Club Car Carryall 500 Maintenance And Service Manual
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Club Car Carryall 500 Maintenance And Service Manual

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2017 Carryall 500 and 700
Maintenance and Service
Manual
Gasoline Vehicle with Subaru EX40 Engine
Electric Vehicle with QuiQ™ ™ ™ Charger
Manual Number 105342204
Edition Code B

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Summary of Contents for Club Car Carryall 500

  • Page 1 2017 Carryall 500 and 700 Maintenance and Service Manual Gasoline Vehicle with Subaru EX40 Engine Electric Vehicle with QuiQ™ ™ ™ Charger Manual Number 105342204 Edition Code B...
  • Page 3 To find your local authorized Club Car dealer, visit www.clubcardealer.com, call 1-800-ClubCar (258–2227), or scan this Quick Response (QR) code to be taken to the Club Car dealer locator. Refer to Figure 1. Download a QR code reader such as RedLaser or Barcode Scanner to your cell phone or tablet.
  • Page 4 Deionizer Filter Replacement Cartridge (non-SPWS) CC PN AM10975 NOTE: This manual represents the most current information at the time of publication. Club Car is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures.

  • Page 5: Table Of Contents

    Tilt Bed ............................... 4-13 Tilt Bed Removal ............................. 4-13 Tilt Bed Installation ..........................4-13 Bed Latch Assembly Removal ........................4-15 Bed Latch Assembly Installation ....................... 4-15 Rear Fenders and Tailskirt..........................4-17 2017 Carryall 500 and 700 Maintenance and Service Manual Page iii...
  • Page 6 Steering Column............................7-3 Steering Column Removal.......................... 7-4 Steering Column Disassembly ........................7-4 Steering Column Assembly ........................7-4 Steering Column Installation........................7-5 Steering Adjustment ............................7-6 Rack and Pinion ............................7-7 Page iv 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 7 General Information ............................11-2 Features ..............................11-2 Plugging the CDT into the Vehicle........................11-2 Introductory Display ..........................11-3 Quick Reference Guide – IQ Plus with Quiq Charger ..................11-4 System Info ..............................11-5 Model Number............................11-5 2017 Carryall 500 and 700 Maintenance and Service Manual Page v...
  • Page 8 V min I ..............................11-14 Signed Battery Current..........................11-14 BDI Percent............................11-14 Charger Inhibit............................11-14 LED Driver ............................. 11-14 Odometer............................... 11-14 BDI Info ..............................11-14 Battery Monitor ............................11-15 Charging Totals ............................11-15 Page vi 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 9 General Information ............................. 12-1 Accessories............................. 12-1 Charge Indicator Light..........................12-1 Key Differences: IQ Plus with QuiQ Charger vs. IQ Plus Charger ............... 12-1 Features ..............................12-2 Wiring Diagrams ............................12-4 Troubleshooting............................12-8 2017 Carryall 500 and 700 Maintenance and Service Manual Page vii...
  • Page 10 Electrolyte Level .............................14-10 Vibration Damage ........................... 14-11 Single Point Watering System (SPWS)......................14-11 Initial Maintenance of the SPWS......................14-11 Watering Batteries with the SPWS ......................14-11 Battery Storage ............................14-13 Page viii 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 11 Features of the Electronic Fuel Injection (EFI) System ................18-2 Troubleshooting Guide ..........................18-2 ECU Error Codes (Displayed by the Low Oil Warning Light) ............... 18-2 Gasoline Powertrain ..........................18-4 2017 Carryall 500 and 700 Maintenance and Service Manual Page ix...
  • Page 12 Reverse Buzzer Limit Switch Removal .....................20-25 Reverse Buzzer Limit Switch Installation ....................20-25 Low Oil Warning Light ..........................20-27 Low Oil Warning Light Removal .......................20-27 Low Oil Warning Light Installation ......................20-27 Page x 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 13 Adjustments and Settings......................... 22-2 Engine Oil – Gasoline Vehicle........................22-2 Spark Plug .............................. 22-5 Breather..............................22-6 Valve Clearance Check and Adjustment....................22-7 Engine Removal ............................22-8 Engine Installation ............................22-9 Flywheel ..............................22-10 2017 Carryall 500 and 700 Maintenance and Service Manual Page xi...
  • Page 14 Fuel Filter Removal..........................23-23 Fuel Filter Installation..........................23-24 Fueling Instructions – Gasoline Vehicle ......................23-24 SECTION 24 — Exhaust System: Gasoline Vehicles ..................24-1 Muffler ................................ 24-1 Muffler Removal ............................24-1 Muffler Installation............................ 24-1 Page xii 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 15 Axle Shaft Oil Seal Installation ........................26-8 Transaxle Removal ............................26-9 Transaxle Installation ..........................26-13 Shifter Cable ..............................26-13 Shifter Cable Removal ..........................26-13 Shifter Cable Installation .........................26-14 Shifter Cable Adjustment.........................26-14 Index ................................Index-1 2017 Carryall 500 and 700 Maintenance and Service Manual Page xiii...

  • Page 17: Section 1 - Safety

    SAFETY DETAILS Safety To ensure the safety of those servicing Club Car vehicles, and to protect the vehicles from possible damage resulting from improper service or maintenance, the procedures in this manual must be followed. It is important to note that throughout this manual there are statements labeled DANGER, WARNING, or CAUTION.
  • Page 18 • The vehicle will not provide protection from lightning, flying objects, or other storm-related hazards. If caught in a storm while driving a Club Car vehicle, exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location.
  • Page 19 • Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the vehicle or battery charger. • Use insulated tools when working near batteries or electrical connections. Use extreme caution to avoid shorting of components or wiring. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 1-3...

  • Page 20: Disabling The Vehicle

    3. Remove positive battery cable. Connect battery cables in reverse order. 2780 3167 Figure 1-1 Battery Cable Removal – Electric Vehicle Figure 1-2 Top-Post Battery- Battery Cable Removal-Gasoline Vehicles Page 1-4 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 21: Disconnecting The Battery-Gasoline Vehicles

    Responsibility for environmental protection must be shared, not only by the manufacturers of the batteries, but by people who use the batteries as well. Please contact your nearest Club Car dealer or distributor for information on how to properly recycle your batteries. 1403...
  • Page 22 2. Read and follow operating instructions. 4. Keep away from children. 6. Explosive gas hazard. Refer to General Warnings for more information. 1642 Figure 1-4 International Safety Symbols on Batteries Page 1-6 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 23 5.6 in (14.2 cm) 5.6 in (14.2 cm) Front wheel tread 36.6 in (92.9 cm) 36.6 in (92.9 cm) Rear wheel tread 39.5 in (100.3 cm) 39.5 in (100.3 cm) 2017 Carryall 500 and 700 Maintenance and Service Manual Page 2-1...

  • Page 24: Section 2 - Vehicle Specifications

    73 dBa Test method: EN 12053:2001 Uncertainty: ±2 dBa Uncertainty: ±2 dBa Vibration at driver's seat 0.6 (m/s 0.7 (m/s Test method: EN 13059:2002 Uncertainty: 0.18 (m/s Uncertainty: 0.21 (m/s Page 2-2 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 25: Quiq Battery Charger Specifications

    Case – Overall width 9.7 in (24.6 cm) Case – Overall height 4.3 in (11 cm) Weight – with standard output cord < 11 lb (< 5 kg) MOUNTING CONFIGURATION Mounting Onboard 2017 Carryall 500 and 700 Maintenance and Service Manual Page 2-3...

  • Page 26: Vehicle Specifications - Gasoline Vehicles

    47.1 in (119.6 cm) 47.1 in (119.6 cm) Overall height: with canopy 70.7 in (179.5 cm) 70.7 in (179.5 cm) Overall height: with cab 74.3 in (188.7 cm) 74.3 in (188.7 cm) Page 2-4 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 27 77.2 dBa Test method: EN 12053:2001 Uncertainty: ±2 dBa Uncertainty: ±2 dBa Vibration at driver's seat 0.7 (m/s 0.8 (m/s Test method: EN 13059:2002 Uncertainty: 0.21 (m/s Uncertainty: 0.22 (m/s 2017 Carryall 500 and 700 Maintenance and Service Manual Page 2-5...
  • Page 28 Vehicle Specifications VEHICLE SPECIFICATIONS Pagination Page Page 2-6 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 29: Section 3 - General Information

    • See General Warnings on page 1-1. Important features unique to the different models covered in this manual are highlighted. Club Car, LLC recommends the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s).

  • Page 30: Storage - Electric Vehicles

    Electrolyte level should be from 1/2 inch (13 mm) above plates to 1/4 inch (6 mm) below the level indicator (Figure 14-3). Page 3-2 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 31: Returning The Stored Electric Vehicle To Service

    Adjust tires to recommended tire pressure. See Vehicle Specifications – Electric Vehicles on page 2-1. Perform the Pre-Operation and Daily Safety Checklist on page 10-1 and the Performance Inspection on page 10-1. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 3-3...

  • Page 32: Storage - Gasoline Vehicles

    Batteries should be clean and free of corrosion. Wash tops and terminals of batteries with a solution of baking soda and water: use 1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water. Rinse solution off batteries. Do Page 3-4 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 33: Returning The Stored Gasoline Vehicle To Service

    Adjust tires to recommended tire pressure. See Vehicle Specifications – Gasoline Vehicles on page 2-4. Perform the Pre-Operation and Daily Safety Checklist on page 10-1 and the Performance Inspection on page 10-1. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 3-5...
  • Page 34 Storage – Gasoline Vehicles GENERAL INFORMATION Pagination Page Page 3-6 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 35: Section 4 - Body And Trim

    More Difficult Stains – Perform previous procedure using full-strength bleach, or allow bleach to puddle on affected area for approximately 30 minutes. Rinse with a water dampened cloth to remove any remaining bleach concentration. See following CAUTION. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 4-1...

  • Page 36: Front Body Repair

    Touch-up is not recommended. Replace the entire body part or have it repaired by a professional paint and body repair shop with experience repairing bodies. TOUCH-UP PAINT COLOR CHART COLOR CC P/N White 105117701 Classic Blue 105117702 Dark Green 105117703 105117704 TABLE CONTINUED ON NEXT PAGE Page 4-2 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 37: Front Body

    Loosen and remove screws (1), washers (3), and locknuts (2) that attach heavy duty (HD) bumper mounting bracket (4) to HD bumper weldment (5) (Figure 4-1, Page 4-4). Remove plastic bumper (13). Remove HD bumper and weldment. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 4-3...
  • Page 38 Front Body BODY AND TRIM 2986 Figure 4-1 Heavy Duty Bumper Page 4-4 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 39: Heavy Duty Bumper Installation

    NOTE: Ensure that cowl is fully engaged to prevent dislodging during use. Connect the batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Connecting the Battery-Gasoline Vehicles on page 1-5. Remove tire chocks. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 4-5...

  • Page 40: Grille Removal

    Loosen and remove the two lower left and right side bolts (1 and 7) that attach the grille and plastic bumper (6). Remove charger receptacle (if equipped) by removing the three screws that attach the receptacle or disconnect connector (quick connect). Page 4-6 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 41: Grille Installation

    Install and tighten upper bolts, then lower right and left side bolts. Tighten to 44 in·lb (5 N·m). Connect the batteries.See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Connecting the Battery-Gasoline Vehicles on page 1-5. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 4-7...
  • Page 42 Front Body BODY AND TRIM 2844 Figure 4-3 Front Grille, Bumper, and Side Fenders Page 4-8 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 43: Front Bumper And Side Fender Removal

    Install HD bumper (if equipped). See Heavy Duty Bumper Installation, Section 4, Page 4-5. Connect the batteries.See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Connecting the Battery-Gasoline Vehicles on page 1-5. Remove tire chocks. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 4-9...

  • Page 44: Instrument Panel Removal

    Snap lower body clips in at each lower corner. Connect the batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Connecting the Battery-Gasoline Vehicles on page 1-5. 2946 Figure 4-4 Instrument Panel Page 4-10 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 45: Dash Removal

    Install cowl. See Cowl Installation, Section 4, Page 4-5. Connect the batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Connecting the Battery-Gasoline Vehicles on page 1-5. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 4-11...
  • Page 46 Front Body BODY AND TRIM 2863 Figure 4-5 Dash Assembly Page 4-12 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 47: Tilt Bed

    Install a nylon lock nut (8) on each bolt (7) and tighten to 15 ft·lb (21 N·m). Lift bed and insert the prop rod (9) in bed mounting hole. Install a 3/8-inch flat washer (17) and a new cotter pin (11) on prop rod. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 4-13...
  • Page 48 Tilt Bed BODY AND TRIM 2980 Figure 4-6 Tilt Bed Mounting Page 4-14 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 49: Bed Latch Assembly Removal

    70 to 80 in·lb (8 to 9 N·m). Connect the batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Connecting the Battery-Gasoline Vehicles on page 1-5. Remove tire chocks. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 4-15...
  • Page 50 Tilt Bed BODY AND TRIM 2982 Figure 4-7 Bed Latch Assembly Page 4-16 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 51: Rear Fenders And Tailskirt

    Figure 4-8 Rear Fender and Tailskirt REAR FENDER AND TAILSKIRT REMOVAL Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL and set the park brake. Chock the wheels. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 4-17...

  • Page 52: Rear Fender And Tailskirt Installation

    Install the tilt bed. See Tilt Bed Installation on page 4-13. Connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. See Connecting the Battery-Gasoline Vehicles on page 1-5. Page 4-18 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 53: Electric Bed Lift

    Install actuator hardware that secures lift (7) (Figure 4-9, Page 4-20). Connect actuator wires. Lower bed. Connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. See Connecting the Battery-Gasoline Vehicles on page 1-5. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 4-19...
  • Page 54 Electric Bed Lift BODY AND TRIM 2983 Figure 4-9 Electric Bed Lift Page 4-20 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 55 BODY AND TRIM Electric Bed Lift 2985 Figure 4-10 Electric Bed Mounting 2017 Carryall 500 and 700 Maintenance and Service Manual Page 4-21...

  • Page 56: Floor Mat

    Install hitch to frame, install two nuts, lockwashers, flat washer, and bolts. Tighten hardware to 15 ft·lb (20.3 N·m). Install tailskirt. See Rear Fender and Tailskirt Installation, Section 4, Page 4-18. Page 4-22 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 57: Section 5 - Accelerator And Brake Pedal Group

    (12) at this time. Secure the equalizer rod (5) to the brake pedal assembly (1) with clevis pin (7) and bow-tie pin (4) as shown. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 5-1...
  • Page 58 Brake Pedal and Park Brake (Gas and Electric Vehicles) ACCELERATOR AND BRAKE PEDAL GROUP Carryall 500 and 700 Electric Vehicle shown, (Gasoline Vehicle similar) 3208 Figure 5-1 Brake and Park Brake Pedal Assembly and Mounting Page 5-2 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 59 – For electric vehicles, see Pedal Group Adjustment – Electric Vehicles on page 5-16. Dimension A: 1/4 inch to 1/2 inch (6 mm to 13 mm) Note: Equalizer bracket may be inverted on some vehicles. 1369 Figure 5-3 Brake Pedal Free-Play Adjustment 2017 Carryall 500 and 700 Maintenance and Service Manual Page 5-3...

  • Page 60: Park Brake Removal (Gas And Electric Vehicles)

    Install the push nut (19) on to the park brake pawl shaft. Install the spacer (23) and torsion spring (22) on the park brake pedal shaft on the brake pedal assembly. Page 5-4 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 61: Accelerator Pedal - Gasoline Vehicles

    Inspect the accelerator pivot rod supports (21) for wear and damage and replace if necessary. If the pivot rod supports do not require replacement, loosen, but do not remove, the four bolts (22) and lock nuts (18) to make installation of the pivot rod easier. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 5-5...

  • Page 62: Accelerator Pedal Installation - Gasoline Vehicles

    (22), flat washers (19), and lock nuts (18). Finger-tighten nuts at this time (Figure 5-6, Page 5-6). Insert the lower end of the accelerator pedal (1) through the floorboard and install the accelerator pivot rod (6) through the uppermost hole in the pedal. Page 5-6 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 63: Accelerator Pedal - Electric Vehicles

    Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack. Place jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands. See following WARNING. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 5-7...
  • Page 64 (22) and lock nuts (15) to make installation of the pivot rod easier. Remove the accelerator pedal (1) from the vehicle. Inspect all parts for wear and damage. Replace as necessary. Page 5-8 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 65 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles 2642 Figure 5-8 Accelerator Pedal – Electric Vehicle with MCOR 2017 Carryall 500 and 700 Maintenance and Service Manual Page 5-9...

  • Page 66: Accelerator Pedal Installation - Electric Vehicles

    Chock wheels and release park brake. Lift rear of vehicle and place jack stands under the axle tubes to support the vehicle. 2.2. To provide slack in the brake cables, loosen the equalizer retaining nuts (1) on the equalizer rod (2) (Figure 5-9, Page 5-11). Page 5-10 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 67 Measure perpendicularly from the floorboard to the back of the brake pedal, then press the brake pedal and measure the distance that the pedal moves before all of the slack is taken out of the brake cables (Figure 5-11, Page 5-11). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 5-11...
  • Page 68 With the park brake locked, make sure at least 75% of ratchet tooth length engages the pawl (Figure 5-14, Page 5-13). Tooth engagement should be between the two lines marked on the pawl. Page 5-12 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 69 5-5/8 inches (14.3 cm). Use a rubber strap to hold pedal in position against the floorboard and then tighten nut to 26 ft·lb (35.3 N·m) (Figure 5-17, Page 5-14). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 5-13...
  • Page 70 Loosen the jam nuts (25) and disconnect the accelerator rod (17) at the accelerator pedal (Figure 5-6, Page 5-6). Adjust the length of the rod to obtain an accelerator cable cam position of 0° to 5° as shown (Figure 5-18, Page 5-15). See following CAUTION. Page 5-14 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 71 Install the electrical box cover and screw. Adjust the brakes. See Brake Adjustment, Section 6, Page 6-6. Connect the battery cables. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 5-15...

  • Page 72: Pedal Group Adjustment - Electric Vehicles

    Proper brake pedal height is 6 inches (15.2 cm) (Figure 5-21, Page 5-17). 2.4. Tighten the jam nut (31) to 8 ft·lb (9.5 N·m) (Figure 5-20, Page 5-17). Page 5-16 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 73 If the gap becomes larger as the park brake pedal is pressed, move the pivot rod supports slightly forward until gap is consistent. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 5-17...
  • Page 74 Loosen the nut and bolt (Figure 5-26, Page 5-19) securing the accelerator pedal to the pivot plate. Clamp the accelerator pedal adjustment tool (CC P/N 101871001) to the accelerator pedal, with the end marked Page 5-18 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 75 Figure 5-27 Accelerator Pedal Height Adjustment Adjust the brakes. See Brake Adjustment, Section 6, Page 6-6. Connect the battery cables. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 5-19...
  • Page 76 Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP Pagination Page Page 5-20 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 77: Section 6 - Wheel Brake Assemblies

    On the back of each brake cluster assembly, locate the heads of two brake shoe retainer pins. It may be necessary to remove sealant material around the head of each pin. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 6-1...
  • Page 78 • The brake shoes are under spring pressure and can release suddenly when brake shoe retainers are removed. Grasp both brake shoes and pull them, together with the springs, out of the brake assembly as shown. Page 6-2 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 79: Brake Assembly Cleaning

    Failure to heed this warning could cause diminished brake performance, possibly resulting in property damage or severe personal injury. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 6-3...
  • Page 80 Use a small brush to carefully apply a light coat of white lithium NLGI #2 grease (Dow Corning BR2-Plus or equivalent) to the brake actuator assembly as shown (Figure 6-9, Page 6-4). See preceding WARNING. 2799 2819 Figure 6-9 Lubricate Actuator Figure 6-10 Lubricate Shoes Page 6-4 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 81: Brake Shoe Installation

    (Figure 6-13, Page 6-6). See following CAUTION. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 6-5...

  • Page 82: Brake Adjustment

    NOTE: All brake cluster components must be clean, lubricated, and in good working condition prior to beginning brake adjustment. All wheels must be installed on the vehicle and lug nuts tightened to 65 ft·lb (88 N·m). Page 6-6 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 83: Brake Cluster Adjustment

    Figure 6-18 Front Brake Adjustment Bolt Use a torque wrench and a 7 mm 8–point socket or Club Car brake adjustment tool (CC P/N 1013582) to turn the brake adjustment bolt (5) on each brake clockwise until it is tightened to 15 ft·lb (20.3 N·m) then back off 5 clicks.
  • Page 84 Brake Adjustment WHEEL BRAKE ASSEMBLIES 2806 Figure 6-19 Front Manually Adjusted Brake Assembly Page 6-8 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 85: Brake Cable Equalization

    Set park brake in the third tooth of the ratchet. Place a wedge between the park brake pedal and brake pedal to prevent the park brake from disengaging while equalizing the brake cables (Figure 6-21, Page 6-10). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 6-9...

  • Page 86: Final Brake Cluster Adjustment

    Brake Cluster Adjustment on page 6-10. See following NOTE. NOTE: Brake pedal free play is the distance the brake pedal can be pressed before the brake actuator arm (at the brake cluster) moves. Page 6-10 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 87: Brake Cluster Removal And Installation

    (Figure 6-23, Page 6-14). Tighten bolts to 30 ft·lb (41 N·m). Adjust brakes as previously described in this section. Use new bow-tie pins when reconnecting brake cables. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 6-11...
  • Page 88 Brake Cluster Removal and Installation WHEEL BRAKE ASSEMBLIES TYPICAL 4 PLACES 2810 Figure 6-22 Front Spindle Assembly Page 6-12 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 89: Rear Brake Cluster Removal

    For electric vehicles: Install the axle shaft. See Axle Shaft and Oil Seal Installation, Section 17, Page 17-4. For gasoline vehicles: Install the wheel hub assembly. See Rear Hub Installation, Section 26, Page 26-4. Adjust brakes as previously described in this section. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 6-13...

  • Page 90: Front Brake Cables

    Front Brake Cables WHEEL BRAKE ASSEMBLIES FRONT BRAKE CABLES See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. 3189 Figure 6-23 Front Brake Cables and Equalizer Page 6-14 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 91: Front Brake Cable Removal

    At original locations, secure brake cable (8 or 18) to chassis with new wire ties (Figure 6-24, Page 6-15). Adjust brakes. See Brake Adjustment on page 6-6. 3190 Figure 6-24 Front Brake Cable Routing Under Cowl and Wire Tie Locations 2017 Carryall 500 and 700 Maintenance and Service Manual Page 6-15...

  • Page 92: Rear Brake Cables

    Rear Brake Cables WHEEL BRAKE ASSEMBLIES REAR BRAKE CABLES 3191 Figure 6-25 Rear Brake Cables and Equalizer Page 6-16 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 93: Rear Brake Cable Removal

    At the rear wheel brakes, connect the cables (7) to the brake actuator arms using clevis pins (5) and new bow-tie pins (8). Place cables (7) in plate under leaf springs and secure with E-clips (6). Adjust brakes. See Brake Adjustment on page 6-6. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 6-17...
  • Page 94 Rear Brake Cables WHEEL BRAKE ASSEMBLIES Pagination Page Page 6-18 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 95: Section 7 - Steering And Front Suspension

    5.5. Remove the steering wheel puller. 5.6. Remove the steering wheel nut (5) and the steering wheel (3) from the steering column (9) (Figure 7-1, Page 7-2). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 7-1...

  • Page 96: Steering Wheel Installation

    Install the plate (2) and screws (1) (Figure 7-1, Page 7-2). Tighten screws to 16 in·lb (1.8 N·m). Connect the battery cables. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Connecting the Battery-Gasoline Vehicles on page 1-5. Page 7-2 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 97: Steering Column

    STEERING AND FRONT SUSPENSION Steering Column STEERING COLUMN See General Warnings on page 1-1. 2609 Figure 7-3 Steering Column 2017 Carryall 500 and 700 Maintenance and Service Manual Page 7-3...

  • Page 98: Steering Column Removal

    The retaining ring should be pressed onto the shaft until 2 inches to 2-1/8 inches (5.1 cm to 5.4 cm) of the shaft extends from the top of the bearing seat in the steering tube (Figure 7-5, Page 7-5). Page 7-4 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 99: Steering Column Installation

    Check the other two bolts of the universal joint (1) to ensure that they are properly tightened to 15 ft·lb (20 N·m) (Figure 7-3, Page 7-3). Install cowl. See Cowl Installation, Section 4, Page 4-5. Install the steering wheel. See Steering Wheel Installation on page 7-2. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 7-5...

  • Page 100: Steering Adjustment

    Also inspect front suspension assemblies as follows: – A-plates (1) (Figure 7-18, Page 7-18) – urethane bushings (2) (Figure 7-18, Page 7-18) – leaf springs (6) (Figure 7-19, Page 7-19) Replace components as necessary. Page 7-6 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 101: Rack And Pinion

    (Figure 7-10, Page 7-10). Remove the bolt (2) and flat washer (3) on the upper universal joint, then remove the rack assembly and universal joint from the vehicle (Figure 7-3, Page 7-3). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 7-7...

  • Page 102: Rack And Pinion Disassembly

    Remove the rack screw lock nut (15), rack guide screw (16), rack guide pressure spring (14), and the rack guide (13) (Figure 7-10, Page 7-10). Remove the universal joint assembly from the pinion (8) by fully removing the bolt and then sliding off the universal joint. Page 7-8 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 103 Figure 7-9 Secure Rack in Vise Inspect the bushing (5) for excessive wear. If wear is excessive, replace the steering box assembly (CC P/N 101878302) (Figure 7-10, Page 7-10). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 7-9...

  • Page 104: Rack And Pinion Assembly

    Tighten the ball joint to 60 ft·lb (81 N·m). Bend the edges of the tab washer (4) up against the ball joint (3) (Figure 7-9, Page 7-9). Page 7-10 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 105 • Do not force the pinion-bearing assembly into the housing. The gear teeth or the small bearing could be damaged. 1500-18400-10263 1500-18400-10264 Figure 7-11 Press In Dust Seal Figure 7-12 Rack and Pinion Adjustment 2017 Carryall 500 and 700 Maintenance and Service Manual Page 7-11...
  • Page 106 • The tie rod and drag link have right-hand threads on one end and left-hand threads on the other end. Right-hand threads are identified by a groove in the tie rod or drag link. Install the ball joint (23) (Figure 7-10, Page 7-10). See preceding CAUTION. Page 7-12 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 107: Rack And Pinion Installation - Maintenance-Free Ball Joints

    Install the drag link ball joint (23) on the spindle arm riser (33) and secure with retaining nut (25). Tighten nut to 40 ft·lb (54 N·m). Adjust the steering. See Steering Adjustment on page 7-6. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 7-13...

  • Page 108: Tie Rod And Drag Link

    Page 7-10). Tighten nut to 40 ft·lb (54 N·m). Adjust camber and toe-in. See Camber Adjustment on page 7-15 and Toe-in Adjustment on page 7-16. Adjust steering. See Steering Adjustment on page 7-6. Page 7-14 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 109: Front Suspension

    After adjusting camber, tighten the four spring retaining nuts (32) (Figure 7-19, Page 7-19) to 23 ft·lb (31 N·m). Then roll the vehicle forward one full tire revolution and recheck the camber. Adjust as required. See also Figure 7-14, Page 7-15. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 7-15...
  • Page 110 There should be equal travel to the left and right. See following NOTE. NOTE: If the minimum turning radius is not the same for both left and right turns, adjust the steering. See Steering Adjustment on page 7-6. Page 7-16 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 111: Front Suspension Components

    NOTE: If the bushings are replaced, ream new bushings from 0.750 inch to 0.752 inch (19.05 to 19.10 mm) in diameter. The reamer should be long enough to ream both bushings from one direction. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 7-17...
  • Page 112 Front Suspension Components STEERING AND FRONT SUSPENSION 2610 Figure 7-18 Front Suspension – Upper Portion Page 7-18 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 113 STEERING AND FRONT SUSPENSION Front Suspension Components 2611 Figure 7-19 Front Suspension – Lower Portion 2017 Carryall 500 and 700 Maintenance and Service Manual Page 7-19...

  • Page 114: Kingpin And Steering Spindle Installation - Maintenance-Free Ball Joints

    NOTE: When installing shock absorbers, make sure front shocks have identical part numbers and rear shocks have identical part numbers. Install the shock absorber by reversing the removal procedure. Tighten the nuts (9 and 38) to 20 ft·lb (27 N·m). Page 7-20 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 115: Front Wheel Bearings And Hubs

    Inspect the surface of the spindle shaft where the seal (6) seats. It should be clean and smooth (Figure 7-20, Page 7-21). 1500-18700-10273 Figure 7-20 Front Wheel Bearings and Hub 2017 Carryall 500 and 700 Maintenance and Service Manual Page 7-21...

  • Page 116: Front Hub And Wheel Bearings Installation

    Repeat the procedure for the opposite wheel. Install the wheels and then finger tighten the lug nuts. Lower the vehicle and finish tightening lug nuts, using a crisscross pattern, to 55 ft·lb (74.6 N·m). Page 7-22 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 117: Section 8 - Wheels And Tires

    • See General Warnings on page 1-1. GENERAL INFORMATION NOTE: Use only Club Car approved tires when replacing tires. Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care. • Keep tires properly inflated. See Vehicle Specifications on page 2-1.

  • Page 118: Tires

    1.2. Immerse the tire in water and then mark the point where bubbles are formed by escaping air. 1.3. Determine the cause of the air leak. See following NOTE. Page 8-2 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 119: Tire Installation

    Adjust air pressure in the tire to recommended pressure. See Vehicle Specifications on page 2-1. Immerse the wheel and tire assembly in water to make sure there are no leaks. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 8-3...
  • Page 120 Tires WHEELS AND TIRES Figure 8-2 Inflate Tire Page 8-4 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 121: Section 9 - Rear Suspension

    2860 Figure 9-1 Shock Absorber Removal SHOCK ABSORBER INSTALLATION NOTE: When installing shock absorbers, make sure front shocks have identical part numbers and rear shocks have identical part numbers. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 9-1...

  • Page 122: Multi-Leaf Springs

    Remove the nut (11) and bolt (17) attaching the front of the spring to the vehicle frame and remove the spring. Inspect the bushings and spacers in the spring eyes and replace them if they are worn or damaged. Page 9-2 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 123: Multi-Leaf Spring Installation

    Tighten the nuts (1) until the rubber bushing (3) expands to the size of the cup washer (4). Connect the battery cables. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Connecting the Battery-Gasoline Vehicles on page 1-5. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 9-3...
  • Page 124 Multi-Leaf Springs REAR SUSPENSION 2987 Figure 9-4 Rear Suspension Assembly and Mounting Page 9-4 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 125: Section 10 - Periodic Maintenance

    Contact your local authorized distributor/dealer to perform all repairs and semiannual and annual periodic service. PRE-OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new vehicle(s), you should become familiar with its controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery.
  • Page 126 Club Car vehicles operate at reduced speed in reverse. When the pedal is released, it should return to the original position and the motor should rotate freely or go into motor braking mode. See Pedal Up Motor Braking below.

  • Page 127: Maintenance

    Any vehicle not functioning correctly should be removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service. WARNING •...

  • Page 128: Periodic Service Schedules

    SPWS) to verify correct valve operation. See page 14-9. TABLE CONTINUED ON NEXT PAGE Page 10-4 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 129 Tires Vehicle Specifications – Gasoline Vehicles on page 2-4. Wash engine compartment and underside of vehicle. General vehicle Do not wash engine when hot. TABLE CONTINUED ON NEXT PAGE 2017 Carryall 500 and 700 Maintenance and Service Manual Page 10-5...
  • Page 130 • If any problems are found during scheduled inspection or service, do not operate the vehicle until repairs are made. Failure to make necessary repairs can result in fire, property damage, severe personal injury, or death. Page 10-6 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 131: Periodic Lubrication Schedules

    (or every 100 hours of operation, whichever comes Inspect front wheel bearings (Repack Chassis Lube – EP NLGI Grade 2 first) as necessary) 2822 Figure 10-1 Lubrication Points – Electric Vehicles 2017 Carryall 500 and 700 Maintenance and Service Manual Page 10-7...
  • Page 132 200 Change engine oil SE or higher hours of operation or annually, See also Figure 22-3, Page 22-5. whichever comes first 2823 Figure 10-2 Lubrication Points – Gasoline Vehicles Page 10-8 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 133: Section 11 - Controller Diagnostic Tool (Cdt)

    6. Main Menu Button 10. Power Button 3. “+” Key 7. System Port 11. Arrow Keys 4. “–” Key 8. USB Port 12. SD-card Slot 3115 Figure 11-1 CDT Overview 2017 Carryall 500 and 700 Maintenance and Service Manual Page 11-1...

  • Page 134: General Information

    • Softkeys: Three versatile softkeys provide multiple functions, depending on context. • Update: The handheld programmer can update its own software. PLUGGING THE CDT INTO THE VEHICLE 2977 Figure 11-2 Communication Port Under Instrument Panel Page 11-2 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 135: Introductory Display

    In the event that the handset does not display any information, or the screen is difficult to read, refer to the CDT troubleshooting procedures. See CDT Troubleshooting on page 11-27. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 11-3...

  • Page 136: Quick Reference Guide - Iq Plus With Quiq Charger

    Run/Tow switch is in “Tow” position. Switch to “Run” position. The controller has failed. The Tow circuit has failed. Check 15 Amp ATC fuse in fuse block, Tow switch, 24-pin connector, and wire harness. Page 11-4 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 137: System Info

    The Parameters menu is where you can view and modify the settings of the controller's adjustable parameters. Navigate through this complex menu using the arrow keys, +/- keys, and softkeys. The parameters displayed will depend on the access level of the handset. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 11-5...
  • Page 138 A vehicle programmed for speed setting 4 does not conform to ANSI Z130.1 – American National Standard for Golf Cars – Safety and Performance Specifications because it is capable of speeds in excess of 15 mph (24.1 km/h). For more information on this feature, contact your local Club Car distributor or dealer. M1/M2 Fast Accel M1/M2 fast accel (fast acceleration) is an option that can be enabled or disabled.
  • Page 139 12.9 mph (20.8 km/h) 14.9 mph (24.0 km/h) 5.8 mph (9.3 km/h) 9.8 mph (15.8 km/h) 12.8 mph (20.6 km/h) 14.8 mph (23.8 km/h) TABLE CONTINUED ON NEXT PAGE 2017 Carryall 500 and 700 Maintenance and Service Manual Page 11-7...
  • Page 140 Battery Type The battery type menu item is intended to be used with Guardian/Visage so that the type of battery could be determined and displayed when remotely monitoring vehicles. Page 11-8 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 141 JE1401-000001 would have 74 for S/N ASCII Letter 1 and 69 for S/N ASCII Letter 2. ASCII NUMBER ASCII CHARACTER ASCII NUMBER ASCII CHARACTER TABLE CONTINUED ON NEXT PAGE 2017 Carryall 500 and 700 Maintenance and Service Manual Page 11-9...
  • Page 142 The following parameters can be monitored in real time with the handset from the Monitor menu: SPEED IN Indicates the approximate ground speed of the vehicle in miles per hour (MPH). Page 11-10 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 143 With the Forward/Reverse switch in the NEUTRAL or REVERSE position, the handset should indicate that the forward input is off. When the Forward/Reverse switch is placed in the FORWARD position, the handset should indicate that the forward input is on. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 11-11...
  • Page 144 Mode 2. If repeated attempts are unsuccessful, the speed controller will permanently lock out access to Mode 2. In the event that Mode 2 is locked out, the controller must be removed and shipped to Club Car before Mode 2 can be activated.
  • Page 145 Displays the number of times the FLD MISSING fault has been detected. See Fault Descriptions on page 11-20. HW FAILSAFE # Displays the number of times the HW FAILSAFE fault has been detected. See Fault Descriptions on page 11-20. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 11-13...
  • Page 146 Open Circuit Voltage Start Open Circuit Voltage Start is the voltage, as determined by the controller, following a cycle of the Run/Tow switch or coming out of sleep mode. Page 11-14 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 147: Amp Hours Display

    Trip Regen Amp Hours Displays amp hours returned to the batteries from regenerative braking since trip amp hours was reset. Relates to communication between the controller and the Guardian/Visage device (if equipped). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 11-15...
  • Page 148 Monitor Menu CONTROLLER DIAGNOSTIC TOOL (CDT) Charger Additional Page 11-16 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 149: Diagnostics Menu

    Each detected fault is listed only once in the fault history menu, the number of fault occurrances are located in the fault counter section of the monitor menu, even if the fault has occurred multiple times. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 11-17...
  • Page 150 9. PASSWORD TRIES count incremented 10. Set Internal Scaled Throttle Signal to Zero 11. Turn off Walk Away Relay 12. Activate Walk Away function 13. Activate Walk Away beeping immediately Page 11-18 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 151: Fault Recovery

    At power up, after SmartKey 27 MAX PASSWORD TRIES Not Field Repairable codes entered 29 RELAY DRVR OFF WalkAway 2,13 Condition clears in WalkAway 30 RELAY COIL FAULT Continuous Condition clears 2017 Carryall 500 and 700 Maintenance and Service Manual Page 11-19...

  • Page 152: Fault Descriptions

    If the Main Contactor Coil develops an open circuit or is disconnected from the controller , a main coil open fault is detected. Walk Away is not affected by this fault. Page 11-20 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 153: 12 Main Dropout

    If the relay driver has been commanded to turn OFF, but remains on, a relay driver on fault is detected. 24 HW FAILSAFE If the speed controller detects a failure of the armature drive FETs or circuitry, an hw failsafe fault is detected. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 11-21...

  • Page 154: 25 Incorrect Password

    The max password tries fault is declared when the incorrect password fault has been declared several times. In the event that the max password tries fault is indicated, the speed controller must be removed and shipped to Club Car before it can ever be placed in Mode 2. See also Password Tries (OEM Access Level Only) on page 11-12.

  • Page 155: Main Cont Dnc

    MCOR device was disconnected and the speed controller detected a fault code associated with the throttle, the fault history should be cleared so that any future problem is not diagnosed incorrectly as a throttle problem. See Fault History Folder on page 11-17. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 11-23...

  • Page 156: Programming

    You can also create folders of your own to hold specific sets of items; these folders will be indicated with the usual folder icon. You may want to create a folder for each type of vehicle or application, or for each customer. Page 11-24 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 157: Hhp Settings

    When set to Off, no pop-up appears as you enter the keyboard screen, but you can still use the Help key ( ? ) at any time. TABLE CONTINUED ON NEXT PAGE 2017 Carryall 500 and 700 Maintenance and Service Manual Page 11-25...

  • Page 158: Plot & Log

    Log, indicating that logging is in progress. To stop logging, press the right-arrow key, and then in the “Stop Logging” screen, press the “OK” softkey. Page 11-26 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 159: Cdt Troubleshooting

    Test Procedure 3 – CDT Ports on page 11-29 Section 12 — Electrical System Speed controller malfunction Troubleshooting: IQ Plus Electric Vehicles Handset has failed Replace handset TABLE CONTINUED ON NEXT PAGE 2017 Carryall 500 and 700 Maintenance and Service Manual Page 11-27...

  • Page 160: Connection Tests

    Index of Test Procedures 1 – Handset Cord 2 – Handset Cord Adaptor 3 – CDT Ports TEST PROCEDURE 1 – Handset Cord See General Warnings on page 1-1. Page 11-28 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 161 See General Warnings on page 1-1. Check the CDT port on the speed controller. 1.1. Remove the controller access panel. 1.2. Disconnect the square four-pin connector (1) from the speed controller. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 11-29...
  • Page 162 Handset Cord Adaptor on page 11-29. The CDT ports and connections should also be thoroughly checked. Section 12 — Electrical System Troubleshooting: IQ Plus Electric Vehicles Figure 11-3 Disconnect Four-pin Connector. Page 11-30 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 163: Section 12 - Electrical System Troubleshooting: Iq Plus Electric Vehicles

    • A new controller is used that has data collecting functions previously performed by the OBC. Pin 22 in the 24-pin connector is now utilized to operate the charge indicator light in the instrument panel. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-1...

  • Page 164: Features

    Contact your Club Car dealer/distributor to inquire about this programmable feature. • Regenerative Braking: When motor braking is activated, the vehicle motor acts as a generator, slowing the vehicle as it creates energy that is used to charge the batteries.
  • Page 165 If either situation arises, an HPD fault is recorded by the speed controller and will be displayed on an CDT handset in the Diagnostic History menu. See CDT Troubleshooting, Section 11, Page 11-27. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-3...

  • Page 166: Wiring Diagrams

    ELECTRICAL SYSTEM TROUBLESHOOTING: Wiring Diagrams IQ PLUS ELECTRIC VEHICLES WIRING DIAGRAMS WD1050496_L_DGM Figure 12-1 Wiring Diagram Page 12-4 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 167 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Wiring Diagrams WD1050496_R_DGM Figure 12-2 Wiring Diagram (Continued) 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-5...
  • Page 168 ELECTRICAL SYSTEM TROUBLESHOOTING: Wiring Diagrams IQ PLUS ELECTRIC VEHICLES WD1050821_DGM_C1 Figure 12-3 Wiring Diagram – Instrument Panel Page 12-6 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 169 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Wiring Diagrams WD1050496_2_DGM Figure 12-4 Wiring Diagram – Accessories 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-7...

  • Page 170: Troubleshooting

    TROUBLESHOOTING THE VEHICLE WITH THE CDT Club Car recommends the use of the CDT handset for troubleshooting vehicles equipped with the IQ Plus electrical system. Troubleshooting Guide 1 is to be used in conjunction with the CDT handset. Refer to the CDT Owner’s Manual for operating instructions.

  • Page 171: Troubleshooting Guide 1

    Repair and/or connect the 24-pin connector to the speed code at speed controller or broken wire controller Test Procedure 8 – Forward/Reverse Rocker Switch on Failed Forward/Reverse rocker switch page 12-24 TABLE CONTINUED ON NEXT PAGE 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-9...
  • Page 172 Diagnostic Menu – MAIN Replace solenoid. See Solenoid Removal on page 13-8. condition or broken wire to solenoid coil DROPOUT fault code TABLE CONTINUED ON NEXT PAGE Page 12-10 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 173 Failure of the motor armature or brushes Section 16 — Motor (Model DA5-4006): Electric Vehicles Failure of the FET’s that control armature Replace the speed controller. See Speed Controller current Removal on page 13-9. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-11...

  • Page 174: Troubleshooting Guide 2

    Failed Run/Tow switch Test Procedure 3 – Run/Tow Switch on page 12-18 Replace speed controller. See Speed Controller Speed controller failure Removal on page 13-9. TABLE CONTINUED ON NEXT PAGE Page 12-12 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 175 Battery charger connections – loose wires at does not charge batteries Check wire connections and tighten if necessary. charger or batteries Battery charger Section 15 — QuiQ High Frequency Charger 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-13...

  • Page 176: Test Procedures

    5 – Circuit Breaker 6 – Wire Harness Diodes 7 – Key Switch and MCOR Limit Switch Circuit 8 – Forward/Reverse Rocker Switch 9 – Solenoid Activating Coil 10 – Solenoid Contacts Page 12-14 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 177 The multimeter should indicate at least 48 volts. If not, check for loose battery connections or a battery installed in reverse polarity. Refer to Batteries: IQ Plus Electric Vehicles on page 14-1 for further details on battery testing. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-15...
  • Page 178 (Viewed from driver side of vehicle) 1. RED probe to battery no. 1 (+). 2. BLACK probe to battery no. 6 (-). 3072 Figure 12-5 Battery Voltage Test – 500/550/700 Page 12-16 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 179 2. BLACK probe to battery no. 8 (-). 2781a Figure 12-7 Battery Discharge Test Turn the discharge machine on and record the voltage reading of battery pack while under load. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-17...
  • Page 180 With the Run/Tow switch in the RUN position, the reading should be approximately 48 to 50 volts. With the switch in the TOW position, the reading should be approximately 0 volts. If the two-pin connector and pink wire continuity readings are correct, replace the Run/Tow switch. Page 12-18 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 181 If neither side of fuse shows BPV, do the following: – Check BPV. – Check condition and connection of large red wires at solenoid. – Check sonic weld_8 in main wire harness. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-19...
  • Page 182 8 negative post. With an insulation-piercing probe, connect the positive (+) lead to the tan wire on the back of the circuit breaker. 5.1. If there is no voltage, replace the circuit breaker. Page 12-20 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 183 3 pin on the 24 pin connector. Use the wiring diagram to find the broken wire. Set the Run/Tow switch to TOW. Disconnect the batteries. Connect the 24 pin connector to the controller. Connect the batteries. Set the Run/Tow switch to RUN. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-21...
  • Page 184 Conducts Current and Shows Continuity 5. Good Diode (Probe Scenario B) - No Continuity 6. Bad Diode - Meter Beeps In Either Direction (Probe Scenarios A and B) 1127 Figure 12-9 Basic Diode Information Page 12-22 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 185 NOTE: The easiest way to test the key switch and MCOR Limit Switch is to check the pin 1 tan wire in the 24-pin connector. Pin 1 is the end of this circuit. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-23...
  • Page 186 INPUT is ON. If the CDT indicates any other reading, check vehicle wiring. See Wiring Diagrams beginning on page 12-4. Also check the 24-pin connector at the speed controller. See 24-Pin Connector on page 12-33. Test REVERSE INPUT. Page 12-24 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 187 (i.e. biased closer to the front of the switch housing and farther from the rear body). TEST PROCEDURE 9 – Solenoid Activating Coil See General Warnings on page 1-1. NOTE: This is a resistance test. If necessary, see Testing Basics on page 12-14. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-25...
  • Page 188 See General Warnings on page 1-1. NOTE: Unlike other controllers used by Club Car, the pre-charge resistor is internal to the IQ Plus controller. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame crossmember between the spring mount and side stringer, just forward of each rear wheel.
  • Page 189 • Vehicle does not maintain speed nor will it accelerate due to MCOR having a “dead-spot” in its pedal travel. • The voltage signal from the MCOR randomly or sporadically fluctuates with pedal at rest, during pedal travel and with pedal fully pressed. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-27...
  • Page 190 With multimeter set to 20 volts DC, place the black (–) probe on battery no. 6 (6 x 8 volt battery set) negative post and the red (+) probe (with insulation-piercing probe) on the yellow wire at a point close to three-pin connector Page 12-28 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 191 Pin 4: Black/White Wire — Ground Pin 5: Light Green Wire — Input to controller (0 to 5 volts) Pin 6: Red Wire — Output from controller (15 volts to sensor) 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-29...
  • Page 192 If the wire continuity is correct, replace the speed controller. 4.3. If the reading is below 14 volts, replace the speed controller. 4.4. If the voltage reading is correct, proceed to the following step. Page 12-30 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 193 (–) probe on the battery no. 8 negative post and place the red (+) probe (with insulation-piercing probe) on the green wire between the three-pin connector and the motor speed sensor. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-31...
  • Page 194 As the accelerator pedal is pressed, the voltage reading should increase from approximately 5 volts RMS when the MCOR limit switch closes, to approximately 32 to 37 volts RMS with the accelerator pedal fully pressed. See following NOTE. Page 12-32 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 195 A procedure is provided for testing each of the wires in the 24-pin connector. Refer to the following chart for the appropriate procedure for each pin in the 24-pin connector. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-33...
  • Page 196 Pins 13, 14, and 15 See General Warnings on page 1-1. Pins 13, 14, and 15 in the 24-pin connector provide a connection point from the MCOR potentiometer to the speed controller. Page 12-34 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 197 Connect the batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Detail A: Front of 24-Pin Connector Figure 12-16 Test: Pins 14 and 15 (Purple/White and Yellow wires) 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-35...
  • Page 198 The multimeter should indicate zero volts when the accelerator pedal is not pressed. If any other reading is obtained, check the following items: – Continuity of the wires in the wire harness. Page 12-36 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 199 – Continuity of the wires in the wire harness – Reverse buzzer for proper operation. See Reverse Buzzer on page 12-42. – Run/Tow switch for proper operation. See Run/Tow Switch on page 12-18. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-37...
  • Page 200 Place the Run/Tow switch in the RUN position and the Forward/Reverse switch in the NEUTRAL position. The multimeter should indicate zero volts DC at this time. While monitoring the multimeter, place the Forward/Reverse switch in the REVERSE position. The multimeter should still indicate zero volts. Page 12-38 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 201 See WARNING “Lift only one end...” in General Warnings on page 1-1. Disconnect the 24-pin connector at the speed controller. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-39...
  • Page 202 See WARNING “Lift only one end...” in General Warnings on page 1-1. Page 12-40 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 203 Push the car to activate walk away braking. When braking activates and reverse buzzer sounds, the reading should be 48 volts. If the reading is zero volts, check the continuity of the green/white wire. if the continuity is good, replace the speed controller. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-41...
  • Page 204 If neither of these conditions are present, test the Motor Speed Sensor. See Motor Speed Sensor on page 12-29. If the Motor Speed Sensor is operational, replace the walk away braking relay. TEST PROCEDURE 18 – Charge Indicator Light See General Warnings on page 1-1. Page 12-42 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 205 Pin 1 – Yellow/Black Pin 4 – White/Black Pin 2 – Red/White Pin 3 – Open (No wire) 2786 Figure 12-21 4-Pin Connector If necessary, see Testing Basics on page 12-14. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12-43...
  • Page 206 If pin 4 has no voltage, the controllers LIN (Local Interconnect bus) may have failed. The vehicle can be driven if it is not used with Guardian or Visage and will not show any symptoms. Otherwise, Guardian or Visage will disable the vehicle until communication is restored. Page 12-44 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 207: Section 13 - Electrical Components: Iq Plus Electric Vehicles

    Refer to the wiring diagram to connect the wires to the key switch terminals. See Wiring Diagrams, Section 12, Page 12-4. Install instrument panel. See Instrument Panel Installation on page 4-10. Connect the batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 13-1...
  • Page 208 ELECTRICAL COMPONENTS: IQ PLUS Key Switch ELECTRIC VEHICLES Figure 13-1 Key Switch Page 13-2 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 209: Forward/Reverse Rocker Switch

    • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. RUN/TOW SWITCH See General Warnings on page 1-1. TESTING THE Run/Tow SWITCH 2017 Carryall 500 and 700 Maintenance and Service Manual Page 13-3...

  • Page 210: Run/Tow Switch Removal

    Insert the circuit breaker and metal nut (2) into the bracket (3). Replace the plactic nut (1) on the circuit breaker. Connect the batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Page 13-4 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 211 ELECTRICAL COMPONENTS: IQ PLUS ELECTRIC VEHICLES Circuit Breaker Figure 13-2 Circuit Breaker 2017 Carryall 500 and 700 Maintenance and Service Manual Page 13-5...

  • Page 212: Motor Controller Output Regulator (Mcor)

    Align the two tabs of the MCOR (2) with the slots in the plastic housing (4) on the chassis (Figure 13-3, Page 13-6). Insert the MCOR into the plastic housing (4) until the tabs engage. See following NOTE. Page 13-6 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 213: Reverse Buzzer

    Press the speed controller cover onto the component mounting plate over the speed controller and other electrical components. Install the three push rivets (5) (Figure 13-5, Page 13-10). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 13-7...

  • Page 214: Solenoid

    Install the blue/white and light blue wires onto the small terminals of the solenoid (Figure 13-4, Page 13-8). Install speed controller cover. See See Installing the Speed Controller Cover on page 13-7. Connect the batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Page 13-8 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 215: Speed Controller

    REVERSE position. The reverse buzzer will sound as a warning when the Forward/Reverse switch is in REVERSE. – Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 13-9...
  • Page 216 ELECTRICAL COMPONENTS: IQ PLUS Speed Controller ELECTRIC VEHICLES 2998 Figure 13-5 Speed Controller Page 13-10 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 217: Charge Indicator Light

    Connect wires to the warning light. Install the instrument panel. See Instrument Panel Installation on page 4-10. Connect the batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 13-11...
  • Page 218 ELECTRICAL COMPONENTS: IQ PLUS Charge Indicator Light ELECTRIC VEHICLES Pagination Page Page 13-12 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 219: Section 14 - Batteries: Iq Plus Electric Vehicles

    The electric vehicle battery is a deep-cycle battery, and the automotive battery is a “starting, lighting, and ignition” (SLI) battery. They should never be substituted for one another. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 14-1...

  • Page 220: Battery Testing Basics - 6 Volt

    BATTERY CELL NUMBERING Cell 1 (Cell with Positive Post Cell 2 (Cell in center of battery) Cell 3 (Cell with Negative Post) 2947 Figure 14-1 Battery Cell Numbering – 6 Volt Page 14-2 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 221: Battery Testing - 6 Volt

    Regrouping is now Club Car’s standard battery replacement method. Regrouping is the practice of placing batteries of similar condition together in one vehicle. For example, if there was an issue with the batteries in two cars and the battery test indicated three failed batteries in each car, after removing the failed batteries, there will be six good batteries remaining.
  • Page 222 Battery Regrouping BATTERIES: IQ PLUS ELECTRIC VEHICLES 3104 Figure 14-2 Battery Regrouping Process Flow Page 14-4 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 223: Battery Replacement

    See Connecting the Batteries – Electric Vehicles on page 1-4. Give the batteries a full charge prior to operation. This ensures all the batteries are fully charged and the cells are equalized prior to use. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 14-5...

  • Page 224: Battery Care

    See General Warnings on page 1-1. WATER QUALITY Water purity is the most important factor in the performance and life span of the vehicle batteries. Club Car is, therefore, placing increased importance on battery water quality. Outlined below are four battery watering procedures, grouped into two categories: Preferred and Alternate methods.

  • Page 225: Deionizer

    Replace filter immediately if the red light comes ON indicating service is required. The following replacement filter is available from Club Car Service Parts: — Use filter P/N 104005901 for Deionizer Systems P/N's 105166801, 104006001, and AM10974.

  • Page 226: Battery Care - Vehicles Equipped With The Single-Point Watering System (Spws)

    • The watering interval must adequately maintain the electrolyte level above the top of the plates (Figure 14-3, Page 14-10). • Water the batteries only AFTER charging. NOTE: Bottled distilled water, with the hand pump, CC PN 104006101, is recommended for private consumer SPWS applications. Page 14-8 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 227: Battery Care - Vehicles Without The Single-Point Watering System (Spws)

    • Do not overfill the batteries. NOTE: A battery watering gun or bottle (CC P/N AM10818) is available from your authorized Club Car dealer. The battery hold-downs should be tight enough so that the batteries do not move while the vehicle is in motion, but not so tight as to crack or buckle the battery case.

  • Page 228: Self-Discharge

    For best results, use a battery watering gun to add water to batteries. Check the electrolyte level more frequently in hot weather or when batteries are old. Page 14-10 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 229: Vibration Damage

    A deionizer for vehicles with SPWS, Club Car Part Number 105166801 is available from Service Parts (DC powered water quality indicator light). Replacement cartridge: 104005901. Bottled distilled water, with hand pump, Club Car Part Number 104006101, is recommended for private consumer applications.
  • Page 230 Locate the battery fill coupling (9) on the driver side of the battery compartment, remove the dust cover (10) from the male connector (Figure 14-6), and connect the hose-end assembly (3) (Figure 14-7). The water flow will begin immediately. Page 14-12 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 231: Battery Storage

    NOTE: When vehicles are being rotated, the CDT (Controller Diagnostic Tool) can be a very helpful service tool. Monitoring the value of the Odometer or Amp-Hours with the CDT simplifies vehicle usage scheduling. See Monitor Menu, Section 11, Page 11-10. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 14-13...

  • Page 232: Deep-Discharge

    50 to 70 times. If they are excessively discharged early in their life, their effective service life will be shortened. It is advisable to limit the use of any vehicle with new batteries for at least the first four weeks and then gradually increase their range. Page 14-14 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 233: Section 15 - Quiq High Frequency Charger

    The enclosure of the charger has been tested successfully to EN60529, meeting IP66. The AC supply inlet is rated to IP20, which is suitable for indoor use only. Keep all AC connections clean and dry. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 15-1...

  • Page 234: How To Identify Charge Algorithm Number

    Disconnect the AC cord from the power outlet. Connect the DC connector. Battery Charger Algorithms CHARGER MODEL (PART NUMBER) ALGORITHM BATTERY TYPE 912–4854–04 algorithm # 72 912–4854–04 algorithm # 3 Trojan Page 15-2 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 235: How To Change The Algorithm

    14 GA. BLACK To Main 6 GA. RED Vehicle Harness Gray 14 GA. RED Connector Solenoid AC Cord ONBOARD BATTERIES CHARGER – Fuse 6 GA. BLACK 2979 Figure 15-3 Charge Circuit 2017 Carryall 500 and 700 Maintenance and Service Manual Page 15-3...

  • Page 236: Onboard Charger Operation

    – Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the battery in accordance with all environmental laws or return to an authorized Club Car dealer. Frozen batteries can explode.
  • Page 237 – Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the vehicle or battery charger. – Use insulated tools when working near batteries or electrical connections. Use extreme caution to avoid shorting of components or wiring. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 15-5...

  • Page 238: Charger Displays

    Bulk charge phase complete, 80% charged. In Absorption phase. (Amber) With no battery connecte, indicates algorithm # selected by number of Flashing: flashes. With battery connected, indicates battery being charged. TABLE CONTINUED ON NEXT PAGE Page 15-6 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 239 Solid Red = Charger Hardware Failure; requires charger to be replaced Fault (Red) Flashing: Flashing Red = Charge Cycle Caution; AC Voltage, DC Voltage, Ambient Temperature, Charge Cycle Timers 2017 Carryall 500 and 700 Maintenance and Service Manual Page 15-7...

  • Page 240: Ac Power Connection

    Vehicles should be restricted to 40 to 50 amp hours of discharge between charges until the batteries have been properly seasoned (20 to 50 charge cycles). For maximum battery life, Club Car recommends that electric vehicles always be recharged after 40 to 50 amp hours of discharge or each night in order to avoid deep discharging the batteries.

  • Page 241: Maintenance

    Any charger not functioning correctly should be removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service WARNING •...

  • Page 242: Troubleshooting

    Reset charger (interrupt AC power for 15 seconds). Reset charger (interrupt AC power for 15 Charger Internal Fault seconds). Return to qualified service depot if fault persists. Page 15-10 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 243: Test Procedures

    7.0 volts and not within 0.5 volts of those batteries above 7.0 volts, replace battery. If readings are below 7.0 volts but within 0.5 volts of each other, the batteries are old. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 15-11...

  • Page 244: Charger Repairs

    Remove the wire ties securing the connector to the charger P-clip. Disconnect the all connectors from the charger AC and DC connector. Remove four lock nuts (5) securing charger to charger mounting plate. Page 15-12 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 245: Onboard Charger Installation

    Connect the AC and DC connector. Connect 8-pin grey connector. Install wire ties to secure connectors to the charger P-clip. Connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 15-13...
  • Page 246 Onboard Charger Removal And Installation QUIQ HIGH FREQUENCY CHARGER Pagination Page Page 15-14 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 247: Section 16 - Motor (Model Da5-4006): Electric Vehicles

    The IQ Plus vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. This 3.7 horsepower motor is designed for use on IQ Plus vehicles only. Club Car recommends that motors requiring major repair be sent to a qualified motor repair shop; however, there are many relatively simple tasks that can be performed by a technician with general knowledge and experience in electric motor repair.

  • Page 248: Motor Removal

    Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor. When not performing a test or service procedure that requires movement of the wheels, lock the brakes. Page 16-2 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 249 • Do not position fingers under motor when sliding motor off of the input shaft in step 9. Fingers may get pinched when motor disengages. Carefully slide the motor away from the transaxle until the motor spline disengages the input shaft and remove the motor from the vehicle. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 16-3...

  • Page 250: Motor Disassembly

    Inspect the speed sensor magnet. See Speed Sensor Magnet Inspection on page 16-9. Figure 16-6 Brush Springs Positioning Figure 16-7 Armature Removal Orient the motor so that the splined end of the armature is facing down. Page 16-4 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 251 Remove the retaining ring that secures the bearing in the end cap (Figure 16-9, Page 16-6). 13.2. Use an arbor press to remove the bearing from the end cap. Inspect the bearing for wear and damage. See Bearing Inspection on page 16-9. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 16-5...
  • Page 252 MOTOR (MODEL DA5-4006): ELECTRIC Motor Disassembly VEHICLES Figure 16-8 Brush Rigging Removal Figure 16-9 Retaining Ring Removal Page 16-6 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 253: Motor Component Testing And Inspection

    With a multimeter set to 200 ohms, place one probe on the commutator (1) and the other on the armature core (2). The multimeter should indicate no continuity (Figure 16-10, Page 16-8). If the reading is incorrect, replace the armature. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 16-7...

  • Page 254: Motor Frame And Field Windings Inspection

    Refer to Motor Assembly on page 16-11 for brush installation. When replacing brushes, replace all four brushes. Never replace only two. Page 16-8 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 255 Figure 16-11 Brush Spring Tension Test Speed Sensor Magnet Inspection Inspect the speed sensor magnet (12) for rust, wear, and cracks (Figure 16-13, Page 16-10). Replace the magnet if necessary. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 16-9...
  • Page 256 MOTOR (MODEL DA5-4006): ELECTRIC Motor Component Testing and Inspection VEHICLES Figure 16-13 Motor Page 16-10 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 257: Reconditioning The Motor

    Secure the brush rigging to the end cap with four bolts. Tighten the bolts to 25 in·lb (2.8 N·m). 2.5. One at a time, push the brushes back until they are completely retracted into their mounting slots (Figure 16-14, Page 16-12). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 16-11...
  • Page 258 (Figure 16-16, Page 16-13). Tighten both screws (2 and 5) to 20 in·lb (2.2 N·m). Make sure the armature turns freely. If it does not turn freely, disassemble the motor to find the problem. Page 16-12 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 259: Motor Installation

    2.5. Use a flat screwdriver to clean the grease out of one of the grooves and allow air to escape when the motor is pushed onto the input shaft. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 16-13...
  • Page 260 Secure the white, orange, green, and blue wires with a wire tie so that none of the motor wires will scrub the motor or transaxle when the vehicle is in operation. 3.10. Connect the three-pin speed sensor plug to the vehicle wire harness. Page 16-14 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 261 REVERSE position. The reverse buzzer will sound as a warning when the Forward/Reverse switch is in REVERSE. • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 16-15...
  • Page 262 MOTOR (MODEL DA5-4006): ELECTRIC Motor Installation VEHICLES Viewed From Driver Side Figure 16-21 Motor Tightening Sequence Page 16-16 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 263: Section 17 - Transaxle: Electric Vehicles

    6.2. Use a press to separate the axle oil seal (15) from the adapter ring (39) (Figure 17-3, Page 17-2). Retain the adapter ring and discard the oil seal. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 17-1...
  • Page 264 Figure 17-1 Remove Internal Retaining Ring Figure 17-2 Axle Seal and Adapter Ring Removal A. Adapter Ring Lip Figure 17-3 Axle Seal and Adapter Ring Figure 17-4 Axle Seal and Adapter Ring Installation Page 17-2 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 265 TRANSAXLE: ELECTRIC VEHICLES Axle Bearing and Shaft Figure 17-5 Transaxle – Type G 2017 Carryall 500 and 700 Maintenance and Service Manual Page 17-3...

  • Page 266: Axle Bearing

    Do not remove the axle bearing (5) from a Type G transaxle. If bearing is worn or damaged, the entire axle assembly (1 or 2) must be replaced (Figure 17-5, Page 17-3). Page 17-4 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 267: Transaxle

    Remove the bow tie pins (1), brake cable clevis pins (2), and cable retaining E-clips (3). Disconnect the brake cables (4) (Figure 17-7, Page 17-5). 2600-30000-10369 Figure 17-7 Brake Cables Figure 17-6 Vehicle Supported on Jack Stands 2017 Carryall 500 and 700 Maintenance and Service Manual Page 17-5...
  • Page 268 Page 17-7) mounting the motor to the transaxle. See following CAUTION. CAUTION • Do not position fingers under motor when sliding motor off of the input shaft. Fingers may get pinched when motor disengages. CAUTION CONTINUED ON NEXT PAGE Page 17-6 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 269 NOTE: Recycle or dispose of used oil or lubricant in accordance with local, state, and federal regulations. Remove the brake assemblies if required. See Wheel Brake Assemblies Section. Appearance of motor may be different from the motor shown above. Figure 17-12 Motor Positioning Bolt 2017 Carryall 500 and 700 Maintenance and Service Manual Page 17-7...

  • Page 270: Transaxle Disassembly, Inspection, And Assembly

    17-5, Page 17-3). See also Figure 17-13, Page 17-8. Press the bearing (18) off the intermediate gear assembly (Figure 17-5, Page 17-3). 1. Press Ram 2. Arbor Figure 17-13 Intermediate Gear Assembly Page 17-8 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 271 • Do not reuse bearings after removing them. Replace bearings with new ones. Inspect parts for wear or damage. Any worn or damaged parts should be replaced. See following NOTE. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 17-9...

  • Page 272: Transaxle Assembly

    Place a 1/4 to 3/8-inch (6 to 10 mm) diameter rod against the retaining ring and tap lightly at four or five locations to ensure it is properly seated. See following WARNING. Page 17-10 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 273 22 ounces of SAE 30 API Class SE, SF, or SG oil (a higher grade may also be used). Install and tighten the level indicator plug (21) to 23 ft·lb (31 N·m). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 17-11...

  • Page 274: Transaxle Installation

    REVERSE position. The reverse buzzer will sound as a warning when the Forward/Reverse switch is in REVERSE. • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. Page 17-12 2017 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 275: Section 18 - Troubleshooting And Electrical System: Pedal-Start Gas Vehicle

    • Below the Battery: The battery, starter/generator, voltage regulator and main wire harness are all grounded to the chassis on the frame rail below the battery. • In Front of Engine: The engine is grounded to the chassis cross-member with an un-insulated, braided wire. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-1...

  • Page 276: Features Of The Electronic Fuel Injection (Efi) System

    Failure Mode Table – After Ignition Has Been In ON Position (i.e. During Use of Vehicle) DISPLAY MODE CONDITION LAMP CONTROL Blink Code No Failure Step 1: Lamp OFF Detect Failure Step 1: Lamp OFF Four Seconds Step 2: Display Blink Code Page 18-2 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 277 NOTE: If codes 22, 23, and 41 blink in-sequence, the gray plug is disconnected from the ECU. If no codes blink, the black plug is disconnected from the ECU. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-3...

  • Page 278: Gasoline Powertrain

    Fuel pump malfunction; fuel pressure to Section 23 — Fuel System: Gasoline Vehicles throttle body too low TABLE CONTINUED ON NEXT PAGE Page 18-4 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 279 Section 22 — Engine (Subaru EX40) Restricted fuel flow Section 23 — Fuel System: Gasoline Vehicles Torque converter is not backshifting properly Section 25 — Clutches: Gasoline Vehicles TABLE CONTINUED ON NEXT PAGE 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-5...
  • Page 280 Starter/generator belt is loose or slipping page 20-13 Voltage regulator failed Test Procedure 13 – Voltage Regulator Battery failed Test Procedure 1 – Battery TABLE CONTINUED ON NEXT PAGE Page 18-6 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 281 Fuel mixture is too lean; check EFI Section 23 — Fuel System: Gasoline Vehicles Throttle stop screw out of adjustment at Section 23 — Fuel System: Gasoline Vehicles governor arm 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-7...
  • Page 282 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM: PEDAL-START GAS VEHICLE WIRING DIAGRAMS WD1050077_DGM_D-L Figure 18-1 Wiring Diagram for Pedal-Start Gasoline Vehicle Page 18-8 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 283 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Wiring Diagrams WD1050077_DGM_D-R Figure 18-2 Wiring Diagram for Pedal-Start Gasoline Vehicle – Continued 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-9...
  • Page 284 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM: PEDAL-START GAS VEHICLE WD1050951_DGM_A Figure 18-3 Wiring Diagram – Instrument Panel and FNR Shifter Page 18-10 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 285 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Wiring Diagrams WD1050081_DGM_D Figure 18-4 Wiring Diagram – EFI and Engine 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-11...
  • Page 286 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM: PEDAL-START GAS VEHICLE 3022 Figure 18-5 Sonic Weld and Diode Locations (Approximate) – CA500/550/Cafe Express Page 18-12 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 287 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Wiring Diagrams 3020 Figure 18-6 Sonic Weld and Diode Locations (Approximate) – CA700 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-13...
  • Page 288 Use the appropriate test procedure to correct the electrical problem. See Test Procedures on page 18-15. For a complete wiring diagram, see Wiring Diagram for Pedal-Start Gasoline Vehicle on page 18-8 or Wiring Diagram for Key-Start Gasoline Vehicle on page 19-2. Page 18-14 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 289 • When testing resistance or continuity, turn off power to the circuit being measured and discharge any capacitor(s). The presence of voltage can cause inaccurate readings. Index of Test Procedures 1 – Battery 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-15...
  • Page 290 23 – Fuel Gauge 24 – Hour Meter 25 – Light Switch 26 – Voltage at Headlight Socket 27 – Voltage Limiter 28 – 4-Pin Connector (for Connected Car Device) Page 18-16 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 291 Read the battery voltage after the load tester has been turned ON for 15 seconds. Compare the battery’s voltage reading with the following table. Make sure you have the correct ambient temperature. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-17...
  • Page 292 8.5 V If the battery is found to be good, or if the electrical problem continues after the battery has been replaced with a good one, test the electrical circuits. Page 18-18 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 293 If only one side shows battery voltage, replace fuse. 3.4. If neither side of a fuse shows battery voltage, inspect the following locations: – Wire connections at the solenoid. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-19...
  • Page 294 5.4. If neither side of a fuse shows battery voltage, inspect the following locations: – 5-amp ATM fuse, 12-pin dash wire harness connector, key switch and sonic weld 3. Page 18-20 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 295 1. Battery Ground 2. Main Wire Harness Ground 3. Engine Ground Cable 4. Starter/Generator Ground (from A1 Terminal) 5. Voltage Regulator Ground Wire (from electrical component box) 3023 Figure 18-8 Ground Wires and Cables 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-21...
  • Page 296 TEST PROCEDURE 4 – EFI System (ECU and Sensors) See General Warnings on page 1-1. WARNING • This procedure involves testing voltage, resistance and continuity. If necessary, see Testing Basics on page 18-15. Page 18-22 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 297 Battery Voltage Voltage: ECU Black Pin 1 (Brown) and ECU Black Pin Black Fuel Pump Input (after pump stops Key ON 10 (Black) running) TABLE CONTINUED ON NEXT PAGE 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-23...
  • Page 298 Continuity: ECU Black Pin 18 (Black) and Ground Meter should beep Key OFF Ground for ECU Black Voltage: ECU Black Pin 18 (Black) and Battery (+) Housing –Battery Voltage Key OFF Terminal Page 18-24 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 299 – The brown/white wire should show battery voltage passing through the key switch to sonic weld 3, the 5-amp fuse, the solenoid, and the 4-pin connected car plug. If it does not show battery voltage, the switch has failed OPEN and must be replaced. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-25...
  • Page 300 NEUTRAL, and the accelerator pedal in the UP position, the reading should be no continuity. With the accelerator pedal pressed, the reading should be continuity. If readings are incorrect, replace the switch. Page 18-26 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 301 – With accelerator pedal pressed: The solenoid should click and the meter should read battery voltage. 5.3. If the readings are incorrect, replace solenoid. See Solenoid Removal, Section 20, Page 20-20. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-27...
  • Page 302 5.2. does work as stated and the MAINTENANCE/OPERATE modes still do not work: – Check the limit switches. – Check continuity of the wires involved. Page 18-28 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 303 Figure 18-13 Neutral Lockout Limit Switch Test If switch does not work as stated in previous step, replace switch. See Neutral Lockout Limit Switch Removal, Section 20, Page 20-19. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-29...
  • Page 304 • Tag the starter/generator wires for identification before disconnecting. • Remove starter/generator wire from one of the “A” terminals and one of the “F” terminals if testing while starter/generator is in vehicle. Page 18-30 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 305 See Starter/Generator Removal on page 20-1. Ensure that wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-31...
  • Page 306 Removal on page 20-15. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. Voltage Regulator 2. Solenoid 3. Battery 4. 20 VDC Setting Figure 18-16 Voltage Regulator Test Page 18-32 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 307 (Figure 18-17, Page 18-33). Reconnect wires to limit switch. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 200 Ohm Setting 2. Lever Up Figure 18-17 Kill Limit Switch Test 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-33...
  • Page 308 The gap should be set at 0.024 to 0.028 in. (0.6 to 0.7 mm). If the gap is correct, replace the spark plug with a new part and test the engine for proper operation. 1. Ignition Gap Test Tool 2. Chassis Figure 18-18 Ignition Spark Test Page 18-34 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 309 White Signal Wire to Ground 9 to 11 kOhms White Signal Wire to Spark 17 to 20 kOhms Plug Cap Spark Plug Cap to Ground 8 to 13 kOhms 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-35...
  • Page 310 If battery voltage is present, use a test lead to ground the black wire terminal of low oil warning light. Light should illuminate. If not, replace low oil warning light. Page 18-36 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 311 If all of the test results are good and the voltage reading is zero, there may be a broken or damaged 6-gauge white wire from the solenoid to the starter/generator. See Starter/Generator (Starter Function) on page 18-30. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-37...
  • Page 312 If necessary, see Testing Basics on page 18-15. Disconnect battery. See Disconnecting the Battery-Gasoline Vehicles on page 1-5. Disconnect the 5-pin connector from the top of the fuel pump module. Page 18-38 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 313 If the readings are correct according to the position of the float, but give an incorrect reading on the fuel gauge/hour meter, test the fuel gauge/hour meter. See Fuel Gauge on page 18-40. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-39...
  • Page 314 (+) probe on the (4) terminal of the fuel gauge/hour meter (Figure 18-22, Page 18-41). The voltage reading should be approximately 4.94 volts. If the reading is incorrect, replace the fuel gauge/hour meter. Page 18-40 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 315 If the hour meter still does not function after the low oil warning light, oil pressure switch, and all of the appropriate wires have been checked for continuity, replace the fuel gauge/hour meter. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-41...
  • Page 316 If there is no voltage reading, check associated wiring, light switch and 10-amp fuse (located in electrical component box). See Test Procedure 2 – Fuses on page 18-19. See Test Procedure 25 – Light Switch on page 18-42. Page 18-42 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 317 Conducts Current and Shows Continuity 4. Good Diode (Probe Scenario B) - No Continuity (Infinite) 5. Bad Diode - Meter Beeps In Either Direction (Probe Scenarios A and B) 3032 Figure 18-24 Voltage Limiter Test 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18-43...
  • Page 318 If pin 4 has no voltage, the ECU LIN (Local Interconnect bus) may have failed. The vehicle can be driven if it is not used with Guardian or Visage and will not show any symptoms. Otherwise, Guardian or Visage will disable the vehicle until communication is restored. Page 18-44 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 319 • Forward/Reverse Shifter: Is not linked to the neutral lockout limit switch on the transaxle because this switch is omitted for key-start applications. In addition to troubleshooting, this section contains general information on the key-start electrical system and the circuits of the key-start electrical system. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 19-1...
  • Page 320 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM: KEY-START GAS VEHICLE WIRING DIAGRAMS WD1050080_DGM_B-L Figure 19-1 Wiring Diagram for Key-Start Gasoline Vehicle Page 19-2 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 321 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START GAS VEHICLE Wiring Diagrams WD1050080_DGM_B-R Figure 19-2 Wiring Diagram for Key-Start Gasoline Vehicle – Continued 2017 Carryall 500 and 700 Maintenance and Service Manual Page 19-3...
  • Page 322 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM: KEY-START GAS VEHICLE WD1050951_DGM_A Figure 19-3 Wiring Diagram – Instrument Panel and FNR Shifter Page 19-4 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 323 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START GAS VEHICLE Wiring Diagrams WD1050081_DGM_D Figure 19-4 Wiring Diagram – EFI and Engine 2017 Carryall 500 and 700 Maintenance and Service Manual Page 19-5...
  • Page 324 In key-start vehicles, pin 12 of the ECU black 18-pin connector is not used. Pin 12 provides Foot Input to the ECU in pedal-start applications only. See Test Procedure 4 – EFI System (ECU and Sensors) on page 18-22 for all other ECU testing. Page 19-6 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 325 – The gray wire should show battery voltage passing through the key switch to sonic weld 20 and the solenoid coil. If it does not show battery voltage, the switch has failed OPEN and must be replaced. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 19-7...
  • Page 326 – With key switch in the START position: The solenoid should click and the meter should read battery voltage. 5.3. If the readings are incorrect, replace solenoid. See Solenoid Removal, Section 21, Page 21-3. Page 19-8 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 327 5.2. does work as stated and the MAINTENANCE/OPERATE modes still do not work: – Check the fuse. – Check the limit switches. – Check continuity of the wires involved. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 19-9...
  • Page 328 If the diode tests good, reconnect the diode leads. See Charging Diode Installation, Section 21, Page 21-5. See also following WARNING. WARNING • Incorrect wiring could result in severe injury or death. WARNING CONTINUED ON NEXT PAGE Page 19-10 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 329 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START GAS VEHICLE Test Procedures WARNING • Diode and solenoid connections must have correct polarity. • Keep all persons clear of engine belts when making final connections. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 19-11...
  • Page 330 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: KEY-START GAS VEHICLE Pagination Page Page 19-12 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 331 Remove brush covers (29 and 30), terminal hardware (25), brush springs (28), and brushes (27) (Figure 20-2, Page 20-2). See following NOTE. NOTE: To clean and inspect the armature/commutator and the bearings, see Disassembly of the Starter/Generator to Service the Armature/Commutator on page 20-4. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 20-1...
  • Page 332 Using a spring scale, test brush spring tension. If any spring has a tension less than 24 ozf (0.68 kgf), replace all four springs (Figure 20-4, Page 20-3). See following CAUTION. Page 20-2 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 333 A2 terminal. Install the remaining three brush covers (29) in the openings in the commutator end cover (23) (Figure 20-2, Page 20-2). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 20-3...
  • Page 334 (P/N 1012812) to remove the pulley from the shaft. Remove the internal retaining ring (32) to release the bearing (35) and armature (33) from the output end cover (36). (Figure 20-6, Page 20-5). Page 20-4 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 335 Do not remove the bearings unless they are to be replaced. Figure 20-7 Bearing Play Inspection 2017 Carryall 500 and 700 Maintenance and Service Manual Page 20-5...
  • Page 336 • Worn, burned, or glazed commutator • Loose or raised commutator bars • Bruised or damaged armature core laminations • Worn armature bearing or shaft • Dirty or oily commutator Page 20-6 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 337 Using a micrometer, measure the outside diameter at two points along the commutator. If the commutator outside diameter is less than 1.535 inches (39 mm), replace the armature and bearings (Figure 20-10, Page 20-8). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 20-7...
  • Page 338 Using a multimeter set on 200 ohms, place the positive (+) probe on the commutator bars and the negative (–) probe on the armature core. The reading should be no continuity. If the reading is incorrect, replace the armature and the two bearings (Figure 20-11, Page 20-9). Page 20-8 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 339 0.006 to 0.01 ohms Generator field coil resistance 4.5 to 5.5 ohms STARTER/GENERATOR ASSEMBLY Slide the bearing retainer (32) onto the output end of the armature shaft (33) (Figure 20-6, Page 20-5). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 20-9...
  • Page 340 NOTE: Secure bottom nut of terminal with wrench before tightening top nut. 9.3. Form wire against starter housing as shown and allow terminal at F1 to self-orient. Tighten nut to 44 in·lb (5 N·m). See preceding NOTE. Page 20-10 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 341 90° 1. Jumper Wire 2. 1 inch (25.4 mm) Minimum Radius 3. Jumper Wire Not Allowed in this Area. 2687 Figure 20-12 A1 to F1 Terminal Jumper Wire Routing 2017 Carryall 500 and 700 Maintenance and Service Manual Page 20-11...
  • Page 342 48 in·lb (5.4 N·m). Connect battery and spark plug wire(s). See Connecting the Battery-Gasoline Vehicles on page 1-5. Page 20-12 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 343 Disconnect battery and spark plug wire(s). See Disconnecting the Battery-Gasoline Vehicles on page 1-5. Access engine compartment. – Remove seat and rear access panel (if equipped). – Raise cargo bed (if equipped). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 20-13...
  • Page 344 6.3. Remove pry bar. A. Remove 3/8 to 1/2 inch (9.5 to 12.7 mm) 1. Before 2. After 2726 Figure 20-17 Belt Tension Tool Modification (If Necessary) Tension belt. Page 20-14 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 345 (7) from the (NO) terminal of the kill limit switch and at the battery frame ground (Figure 20-18, Page 20-16). Remove the voltage regulator mounting screw (8) and remove the voltage regulator (9). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 20-15...
  • Page 346 Place Forward/Reverse handle in NEUTRAL and place the neutral lockout switch in the MAINTENANCE position. Start the engine and check regulator for proper functioning as described in the voltage regulator test procedure. See Voltage Regulator on page 18-32. Page 20-16 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 347 Install gray connector to the gray port on the ECU. See preceding WARNING. Install black connector to the black port on the ECU. Connect the battery. See Connecting the Battery-Gasoline Vehicles on page 1-5. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 20-17...
  • Page 348 Refer to the wiring diagram to connect the wires to the key switch terminals. See Wiring Diagrams, Section 18, Page 18-8. Install instrument panel. See Instrument Panel Installation on page 4-10. Connect the battery and spark plug. 2931 Figure 20-19 Key Switch Page 20-18 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 349 Install the limit switch (1) with washers (4) and nuts (3) and tighten to 5 in·lb (0.6 N·m). Move the Forward/Reverse handle to make sure the switch actuates. See following CAUTION. CAUTION • Do not overtighten the retaining nuts. If the nuts are overtightened, limit switches could be damaged. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 20-19...
  • Page 350 See General Warnings on page 1-1. ATC-style fuses are located inside the electrical component box near the battery. ATM-style fuses are located on the main wire harness in front of the engine. Page 20-20 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 351 ATC Fuse Only: Install the snap-on electrical box cover by pressing down firmly on all corners and install the screw, tightening to 18 in·lb (2 N·m). ATM Fuse Only: Install the fuse holder cover. Connect battery. See Connecting the Battery-Gasoline Vehicles on page 1-5. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 20-21...
  • Page 352 Install electrical component box cover (1) (Figure 20-20, Page 20-23). Be sure to press down firmly all corners. Install screw (20) and tighten to 18 in·lb (2 N·m). Connect battery and spark plug wire(s). See Connecting the Battery-Gasoline Vehicles on page 1-5. Page 20-22 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 353 Connect battery and spark plug wire(s). See Connecting the Battery-Gasoline Vehicles on page 1-5. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 20-23...
  • Page 354 ELECTRICAL COMPONENTS: PEDAL-START Reverse Warning Buzzer GAS VEHICLE 3003 Figure 20-21 Instrument Panel Switches Page 20-24 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 355 Connect battery and spark plug wire(s). See Connecting the Battery-Gasoline Vehicles on page 1-5. Turn the key switch to the ON position. Shift the Forward/Reverse handle to the REVERSE position. The buzzer should sound. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 20-25...
  • Page 356 ELECTRICAL COMPONENTS: PEDAL-START Reverse Buzzer Limit Switch GAS VEHICLE 3001 Figure 20-22 Forward/Reverse Assembly Switches Page 20-26 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 357 Remove the instrument panel. See Instrument Panel Removal, Section 4, Page 4-10. Disconnect the wires from the fuel gauge/hour meter (6). Do not allow wires to touch. (Figure 20-21, Page 20-24). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 20-27...
  • Page 358 See Oil Level Sensor Removal on page 22-12. OIL LEVEL SENSOR INSTALLATION See Oil Level Sensor Installation on page 22-12. VOLTAGE LIMITER See General Warnings on page 1-1. TESTING THE VOLTAGE LIMITER Page 20-28 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 359 Install the cowl. See Cowl Installation, Section 4, Page 4-5. Connect battery and spark plug wire(s). See Connecting the Battery-Gasoline Vehicles on page 1-5. 3002 Figure 20-23 Voltage Limiter 2017 Carryall 500 and 700 Maintenance and Service Manual Page 20-29...
  • Page 360 Install the front fenders. See Front Bumper and Side Fender Installation, Section 4, Page 4-9. Install the cowl. See Cowl Installation, Section 4, Page 4-5. Connect the batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Page 20-30 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 361 Connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. Install front fenders. See Front Bumper and Side Fender Installation, Section 4, Page 4-9. Install cowl. See Cowl Installation, Section 4, Page 4-5. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 20-31...
  • Page 362 ELECTRICAL COMPONENTS: PEDAL-START Headlights GAS VEHICLE 2993 Figure 20-24 Headlight Assembly Page 20-32 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 363 To keep the battery in good operating condition, remove any corrosion immediately. Post connections should be clean and tight. Any frayed or worn wires should be replaced. After all cables have been connected and properly 2017 Carryall 500 and 700 Maintenance and Service Manual Page 20-33...
  • Page 364 The acid that is lost reduces the capacity of the battery and cannot be replaced. Page 20-34 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 365 N·m). A loose battery clamp may allow the battery to become damaged from vibration or jarring. Connect battery and spark plug wire(s). See Connecting the Battery-Gasoline Vehicles on page 1-5. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 20-35...
  • Page 366 NOTE: Verify that all cables (fuel tank, engine, battery, starter/generator and voltage regulator) are connected securely. TESTING THE GROUND CABLES See Test Procedure 3 – Ground Cables on page 18-21. Page 20-36 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 367 NOTE: Take care to prevent key switch terminals and wires from touching the metal frame around the dash. Disconnect the wires from the key switch. Do not allow wires to touch. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 21-1...
  • Page 368 Refer to the wiring diagram to connect the wires to the key switch terminals. See Wiring Diagrams, Section 19, Page 19-2. Install instrument panel. See Instrument Panel Installation on page 4-10. Connect the battery and spark plug. 2931 Figure 21-1 Key Switch Page 21-2 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 369 Connect the 4-gauge red wire from the positive (+) battery terminal, the 10-gauge red wire and 16-gauge orange wire from the fuse blocks, and the 10-gauge red wire from the charging diode to the other large post on the solenoid. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 21-3...
  • Page 370 (9) from the voltage regulator and the white wire (10) from the starter/generator. Remove the nut (11), the charging diode (6), and thermal transfer pad (12) from the chassis. Discard transfer pad (12). Page 21-4 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 371 Connect the 10-gauge red wire (4) from the charging diode to the solenoid post with the fuse block and battery red wires (7 and 8). Tighten locknut (3) to 55 in·lb (6.2 N·m) (Figure 21-2, Page 21-5). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 21-5...
  • Page 372 Replace the electrical component box cover (2) and screw (1) and tighten the screw to 18 in·lb (2.0 N·m). Connect battery and spark plug wire(s). See Connecting the Battery-Gasoline Vehicles on page 1-5. Page 21-6 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 373 Anyone attempting engine service should have knowledge and experience in small engine service and repair. ENGINE ROTATION When turning the crankshaft by hand, always turn it counterclockwise as viewed from the clutch side of the engine. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 22-1...
  • Page 374 Remove the oil level dipstick from the oil filler tube, and wipe oil off dipstick (Figure 22-1). See following CAUTION. CAUTION • Do not remove dipstick while engine is running. Page 22-2 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 375 Access the engine compartment and place the Maintenance/Operate switch in the MAINTENANCE position. Disconnect battery and spark plug wire. See Disconnecting the Battery-Gasoline Vehicles on page 1-5. Position a pan designed for oil changes under the drain plug (1) (Figure 22-2). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 22-3...
  • Page 376 The engine requires 40.5 fl-oz (1.2 L) of oil per change. 10W-30 or 5W-30 grade SE or higher is recommended. Refer to oil viscosity guidelines for selection of oil grade (Figure 22-3). Replace the dipstick. Page 22-4 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 377 • Remove spark plug wire to avoid accidental start up of the engine when servicing vehicle. To avoid ignition of fuel and serious personal injury or death, never try to start the engine with plug removed from engine. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 22-5...
  • Page 378 Oil laden air in the crankcase passes through the reed valve and expands into the rocker chamber. In the rocker chamber most oil separates from the air and drains back to the crankcase. The air passes through a tube and vents to the intake manifold. Page 22-6 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 379 1. Feeler Gauge 2. Lock Nut 3. Adjuster Screw 4. Rocker Arm cylinder head surface. (exhaust) 5. Rocker Arm (intake) 3034 3035 Figure 22-5 Top Dead Center (TDC) – EX40 Engine Figure 22-6 Setting Valve Clearance – EX40 Engine 2017 Carryall 500 and 700 Maintenance and Service Manual Page 22-7...
  • Page 380 Figure 22-7 EX40 Engine and Mounting Brackets CAUTION • Before removal and disassembly, clean the engine. Disconnect battery and spark plug wire(s). See Disconnecting the Battery-Gasoline Vehicles on page 1-5. Page 22-8 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 381 Gasoline Vehicles, Section 23, Page 23-1. If equipped, install air deflector on top of engine. Secure accelerator cable and governor cable P-clamps to engine. Tighten P-clamp bolts to 36 in·lb (4.0 N·m). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 22-9...
  • Page 382 See General Warnings on page 1-1. 3037 Figure 22-8 Flywheel, Fan and Fan Housing – EX40 FLYWHEEL REMOVAL Remove screws (1) and fan housing (2) (Figure 22-8, Page 22-10). Page 22-10 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 383 • Be careful not to damage the fan blades. Use a strap wrench to hold flywheel. Do not place screwdriver or pry bar between fan blades. Install fan housing (2) and tighten screws (1) to 90 in·lb (10 N·m) (Figure 22-8, Page 22-10). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 22-11...
  • Page 384 Install flywheel and fan shroud. See Ignition Coil Removal on page 22-13. Fill engine to proper level with correct type of oil. See Engine Oil – Gasoline Vehicle, Section 22, Page 22-2. 3038 Figure 22-11 Oil Level Sensor – EX40 Page 22-12 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 385 0.012 to 0.020 in. (0.3 to 0.5 mm) (Figure 22-13, Page 22-13). Tighten ignition coil bolts (6) to 71 in·lb (8 N·m). Connect ignition coil primary lead wire (12) to terminal (13) on coil (Figure 22-12, Page 22-13). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 22-13...
  • Page 386 Slide snubber (2) onto bracket (5) (Figure 22-14, Page 22-14). Install bracket and snubber assembly onto engine pan (1). Tighten lock nuts (4) from 20 to 25 ft·lb (27.1 to 33.9 N·m). 3039 Figure 22-14 Snubber Page 22-14 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 387 • Flow: 16 L per hour minimum @ 12-volts/36 psig (250 kPa) • Current draw: 2-amps maximum • Throttle Body Bore: 31 mm diameter • Open-loop system (i.e. oxygen sensor not used) • Separate EFI wire harness • Fail-safe function 2017 Carryall 500 and 700 Maintenance and Service Manual Page 23-1...
  • Page 388 • Unplug fuel pump module at fuel tank and crank engine for 5 seconds to start reducing fuel pressure. Pause and repeat an additional 5 seconds to allow pressure to dissipate. Page 23-2 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 389 Loosen air intake hose clamp and disconnect air intake hose. Remove two flange nuts (7) and slide air intake adapter (3), bracket (4), gaskets (8), insulator (9), and throttle body (1) off threaded studs. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 23-3...
  • Page 390 Install two flange nuts (7) and tighten to 53 to 71 in·lb (6 to 8 N·m). Connect fuel line (6) and vent hose (5). Secure with spring clamps. Connect fuel injector and MAP sensor. Page 23-4 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 391 • Repair all fuel leaks before returning the vehicle to service. If no leaks are found, place the neutral lockout switch in the OPERATE position (Figure 26-1, Page 26-1). Test drive vehicle to ensure proper operation. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 23-5...
  • Page 392 See following CAUTION. CAUTION • Improper adjustment can result in poor vehicle performance and/or damage to the engine components. 3042 Figure 23-3 Engine Control Linkages – EFI vehicles Page 23-6 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 393 • Be sure that approximately an equal number of threads are exposed at each end of the accelerator rod. Install the accelerator rod on the bell crank ball joint on the electrical component box (Figure 23-5, Page 23-7). See following CAUTION. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 23-7...
  • Page 394 Install the electrical component box cover and tighten retaining screw to 18 in·lb (2.0 N·m). Connect battery and spark plug wire(s). See Connecting the Battery-Gasoline Vehicles on page 1-5. Page 23-8 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 395 Adjust gap between governor arm (4) and throttle stop screw (7) to 0.055 in. (±0.039) (1.4 mm (±1)) as shown. Tighten stop screw jam nut (6) to 36 in·lb (4.0 N·m). Check engine RPM adjustment. See Engine RPM Adjustment on page 23-13. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 23-9...
  • Page 396 FUEL SYSTEM: GASOLINE VEHICLES A = 0.055 in. ± 0.039 (1.4 mm ± 1) 3110 3111 Figure 23-8 Governor and Accelerator Cables At Governor Figure 23-9 Throttle Stop Screw Gap Page 23-10 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 397 RPM Adjustment on page 23-13. 2.4. Install electrical component box cover and tighten screw to 18 in·lb (2.0 N·m). Connect battery and spark plug wire(s). See Connecting the Battery-Gasoline Vehicles on page 1-5. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 23-11...
  • Page 398 (360 degrees). 3047 Figure 23-11 Idle Screw CLOSED THROTTLE OR IDLE ADJUSTMENT – KEY-START VEHICLES Adjust the idle screw until idle RPM is 1200 (±25) (Figure 23-11, Page 23-12). Page 23-12 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 399 Excessive drive belt and clutch wear can also prevent proper ground speed adjustment. Check them for excessive wear. Section 25 — Clutches: Gasoline Vehicles 2017 Carryall 500 and 700 Maintenance and Service Manual Page 23-13...
  • Page 400 Air Intake System FUEL SYSTEM: GASOLINE VEHICLES AIR INTAKE SYSTEM See General Warnings on page 1-1. 3048 Figure 23-12 Air Intake System – CA 500/550/700/TRANSPORTER/Cafe Express Page 23-14 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 401 • Engine damage will occur if the air cleaner cap is not properly secured. • If air cleaner is extremely dirty, remove air cleaner from vehicle and clean thoroughly. • Use only Club Car replacement air filters. The use of other air filters could result in engine damage and void the warranty.
  • Page 402 NOTE: This EFI gasoline vehicle is equipped with SAEJ30R9 fuel hose rated for high-pressure systems. Always replace the fuel line on this vehicle with approved Club Car replacement part. Do not attempt to repair, patch or splice the fuel line.
  • Page 403 • Repair all fuel leaks before returning the vehicle to service. If no leaks are found, place the neutral lockout switch in the OPERATE position (Figure 26-1, Page 26-1). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 23-17...
  • Page 404 Lower fuel pump module (1) into fuel tank noting correct orientation marked before removal. See following NOTE and CAUTION. NOTE: If equipped with a fuel level sending unit, carefully maneuver module so as to avoid damaging the float arm mechanism. Page 23-18 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 405 • Repair all fuel leaks before returning the vehicle to service. If no leaks are found, place the neutral lockout switch in the OPERATE position (Figure 26-1, Page 26-1). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 23-19...
  • Page 406 Fuel Pump Module FUEL SYSTEM: GASOLINE VEHICLES 3052 Figure 23-15 Fuel System (Side-Fill) – Exploded View Page 23-20 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 407 SAEJ30R9 1/4 in (6.3 mm) fuel vent hose (CC P/N 102865101) and 3/16 in (4.78 mm) fuel vent hose (CC P/N 1015137). To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car P/N's 102865101, 1015137, or equivalent. FUEL TANK REMOVAL Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels, and the neutral lockout switch in the MAINTENANCE position.
  • Page 408 3/16 in (4.78 mm) fuel vent hose (CC P/N 1015137). To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car P/N's 102865101, 1015137, or equivalent. Place fuel tank (10) in vehicle.
  • Page 409 Pull hose retainer clip straight up and out of filter (14). Do not discard clip. 4.2. Pull flex hoses (12 and 13) straight out of filter inlet and outlet. Remove filter (14) from module (1) and dispose of properly. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 23-23...
  • Page 410 • If the vehicle has an all-weather enclosure installed, be sure the fuel tank is properly vented as shown in Figure 23-16. • To avoid the possibility of fire, clean up any spilled fuel before operating the vehicle. Page 23-24 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 411 See preceding CAUTION and NOTE. Replace fuel cap on tank. Ensure cap is tightened securely (tighten until it clicks). 1. Vent 2. Fuel Vent Line 3. Fuel Tank 2832 Figure 23-16 Fuel Tank 2017 Carryall 500 and 700 Maintenance and Service Manual Page 23-25...
  • Page 412 Fueling Instructions – Gasoline Vehicle FUEL SYSTEM: GASOLINE VEHICLES Pagination Page Page 23-26 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 413 Start the engine and check for exhaust leaks and proper engine operation. See following DANGER. DANGER • Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 24-1...
  • Page 414 Muffler EXHAUST SYSTEM: GASOLINE VEHICLES 3112a Figure 24-1 Exhaust System Page 24-2 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 415 Inspect the driven clutch for dirt and dust buildup on its component parts. Clean the driven clutch with water to remove any dust or dirt, then drive the vehicle and check for proper operation. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 25-1...
  • Page 416 1. Drive Clutch Hub Puller 2. Driven Clutch Cam Puller 3. Driven Clutch Cam Press Tool 4. Drive Clutch Holder Tool 5. Driven Clutch Puller Plug 6. Cam Installation Tool 7. Drive Clutch Puller 2963 Figure 25-1 Clutch Tools Page 25-2 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 417 With the belt started onto the driven clutch (1), rotate the driven clutch counterclockwise and roll the belt over the outer, moveable sheave. Connect battery and spark plug wire(s). See Connecting the Battery-Gasoline Vehicles on page 1-5. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 25-3...
  • Page 418 5. Drive Hub Assy, Drive Clutch 14. Spacer, Fixed Face Shaft 6. Ring, 0.810 in. (20.5 mm) Internal Retaining 15. Spring, Drive Clutch 7. Drive Clutch Button 16. No Item to Show Page 25-4 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 419 The weight of the powertrain will allow the centerline of the drive clutch to drop below the frame I-beam for access to the bolt securing the drive clutch. See following WARNING. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 25-5...
  • Page 420 Inspect the belt contact surfaces of the clutch sheaves for wear. If any area of a sheave contact surface has wear of 0.060 in. (1.52 mm) or more, the clutch should be replaced. Page 25-6 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 421 Remove the thrust washer (9) from the moveable sheave (13) (Figure 25-3, Page 25-4). Remove the drive buttons (3) by removing the screws (1), flat washers (2), and drive button take-up springs (4) as shown (Figure 25-8, Page 25-8). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 25-7...
  • Page 422 NOTE: Before removing, note the orientation of the wave washer (1) and secondary weight (2) on the primary weight (3) (Figure 25-10, Page 25-9). 5.3. Remove the plastic washers, weights (2 and 3) and wave washer (1) from the pin (4). Retain all parts. Page 25-8 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 423 Replace the shaft if it is worn, scratched, or damaged. Inspect the thrust washer (9) for wear. If it is worn more than 0.030 in. (0.76 mm), turn it over or replace it with a new one. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 25-9...
  • Page 424 (Figure 25-12, Page 25-10). Figure 25-12 Install White Washers Install the 1/4-20 bolts (1) and washers (2) and tighten them to 10 ft·lb (13 N·m) (Figure 25-9, Page 25-8). See following NOTE. Page 25-10 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 425 Install the drive belt as instructed. See Drive Belt Installation on page 25-3. Connect battery and spark plug wire(s). See Connecting the Battery-Gasoline Vehicles on page 1-5. Drive the vehicle and check for proper operation. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 25-11...
  • Page 426 7. Screw, #8-32 X 3/4, Socket-Head Cap 2. Washer, Driven Clutch 8. Button, Drive 3. Ring, Retaining 9. Sheave, Movable, Driven 4. Key, Driven Clutch 10. Washer, Acetal, Driven Clutch Page 25-12 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 427 (1) (CC P/N 1014508) to remove the cam (3) from the fixed sheave. Remove the spring (6) (Figure 25-14, Page 25-12). Retain the key (4). Slide the moveable sheave (9) off the fixed sheave (11). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 25-13...
  • Page 428 Press Assembly Process: 5.1.1. Place the clutch assembly in a press and position the cam press tool (CC P/N 101809101) on the cam (2) as shown (Figure 25-17, Page 25-15). Page 25-14 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 429 (Figure 25-17, Page 25-15). 5.2.5. Place the cam press hub (6) onto the cam installation bolt and thread it down onto the cam hub, centering the press hub onto the cam hub. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 25-15...
  • Page 430 NOTE: The bolt (1) must be replaced with a new bolt (CC P/N 102242101) containing a locking patch that will prevent the bolt from loosening. Tighten the bolt (1) to 18 ft·lb (24.4 N·m). Connect battery and spark plug wire(s). See Connecting the Battery-Gasoline Vehicles on page 1-5. Page 25-16 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 431 With the switch in this position, the vehicle will not operate if the Forward/Reverse handle is placed in either the FORWARD or REVERSE position. See following WARNING and NOTE. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 26-1...
  • Page 432 When draining transaxle oil, remove both plugs to allow the oil to drain faster. Clean and reinstall the drain plug and gasket before filling the transaxle with new lubricant. Tighten drain plug to 17 ft·lb (23 N·m). Page 26-2 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 433 16-in. rolling head prybar 5/8-in. socket, 3/8- in. drive 1/4-in. nut driver Plastic or rubber mallet Axle seal tool (CC P/N 1014162) 5/16-in. nut driver Ratchet wrench, 3/8-in. drive 7/16-in. combination wrench 2017 Carryall 500 and 700 Maintenance and Service Manual Page 26-3...
  • Page 434 NOTE: If brake shoes are replaced on one side, replace the opposite side also. Clean the splines and threaded portion of the axle shaft. Apply anti-seize compound to both the axle shaft splines and hub (6) splines. See following CAUTION. Page 26-4 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 435 Connect battery and spark plug wire(s). See Connecting the Battery-Gasoline Vehicles on page 1-5. A = 1.49 in. (38 mm) maximum diameter allowable area for cotter pin after deformation. 3057 Figure 26-4 Cotter Pin Deformation 2017 Carryall 500 and 700 Maintenance and Service Manual Page 26-5...
  • Page 436 Avoiding damage caused by dragging splines across lip of oil seal (7) in transaxle gearcase, carefully pull axle tube (2) and shaft (3) from transaxle. 3058 Figure 26-5 Axle Tube, Shaft, Bearing and Oil Seal Page 26-6 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 437 The rear axle tubes (2) must be unbolted from the transaxle to replace oil seals (7) (Figure 26-5, Page 26-6). Clean debris from drain plug and area around it at the bottom of the transaxle. Drain oil. Install plug after draining. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 26-7...
  • Page 438 See Axle Tube and Axle Shaft Installation on page 26-7. Refill transaxle with appropriate type and volume of oil. See Oil Change – Transaxle on page 26-2. Page 26-8 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 439 Figure 26-7 Disconnect Shock Absorbers Disconnect brake cables from brake assemblies. See Wheel Brake Assemblies section. Remove lower shock mounting hardware from both rear shocks (Figure 26-7, Page 26-9). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 26-9...
  • Page 440 Gently lower front of powertrain to the floor (Figure 26-11, Page 26-11). The powertrain should be completely disconnected from vehicle and resting on floor. Page 26-10 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 441 NOTE: The transaxle weighs approximately 58 lb (26.2 kg). If replacing transaxle, remove leaf springs, wheels, hubs and brake assemblies and retain for installation on new transaxle. See Rear Suspension section. See Wheel Brake Assemblies section. 2017 Carryall 500 and 700 Maintenance and Service Manual Page 26-11...
  • Page 442 Transaxle Removal TRANSAXLE (ED65): GASOLINE VEHICLES 3063 Figure 26-12 Transaxle Mounting Bolts Page 26-12 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 443 Loosen jam nuts (1) securing shifter cable (2) to FNR/accelerator cable bracket (3) (Figure 26-14, Page 26-14). Then, remove bowtie clip (3) to disconnect shifter cable end (4) from transaxle shift lever (5). 2017 Carryall 500 and 700 Maintenance and Service Manual Page 26-13...
  • Page 444 To adjust, the jam nuts (6) at the FNR/accelerator cable bracket must be loosened and moved forward or backward as required (Figure 26-14, Page 26-14). Tighten jam nuts (6) to 22 ft·lb (29.8 N·m). Page 26-14 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 445 ..........14-10 storage ............14-13 amp hours ............11-9 testing ............... 14-3 anti-tamper speed ..........11-8 basics ............14-2 audible charging indicator ........11-9 voltage test........... 12-15 battery type............11-8 2017 Carryall 500 and 700 Maintenance and Service Manual Index-1...
  • Page 446 (torque converter) troubleshooting....25-1 installation ............25-16 clutch, drive removal ............25-13 see drive clutch ..........25-4 clutch, driven see driven clutch ..........25-12 column, steering see steering column ..........7-3 Index-2 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 447 .......... 20-27 see also lighting circuit........18-42 fuel gauge circuit testing ............. 18-42 testing ............18-40 high pedal detect ........... 12-2 fuel level sending unit ........20-28 hubs 2017 Carryall 500 and 700 Maintenance and Service Manual Index-3...
  • Page 448 ............20-22 see regenerative braking ........12-2 removal ............20-22 motor controller output regulator (MCOR) kill limit switch, engine testing ........... 12-23, 12-27 testing ............. 18-33 Index-4 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 449 ..........12-2 inspection..........20-5–20-6 reverse buzzer removal ............20-6 installation ..........13-7, 20-23 belt tension adjustment ........20-13 limit switch brush spring installation ............ 20-25 inspection............20-2 removal ............20-25 2017 Carryall 500 and 700 Maintenance and Service Manual Index-5...
  • Page 450 ..........18-37 inspection and removal........9-1 ECU ..............18-22 installation ............9-1 EFI ..............18-22 engine temperature sensor ....... 18-22 fuel gauge............18-40 fuel injector ............18-22 Index-6 2017 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 451 ............26-2 removal ............. 26-9 service............... 26-2 transaxle, type g assembly ............17-10 axle bearing ............17-4 axle shaft installation ............17-4 removal ............17-1 disassembly............17-8 inspection ............17-8 2017 Carryall 500 and 700 Maintenance and Service Manual Index-7...
  • Page 452 NOTES...
  • Page 453 NOTES...
  • Page 454 NOTES...

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