pressure
412
Fuel Line
412
Fuel Line Removal
413
Fuel Line Installation
414
Fuel Pump Module
416
General Information
416
Fuel Pump Module Removal
417
Fuel Pump Module Installation
418
Fuel Tank
419
General Information
419
Fuel Tank Removal
420
Fuel Tank Disposal
421
Fuel Tank Storage
421
Fuel Tank Installation
422
Fuel Filter
423
General Information
423
Fuel Filter Removal
423
Fuel Filter Installation
423
SECTION 22 - Gasoline Vehicle - Exhaust System
425
Muffler
425
Muffler Removal
425
Muffler Installation
426
SECTION 23 - Gasoline Vehicle - Clutches
427
General Information
427
Troubleshooting
427
Drive Belt
429
Drive Belt Removal
429
Drive Belt Installation
429
Drive Clutch
430
Drive Clutch Removal
431
Drive Clutch Cleaning and Inspection
432
Drive Clutch Disassembly
433
Inspection of Drive Clutch Parts
435
Drive Clutch Assembly
436
Drive Clutch Installation
437
Driven Clutch
438
Driven Clutch Removal
439
Driven Clutch Disassembly
439
Driven Clutch Inspection
442
Driven Clutch Assembly
442
Driven Clutch Installation
445
SECTION 24 - Gasoline Vehicle - Transaxle
447
General Information
447
Forward/Neutral/Reverse Control (FNR)
447
Maintenance/Operate Switch
447
Governor System
448
Transaxle Service
448
Lubrication
448
Tools Required for this Section
449
Rear Hubs
450
Rear Hub Removal
450
Rear Hub Installation
450
Axle Tubes, Axle Shafts, Differential Guard, and Wheel Bearings
452
Differential Guard Removal
452
Differential Guard Installation
452
Axle Tube and Axle Shaft Removal
453
Axle Tube and Axle Shaft Installation
454
Rear Wheel Bearing Removal
454
Rear Wheel Bearing Installation
455
Axle Shaft Oil Seal Removal
455
Axle Shaft Oil Seal Installation
455
Transaxle Removal
456
Transaxle Installation
460
Shifter Cable
460
Shifter Cable Removal
460
Shifter Cable Installation
461
Shifter Cable Adjustment
461
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