Table Of Contents - Club Car Carryall 550 2017 Maintenance And Service Manual

Table of Contents

Maintenance Itemns4
Contents5
Safety17
Safety Details17
General Warnings17
Electric Vehicles18
Gasoline Vehicles18
Disabling The Vehicle20
Disconnecting The Batteries - Electric Vehicles20
Connecting The Batteries - Electric Vehicles20
Disconnecting The Battery - Gasoline Vehicles20
Connecting The Battery21
Recycling Lead-Acid Batteries21
International Safety Symbols21
Vehicle Specifications23
General Information29
Carryall 550 Wheels29
Model Identification29
Storage - Electric Vehicle30
Preparing The Electric Vehicle For Extended Storage30
Serial Number Decal30
Returning The Stored Electric Vehicle To Service31
Preparing The Gasoline Vehicle For Extended Storage32
Body And Trim35
Cleaning The Vehicle35
Seat Cleaning35
Front Body Repair36
Light Scratches36
Abrasions And Haze36
Large Scratches And Abrasions36
Touch-Up Paint Color Chart37
Front Body38
Heavy Duty Bumper Removal38
Heavy Duty Bumper39
Heavy Duty Bumper Installation40
Cowl Removal40
Cowl Installation40
Grille Removal41
Front Grille, Bumper And Side Fenders42
Grille Installation43
Front Bumper And Side Fender Removal43
Front Bumper And Side Fender Installation43
Instrument Panel Removal44
Instrument Panel Installation44
Dash Removal45
Dash Installation45
Dash Assembly46
Tilt Bed47
Tilt Bed Removal47
Tilt Bed Installation47
Tilt Bed Mounting48
Bed Latch Assembly Removal49
Bed Latch Assembly Installation49
Bed Latch Assembly50
Rear Fenders And Tailskirt51
Rear Fender And Tailskirt Removal51
Rear Fender And Tailskirt Installation51
Electric Bed Lift53
Electric Bed Lift Removal53
Electric Bed Mounting53
Electric Bed Lift Installation54
Floor Mat56
Floor Mat Removal56
Floor Mat Installation56
Trailer Hitch Removal56
Accelerator And Brake Pedal Group57
Brake Pedal And Park Brake57
Brake Pedal Removal57
Brake Pedal Installation57
Brake Pedal Weldment Through Floor59
Brake Pedal Free-Play Adjustment59
Park Brake Removal60
Park Brake Installation60
Park Brake Assembly60
Torsion Spring Installation60
Accelerator Pedal Removal61
Accelerator Pedal Installation62
Ratchet Installation63
Pedal Group Adjustment66
Loosen Rear Brake Equalizer Rod Nuts67
Brake Pedal Height Adjustment67
Brake Pedal Height Measurement67
Park Brake Ratchet/Pawl Gap Adjustment68
Accelerator Pedal Height Measurement69
Ratchet/Pawl Tooth Engagement69
Brake Rod Adjustment69
Accelerator Pedal Height Adjustment69
Accelerator Cable71
Wheel Brake Assemblies77
Asbestos Dust Warning77
Brake Shoe Removal77
Loosen Equalizer Nut78
Shoe Retainer Pins78
Brake Assembly Cleaning79
Rotate Clip Retainer79
Remove Shoes79
Lubricate Slide79
Lubricate Rosses80
Lubricate Brake Shoes And Slots80
Lubricate Actuator80
Lubricate Shoes80
Brake Shoe Installation81
Position Shoes81
Retainer Clip81
Brake Adjustment82
Insert Shoes82
Brake Cluster Adjustment83
Rear Equalizer Adjustment83
Front Equalizer Adjustment83
Rear Brake Adjustment Bolt83
Front Manually Adjusted Brake Assembly84
Brake Cable Equalization85
Rear Manually-Adjusted Brake Assembly85
Final Brake Cluster Adjustment86
Test Drive Vehicle86
Set Park Brake And Insert Wedge86
Brake Cluster Removal And Installation87
Front Brake Cluster Removal87
Front Brake Cluster Installation87
Front Spindle Assembly88
Rear Brake Cluster Removal89
Rear Brake Cluster Installation89
Front Brake Cables90
Front Brake Cables And Equalizer90
Front Brake Cable Removal91
Front Brake Cable Installation91
Front Brake Cable Routing Under Cowl And Wire Tie Locations91
Rear Brake Cables92
Rear Brake Cables And Equalizer92
Rear Brake Cable Removal93
Rear Brake Cable Installation93
Steering And Front Suspension95
Steering Wheel95
Steering Wheel Removal95
Steering Wheel Installation96
Steering Column97
Steering Column Removal98
Steering Column Disassembly98
Steering Column Assembly98
Steering Column Installation99
Steering Shaft - Bottom End99
Steering Shaft - Top End99
Steering Adjustment100
Rack And Pinion101
Rack And Pinion Inspection101
Rack And Pinion Removal - Maintenance Free Ball Joints101
Rack And Pinion Disassembly102
Adjust Steering Alignment102
Remove Pinion From Housing103
Remove Bearing From Pinion103
Secure Rack In Vise103
Rack And Pinion Assembly104
Steering Gear - Maintenance-Free Ball Joints104
Press In Dust Seal105
Rack And Pinion Adjustment105
Rack And Pinion Resistance106
Rack And Pinion Installation - Maintenance-Free Ball Joints107
Tie Rod And Drag Link108
Tie Rod And Drag Link Removal108
Tie Rod And Drag Link Installation108
Front Suspension109
Lubrication109
Wheel Alignment109
Camber Adjustment109
Toe-In Adjustment110
Front Suspension Components111
Leaf Spring Removal111
Leaf Spring Installation111
Kingpin And Steering Spindle Removal111
Front Suspension - Upper Portion112
Front Suspension - Lower Portion113
Delta A-Plate Removal114
Delta A-Plate Installation114
Shock Absorber Removal114
Shock Absorber Installation114
Front Wheel Bearings And Hubs115
Front Wheel Free Play Inspection115
Front Hub And Wheel Bearings Removal115
Front Hub And Wheel Bearings Installation116
Wheels And Tires117
Wheel Removal117
Wheel Installation117
Tires118
Tire Removal118
Tire Repair118
Tire Installation119
Inflate Tire120
Rear Suspension121
Shock Absorbers121
Multi-Leaf Springs122
Multi-Leaf Spring Removal122
Multi-Leaf Spring Installation123
Support Vehicle On Jack Stands123
Disconnect Brake Cable123
Rear Suspension Assembly And Mounting124
Periodic Maintenance125
Pre-Operation And Daily Safety Checklist125
Performance Inspection125
All Vehicles126
Maintenance127
Periodic Service Schedules128
Periodic Lubrication Schedules131
Lubrication Points131
Controller Diagnostic Tool133
Cdt Overview133
Features134
Plugging The Cdt Into The Vehicle134
Communication Port Under Instrument Panel134
Introductory Display135
Quick Reference Guide - Iq Plus With Quiq Charger136
System Info137
Model Number137
Serial Number137
Hardware Version137
Settings138
M1/M2 Speed138
M1/M2 Fast Accel138
M1/M2 Pedal Up138
M1/M2 Speed Cal139
Control Mode140
Anti-Tamper140
Deterrent Demo140
Walkaway Deterrent140
Charger Control141
Amp Hours141
Access Codes141
Vehicle Id141
Monitor Menu142
Vehicle Date Of Manufacture142
Vehicle S/N142
Vehicle Decal142
Throttle %143
Batt Voltage143
Heatsink Temp143
Arm Current143
Reverse Input144
Mode Switch144
Wk Away Relay144
Main Cont144
Relay Welded145
Spd Sensor145
Main Drv On145
Main Coil Opn145
Drvr Overcur146
Rly Drvr On146
Rly Drvr Off146
Signed Battery Current146
Battery Monitor147
Open Circuit Soc Start147
Lowest Battery Voltage147
Amp Hours Display147
Diagnostics Menu149
Present Errors Folder149
Fault History Folder149
System Faults149
Causes Of Faults150
Fault Recovery151
Fault Descriptions152
Throttle Fault152
Low Battery Voltage152
Overvoltage152
Main Dropout153
Motor Stall153
Main Driver Off153
Relay Dnc153
Incorrect Password154
Circuit Brkr Open154
Max Password Tries154
Lockout Fault154
Main Cont Dnc155
Main Coil Fault155
Proc/Wiring155
Fault History155
Programming156
Cloning156
Favorites156
Hhp Settings157
Plot158
Log158
Cdt Troubleshooting159
Connection Tests160
Index Of Test Procedures160
Handset Cord160
Handset Cord Adaptor161
Cdt Ports161
Disconnect Four-Pin Connector162
Electrical System Troubleshooting163
Iq Plus Electric Vehicles163
Accessories163
Charge Indicator Light163
Wiring Diagrams166
Troubleshooting170
Troubleshooting The Vehicle With The Cdt170
Troubleshooting Guide 1171
Test Procedures176
Testing Basics176
Index176
Batteries/Voltage Check177
Batteries/Voltage Check With The Cdt Handset177
Batteries/Voltage Check Without The Cdt Handset177
Battery Voltage Test178
48-Volt Battery Pack Voltage Under Load179
Battery Discharge Test179
Tow/Run Switch180
Fuses181
Testing The Fuse181
Circuit Breaker182
Wire Harness Diodes183
Basic Diode Information183
Key Switch And Mcor Limit Switch Circuit184
Forward/Reverse Rocker Switch185
Solenoid Activating Coil186
Solenoid Contacts187
Charger Interlock187
Mcor Voltage188
Testing The Interlock Circuit188
Mcor Voltage Test With The Cdt Handset189
Mcor Voltage Test Without The Cdt Handset189
Motor Speed Sensor190
Motor Speed Sensor Test With The Cdt Handset190
Motor Speed Sensor Without The Cdt Handset190
Speed Sensor Black/White Wire191
Speed Sensor Red Wire192
Speed Sensor Light Green Wire192
A1 And A2 Motor Voltage193
Speed Sensor Green Wire193
24-Pin Connector194
Test A1 And A2 Motor Voltage194
Caution196
Pins 14 And 15196
Pin 8197
Pins 10 And 11199
Pin 19199
Pin 10200
Pin 1201
Pin 3202
Pin 20202
Reverse Buzzer203
Walk Away Braking Relay203
4-Pin Connector204
Electrical Components207
Key Switch207
Testing The Key Switch207
Tow/Run Switch Removal210
Tow/Run Switch Installation210
Testing The Circuit Breaker210
Circuit Breaker Removal210
Motor Controller Output Regulator212
Mcor Removal212
Mcor Installation212
Mcor Mounting212
Testing The Reverse Buzzer213
Reverse Buzzer Removal213
Reverse Buzzer Installation213
Removing The Speed Controller Cover213
Solenoid214
Testing The Solenoid214
Solenoid Removal214
Solenoid Installation214
Speed Controller215
Speed Controller Removal215
Speed Controller Installation215
Charge Indicator Light Removal217
Charge Indicator Light Installation217
Battery Testing Basics220
Measuring Voltage220
Battery Cell Numbering220
Battery Regrouping221
Battery Regrouping Process Flow222
Battery Replacement223
Battery Care224
Water Quality224
Preferred Methods224
Alternate Methods224
Deionizer225
Regular Maintenance225
Decals225
Seasonal Maintenance226
Establishing The Watering Interval For New Vehicles227
Self-Discharge228
Electrolyte Level228