Page 1 2021 Carryall 300 Maintenance and Service Manual Gasoline Vehicle with Kohler ECH440 Engine Electric Vehicle with ERIC Charging System Manual Number 86753090054 Edition Code A...
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 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
CONTENTS SECTION 1 — Safety............................1-1 Safety Details ..............................1-1 Personal Safety ............................1-1 Machine Safety............................1-1 Information..............................1-1 General Warnings............................1-1 Disable The Vehicle ........................... 1-3 Disconnect the Battery- Gasoline Vehicles ....................1-4 Connect the Battery- Gasoline Vehicles....................... 1-4 Disconnect the Batteries –...
Page 6 Rear Fender and Tailskirt Installation ......................4-17 Rear Triangle Reflector ..........................4-18 Rear Triangle Reflector Removal ......................4-18 Rear Triangle Reflector Installation ......................4-18 Floor Mat ..............................4-19 Floor Mat Removal ..........................4-19 Floor Mat Installation..........................4-19 SECTION 5 — Accelerator and Brake Pedal Group ..................... 5-1 Brake Pedal and Park Brake (Gas and Electric Vehicles)..................
Page 7 Leaf Spring Installation..........................7-17 Kingpin and Steering Spindle Removal – Maintenance-Free Ball Joints............7-17 Kingpin and Steering Spindle Installation – Maintenance-Free Ball Joints............ 7-20 Delta A-Plate Removal..........................7-20 Delta A-Plate Installation .......................... 7-20 Shock Absorber Removal......................... 7-20 Shock Absorber Installation ........................7-20 Front Wheel Bearings and Hubs ........................
Page 8 SECTION 11 — Controller Diagnostic Tool (CDT) ....................11-1 General Information ............................11-2 Features ..............................11-2 Plugging the CDT into the Vehicle........................11-3 Introductory Display ..........................11-3 Quick Reference Guide – Excel with ERIC Charging System................11-4 System Info ..............................11-5 Model Number............................11-5 Serial Number ............................11-5 Hardware Version .............................11-5 Protocol Version ............................11-5 Param Block Version..........................11-5 MFG Date Code ............................11-5...
Page 9 Overvoltage............................11-18 Thermal Cutback ............................ 11-19 Anti-Tamper Fault ........................... 11-19 HPD ..............................11-19 Main Drvr OverCurrent..........................11-19 Lockout Fault ............................11-19 Low SOC ............................... 11-19 Main Welded ............................11-20 High Speed WalkAway..........................11-20 Speed sensor ............................11-20 Main Driver On ............................11-20 Main Coil Open............................
Page 10 MCOR Installation ........................... 13-4 Reverse Buzzer............................13-5 Reverse Buzzer Removal......................... 13-5 Reverse Buzzer Installation ........................13-5 Solenoid..............................13-6 Testing the Solenoid ..........................13-6 Solenoid Removal ........................... 13-6 Solenoid Installation..........................13-6 Speed Controller ............................13-7 Testing the Solid State Speed Controller ....................13-7 Speed Controller Removal ........................
Page 11 Deep-Discharge ............................14-14 Early Excessive Discharging ........................14-14 SECTION 15 — Electric Vehicle - Battery Charger ..................... 15-1 General Information ............................. 15-2 USB Service Port............................. 15-3 UL and CSA Listing ..........................15-3 CE Compliance ............................15-3 Plug and Receptacle..........................15-3 Charger Power Connection Fuse ......................15-3 Charger Interlock .............................
Page 12 SECTION 17 — Electric Vehicle - Transaxle ...................... 17-1 Lubrication ..............................17-1 Axle Bearing and Shaft ..........................17-1 Axle Shaft ............................... 17-1 Axle Bearing............................17-4 Transaxle ..............................17-5 Transaxle Removal ..........................17-5 Transaxle Disassembly, Inspection, and Assembly..................17-8 Transaxle Disassembly and Inspection...................... 17-8 Transaxle Assembly..........................17-10 Transaxle Installation ..........................17-12 SECTION 18 —...
Page 13 Solenoid Installation..........................19-27 Fuse ................................19-28 Fuse Removal ............................19-29 Fuse Installation .............................19-29 Accelerator Pedal Limit Switch ........................19-30 Accelerator Pedal Limit Switch Removal ....................19-30 Accelerator Pedal Limit Switch Installation....................19-30 Kill Limit Switch ............................19-31 Kill Limit Switch Removal ........................19-31 Kill Limit Switch Installation ........................19-31 Reverse Warning Buzzer..........................19-32 Reverse Warning Buzzer Removal ......................19-32 Reverse Warning Buzzer Installation......................19-32...
Page 14 SECTION 20 — Gasoline Vehicle - Engine ......................20-1 General Information ............................. 20-1 Before Servicing ............................20-1 Louver Arm ..............................20-2 Engine Removal ............................20-3 Engine Installation ............................20-6 Snubber ..............................20-9 Snubber Removal............................ 20-9 Snubber Installation ..........................20-9 SECTION 21 — Gasoline Vehicle - Fuel System ....................21-1 General Information .............................
Page 15 Drive Clutch Disassembly......................... 23-7 Inspection of Drive Clutch Parts........................ 23-9 Drive Clutch Assembly ..........................23-10 Drive Clutch Installation .......................... 23-11 Driven Clutch .............................23-12 Driven Clutch Removal ...........................23-13 Driven Clutch Disassembly........................23-13 Driven Clutch Inspection .........................23-16 Driven Clutch Assembly ..........................23-16 Driven Clutch Installation.........................23-19 SECTION 24 —...
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: Disable The Vehicle
SAFETY General Warnings WARNING Gasoline vehicles only: • To avoid unintentionally starting a gasoline vehicle, disconnect the battery and spark plug wire. • Frame ground – Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wiring.
Page 20: Disconnect The Battery- Gasoline Vehicles
General Warnings SAFETY DISCONNECT THE BATTERY- GASOLINE VEHICLES Disable the vehicle. Remove positive terminal cover. Disconnect the negative (-) cable (1) (Figure 1-1, Page 1-4). Figure 1-1 Battery - Gasoline Vehicles Disconnect the positive (+) cable (2). CONNECT THE BATTERY- GASOLINE VEHICLES Connect the positive (+) cable (2) (Figure 1-1, Page 1-4).
Page 21: Disconnect The Batteries - Electric Vehicles
SAFETY General Warnings DISCONNECT THE BATTERIES – ELECTRIC VEHICLES WARNING • Place Run/Tow switch in the TOW position before disconnecting or connecting the batteries. Failure to heed this warning can result in a battery explosion or severe personal injury. Disable the vehicle. Set the Run/Tow switch to TOW.
Page 22: International Safety Symbols On Batteries
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 23 SECTION 2 — VEHICLE SPECIFICATIONS VEHICLE SPECIFICATIONS Vehicle Specifications VEHICLE SPECIFICATIONS – ELECTRIC VEHICLES SPECIFICATIONS CARRYALL 300 POWER SOURCE ELECTRIC Drive motor: Direct drive, 48 volts DC, shunt wound, 3.3 hp ● Transaxle: Double reduction helical gear with 12.3:1 direct drive axle ●...
Page 24: Section 2 - Vehicle Specifications
Vehicle Specifications VEHICLE SPECIFICATIONS SPECIFICATIONS CARRYALL 300 POWER SOURCE ELECTRIC Intersecting aisle clearance 87 in (221 cm) Floorboard height 12.5 in (31.7 cm) Load bed height 29.5 in (74.93 cm) 36.2 x 47.5 x 10.5 in Load bed size: Box bed inside dimensions (91.9 x 120.6 x 26.6 cm) 36.5 x 48.8 in Load bed size: Flat bed inside dimensions...
Page 25: E.r.i.c. Battery Charger Specifications
VEHICLE SPECIFICATIONS Vehicle Specifications E.R.I.C. BATTERY CHARGER SPECIFICATIONS E.R.I.C. BATTERY CHARGER SPECIFICATIONS MODEL NUMBER IC650-048-CC AC INPUT AC voltage 100 to 240 VAC Frequency 50 / 60 Hz POWER CONSUMPTION Maximum AC input current (amps) DC OUTPUT Rated DC voltage (VDC) Maximum DC voltage (VDC) Maximum DC output current (amps) 13.5...
Page 26: Vehicle Specifications - Gasoline Vehicles
Vehicle Specifications VEHICLE SPECIFICATIONS VEHICLE SPECIFICATIONS – GASOLINE VEHICLES NOTE: Engine horsepower and torque specifications are provided by the engine manufacturer. Actual horsepower and torque in use may differ and are dependent on environmental conditions as well as maintenance condition of the engine. SPECIFICATIONS CARRYALL 300 POWER SOURCE...
Page 27 VEHICLE SPECIFICATIONS Vehicle Specifications SPECIFICATIONS CARRYALL 300 POWER SOURCE GASOLINE Rear wheel tread 39.5 in (100.3 cm) Weight: Standard gasoline vehicle (dry fuel tank) 789 lb (357.8 kg) Curb weight 817 lb (370. 5 kg) Maximum forward speed 15 to 17 mph (24 to 27 km/h) Curb clearance circle (diameter) 230.5 in (585.4 cm) Turning radius (per SAE J 695)
Page 28 Vehicle Specifications VEHICLE SPECIFICATIONS Pagination Page Page 2-6 2021 Carryall 300 Maintenance and Service Manual...
Page 29: Section 3 - General Information
SECTION 3 — GENERAL INFORMATION DANGER General Information • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. This manual features Carryall 300 vehicles. The electric Carryall 300 vehicle is equipped with the ERIC (Efficient, Reliable, Intelligent, Connected) battery charging system.
Page 30: Storage - Electric Vehicles
Storage – Electric Vehicles GENERAL INFORMATION 2843 Figure 3-1 Serial Number Decal STORAGE – ELECTRIC VEHICLES See General Warnings on page 1-1. WARNING • Turn the key switch to the OFF position, remove the key, and leave the Forward/Neutral/Reverse control (FNR) or switch in the NEUTRAL position during storage. This is to prevent unintentionally starting the vehicle or a fire hazard.
Page 31: Returning The Stored Electric Vehicle To Service
GENERAL INFORMATION Storage – Electric Vehicles Turn the key switch to the OFF position, remove the key, and leave the Forward/Neutral/Reverse control (FNR) in the NEUTRAL position during storage. If so installed, turn off all accessories, including GPS units, fans, etc. Place the Run/Tow switch in the TOW position.
Page 32: Storage - Gasoline Vehicles
Storage – Gasoline Vehicles GENERAL INFORMATION Perform the Pre-Operation and Daily Safety Checklist on page 10-1 and the Performance Inspection on page 10-1. STORAGE – GASOLINE VEHICLES See General Warnings on page 1-1. DANGER • Do not attempt to drain fuel when the engine is hot or while it is running. •...
Page 33: Returning The Stored Gasoline Vehicle To Service
GENERAL INFORMATION Storage – Gasoline Vehicles Figure 3-2 Plug Vent NOTE: It is not necessary to drain the fuel line. Disconnect the battery and the spark plug wire. 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.
Page 34 Storage – Gasoline Vehicles GENERAL INFORMATION Figure 3-3 Plug Vent 1.2. Connect vent tube to fuel tank vent. Connect battery and spark plug wire. Place the Forward/Neutral/Reverse control (FNR) in the NEUTRAL position and the Maintenance/Operate switch in the MAINTENANCE position. Crank the engine until the engine starts. Turn the engine off and return the Maintenance/Operate switch to the OPERATE position.
Page 35: Section 4 - Body And Trim
SECTION 4 — BODY AND TRIM DANGER Body and Trim • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. CLEANING THE VEHICLE See General Warnings on page 1-1. CAUTION • Do not use detergents or cleaning solvents that contain ammonia, aromatic solvents, or alkali materials on body panels or seats.
Page 36: Front Body Repair
Front Body Repair BODY AND TRIM CAUTION • To prevent damage to the vehicle when removing difficult stains or heavy soiling, remove the seat from the vehicle first. FRONT BODY REPAIR See General Warnings on page 1-1. LIGHT SCRATCHES Clean entire area to be repaired with clean, clear water. Using 1200 grit sandpaper, water-sand entire area of scratch until original scratch is no longer visible, either with finishing sander or wet sanding block.
Page 37: Front Body
BODY AND TRIM Front Body FRONT BODY See General Warnings on page 1-1. BRUSHGUARD REMOVAL Disconnect the batteries. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. See Disconnect the Battery- Gasoline Vehicles on page 1-4. Remove the bolts (1) (Figure 4-1, Page 4-3). Remove the screws (2) and washers (3).
Page 38: Cowl Removal
Front Body BODY AND TRIM COWL REMOVAL Disable the vehicle. Disconnect the batteries. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. See Disconnect the Battery- Gasoline Vehicles on page 1-4. The cowl (1) is secured by tabs (2) located behind the front fenders (3), and under the lip of the dash (4) (Figure 4-2, Page 4-5).
Page 39: Grille Removal
BODY AND TRIM Front Body 2846D Figure 4-2 Front Cowl GRILLE REMOVAL Park vehicle and chock the tires. Disconnect the batteries. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. See Disconnect the Battery- Gasoline Vehicles on page 1-4. Remove HD bumper (if equipped).
Page 40 Front Body BODY AND TRIM Install and tighten upper bolts, then lower right and left side bolts. Tighten to 44 in·lb (5 N·m). Connect the batteries.See Connect the Batteries – Electric Vehicles, Section 1, Page 1-5. See Connect the Battery- Gasoline Vehicles on page 1-4. Page 4-6 2021 Carryall 300 Maintenance and Service Manual...
Page 41 BODY AND TRIM Front Body 2844 Figure 4-3 Front Grille, Bumper, and Side Fenders 2021 Carryall 300 Maintenance and Service Manual Page 4-7...
Page 42: Front Bumper And Side Fender Removal
Front Body BODY AND TRIM FRONT BUMPER AND SIDE FENDER REMOVAL Park the vehicle, chock tires. Disconnect the batteries. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. See Disconnect the Battery- Gasoline Vehicles on page 1-4. Remove HD bumper, (if equipped). See Brushguard Removal on page 4-3. Remove the front cowl.
Page 43: Instrument Panel Removal
BODY AND TRIM Front Body INSTRUMENT PANEL REMOVAL Disconnect the batteries. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. See Disconnect the Battery- Gasoline Vehicles on page 1-4. Remove front cowl. See Cowl Removal, Section 4, Page 4-4. From the inside of the dash, press upper snap tabs (1) of the instrument panel inward to release from dash.
Page 44: Dash Removal
Front Body BODY AND TRIM DASH REMOVAL Disconnect the batteries. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. See Disconnect the Battery- Gasoline Vehicles on page 1-4. Remove cowl. See Cowl Removal on page 4-4. Remove steering wheel. See Steering Wheel Removal, Section 7, Page 7-1. Disconnect instrument panel wiring.
Page 45 BODY AND TRIM Front Body 2863 Figure 4-5 Dash Assembly 2021 Carryall 300 Maintenance and Service Manual Page 4-11...
Page 46: Tilt Bed
Tilt Bed BODY AND TRIM TILT BED See General Warnings on page 1-1. 2981 Figure 4-6 Tilt Bed Mounting Page 4-12 2021 Carryall 300 Maintenance and Service Manual...
Page 47: Tilt Bed Removal
BODY AND TRIM Tilt Bed TILT BED REMOVAL NOTE: This procedure requires two people. WARNING • Remove all cargo before raising the bed or servicing the vehicle. If the vehicle is equipped with a prop rod, ensure that it is securely engaged while bed is raised. Do not close bed until all persons are clear of cargo bed area.
Page 48: Bed Latch Assembly Removal
Tilt Bed BODY AND TRIM Use a small hammer to lightly tap bolts through hinge assembly (Figure 4-6, Page 4-12). Adjust the striker plates (12), if necessary. Install a locknut (7) on each bolt (6) and tighten to 15 ft·lb (21 N·m). Connect the batteries.
Page 49 BODY AND TRIM Tilt Bed 2982 Figure 4-7 Bed Latch Assembly 2021 Carryall 300 Maintenance and Service Manual Page 4-15...
Page 50: Rear Fenders And Tailskirt
Rear Fenders and Tailskirt BODY AND TRIM REAR FENDERS AND TAILSKIRT See General Warnings on page 1-1. 2984 Figure 4-8 Rear Fender and Tailskirt REAR FENDER AND TAILSKIRT REMOVAL Turn the key switch OFF and remove the key. Place the Forward/Neutral/Reverse control (FNR) in NEUTRAL and set the park brake.
Page 51: Rear Fender And Tailskirt Installation
BODY AND TRIM Rear Fenders and Tailskirt Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. See Disconnect the Battery- Gasoline Vehicles on page 1-4. Remove the tilt bed.
Page 52: Rear Triangle Reflector
Rear Triangle Reflector BODY AND TRIM REAR TRIANGLE REFLECTOR Figure 4-9 REAR TRIANGLE REFLECTOR REMOVAL Disable the vehicle. Remove the four rivets (1) and washers (2) (Figure 4-9). Discard the rivets. Remove the rear triangle reflector (3). REAR TRIANGLE REFLECTOR INSTALLATION If the rear triangle reflector has never been installed: 1.1.
Page 53: Floor Mat
BODY AND TRIM Floor Mat Clean the triangle plate surface area with an Isopropyl Alcohol prep pad (70 percent Isopropyl Alcohol and 30 percent water). Wipe dry before the Isopropyl Alcohol dries. Install the reflective triangle decal (5) on the triangle plate. Make sure to keep proper alignment and remove any air bubbles.
Page 54 Floor Mat BODY AND TRIM Pagination Page Page 4-20 2021 Carryall 300 Maintenance and Service Manual...
Page 55: Section 5 - Accelerator And Brake Pedal Group
SECTION 5 — ACCELERATOR AND BRAKE PEDAL GROUP DANGER Accelerator and Brake Pedal Group • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. BRAKE PEDAL AND PARK BRAKE (GAS AND ELECTRIC VEHICLES) See General Warnings on page 1-1. BRAKE PEDAL REMOVAL (GAS AND ELECTRIC VEHICLES) Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire.
Page 56 Brake Pedal and Park Brake (Gas and Electric Vehicles) ACCELERATOR AND BRAKE PEDAL GROUP 3206 Figure 5-1 Brake and Park Brake Pedal Assembly and Mounting Page 5-2 2021 Carryall 300 Maintenance and Service Manual...
Page 57 ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake (Gas and Electric Vehicles) 2999 Figure 5-2 Brake Pedal Weldment Through Floor Position and attach brake pedal assembly, mounting blocks (3 and 7), and washers (9) to vehicle frame as shown. Tighten the bolts (10) and nuts to 95 in·lb (10.7 N·m).
Page 58: Park Brake Removal (Gas And Electric Vehicles)
Brake Pedal and Park Brake (Gas and Electric Vehicles) ACCELERATOR AND BRAKE PEDAL GROUP PARK BRAKE REMOVAL (GAS AND ELECTRIC VEHICLES) Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. See Disconnect the Battery- Gasoline Vehicles on page 1-4.
Page 59: Accelerator Pedal - Gasoline Vehicles
ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles Install the two bushings (30) in the park brake pedal and position the park brake pedal on the shaft on the brake pedal assembly weldment (10). Then attach the ends of the torsion spring to the park brake pedal and to the brake pedal weldment as shown (Figure 5-5, Page 5-4).
Page 60 Accelerator Pedal – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP Remove the accelerator pedal (1) from the vehicle. Inspect all parts for wear and damage. Replace as necessary. 3000 Figure 5-6 Accelerator Pedal – Gasoline Vehicles Page 5-6 2021 Carryall 300 Maintenance and Service Manual...
Page 61: Accelerator Pedal Installation - Gasoline Vehicles
ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles ACCELERATOR PEDAL INSTALLATION – GASOLINE VEHICLES If the accelerator pivot rod supports were replaced, position the supports (21) on the vehicle frame and install the four bolts (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 62: Accelerator Pedal - Electric Vehicles
Accelerator Pedal – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP ACCELERATOR PEDAL – ELECTRIC VEHICLES See General Warnings on page 1-1. ACCELERATOR PEDAL REMOVAL – ELECTRIC VEHICLES Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5.
Page 63 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles 2642 Figure 5-8 Accelerator Pedal – Electric Vehicle with MCOR 2021 Carryall 300 Maintenance and Service Manual Page 5-9...
Page 64: Accelerator Pedal Installation - Electric Vehicles
Pedal Group Adjustment – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP ACCELERATOR PEDAL INSTALLATION – ELECTRIC VEHICLES If the accelerator pivot rod supports were replaced, position the supports (21) on the vehicle frame and install the four bolts (22), flat washers (16), and lock nuts (15) (Figure 5-8, Page 5-9). Finger-tighten nuts at this time. 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 65 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles Figure 5-9 Loosen Rear Brake Equalizer Rod Nuts 2.3. Loosen the brake stop jam nut (31), then relieve pedal pressure on the stop by pushing down slightly on the pedal. Next, adjust the brake stop bumper (22) up or down (Figure 5-10, Page 5-11). Adjusting the bumper upward decreases distance between pedal and floorboard.
Page 66 Pedal Group Adjustment – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP 3.2. Tighten the nut (2) on the equalizer rod (1) so that the brake pedal free play is 1/4 to 1/2 inch (6 mm to 13 mm) (Figure 5-3, Page 5-3). 3.3.
Page 67 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles 1. Locked Position 2. Ratchet (B) Tooth Length 3. Make sure pawl (A) engages at least 75% of ratchet tooth length (B). Figure 5-13 Accelerator Pedal Height Measurement Figure 5-14 Ratchet/Pawl Tooth Engagement 4.5.
Page 68 Pedal Group Adjustment – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP 1. Accelerator Pedal Adjustment Tool 2. Rubber Strap Figure 5-17 Accelerator Pedal Height Adjustment Adjust the accelerator rod. See following DANGER. DANGER • Before servicing, turn the key switch to the OFF position and place the Forward/Neutral/Reverse control (FNR) in the NEUTRAL position.
Page 69: Pedal Group Adjustment - Electric Vehicles
ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles CAUTION • After accelerator rod adjustment, make sure that approximately the same number of threads are exposed at each end of the accelerator rod. • If the lever on the limit switch in the electrical box is bent, replace the limit switch. •...
Page 70 Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP 1400-18100-10209 Figure 5-19 Loosen Rear Brake Equalizer Rod Nuts 2.3. Loosen the brake stop jam nut (31), then relieve pedal pressure on the stop by pushing down slightly on the pedal.
Page 71 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles 3.1. 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 5-21, Page 5-16).
Page 72 Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP 1. Locked Position 2. Ratchet (B) Tooth Length 3. Make sure pawl (A) engages at least 75% of ratchet tooth length (B). Figure 5-23 Accelerator Pedal Height Measurement Figure 5-24 Ratchet/Pawl Tooth Engagement 4.5.
Page 73 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles 1. Accelerator Pedal Adjustment Tool 2. Rubber Strap Figure 5-27 Accelerator Pedal Height Adjustment Adjust the brakes. See Brake Adjustment, Section 6, Page 6-9. Connect the battery cables. See Connect the Batteries – Electric Vehicles, Section 1, Page 1-5. 2021 Carryall 300 Maintenance and Service Manual Page 5-19...
Page 74 Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP Pagination Page Page 5-20 2021 Carryall 300 Maintenance and Service Manual...
Page 75: Section 6 - Wheel Brake Assemblies
SECTION 6 — WHEEL BRAKE ASSEMBLIES DANGER Wheel Brake Assemblies • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. Asbestos Dust Warning • Some aftermarket brake shoes contain asbestos dust. Asbestos dust is created when these brake mechanisms are handled.
Page 76 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES 1400-18100-10209 1400-18100-10220 Figure 6-1 Loosen Brake Cables Figure 6-2 Shoe Retainer Pins 5.2. Insert a 1/2 inch x 5/8 inch (1.27 x 1.58 cm) cold chisel (1) under the head of each pin (2) and shear them off as illustrated (Figure 6-2, Page 6-2).
Page 77: Brake Shoe Removal
WHEEL BRAKE ASSEMBLIES Brake Shoe Removal 1400-18100-10222 1400-17700-10225 Figure 6-3 Remove Shoe Retainer Clip Figure 6-4 Remove Brake Shoes 1. Slide Figure 6-5 Remove Adjuster Wheel Figure 6-6 Lubricate Slide and Slide Plate 2021 Carryall 300 Maintenance and Service Manual Page 6-3...
Page 78 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES A. Electric Vehicle B. Gasoline Vehicle 2902 Figure 6-7 Self-adjusting Wheel Brake Assembly Page 6-4 2021 Carryall 300 Maintenance and Service Manual...
Page 79: Brake Assembly Cleaning
WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning BRAKE ASSEMBLY CLEANING See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. Carefully clean the brake backing plate and all of its mechanical components. Remove the rubber boot from backing plate and wipe with a clean damp cloth. For vehicles equipped without a slide plate (2), lubricate the backing plate, where the slide operates, with dry moly lubricant.
Page 80 Brake Assembly Cleaning WHEEL BRAKE ASSEMBLIES Figure 6-10 Apply Grease To Brake Adjuster Figure 6-11 Install Adjuster Wheel, Trailing Shoe Page 6-6 2021 Carryall 300 Maintenance and Service Manual...
Page 81: Brake Shoe Installation
WHEEL BRAKE ASSEMBLIES Brake Shoe Installation BRAKE SHOE INSTALLATION See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. Turn the adjusting wheel screw so that the shoe slot is vertical, then position the trailing shoe in the slots in the shoe mounting block and adjuster assembly (Figure 6-11, Page 6-6).
Page 82 Brake Shoe Installation WHEEL BRAKE ASSEMBLIES Figure 6-14 Install Leading Shoe Figure 6-15 Check Shoe Positions Place a flatblade screwdriver under the adjusting arm (1) and raise the arm off of the adjusting wheel (2). While holding the arm (1) up, turn the wheel (2) upward until it stops (Figure 6-16, Page 6-8). Arm must engage teeth of the wheel.
Page 83: Brake Adjustment
WHEEL BRAKE ASSEMBLIES Brake Adjustment BRAKE ADJUSTMENT See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. When cleaning or repair on both wheels is complete, and with the brake cable still loose, lower the vehicle to the floor.
Page 84: Brake Assembly Removal And Installation
Brake Assembly Removal and Installation WHEEL BRAKE ASSEMBLIES BRAKE ASSEMBLY REMOVAL AND INSTALLATION See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. BRAKE ASSEMBLY REMOVAL Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire. See Disconnect the Batteries –...
Page 85: Brake Cable Removal And Installation
WHEEL BRAKE ASSEMBLIES Brake Cable Removal and Installation BRAKE CABLE REMOVAL AND INSTALLATION See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. BRAKE CABLE REMOVAL Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire. See Disconnect the Batteries –...
Page 86 Brake Cable Removal and Installation WHEEL BRAKE ASSEMBLIES Pagination Page Page 6-12 2021 Carryall 300 Maintenance and Service Manual...
Page 87: Section 7 - Steering And Front Suspension
SECTION 7 — STEERING AND FRONT SUSPENSION DANGER Steering and Front Suspension • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION Steering is controlled through a rack and pinion steering assembly that is connected by a steering column to a steering wheel.
Page 88: Steering Wheel Installation
Steering Wheel STEERING AND FRONT SUSPENSION 2862 1500-18300-10253 Figure 7-1 Steering Wheel Figure 7-2 Steering Wheel Puller STEERING WHEEL INSTALLATION NOTE: To minimize corrosion and to make future removal of the steering wheel easier, apply a small amount of oil or anti-seize compound to steering shaft splines and taper before installing the steering wheel.
Page 89: Steering Column
STEERING AND FRONT SUSPENSION Steering Column STEERING COLUMN See General Warnings on page 1-1. STEERING COLUMN REMOVAL Remove the steering wheel as previously instructed. Remove the front cowl. See Front Body, Section 4, Page 4-3. Remove the grille and bumper. Remove steering column sleeve.
Page 90 Steering Column STEERING AND FRONT SUSPENSION 2609 Figure 7-3 Steering Column Page 7-4 2021 Carryall 300 Maintenance and Service Manual...
Page 91: Steering Column Installation
STEERING AND FRONT SUSPENSION Steering Column 1. Step 1 1. Step 1 2. Step 2 2. Step 2 3. Step 3 3. Step 3 1500-18200-10255 1500-18200-10256 Figure 7-4 Steering Shaft – Bottom End Figure 7-5 Steering Shaft – Top End STEERING COLUMN INSTALLATION Install boot (12).
Page 92: Steering Adjustment
Steering Adjustment STEERING AND FRONT SUSPENSION STEERING ADJUSTMENT See General Warnings on page 1-1. Turn the steering wheel all the way to the right. Note the distance between the passenger side spindle stop (2) and passenger side A-plate (3) (Figure 7-6, Page 7-8). The internal stop on the rack must reach its limit of travel against rack and pinion housing at exactly the same time the spindle stops against the passenger side A-plate (with vehicle wheels turned to the right).
Page 93: Rack And Pinion
STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION See General Warnings on page 1-1. CAUTION • Front impacts that bend tie rods and/or drag links can possibly damage internal steering gear components. See Rack and Pinion Inspection on page 7-7. The manufacturer recommends inspecting the rack and pinion and replacing if damaged.
Page 94: Rack And Pinion Disassembly
Rack and Pinion STEERING AND FRONT SUSPENSION 1838 Figure 7-6 Adjust Steering Alignment RACK AND PINION DISASSEMBLY CAUTION • The ball joint (23) (Figure 7-10, Page 7-10) has left-hand threads. Remove ball joint from the spindle and inspect it for excessive wear. Remove the drag link (28) (Figure 7-10, Page 7-10).
Page 95 STEERING AND FRONT SUSPENSION Rack and Pinion 1. Press Ram 2. Pinion Gear 3. Bearing 1500-18400-10259 1500-18400-10260 Figure 7-7 Remove Pinion from Housing Figure 7-8 Remove Bearing from Pinion If necessary, remove the dust seal (12). See following NOTE. NOTE: If the dust seal (12) is removed, replace with a new one. Use snap ring pliers to remove the internal snap ring (11) (Figure 7-10, Page 7-10).
Page 96: Rack And Pinion Assembly
Rack and Pinion STEERING AND FRONT SUSPENSION 1839 Figure 7-10 Steering Gear – Maintenance-Free Ball Joints RACK AND PINION ASSEMBLY Install a new tab washer (4) and an inner ball joint (3) (Figure 7-9, Page 7-9). Install the ball joint onto the rack by securing the rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack from damage.
Page 97 STEERING AND FRONT SUSPENSION Rack and Pinion Apply a light coating of EP grease to the teeth of the rack (17), then slide the rack through the bushing (5) and housing (6). Install the stop washer (18) and retaining ring (19) to the end of the rack (Figure 7-10, Page 7-10). CAUTION •...
Page 98 Rack and Pinion STEERING AND FRONT SUSPENSION 1500-18400-10265 Figure 7-13 Rack and Pinion Resistance Install the internal snap ring (11) (Figure 7-10, Page 7-10). Using an appropriate size deep well socket (1) to apply pressure evenly, press in a new dust seal (2) (Figure 7-11, Page 7-11).
Page 99: Rack And Pinion Installation - Maintenance-Free Ball Joints
STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION INSTALLATION – MAINTENANCE-FREE BALL JOINTS Position the steering gear box assembly on the shock and gear support and install the bolts (30), washers (31), and nuts (32). Do not tighten the mounting bolts (Figure 7-10, Page 7-10). For ease of assembly and to prevent corrosion, apply a light coat of anti-seize and lubricating compound to the splined end of the steering column shaft.
Page 100: Tie Rod And Drag Link
Tie Rod and Drag Link STEERING AND FRONT SUSPENSION TIE ROD AND DRAG LINK See General Warnings on page 1-1. TIE ROD AND DRAG LINK REMOVAL – MAINTENANCE-FREE BALL JOINTS Using locking pliers to hold tie rod and drag link, loosen jam nuts (7 and 12) on tie rod ball joints (Figure 7-18, Page 7-18) and loosen jam nuts (27 and 29) on the drag link (Figure 7-10, Page 7-10).
Page 101: Front Suspension
STEERING AND FRONT SUSPENSION Front Suspension FRONT SUSPENSION See General Warnings on page 1-1. LUBRICATION Two grease fittings (one in each spindle housing) are provided. Lubricate these fittings at the recommended interval with the proper lubricant. See Periodic Lubrication Schedules, Section 10, Page 10-7. WHEEL ALIGNMENT Wheel alignment is limited to equalizing the camber angle of each front wheel and adjusting toe-in of the front wheels.
Page 102 Front Suspension STEERING AND FRONT SUSPENSION Tighten the hex nut (8) on the adjustment eccentric (7) to 23 ft·lb (31 N·m) (Figure 7-19, Page 7-19). See also Figure 7-15, Page 7-15. Toe-in Adjustment On a level surface, roll the vehicle forward, then stop. Make sure the front wheels are pointed straight ahead. Do not turn the steering wheel again during this procedure.
Page 103: Front Suspension Components
STEERING AND FRONT SUSPENSION Front Suspension Components FRONT SUSPENSION COMPONENTS See General Warnings on page 1-1. LEAF SPRING REMOVAL Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. See Disconnect the Battery- Gasoline Vehicles on page 1-4.
Page 104 Front Suspension Components STEERING AND FRONT SUSPENSION 2849 Figure 7-18 Front Suspension – Upper Portion Page 7-18 2021 Carryall 300 Maintenance and Service Manual...
Page 105 STEERING AND FRONT SUSPENSION Front Suspension Components 32 x 4 2847 Figure 7-19 Front Suspension – Lower Portion 2021 Carryall 300 Maintenance and Service Manual Page 7-19...
Page 106: Kingpin And Steering Spindle Installation - Maintenance-Free Ball Joints
Front Suspension Components STEERING AND FRONT SUSPENSION KINGPIN AND STEERING SPINDLE INSTALLATION – MAINTENANCE-FREE BALL JOINTS Inspect all parts and replace them as necessary. Install the kingpin (26) over the leaf spring eye. Insert the bolt (25) and install the nut (14) (Figure 7-19, Page 7-19).
Page 107: Front Wheel Bearings And Hubs
STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs FRONT WHEEL BEARINGS AND HUBS See General Warnings on page 1-1. NOTE: The front wheel bearings are pressed into the spindle and are not serviceable. If excessive free-play is detected the entire hub should be replaced. FRONT WHEEL FREE PLAY INSPECTION Raise the front of the vehicle.
Page 108 Front Wheel Bearings and Hubs STEERING AND FRONT SUSPENSION Pagination Page Page 7-22 2021 Carryall 300 Maintenance and Service Manual...
Page 109: 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 110: Tires
Tires WHEELS AND TIRES TIRES See General Warnings on page 1-1. TIRE REMOVAL NOTE: Tire must be removed or installed from the valve stem side of the rim. Remove the tire and wheel assembly from the vehicle as instructed above. See Wheel Removal on page 8-1. Remove the valve cap and valve core and allow air to escape from the tire.
Page 111: Tire Installation
WHEELS AND TIRES Tires NOTE: An air leak could be due to a punctured casing, faulty valve core, improperly seated valve stem, or improperly seated tire bead. Small holes in the casing can be plugged using a standard automotive tubeless tire repair kit available at auto supply stores.
Page 112 Tires WHEELS AND TIRES Figure 8-2 Inflate Tire Page 8-4 2021 Carryall 300 Maintenance and Service Manual...
Page 113: Section 9 - Rear Suspension
SECTION 9 — REAR SUSPENSION DANGER Rear Suspension • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION The rear suspension and powertrain of the vehicle move independently from the vehicle frame. The suspension includes three multi-leaf springs controlled by two hydraulic shock absorbers mounted between the spring mounting plate and the frame.
Page 114: Shock Absorber Installation
Multi-Leaf Springs REAR SUSPENSION SHOCK ABSORBER INSTALLATION NOTE: When installing shock absorbers, make sure front shocks have identical part numbers and rear shocks have identical part numbers. NOTE: Tighten 3/8 hex nut at shock absorber until shock absorber cushions are approximately the same diameter as the retainers.
Page 115 REAR SUSPENSION Multi-Leaf Springs 2865 Figure 9-2 Lifting Position Place a floor jack under the transaxle differential casing to support (but not lift) the drivetrain. Raise it just enough to relieve tension on the shock absorbers without compressing them. Remove the tire and wheel assembly on the side from which the spring is to be removed. Thread one lug nut onto a stud on the rear hub.
Page 116 Multi-Leaf Springs REAR SUSPENSION 2861 Figure 9-5 Rear Suspension Assembly and Mounting Page 9-4 2021 Carryall 300 Maintenance and Service Manual...
Page 117: Multi-Leaf Spring Installation
REAR SUSPENSION Jounce Bumpers MULTI-LEAF SPRING INSTALLATION NOTE: When installing rear leaf springs, make sure that both springs have identical part numbers. Tighten flange bolt (19) after clamp from brake cable has been positioned between nut and frame component. Place front of leaf spring (20) into vehicle frame and insert bolt (22) through frame and leaf spring eye (Figure 9-5, Page 9-4).
Page 118 Jounce Bumpers REAR SUSPENSION Pagination Page Page 9-6 2021 Carryall 300 Maintenance and Service Manual...
Page 119: Section 10 - Periodic Maintenance
Contact your local Club Car 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 120 Use the following checklist, in conjunction with the Pre-Operation and Daily Safety Checklist, as a guide to inspect the vehicle and check daily for proper operation. Any problems should be corrected by a Club Car distributor/dealer or a trained technician.
Page 121: Maintenance
PERIODIC MAINTENANCE Maintenance MAINTENANCE WARNING • 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 122 Periodic Service Schedules PERIODIC MAINTENANCE Both the Periodic Service Schedules and the Periodic Lubrication Schedules must be followed to keep vehicle in optimum operating condition. PERIODIC SERVICE SCHEDULE – ELECTRIC VEHICLES REGULAR INTERVAL SERVICE Pre-Operation and Daily Safety Checklist See Pre-Operation and Daily Safety Checklist. Daily service by owner Performance Inspection See Performance Inspection.
Page 123 PERIODIC MAINTENANCE Periodic Service Schedules PERIODIC SERVICE SCHEDULE – GASOLINE VEHICLES REGULAR INTERVAL SERVICE Pre-Operation and Daily Safety Checklist See Pre-Operation and Daily Safety Checklist. Daily service by owner Performance Inspection See Performance Inspection. Check engine oil level; change if necessary. Dispose of used oil properly.
Page 124 Periodic Service Schedules PERIODIC MAINTENANCE PERIODIC SERVICE SCHEDULE – GASOLINE VEHICLES REGULAR INTERVAL SERVICE Inspect the drive belt and starter/generator Belts belt. Replace and adjust as necessary. Check for leaks around gaskets, fill plugs, etc. Engine Inspect, clean and gap spark plug; replace if necessary.
Page 125: Periodic Lubrication Schedules
PERIODIC MAINTENANCE Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE – ELECTRIC VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Brake pedal shaft bearings Dry Moly Lube Semiannually by owner or Brake linkage and pivots Dry Moly Lube trained technician (or every 50 hours of operation, whichever Accelerator pivot rod supports Dry Moly Lube...
Page 126 Periodic Lubrication Schedules PERIODIC MAINTENANCE PERIODIC LUBRICATION SCHEDULE – GASOLINE VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Brake pedal shaft bearings Dry Moly Lube Brake linkage and pivots Dry Moly Lube Semiannually by owner or trained technician (or every 50 Accelerator pivot rod supports and Dry Moly Lube hours of operation, whichever...
Page 127: Air Filter
• 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 128: Engine Oil
Engine Oil PERIODIC MAINTENANCE Install the air cleaner cover (2). Engage the latches (1). ENGINE OIL ENGINE OIL VISCOSITY Select the engine oil viscosity for your environmental conditions. Figure 10-4 Engine Oil Viscosity ENGINE OIL LEVEL INSPECTION Before the engine oil is examined: •...
Page 129: Engine Oil Replacement
PERIODIC MAINTENANCE Engine Oil Figure 10-5 Dipstick Location Make sure that the oil level is between the maximum (1) and minimum (2) indicators (Figure 10-6, Page 10-11). Figure 10-6 Dipstick Indicators If the oil level is below the minimum indicator, add engine oil. Install the dipstick.
Page 130 Engine Oil PERIODIC MAINTENANCE Before the engine oil is replaced: • Disable the vehicle. • Disconnect the battery. To replace the engine oil: Remove the dipstick (1) (Figure 10-7, Page 10-12). Figure 10-7 Dipstick Location Clean the area around the oil drain plug (2) (Figure 10-8, Page 10-13). Page 10-12 2021 Carryall 300 Maintenance and Service Manual...
Page 131 PERIODIC MAINTENANCE Engine Oil Figure 10-8 Oil Drain Plug Put a drain pan below the oil drain plug. Remove the oil drain plug. Drain the oil fully. Clean the oil drain plug. Examine the gasket on the oil drain plug for damage. Replace if necessary. Install the oil drain plug and tighten to 13 lb·ft (18 N·m).
Page 132: Add Engine Oil
Engine Oil PERIODIC MAINTENANCE Figure 10-9 Oil Fill Location Install the dipstick. Connect the battery. Correctly discard the used engine oil. ADD ENGINE OIL CAUTION • Hot engine oil will cause skin burns. Do not change the engine oil when the engine is hot. Let the engine temperature decrease before the oil is changed.
Page 133: Refuel
PERIODIC MAINTENANCE Refuel Figure 10-10 Dipstick Location Add engine oil until the oil level is between the maximum (1) and minimum (2) indicators (Figure 10-11, Page 10-15). Figure 10-11 Dipstick Indicators Install the dipstick. REFUEL DANGER • Fuel is flammable and explosive. Do not add fuel with the key switch set to ON. Before fuel is added, turn the key switch to OFF.
Page 134: Lift The Vehicle
Lift The Vehicle PERIODIC MAINTENANCE DANGER • Fuel is flammable and explosive. Do not fill the fuel tank when the engine is on or hot. Wait for the engine temperature to decrease before fuel is added. • Fuel is flammable and explosive. Do not operate the vehicle when fuel is spilled. Correctly clean the spilled fuel.
Page 135: Lift The Rear Of The Vehicle
PERIODIC MAINTENANCE Lift The Vehicle • Use a jack and jack stands rated for the vehicle. To lift the front of the vehicle: Figure 10-12 Lift The Front Place the jack in the center of the lift point. Lift the front of the vehicle. Put jack stands under the frame rails.
Page 136: Lower The Front Of The Vehicle
Lift The Vehicle PERIODIC MAINTENANCE Figure 10-13 Lift The Rear Place the jack in the center of the lift point. Lift the rear of the vehicle. Put jack stands under the frame rails. Lower the vehicle onto the jack stands. LOWER THE FRONT OF THE VEHICLE Before the vehicle is lowered: •...
Page 137: Lower The Rear Of The Vehicle
PERIODIC MAINTENANCE Lift The Vehicle Figure 10-14 Lower The Front Place the jack in the center of the lift point. Lift the vehicle off of the jack stands. Remove the jack stands. Lower the vehicle. LOWER THE REAR OF THE VEHICLE Before the vehicle is lowered: •...
Page 138: Spark Plug
Spark Plug PERIODIC MAINTENANCE Figure 10-15 Lower The Rear Place the jack in the center of the lift point. Lift the vehicle off of the jack stands. Remove the jack stands. Lower the vehicle. SPARK PLUG SPARK PLUG REMOVAL Before the spark plug is removed: •...
Page 139: Spark Plug Inspection
PERIODIC MAINTENANCE Spark Plug Figure 10-16 Spark Plug Wire Disconnect Use a spark plug socket to remove the spark plug. SPARK PLUG INSPECTION Use a wire brush to clean the electrodes (1). Figure 10-17 Spark Plug Inspection Examine the spark plug electrodes for corrosion and damage. Examine the spark plug insulator (2) for cracks.
Page 140: Spark Plug Installation
Valve Clearance Check and Adjustment PERIODIC MAINTENANCE Figure 10-18 Spark Plug Gap SPARK PLUG INSTALLATION Apply a thin layer of high temperature anti-seize lubricant to the spark plug threads. Use a spark plug socket to install and tighten the spark plug to 20 lb·ft (27 N·m). Connect the spark plug wire (1) (Figure 10-19, Page 10-22).
Page 141: Section 11 - Controller Diagnostic Tool (Cdt)
SECTION 11 — CONTROLLER DIAGNOSTIC TOOL (CDT) DANGER Controller Diagnostic Tool (CDT) • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. NOTE: The information presented in this section addresses the following: • The Controller Diagnostic Tool (CDT) handheld programmer which replaced the IQDM series 2 handset. •...
Page 142: General Information
General Information CONTROLLER DIAGNOSTIC TOOL (CDT) GENERAL INFORMATION The CDT is used to adjust and save parameter settings of the controller, monitor real-time data, and perform diagnostics and troubleshooting of the electric vehicle. FEATURES • Batteries: Two AA batteries provide power for the CDT’s real-time clock and they allow for use of the CDT when not connected to a vehicle.
Page 143: Plugging The Cdt Into The Vehicle
CONTROLLER DIAGNOSTIC TOOL (CDT) Plugging the CDT into the Vehicle PLUGGING THE CDT INTO THE VEHICLE Figure 11-2 Communication Port Under Instrument Panel Connect one end of the cable to the port located on the bottom of the CDT. Connect the cable adaptor to the CDT cable. Find the communication port on the vehicle (Figure 11-2, Page 11-3).
Page 144: Quick Reference Guide - Excel With Eric Charging System
Quick Reference Guide – Excel with ERIC Charging System CONTROLLER DIAGNOSTIC TOOL (CDT) QUICK REFERENCE GUIDE – EXCEL WITH ERIC CHARGING SYSTEM OPERATION: Change screen contrast for better viewing by selecting the following: HPP Settings, Backlight Preset Favorites: Select a frequently viewed screen, press “Add to” softkey, highlight “Favorites”, press “Select” softkey. CONTROLLER FAULTS: Anti Tamper: If car is not equipped with Visage, make sure Control Main Driver Off: Replace controller.
Page 145: System Info
CONTROLLER DIAGNOSTIC TOOL (CDT) System Info SYSTEM INFO The System Info menu is accessed by using the arrow keys to highlight System Info and pressing the Select softkey to activate the menu. The System Info selection displays information pertaining to the controller. The information provided from this menu selection includes: MODEL NUMBER Displays the model number of the controller.
Page 146: Settings
Parameters CONTROLLER DIAGNOSTIC TOOL (CDT) 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. Be aware when changing parameter settings, the new values replace the earlier values.
Page 147 CONTROLLER DIAGNOSTIC TOOL (CDT) Parameters PEDAL UP MODE SETTING MODE OPERATION DESCRIPTION Pedal up motor braking is disabled Mild pedal up Mild pedal up motor braking Aggressive pedal up Aggressive pedal up motor braking Speed Cal The speed cal (speed calibration) menu item allows the user to fine tune the vehicle speed. This feature cannot be used to increase the vehicle speed.
Page 148: Amp Hours
15 mph (24.1 km/h). For more information on this feature, contact your local Club Car distributor or dealer. NOTE: If controller is replaced, the information below must be entered into the new controller. See Speed Controller Installation, Section 13, Page 13-8.
Page 149: Vehicle Id
CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu VEHICLE ID S/N ASCII Letter 1 S/N ASCII Letter 2 The two-letter serial number prefix is coded as two separate ASCII characters per the following table. For example, serial number 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...
Page 150: Batt Voltage
Monitor Menu CONTROLLER DIAGNOSTIC TOOL (CDT) WARNING • The vehicle operator should not monitor the handset while the vehicle is in motion. A technician can monitor the handset while traveling as a passenger in the vehicle. Failure to heed this warning could result in severe personal injury or death.
Page 151: Field Pwm
CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu FIELD PWM Displays motor field PWM (pulse width modulation). The range of pulse width modulation is 0% to 100%. When the vehicle is in operation, the pulse width modulation will fluctuate in response to the terrain and throttle input. SPEED PULSES The speed pulses menu item displays the activity of the motor speed sensor.
Page 152: Odometer
“private speed mode”. In the event that “private speed mode” is locked out, the controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 11-8.
Page 153: Amp Hours Display
CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu AMP HOURS DISPLAY Signed Battery Current While driving the vehicle, this displays either the current being pulled out of the batteries or the current being returned to the batteries during regenerative motor braking. It has a range from negative (–) 300 amps to positive (+) 300 amps. Amp Hours Displays total accumulated amp hours removed from batteries since initial vehicle start-up.
Page 154: Diagnostics Menu
Diagnostics Menu CONTROLLER DIAGNOSTIC TOOL (CDT) DIAGNOSTICS MENU CAUTION • A failed motor will damage the controller. Always inspect the motor before replacing the controller. See External Motor Testing, Section 16, Page 16-1. NOTE: The software is subject to frequent updates, and this manual may span many versions. Be aware that some faults listed in this manual may not display in the CDT, indicating older software.
Page 155: Causes Of Faults
CONTROLLER DIAGNOSTIC TOOL (CDT) Diagnostics Menu CAUSES OF FAULTS Some common causes of faults are: • Loose, broken, or disconnected wires or connectors • Failed components • Improper adjustment or installation of electrical or mechanical components (examples: brake adjustment, improper MCOR installation) •...
Page 156 Diagnostics Menu CONTROLLER DIAGNOSTIC TOOL (CDT) CONTROLLER FAULT CONTROLLER RESPONSE VEHICLE RESPONSE HW FAILSAFE A, B, C Vehicle comes to a stop THROTTLE FAULT A, C Vehicle comes to a stop SPEED SENSOR Vehicle runs at slow speed MAIN WELDED Vehicle runs at slow speed MAIN DRIVER ON A, B...
Page 157: Fault Recovery
CONTROLLER DIAGNOSTIC TOOL (CDT) Diagnostics Menu FAULT RECOVERY When a fault is detected by the controller, the controller will attempt to recover from the fault and resume normal operation. In the case of an intermittent problem, such as a loose wiring connection, the controller may be able to recover and operate normally for a while, but the problem should be repaired before placing the vehicle in service.
Page 158: Fault Descriptions
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 “private speed mode”. See Code A, Code B, and Code C on page 11-8. See also Password Tries (OEM Access Level Only) on page 11-11.
Page 159: Thermal Cutback
CONTROLLER DIAGNOSTIC TOOL (CDT) Fault Descriptions THERMAL CUTBACK If the controller heatsink temperature is found to be in excess of 185 °F (±9) (85 °C (±5)) or below –13 °F (±9) (–25 °C (±5)), the thermal cutback fault is detected. What it means: Heatsink temperature rises above 185 °F (85 °C).
Page 160: Main Welded
Fault Descriptions CONTROLLER DIAGNOSTIC TOOL (CDT) What it means: This is a symptom, not a cause. The controller records the number of times this occurs. What to do: Charge batteries. If fault occurs more frequently than normal, test battery pack. Section 14 — Electric Vehicle - Batteries MAIN WELDED If the speed controller detects that the solenoid contacts are welded closed, a main welded fault is detected.
Page 161: Main Dropout (1 Or 2)
CONTROLLER DIAGNOSTIC TOOL (CDT) Fault Descriptions large solenoids should read 180 to 190 ohms; small solenoids 200 to 250 ohms), a broken blue/white wire at the 16-pin controller plug or its terminal is loose in the 16-pin plug. MAIN DROPOUT (1 OR 2) If the controller detects that the solenoid contacts have opened while the vehicle is in operation, a main dropout fault is detected.
Page 162: Fld (Field) Missing
Programming CONTROLLER DIAGNOSTIC TOOL (CDT) FLD (FIELD) MISSING If the speed controller is operating at a duty cycle of greater than 90% (almost full speed) and the field current is less than 3 amps, a field missing fault is detected by the speed controller. CAUTION •...
Page 163: Cloning
CONTROLLER DIAGNOSTIC TOOL (CDT) Favorites CLONING Use the “Restore .cpf File” function to clone a controller with a saved .cpf file stored in the CDT. If using an OEM-level CDT, after you highlight a stored .cpf file and choose “Restore,” a pop-up window will ask whether you want to enable Advanced Cloning (“Yes”/“No”) using the softkeys.
Page 164 HHP Settings CONTROLLER DIAGNOSTIC TOOL (CDT) MENU ITEM DESCRIPTIONS Backlight Here you can set the brightness of the programmer’s LCD display—from 100% to 20%, in 5% increments. Keytone You can choose between several tones to sound each time you press a key, or you can turn the keytone Off for silent programmer operation.
Page 165: Plot & Log
CONTROLLER DIAGNOSTIC TOOL (CDT) Plot & Log PLOT & LOG The Plot & Log menu selection allows the user, with the Plot program, to plot real-time variables on the CDT display screen; or, with the Log program, to create a log file of variable values to view later in a spreadsheet program on a PC. The first step is to add the desired items to the Plot Variable List or the Log Variable List.
Page 166: Cdt Troubleshooting
CDT Troubleshooting CONTROLLER DIAGNOSTIC TOOL (CDT) CDT TROUBLESHOOTING In the event that the handset does not function as described in this manual, the following troubleshooting guide should be studied and the referenced test procedures should be performed to troubleshoot the handset. TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES...
Page 167: Connection Tests
CONTROLLER DIAGNOSTIC TOOL (CDT) Connection Tests TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Disconnect the CDT cord from the vehicle. Handset malfunction Wait a few seconds and reconnect the handset to the vehicle Vehicle batteries – loose terminals or corrosion Section 14 —...
Page 168 Connection Tests CONTROLLER DIAGNOSTIC TOOL (CDT) Place the black (–) probe on each of the pins, one at a time, on the other plug of the adaptor. The multimeter should indicate continuity on only one pin. If any other reading is obtained, the adaptor must be replaced.
Page 169 CONTROLLER DIAGNOSTIC TOOL (CDT) Connection Tests Figure 11-3 Disconnect Four-pin Connector. 2021 Carryall 300 Maintenance and Service Manual Page 11-29...
Page 170 Connection Tests CONTROLLER DIAGNOSTIC TOOL (CDT) Pagination Page Page 11-30 2021 Carryall 300 Maintenance and Service Manual...
Page 171: Section 12 - Electric Vehicle - Electrical System Troubleshooting
SECTION 12 — ELECTRIC VEHICLE - ELECTRICAL SYSTEM TROUBLESHOOTING DANGER Electric Vehicle - Electrical System Troubleshooting • General Warnings WARNING • General Warnings • Shorting of battery terminals can cause personal injury or death. – Do not place component mounting plate directly on top of batteries when removing or installing plate.
Page 172: Key Differences: Excel With Eric Charging System Vs. Powerdrive Chargers
ELECTRIC VEHICLE - ELECTRICAL SYSTEM General Information TROUBLESHOOTING • The Excel minimum motor braking speed has been lowered to almost zero. • Excel has higher energy output during regenerative braking due to the lowered minimum motor braking speed. • The Excel accelerator pedal has more control of downhill speed. •...
Page 173 ELECTRIC VEHICLE - ELECTRICAL SYSTEM TROUBLESHOOTING General Information km/h). If the walk away braking function remains engaged for two seconds or more, a warning buzzer will sound to alert the driver that motor braking has been activated. WARNING • Walk Away Braking will not limit vehicle speed to 3 mph (4.8 km/h) on very steep grades. Do not operate vehicle on slopes exceeding 20% grades.
Page 174: Sonic Weld, Diode, And 10K Ohm Resistor Locations
ELECTRIC VEHICLE - ELECTRICAL SYSTEM Sonic Weld, Diode, and 10k Ohm Resistor Locations TROUBLESHOOTING SONIC WELD, DIODE, AND 10K OHM RESISTOR LOCATIONS 3119 Figure 12-1 Sonic Weld, Diode and 10k Ohm Resistor Locations (Approximate) – CA300 with ERIC Charging Page 12-4 2021 Carryall 300 Maintenance and Service Manual...
Page 175: Troubleshooting
TROUBLESHOOTING THE VEHICLE WITH THE CDT Club Car recommends the use of the CDT handheld programmer for troubleshooting vehicles equipped with the Excel electrical system. Troubleshooting Guide 1 is to be used in conjunction with the CDT handheld programmer. See 11 Controller Diagnostic Tool (CDT)for operating instructions.
Page 176 ELECTRIC VEHICLE - ELECTRICAL SYSTEM Troubleshooting TROUBLESHOOTING TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected motor speed sensor Repair and/or connect the three-pin connector or broken wire to the motor speed sensor Monitor Menu – SPEED PULSES menu item indicates that speed pulses are OFF when Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector...
Page 177 ELECTRIC VEHICLE - ELECTRICAL SYSTEM TROUBLESHOOTING Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected three-pin connector at Repair and/or connect the three-pin connector the MCOR or broken wire to the MCOR Diagnostic Menu – THROTTLE FAULT fault Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector code...
Page 178: Troubleshooting Guide 2
ELECTRIC VEHICLE - ELECTRICAL SYSTEM Troubleshooting TROUBLESHOOTING TROUBLESHOOTING GUIDE 2 In the event that the vehicle is not functioning properly after completing Troubleshooting Guide 1, use Troubleshooting Guide 2. If a CDT handheld programmer is unavailable, use Troubleshooting Guide 2. Page 12-8 2021 Carryall 300 Maintenance and Service Manual...
Page 179 ELECTRIC VEHICLE - ELECTRICAL SYSTEM TROUBLESHOOTING Troubleshooting TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Batteries – batteries discharged Charge batteries Check vehicle wiring. See Sonic Weld, Diode, Batteries – battery connections and 10k Ohm Resistor Locations on page 12-4. Battery charger is connected to the vehicle Disconnect the battery charger from the –...
Page 180 ELECTRIC VEHICLE - ELECTRICAL SYSTEM Troubleshooting TROUBLESHOOTING TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Procedure 12 – Motor Speed Sensor on Speed sensor disconnected or failed page 12-27 To change the programmed top speed of Incorrect speed setting the vehicle, an OEM-level CDT handheld programmer must be used Check vehicle wiring.
Page 181 ELECTRIC VEHICLE - ELECTRICAL SYSTEM TROUBLESHOOTING Troubleshooting TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Procedure 10 – Charger Interlock on page Charger interlock failure 12-24 Vehicle operates, but battery charger does not Battery charger connections – loose plug or Check wire connections and tighten if charge batteries wires at charger, receptacle or batteries...
Page 182: Test Procedures
ELECTRIC VEHICLE - ELECTRICAL SYSTEM Test Procedures TROUBLESHOOTING TEST PROCEDURES Using the following procedures, the entire electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
Page 183 ELECTRIC VEHICLE - ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures CAUTION • Be careful not to damage the wire or terminal when back-probing. • When testing voltage, the batteries must remain connected. • When testing voltage, unless specifically directed to do otherwise in a procedure, connect the black (–) probe of the multimeter to the negative post of battery no.
Page 184 ELECTRIC VEHICLE - ELECTRICAL SYSTEM Test Procedures TROUBLESHOOTING TEST PROCEDURE 1 – Batteries / Voltage Check (BPV) See General Warnings on page 1-1. NOTE: This is a voltage test. The batteries must be properly maintained and fully charged in order to perform the following test procedures. Battery maintenance procedures, including watering information and allowable mineral content, can be found in the Battery section of this manual.
Page 185 ELECTRIC VEHICLE - ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures TEST PROCEDURE 2 – 48-Volt Battery Pack Voltage Under Load See General Warnings on page 1-1. NOTE: This is a voltage test. If necessary, see Testing Basics on page 12-12. Be sure the batteries are fully charged and that the electrolyte level is correct in all cells. Connect the tester leads to the positive (+) post of battery no.1 and negative (–) post of battery no.6 (Figure 12-3, Page 12-15).
Page 186 ELECTRIC VEHICLE - ELECTRICAL SYSTEM Test Procedures TROUBLESHOOTING If no voltage is coming to the Run/Tow Switch, inspect the red-to-pink wire spade connection at the solenoid. Run/Tow Switch Test with the CDT Handset With the Run/Tow switch in the RUN position, connect the CDT to the vehicle. Immediately after the CDT is connected to the vehicle, the screen should display a copyright notice and the CDT model number.
Page 187 ELECTRIC VEHICLE - ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures 2976 Figure 12-4 Testing the Fuse If necessary, see Testing Basics on page 12-12. Access the fuses but do not remove them. Fuses are found at the following locations: – On Controller Mounting Plate: 15-amp fuse to DC/DC converter, 2-amp fuse to connected car device (Guardian/Visage V3 Circuit), and 15-amp fuse to electric powertrain –...
Page 188 ELECTRIC VEHICLE - ELECTRICAL SYSTEM Test Procedures TROUBLESHOOTING 20-Amp ATC Fuse Near MCOR and ATM Fuses Under Front Cowl: With the batteries connected, key switch ON and DC/DC converter operating: NOTE: For these fuses only, connect the black probe of the meter to the 12 volt ground terminal block located under the front cowl.
Page 189 ELECTRIC VEHICLE - ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures TEST PROCEDURE 5 – Key Switch and MCOR Limit Switch Circuit See General Warnings on page 1-1. NOTE: This is a voltage test. The MCOR provides FOOT INPUT to the controller. The key switch provides KEY INPUT to the controller. Key Switch and MCOR Limit Switch Circuit Test with the CDT Handset Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack.
Page 190 ELECTRIC VEHICLE - ELECTRICAL SYSTEM Test Procedures TROUBLESHOOTING NOTE: The easiest way to test the key switch and MCOR Limit Switch is to check the pin 6 green wire in the 16-pin connector. Pin 6 is the end of this circuit. 4.1.
Page 191 ELECTRIC VEHICLE - ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures 3.2. Place the Forward/Neutral/Reverse control (FNR) in the F position. The CDT should indicate that FORWARD INPUT is ON. If the CDT indicates any other reading, check vehicle wiring. See Sonic Weld, Diode, and 10k Ohm Resistor Locations on page 12-4.
Page 192 ELECTRIC VEHICLE - ELECTRICAL SYSTEM Test Procedures TROUBLESHOOTING TEST PROCEDURE 7 – Solenoid Activating Coil See General Warnings on page 1-1. NOTE: This is a resistance test. Be aware that one of two different solenoids may be found on the vehicle. Visually, the production solenoid is smaller than the service replacement.
Page 193 ELECTRIC VEHICLE - ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures 5.2. If pre-charge resistor test is good reinstall. Place the Run/Tow switch in the TOW position and connect the batteries. See Connect the Batteries – Electric Vehicles on page 1-5. TEST PROCEDURE 9 – Solenoid Continuity See General Warnings on page 1-1.
Page 194 ELECTRIC VEHICLE - ELECTRICAL SYSTEM Test Procedures TROUBLESHOOTING Place the Run/Tow switch in the RUN position, turn the key switch to the ON position, place the Forward/Reverse rocker switch in the F position, and press the accelerator pedal. The rear tire should rotate and the multimeter should show a change in resistance.
Page 195 ELECTRIC VEHICLE - ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures If the meter does not indicate continuity, check and repair related connections, Run/Tow switch and wiring. If necessary, replace affected wire harness, charger receptacle or Run/Tow switch. When finished, install 15-amp fuse and fuse cover. TEST PROCEDURE 11 –...
Page 196 ELECTRIC VEHICLE - ELECTRICAL SYSTEM Test Procedures TROUBLESHOOTING WARNING • The key switch should be placed in the OFF position and left in the OFF position for the duration of this test. With the batteries connected, place Run/Tow switch in RUN. Using a multimeter set to 200 volts DC, place red (+) probe on battery no.
Page 197 ELECTRIC VEHICLE - ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures TEST PROCEDURE 12 – Motor Speed Sensor See General Warnings on page 1-1. Motor Speed Sensor Test without any Tool CAUTION • Perform the following procedure only on a level surface. To avoid injury or property damage, ensure that the path of the vehicle is clear before pushing vehicle.
Page 198 ELECTRIC VEHICLE - ELECTRICAL SYSTEM Test Procedures TROUBLESHOOTING 4.1. With Run/Tow switch in the RUN position and using a multimeter set to 20 volts DC, place the black (–) probe on the battery no. 6 (6 x 8-Volt battery set) negative post and place red (+) probe on red wire terminal socket in three-pin connector.
Page 199 ELECTRIC VEHICLE - ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures As the accelerator pedal is pressed, the voltage reading should increase from approximately 5 volts RMS when the MCOR limit switch closes, to approximately 48 volts RMS with the accelerator pedal fully pressed. See following NOTE.
Page 200 ELECTRIC VEHICLE - ELECTRICAL SYSTEM Test Procedures TROUBLESHOOTING TEST PROCEDURE 15 – 16-Pin Connector See General Warnings on page 1-1. Pin 1 – White Pin 5 – Light Blue Pin 9 – Gray Pin 13 – White/Black Pin 2 – Yellow Pin 6 –...
Page 201 ELECTRIC VEHICLE - ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures If 16-pin must be disconnected: Keep the 16-pin connector disconnected from the controller. With Run/Tow switch in the TOW position, reconnect the batteries. See Connect the Batteries – Electric Vehicles on page 1-5. Place the Run/Tow switch in the RUN position and then check the appropriate wires.
Page 202 ELECTRIC VEHICLE - ELECTRICAL SYSTEM Test Procedures TROUBLESHOOTING PERFORM TEST WITH 16-PIN CONTROLLER INPUTS CONNECTED TO CONTROLLER? (IF TEST PROCEDURE YES, BACK-PROBE TO TEST) FORWARD INPUT BPV from Forward/Neutral/Reverse control Pin 8 – Brown (FNR) in FWD (Key switch either ON or OFF) B+ INPUT Pin 9 –...
Page 203 ELECTRIC VEHICLE - ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures If necessary, see Testing Basics on page 12-12. Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles on page 1-5. Remove the instrument panel. See Instrument Panel Removal, Section 4, Page 4-9. Disconnect the orange/white and pink wires from the reverse buzzer.
Page 204 ELECTRIC VEHICLE - ELECTRICAL SYSTEM Test Procedures TROUBLESHOOTING – Condition of the 9-pin connector behind instrument panel. – Condition of the yellow/green wire terminal in the instrument panel wire harness. – Continuity of the wires in the wire harnesses. If no problems exist in the above items, replace the charge indicator light. TEST PROCEDURE 18 –...
Page 205: Section 13 - Electric Vehicle - Electrical Components
SECTION 13 — ELECTRIC VEHICLE - ELECTRICAL COMPONENTS DANGER Electric Vehicle - Electrical Components • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. KEY SWITCH See General Warnings on page 1-1. TESTING THE KEY SWITCH See Test Procedure 5 –...
Page 206: Forward/Neutral/Reverse Control (Fnr)
ELECTRIC VEHICLE - ELECTRICAL Forward/Neutral/Reverse control (FNR) COMPONENTS Figure 13-1 Key Switch FORWARD/NEUTRAL/REVERSE CONTROL (FNR) See General Warnings on page 1-1. TESTING THE FORWARD/NEUTRAL/REVERSE CONTROL (FNR) See Test Procedure 6 – Forward/Neutral/Reverse control (FNR) on page 12-20. FORWARD/NEUTRAL/REVERSE CONTROL (FNR) REMOVAL Disconnect the batteries and discharge the controller.
Page 207: Run/Tow Switch
ELECTRIC VEHICLE - ELECTRICAL COMPONENTS Run/Tow Switch WARNING • Make sure that the vehicle operates in the forward direction when the Forward/Neutral/Reverse control (FNR) is in the F position. • Make sure that the vehicle operates in the reverse direction when the Forward/Neutral/Reverse control (FNR) is in the REVERSE position.
Page 208: Motor Controller Output Regulator (Mcor)
ELECTRIC VEHICLE - ELECTRICAL Motor Controller Output Regulator (MCOR) COMPONENTS MOTOR CONTROLLER OUTPUT REGULATOR (MCOR) See General Warnings on page 1-1. TESTING THE MCOR 11 – MCOR Voltage MCOR REMOVAL Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5.
Page 209: Reverse Buzzer
ELECTRIC VEHICLE - ELECTRICAL COMPONENTS Reverse Buzzer REVERSE BUZZER See General Warnings on page 1-1. TESTING THE REVERSE BUZZER 16 – Reverse Buzzer REVERSE BUZZER REMOVAL Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5.
Page 210: Solenoid
ELECTRIC VEHICLE - ELECTRICAL Solenoid COMPONENTS SOLENOID See General Warnings on page 1-1. The solenoid is located on the driver side of the electrical component mounting plate. TESTING THE SOLENOID 7 – Solenoid Activating Coil SOLENOID REMOVAL Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5.
Page 211: Speed Controller
ELECTRIC VEHICLE - ELECTRICAL COMPONENTS Speed Controller SPEED CONTROLLER See General Warnings on page 1-1. TESTING THE SOLID STATE SPEED CONTROLLER See Test Procedure 13 – A1 and A2 Motor Voltage on page 12-28. SPEED CONTROLLER REMOVAL Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles on page 1-5.
Page 212: Speed Controller Installation
Select Program, Vehicle ID, Vehicle Date of Manufacture and enter the number on the model year and week from the vehicle serial number. 6.7. Select Information, Software Version and verify the value is 13 or higher. If not, contact a Club Car Technical Representative. Page 13-8...
Page 213: Charger Receptacle
ELECTRIC VEHICLE - ELECTRICAL COMPONENTS Charger Receptacle 6.8. Place the Run/Tow switch in the TOW position for 30 seconds. Then return it to RUN. Inspect the vehicle for proper operation. WARNING • Make sure that the vehicle operates in the forward direction when the Forward/Neutral/Reverse control (FNR) is in the F position.
Page 214: Charge Indicator Light
ELECTRIC VEHICLE - ELECTRICAL Charge Indicator Light COMPONENTS Install the three screws (1) that secure the receptacle to the grille. Tighten screws to 16 in·lb (1.8 N·m). Connect three-pin connector. Install cowl. See Cowl Installation on page 4-4. Place the Run/Tow switch in the TOW position and connect the batteries. See Connect the Batteries – Electric Vehicles on page 1-5.
Page 215: Dc/Dc Converter Installation
ELECTRIC VEHICLE - ELECTRICAL COMPONENTS Fuse Block DC/DC CONVERTER INSTALLATION Install the DC/DC converter (5) to the frame and secure with new locknuts (4). Tighten locknuts (4) to 75 in·lb (8.5 N·m). Connect the three pin (1) and the two pin plugs (2) of the wire harness (3) to the DC/DC converter (5) leads. Connect the batteries.
Page 216: Headlight Switch
ELECTRIC VEHICLE - ELECTRICAL Headlight Switch COMPONENTS HEADLIGHT SWITCH See General Warnings on page 1-1. TESTING THE LIGHT SWITCH See Test Procedure 23 – Headlight Switch on page 18-38. HEADLIGHT SWITCH REMOVAL Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5.
Page 217: Headlight Bulb Removal (Halogen)
ELECTRIC VEHICLE - ELECTRICAL COMPONENTS Headlights HEADLIGHT BULB REMOVAL (HALOGEN) Disconnect the batteries. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. Remove cowl. See Cowl Removal, Section 4, Page 4-4. Remove front fenders. See Front Bumper and Side Fender Removal, Section 4, Page 4-8. Rotate (but do not touch) bulb (4) in a 90°...
Page 218 ELECTRIC VEHICLE - ELECTRICAL Headlights COMPONENTS 2993 Figure 13-7 Headlight Assembly Page 13-14 2021 Carryall 300 Maintenance and Service Manual...
Page 219: Usb Receptacle
ELECTRIC VEHICLE - ELECTRICAL COMPONENTS USB Receptacle USB RECEPTACLE The 5-volt, 2.1 amp USB receptacle supplies electricity to power and charge portable devices. The USB receptacle is not for movement of data. The USB receptacle will only operate when a shielded USB cord is connected. When the USB receptacle is not in use, remove the shielded USB cord to prevent battery drain.
Page 220 ELECTRIC VEHICLE - ELECTRICAL USB Receptacle COMPONENTS Connect the USB black wire to the jumper wire (3). Connect the USB red wire to the main harness red wire (2) and the 12V power point (1). Install the cowl. Connect the batteries. Page 13-16 2021 Carryall 300 Maintenance and Service Manual...
Page 221: Section 14 - Electric Vehicle - Batteries
SECTION 14 — ELECTRIC VEHICLE - BATTERIES DANGER Electric Vehicle - Batteries • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area.
Page 222: Battery Testing Basics - 8 Volt
Battery Testing Basics – 8 Volt ELECTRIC VEHICLE - BATTERIES BATTERY TESTING BASICS – 8 VOLT See General Warnings on page 1-1. OBSERVATION Inspect the battery compartment for the following items: • Rusted, corroded, or broken battery posts • Rusted, corroded, loose or broken wires •...
Page 223: Battery Testing - 8 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 224 Battery Regrouping ELECTRIC VEHICLE - BATTERIES 3104 Figure 14-2 Battery Regrouping Process Flow Page 14-4 2021 Carryall 300 Maintenance and Service Manual...
Page 225: Battery Replacement
ELECTRIC VEHICLE - BATTERIES Battery Replacement BATTERY REPLACEMENT See General Warnings on page 1-1. WARNING • Wear steel-toe shoes when replacing batteries. • To prevent electrolyte leakage from the battery vents, batteries must be kept in an upright position. Tipping a battery beyond a 45° angle in any direction can allow a small amount of electrolyte to leak out the vent hole.
Page 226: 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 227: Deionizer
Replace filter immediately if the red light comes ON indicating service is required. Replacement filters are available from Club Car Service Parts. • Inspect the condition of all tubing, connections, and couplers. Make sure that all parts are in good working condition, secure, leak free, and properly connected.
Page 228: Battery Care - Vehicles Equipped With The Single-Point Watering System (Spws)
Battery Care ELECTRIC VEHICLE - BATTERIES Single point watering systems will require seasonal maintenance if vehicles are taken out of service or put into storage for a period of 6 weeks or longer. To prepare the SPWS, ensure the feed tube and coupler are on top of battery. Then, use the following steps to bring vehicle back into service: After the batteries have been fully charged/equalized, connect the system to its water supply for 3 to 5 seconds, then disconnect regardless of whether or not the batteries are completely full.
Page 229: Battery Care - Vehicles Without The Single-Point Watering System (Spws)
• Do not overfill the batteries. NOTE: A battery watering gun or bottle 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 230: Self-Discharge
Battery Care ELECTRIC VEHICLE - BATTERIES 1. Level Indicator 2. Cap 3. Plates Maintain electrolyte level from at least 1/2 inch (13 mm) above plates to 1/4 inch (6 mm) below level indicator. Figure 14-3 Electric Battery Electrolyte Level SELF-DISCHARGE Contaminants on dirty batteries can provide a path for a small current draw that can slowly discharge batteries, thus wasting valuable energy.
Page 231: Vibration Damage
ELECTRIC VEHICLE - BATTERIES Single Point Watering System (SPWS) CAUTION 1. Level Indicator 2. Cap 3. Plates Maintain electrolyte level from at least 1/2 inch (13 mm) above plates to 1/4 inch (6 mm) below level indicator. Figure 14-4 Electric Battery Electrolyte Level Add water only after charging unless the electrolyte is below the level of the plates.
Page 232: Initial Maintenance Of The Spws
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 233 ELECTRIC VEHICLE - BATTERIES Single Point Watering System (SPWS) 3083 Figure 14-5 Connecting Hose with Filter to Water Source Figure 14-6 Checking the Water Flow Rate Completely open the water faucet until the water flows out of the hose-end assembly (3), and note the movement of the red flow indicator balls (6).
Page 234: Battery Storage
Battery Storage ELECTRIC VEHICLE - BATTERIES CAUTION • If at any time water overflows from the batteries, immediately stop the refill process, disconnect the pressure regulator from the battery fill coupling, and call for service. When the red flow indicator balls stop moving, immediately press the grey button to disconnect the hose-end assembly from the battery fill coupling (9), and squeeze the dust cover (10) to lightly secure it to the male connector of the battery fill coupling (Figure 14-7).
Page 235: Section 15 - Electric Vehicle - Battery Charger
WARNING • Only trained technicians should repair or service the charger. Contact your nearest Club Car distributor/dealer. • This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.
Page 236: General Information
This section includes information, troubleshooting and service procedures pertaining to the external high-frequency battery charger (model number IC0650-048-CC). Do not attempt to service a battery charger that has not been properly identified. If a charger cannot be properly identified, contact your local Club Car dealer or distributor. COV-1481 Figure 15-1 High-Frequency Battery Charger –...
Page 237: Usb Service Port
USB SERVICE PORT The ERIC charger has a USB port for use by Club Car authorized technicians for data transfer, reconfiguration, and updates. Keep the USB port cover in place when the port is not in use. See USB Service Port Cleaning and Care on page 15-22.
Page 238: Ac Input Voltage Detection
General Information ELECTRIC VEHICLE - BATTERY CHARGER Onboard Charger: While the charger AC cord is plugged into an electrical outlet, the vehicle control circuit is locked out, preventing operation of the vehicle, as well as the possibility of consequent damage to the charger and the vehicle. AC INPUT VOLTAGE DETECTION The high-frequency charger automatically detects the AC input voltage and will operate at full power if the voltage is within the 100 to 240 VAC range.
Page 239: Onboard Charger Status Indicators
ELECTRIC VEHICLE - BATTERY CHARGER General Information Solid green Charging is complete. Battery pack is fully charged. Solid green Flashing green Charging is in progress. Battery pack has reached a high state of charge. Solid green Charging is in progress. Battery pack has NOT reached a high state of charge. Flashing green AC power to charger is present.
Page 240: Long-Term Storage
General Information ELECTRIC VEHICLE - BATTERY CHARGER Solid green Charging is complete. Battery pack is fully charged. Solid green Flashing green Charging is in progress. Battery pack has reached a high state of charge. Solid green Charging is in progress. Battery pack has NOT reached a high state of charge. Flashing green AC power to charger is present.
Page 241: External Charger Mounting
ELECTRIC VEHICLE - BATTERY CHARGER External Charger Mounting EXTERNAL CHARGER MOUNTING WARNING • Make sure the charger is securely mounted. Do not hang the charger by its handle. • Place all cords so they will not be stepped on, tripped over, or otherwise subjected to damage or stress. CAUTION •...
Page 242: Ac Power Connection
AC Power Connection ELECTRIC VEHICLE - BATTERY CHARGER 1. AC Cord 2. Wire Tie 2758 Figure 15-4 AC Cord Drip-Loop Example AC POWER CONNECTION WARNING • Install surge arrestors on incoming AC power lines. Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightning strikes.
Page 243: The Charge Circuit
NOTE: Make sure that the AC cord provided with your charger has the proper AC plug for your location. If it does not, contact your Club Car representative to obtain the proper cord or plug. Two of these high-frequency chargers can be used on a dedicated 15 or 20 ampere, single-phase branch circuit. This high-frequency charger caps current draw at 6 amps and will operate at full power if the voltage is within the 100 to 240 VAC and 50 to 60 Hz ranges.
Page 244: Battery Charging
Battery Charging ELECTRIC VEHICLE - BATTERY CHARGER 2788 Figure 15-5 Charge Circuit – External High-Frequency Charger BATTERY CHARGING See Dangers and Warnings beginning on page 15-1. DANGER • Charging batteries emit hydrogen gas, that is explosive above 2% air concentration. Charge the batteries in a ventilated area without covers or enclosures.
Page 245: Charging With External Charger
Vehicles should be restricted to 40 to 50 amp hours of discharge between charges until the batteries have been properly seasoned (50 to 70 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 deeply discharging the batteries.
Page 246: Charging With Onboard Charger
Battery Charging ELECTRIC VEHICLE - BATTERY CHARGER Turn off all accessories. Connect the AC cord to the charger. Connect the AC cord to the power source. CAUTION • Incorrect removal and installation of the DC cord can cause DC cord damage and vehicle charger receptacle damage.
Page 247 ELECTRIC VEHICLE - BATTERY CHARGER Battery Charging Figure 15-7 AC Cord Before vehicle operation: 4.1. Disconnect the AC cord from the power source. 4.2. Retract the AC cord. 2021 Carryall 300 Maintenance and Service Manual Page 15-13...
Page 248: Algorithm
Club Car only recommends OEM replacement batteries. Contact your authorized Club Car dealer/distributor with any questions about battery and charger compatibility or algorithm updates.
Page 249 ELECTRIC VEHICLE - BATTERY CHARGER Algorithm Go to CHARGER/RESP/Battery charger serial number/SETTING (Figure 15-9). G-130898-000051 Figure 15-9 Setting.txt File Location Open the Setting.txt file (Figure 15-10). G-130898-000052 Figure 15-10 Setting.txt File The Active Charging Profile (1) displays the active algorithm. The Available Charging Profile(s) (2) displays the algorithms that are loaded on the battery charger.
Page 250 Battery Charger With USB. Format a USB 2.0 flash drive as FAT16 or FAT32. Make sure the USB is blank. Login to Club Car Links via https://www.clubcar.com. Click on the Tech/Warranty drop-down menu and select Service and Warranty Bulletins (Figure 15-11).
Page 251 ELECTRIC VEHICLE - BATTERY CHARGER Algorithm Click on the Trojan - ERIC Shelf Charger Algorithm link (Figure 15-12). G-130898-000053 Figure 15-12 Trojan - ERIC Shelf Charger Algorithm Open the Trojan - ERIC Shelf Charger Algorithm.zip file. Copy the CHARGER folder to the USB flash drive (Figure 15-13). G-130898-000049 Figure 15-13 CHARGER Folder Safely eject the USB flash drive from the computer.
Page 252 Algorithm ELECTRIC VEHICLE - BATTERY CHARGER Wait until only the blue light (1) is on (Figure 15-14). Figure 15-14 USB Dust Cover Remove the USB dust cover (2). Connect the USB flash drive to the battery charger. The blue light and green triangle light (3) will turn off and on for approximately three minutes.
Page 253: Onboard Battery Charger
ELECTRIC VEHICLE - BATTERY CHARGER Algorithm ONBOARD BATTERY CHARGER How To View Algorithm - Onboard Battery Charger Disconnect the AC cord from the battery charger. Wait 30 seconds. Push and hold the Select Charge Profile button (1) (Figure 15-15, Page 15-19). Figure 15-15 Algorithm Change While pushing the Select Charge Profile button, connect the AC cord to the battery charger.
Page 254 Algorithm ELECTRIC VEHICLE - BATTERY CHARGER Figure 15-16 Algorithm Change While pushing the Select Charge Profile button, connect the AC cord to the battery charger. Continue to push the Select Charge Profile button until the Error/Fault Indicator (2) illuminates amber and the Battery Charging Indicator (3) is flashing green.
Page 255: Update Battery Charger With Usb
Algorithm UPDATE BATTERY CHARGER WITH USB Contact Club Car to obtain the required algorithm, software, and settings files for the correct battery charger and vehicle model. Format a USB 2.0 flash drive as FAT16 or FAT32. Make sure that the USB flash drive is blank.
Page 256: Charger Maintenance
Charger Maintenance ELECTRIC VEHICLE - BATTERY CHARGER CHARGER MAINTENANCE See General Warnings on page 1-1. To ensure trouble-free performance, it is very important to follow an established preventive maintenance program. Regular and consistent maintenance can prevent vehicle downtime and expensive repairs that can result from neglect. Any charger not functioning correctly should be removed from use until it is properly repaired.
Page 257: Charger Troubleshooting
ELECTRIC VEHICLE - BATTERY CHARGER Charger Troubleshooting CHARGER TROUBLESHOOTING See General Warnings on page 1-1. DANGER • Do not touch any wire or component in the battery charger while AC power is present. Failure to heed this warning will result in an electric shock. WARNING •...
Page 258: Terminal Block Cover
When the blue AC status indicator light comes on, reconnect the DC cord under the rear-facing seat. If the triangular status indicator light comes on, contact your Club Car dealer. If the light does not come back on, attempt to charge the vehicle as usual.
Page 259: External Charger Troubleshooting Indicators
ELECTRIC VEHICLE - BATTERY CHARGER Charger Troubleshooting EXTERNAL CHARGER TROUBLESHOOTING INDICATORS If a fault occurs, count the number of red flashes (on the charger or dash) between pauses and refer to the table below: EXTERNAL CHARGER TROUBLESHOOTING GUIDE CHECK STATUS STATUS POSSIBLE CAUSES STATUS...
Page 260 Charger Troubleshooting ELECTRIC VEHICLE - BATTERY CHARGER EXTERNAL CHARGER TROUBLESHOOTING GUIDE 1. Erroneous event (an unknown variable; Reset charger power. See Resetting Power – External something occurred to Charger on page 15-24. Reconnect DC cord to vehicle. the charger or vehicle that If status goes away, continue using charger.
Page 261: Onboard Charger Fault Codes
ELECTRIC VEHICLE - BATTERY CHARGER Charger Troubleshooting ONBOARD CHARGER FAULT CODES The “E” and “F” codes will appear in the display panel followed by three numbers and a period to indicate the different conditions. ONBOARD CHARGER FAULT CODES FAULT CODE DESCRIPTION SOLUTIONS F-0-0-1...
Page 262 Charger Troubleshooting ELECTRIC VEHICLE - BATTERY CHARGER ONBOARD CHARGER FAULT CODES Possible causes: Poor battery health, discharged battery, battery not connected correctly, and/or high parasitic loads on the battery while it is charging. • Replace the battery pack. E-0-0-7 Battery amp hour limit reached •...
Page 263: Test Procedures
ELECTRIC VEHICLE - BATTERY CHARGER Test Procedures ONBOARD CHARGER FAULT CODES There has been a problem connecting or disconnect- ing the USB flash drive. • Disconnect and reconnect the USB flash drive. E-0-1-7 USB error • If the problem persists, remove AC and battery for E-0-2-7 minimum 30 seconds and retry charger.
Page 264 Test Procedures ELECTRIC VEHICLE - BATTERY CHARGER 3.1. Verify that the 10-gauge red wire from the charger receptacle is connected to the large post of solenoid with 6-gauge red wire (Figure 15-5, Page 15-10). 3.2. Verify that the 10-gauge black wire from the charger receptacle is connected to the B- terminal of controller. 3.3.
Page 265 ELECTRIC VEHICLE - BATTERY CHARGER Test Procedures With a multimeter set to 500 volts AC, check incoming AC voltage. Insert multimeter test probes into AC wall outlet; voltage should be between 85 and 270 volts. See AC Input Voltage Detection on page 15-4. If proper voltage is not present, have building wiring checked by a licensed electrical contractor.
Page 266: External Charger Repairs
External Charger Repairs ELECTRIC VEHICLE - BATTERY CHARGER EXTERNAL CHARGER REPAIRS See General Warnings on page 1-1. WARNING • Knowledge of battery charger wiring and component terminology is required before attempting any repair (Figure 15-5, Page 15-10). • Prior to servicing the charger, disconnect the DC plug from the vehicle charger receptacle and the AC cord from the AC outlet.
Page 267: Terminal Block Cover Installation
ELECTRIC VEHICLE - BATTERY CHARGER External Charger Repairs 2791 Figure 15-19 Terminal Block Cover Mounting Tabs TERMINAL BLOCK COVER INSTALLATION WARNING • The terminal block cover (3) on the DC terminal block (4) must be installed properly to comply with UL code.
Page 268: Handle Installation
External Charger Repairs ELECTRIC VEHICLE - BATTERY CHARGER HANDLE INSTALLATION Place handle (9) onto charger and seat it onto mounting bosses of charger. See following NOTE. NOTE: The handle (9) features locating tabs to aid installation. Secure handle (9) to charger with two torx screws (8). Tighten screws (8) to 39.8 in·lb (4.5 N·m). FOOT REMOVAL Disconnect DC cord (1) from vehicle.
Page 269: Section 16 - Electric Vehicle - Motor
The vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. The shunt-wound motor is designed for use in Excel System vehicles. 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 270 External Motor Testing ELECTRIC VEHICLE - MOTOR TEST PROCEDURE 1 – Motor Continuity Test Disable the vehicle. Disconnect the batteries and discharge the controller. Disconnect the wires from the motor. Set a multimeter to check for continuity. Check the continuity readings between the motor terminals below: MOTOR TERMINALS CONTINUITY TEST RESULT...
Page 271 ELECTRIC VEHICLE - MOTOR External Motor Testing TEST PROCEDURE 3 – Armature Circuit Open See General Warnings on page 1-1. Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. Disconnect wires from the A1 and A2 terminals on the motor using two wrenches to prevent posts from turning. Set a multimeter to 200 ohms and place the red (+) probe on the A1 terminal and black (–) probe on the A2 terminal.
Page 272: Motor Removal
Motor Removal ELECTRIC VEHICLE - MOTOR MOTOR REMOVAL See General Warnings on page 1-1. Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. Disconnect wires from the terminals on the motor using two wrenches to prevent posts from turning. Label the wires to ensure proper reconnection.
Page 273 ELECTRIC VEHICLE - MOTOR Motor Removal Figure 16-3 Lower Axle Remove the bolts and lock washers that secure the motor to the transaxle (Figure 16-25, Page 16-18). See following CAUTION. CAUTION • Do not position fingers under motor when sliding motor off of the input shaft in step 9. Fingers may get pinched when motor disengages.
Page 274: Motor Disassembly
Motor Disassembly ELECTRIC VEHICLE - MOTOR MOTOR DISASSEMBLY Before beginning disassembly, place match marks on the motor end cap and motor frame. Remove speed sensor and magnet. 2.1. Remove the two screws (25) and clamp that secure the speed sensor (10) to the end cap (11) (Figure 16-15, Page 16-12).
Page 275 ELECTRIC VEHICLE - MOTOR Motor Disassembly CAUTION • Removing the armature from the end cap requires two people: one to operate the press, and another to hold the armature. Failure to heed this CAUTION could result in personal injury and/or damage to the armature resulting from an unsupported armature falling after it becomes disengaged from the end cap bearing.
Page 276: Motor Component Testing And Inspection
Motor Component Testing and Inspection ELECTRIC VEHICLE - MOTOR Figure 16-10 Brush Rigging Figure 16-11 Bearing Retaining Ring MOTOR COMPONENT TESTING AND INSPECTION See General Warnings on page 1-1. ARMATURE INSPECTION AND TESTING Remove the motor from the vehicle. See Motor Removal on page 16-4. Remove the end cap and armature by performing steps 1 through 7 of Motor Disassembly on page 16-6.
Page 277 ELECTRIC VEHICLE - MOTOR Motor Component Testing and Inspection CAUTION • Do not use emery cloth to polish the commutator. Particles of emery are conductive and may short-circuit the commutator bars. Do not use oil or lubricants on the commutator or brushes. NOTE: Oil on the commutator may indicate a faulty transaxle input shaft oil seal.
Page 278: Motor Frame And Field Windings Inspection
Motor Component Testing and Inspection ELECTRIC VEHICLE - MOTOR MOTOR FRAME AND FIELD WINDINGS INSPECTION Remove the motor from the vehicle. See Motor Removal on page 16-4. Remove the and cap and armature by performing steps 1 through 7 of Motor Disassembly on page 16-6. Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings.
Page 279 ELECTRIC VEHICLE - MOTOR Motor Component Testing and Inspection Bearing Inspection NOTE: Replacement of the end cap bearing is highly-recommended if the end cap is removed from the motor. The following procedure is provided as a guideline for determining general bearing failure. Remove the motor from the vehicle.
Page 280 Motor Component Testing and Inspection ELECTRIC VEHICLE - MOTOR 2613 Figure 16-15 Electric Motor (EJ8-4001A) Page 16-12 2021 Carryall 300 Maintenance and Service Manual...
Page 281: Reconditioning The Motor
ELECTRIC VEHICLE - MOTOR Reconditioning the Motor RECONDITIONING THE MOTOR See General Warnings on page 1-1. Motor reconditioning must be performed by a qualified motor repair technician. The use of proper tools and procedures is absolutely essential for successful motor reconditioning. MOTOR SPECIFICATIONS Any rework must be performed by a qualified technician.
Page 282 Motor Assembly ELECTRIC VEHICLE - MOTOR Figure 16-16 Brush Rigging Figure 16-17 Retracted Brushes Figure 16-18 Armature Installation Figure 16-19 Brush Setting With the brushes retracted, use an arbor press to press the armature shaft into the end cap bearing (Figure 16-18, Page 16-14).
Page 283: Motor Installation
ELECTRIC VEHICLE - MOTOR Motor Installation Install clamp (3) onto sensor wires (4) and secure with other screw (5) finger-tight. Ensure clamp (3) and wires (4) are oriented as shown (Figure 16-20, Page 16-15). Tighten both screws (2 and 5) to 20 in·lb (2.2 N·m). Make sure the armature turns freely.
Page 284 Motor Installation ELECTRIC VEHICLE - MOTOR inch inch 1/8 INCH 3/8 INCH (9.5 MM) (3.1 MM) Figure 16-21 Grease on Putty Knife Figure 16-22 Application of grease to Input Shaft Grooves 2.6. Check the chamfer (1) and end (2) of the input shaft to ensure these areas are completely clean of grease as shown (Figure 16-23, Page 16-17).
Page 285 ELECTRIC VEHICLE - MOTOR Motor Installation 1/16 INCH (1.6 MM) Figure 16-23 Clean Chamfer and Input Shaft End Figure 16-24 Gap at Motor and Transaxle 4.2. Loosely install the three bolts and lock washers that secure the motor to the transaxle (Figure 16-25, Page 16-18).
Page 286 Motor Installation ELECTRIC VEHICLE - MOTOR Insert the mounting bolts through the spring shackles and the bushings in the leaf spring eyes and install lock nuts. Tighten the bolts to 23 ft·lb (31 N·m). See Multi-Leaf Spring Installation, Section 9, Page 9-5. Install the shock absorbers.
Page 287: Section 17 - Electric Vehicle - Transaxle
SECTION 17 — ELECTRIC VEHICLE - TRANSAXLE DANGER Electric Vehicle - Transaxle • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. LUBRICATION See General Warnings on page 1-1. There are two plugs located on the lower half of the transaxle housing. The upper plug (21) (as viewed when the vehicle is on a level surface) is used as a lubricant level indicator (Figure 17-5, Page 17-3).
Page 288 Axle Bearing and Shaft ELECTRIC VEHICLE - TRANSAXLE 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. Inspect the axle shaft assembly to be sure the bearing and collar have not slipped and are still seated against the shoulder on the axle shaft.
Page 289 ELECTRIC VEHICLE - TRANSAXLE Axle Bearing and Shaft Figure 17-5 Transaxle – Type G 2021 Carryall 300 Maintenance and Service Manual Page 17-3...
Page 290: Axle Bearing
Axle Bearing and Shaft ELECTRIC VEHICLE - TRANSAXLE Axle Shaft and Oil Seal Installation If previously removed, install a new oil seal. 1.1. Clean seal seat in the adapter ring (39) (Figure 17-3, Page 17-2). 1.2. Place a new seal (15) in the adapter ring with the seal lip facing toward the adapter ring lip (Figure 17-3, Page 17-2).
Page 291: Transaxle
ELECTRIC VEHICLE - TRANSAXLE Transaxle TRANSAXLE See General Warnings on page 1-1. TRANSAXLE REMOVAL Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. Place chocks at the front wheels and slightly loosen lug nuts on both rear wheels. Place a floor jack under the transaxle and raise the rear of the vehicle.
Page 292 Transaxle ELECTRIC VEHICLE - TRANSAXLE 2629 2631 Figure 17-8 Disconnect Shocks Figure 17-9 Detach Spring From Shackles Disconnect the shock absorbers from their lower mounts (Figure 17-8, Page 17-6). Disconnect the four motor wires. Use two wrenches to prevent the post from turning. With a floor jack supporting the transaxle, remove lower spring shackle nuts and bolts.
Page 293 ELECTRIC VEHICLE - TRANSAXLE Transaxle CAUTION 1. Motor Mounting Bolts 2. Input Pinion Gear 3. Intermediate Gear Assembly 4. Differential Gear Case 2639 Figure 17-11 Motor Mounting Bolts and Gear Assembly Figure 17-10 Detach Axle From Leaf Springs Carefully remove the motor from the transaxle. Slide the motor away from the transaxle until the motor spline becomes disengaged from the input shaft, then lift motor out.
Page 294: Transaxle Disassembly, Inspection, And Assembly
Transaxle Disassembly, Inspection, and Assembly ELECTRIC VEHICLE - TRANSAXLE TRANSAXLE DISASSEMBLY, INSPECTION, AND ASSEMBLY See General Warnings on page 1-1. TRANSAXLE DISASSEMBLY AND INSPECTION To detach axle tubes (14 and 35) from the transaxle housing, remove the bolts (8) (Figure 17-5, Page 17-3). Remove 11 bolts (24) that hold housing together.
Page 295 ELECTRIC VEHICLE - TRANSAXLE Transaxle Disassembly, Inspection, and Assembly Disassemble the differential gear case: 8.1. Remove the hex bolts (33) and the ring gear (32) from the differential case (Figure 17-5, Page 17-3). 8.2. Remove the ring gear. 8.3. Separate the differential gear case housing. If necessary, install two of the hex bolts (removed previously in step 8.1) into the differential gear unit and, while holding the unit slightly above the work area, lightly tap the bolt heads (Figure 17-14, Page 17-9).
Page 296: Transaxle Assembly
Transaxle Disassembly, Inspection, and Assembly ELECTRIC VEHICLE - TRANSAXLE NOTE: Damaged or worn gears should be replaced as sets. TRANSAXLE ASSEMBLY CAUTION • Do not press against the bearing outer race. • The housing and all parts must be wiped clean and dry before reassembly. If bearings (13) were removed during disassembly, install new bearings using an arbor press (Figure 17-5, Page 17-3).
Page 297 ELECTRIC VEHICLE - TRANSAXLE Transaxle Disassembly, Inspection, and Assembly WARNING • Be sure retaining ring is properly seated in its groove. If ring is not properly installed, the axle assembly will separate from the transaxle and damage the axle assembly and other components. Loss of vehicle control could result in severe personal injury or death.
Page 298: Transaxle Installation
Transaxle Installation ELECTRIC VEHICLE - TRANSAXLE TRANSAXLE INSTALLATION See General Warnings on page 1-1. If using a chain hoist, raise the vehicle and place transaxle in position on the jack stands. If using a floor jack, lower the jack stands to their lowest settings and place the transaxle in position on the jack stands. Align the center hole in the saddle of the transaxle with the pilot bolt in the leaf spring assembly.
Page 299: Section 18 - Gasoline Vehicle - Troubleshooting And Electrical System
SECTION 18 — GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM DANGER Gasoline Vehicle - Troubleshooting and Electrical System • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION WARNING • To prevent damage to the ECU, never mix the black and gray connectors that attach to it. The black connector is tethered to the ECU mounting plate to help avoid installing it in the gray port.
Page 300: Malfunction Indicator Light
GASOLINE VEHICLE - TROUBLESHOOTING General Information AND ELECTRICAL SYSTEM The low oil warning light gives a visual indication of an oil level problem. If equipped with Kit Instruction TPCC040401EN019 Edition B ECH440 Engine Oil Dilution Prevention, the engine temperature is too high Figure 18-1 Low Oil Warning Light STATUS CONDITION...
Page 301: Ground Locations
GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide STATUS CONDITION Normal Operation ON (for three seconds) Normal Operation when the key switch is set to ON. The engine temperature is at or above 283.1°F (139.5°C). When possible: Stop the vehicle. FLASHING Turn the key to OFF.
Page 302: Gasoline Powertrain
GASOLINE VEHICLE - TROUBLESHOOTING Troubleshooting Guide AND ELECTRICAL SYSTEM GASOLINE POWERTRAIN TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION If a engine oil dilution prevention kit has The engine temperature is too high. The ECU been installed, open the engine fan louver. Engine starts to run rough and continuously is derating the engine.
Page 303 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Transmission shifter linkage is binding or is See the Transaxle (ED65) Section out of adjustment Insufficient (low) level of lubricant or wrong Transmission does not engage or disengage See the Transaxle (ED65) Section type of lubricant in transmission smoothly.
Page 304: Electrical System
GASOLINE VEHICLE - TROUBLESHOOTING Electrical System AND ELECTRICAL SYSTEM ELECTRICAL SYSTEM The electrical system on the gasoline vehicle is 12 volts DC with negative (–) ground to frame, and consists of the following circuits that are easily identified: • Starter Circuit •...
Page 305: Test Procedures
GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURES Using the following procedures, the entire electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
Page 306 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM 2 – Fuses 3 – Ground Cables 4 – Key Switch (Start Circuit) - Pedal-Start Vehicles Only 5 – Key Switch (Engine Kill Circuit) - Pedal-Start Vehicles Only 6 – Accelerator Pedal Limit Switch – Pedal-Start Vehicles Only 7 –...
Page 307 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 1 – Battery See General Warnings on page 1-1. DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working near a battery.
Page 308 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM IF TEMPERATURE IS MINIMUM CRANKING VOLTAGE 70 °F (20 °C and above) 9.6 V 60 °F (16 °C) 9.5 V 50 °F (10 °C) 9.4 V 40 °F (4 °C) 9.3 V 30 °F (-1 °C) 9.1 V 20 °F (-7 °C)
Page 309 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 2 – Fuses See General Warnings on page 1-1. WARNING • Failure to use properly rated fuse can result in a fire hazard. NOTE: These vehicles predominately use a combination of ATC-style and ATM-style blade fuses. A single ABC-style glass fuse is used for the Guardian/Visage 4-pin connector that is labeled “V3 circuit”...
Page 310 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM 5-amp ATM Fuse Only: With the key switch in the ON position: 4.1. Probe the two, small metal contacts on the top of the fuse (Figure 18-2, Page 18-11). 4.2. Each contact should show battery voltage. 4.3.
Page 311 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 3 – Ground Cables See General Warnings on page 1-1. NOTE: This is a continuity test for the main ground wire of the vehicle. An additional ground wire is located on top of the fuel tank.
Page 312 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 4 – Key Switch (Start Circuit) - Pedal-Start Vehicles Only See General Warnings on page 1-1. NOTE: This is a voltage test. The key switch provides power and KEY INPUT to the ECU. If necessary, see Testing Basics.
Page 313 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 5 – Key Switch (Engine Kill Circuit) - Pedal-Start Vehicles Only See General Warnings on page 1-1. NOTE: This is a continuity test. If necessary, see Testing Basics. Disconnect battery and spark plug wire. Remove the instrument panel.
Page 314 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 6 – Accelerator Pedal Limit Switch – Pedal-Start Vehicles Only See General Warnings on page 1-1. NOTE: This is a continuity test. The accelerator pedal limit switch (1) is the top switch located in the electrical component box (Figure 18-5). There is a green wire and a pink wire connected to this limit switch.
Page 315 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 7 – Solenoid - Pedal-Start Vehicles Only See General Warnings on page 1-1. NOTE: This is a resistance and voltage test. If necessary, see Testing Basics. Remove the electrical component box cover (1) (Figure 18-6). 3025B Figure 18-6 Solenoid Wires Make sure that the wires are connected correctly and are tight.
Page 316 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM Check the voltage between the empty large post (1) and ground (Figure 18-7, Page 18-18). WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 3027B Figure 18-7 Solenoid Voltage Test With accelerator pedal in the UP position: The meter should read no voltage. 10.1.
Page 317 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 8 – Maintenance/Operate Switch – Pedal-Start Vehicles See General Warnings on page 1-1. NOTE: This is a continuity test. The Maintenance/Operate Switch is also known as the Neutral Lockout Switch. If necessary, see Testing Basics.
Page 318 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 9 – Neutral Lockout Limit Switch – Pedal-Start Vehicles Only See General Warnings on page 1-1. NOTE: This is a continuity test. This switch is located on the transaxle. A black/white wire, a gray wire, and a red wire are connected to this limit switch with a 3-pin connector.
Page 319 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 10 – Kill Limit Switch – Pedal-Start Vehicles Only See General Warnings on page 1-1. NOTE: This is a continuity test. The kill limit switch (1) is the lower of the two limit switches located in the electrical component box (Figure 18-10). There is a white/black wire and a blue wire connected to this limit switch.
Page 320 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 476B Figure 18-11 Kill Limit Switch Test 8.1. If there is continuity, replace the kill limit switch. 8.2. If there is no continuity, go to the next step. Press the lever and check for continuity.
Page 321 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 3029B Figure 18-12 Jumper Wire Ground – DF to A1 Cover terminal on yellow wire to make sure it will not short to ground. Use a jumper wire (3) to ground DF terminal to A1 terminal (4). Set the multimeter 20 VDC.
Page 322 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM MOTOR TERMINALS CONTINUITY TEST RESULT A1 to A2 Continuity F1 to F2 A1 to F1 No Continuity A1 to F2 A2 to F1 No Continuity A2 to F2 A1 to Ground No Continuity A2 to Ground F1 to Ground...
Page 323 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures – A grounded armature/commutator. – A grounded A1 or A2 terminal. Put the red (+) probe on the F1 terminal and the black (–) probe on the F2 terminal. The reading should be between approximately 0.1 and 0.3 ohms.
Page 324 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 13 – Voltage Regulator See General Warnings on page 1-1. NOTE: This is a voltage test. Keep the battery connected while performing this test procedure. If necessary, see Testing Basics. Disable the vehicle.
Page 325 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 15.4.1. If the starter/generator is good, replace the voltage regulator. TEST PROCEDURE 14 – Ignition Spark See General Warnings on page 1-1. NOTE: Keep the battery connected while performing this test procedure. ®...
Page 326 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 15 – Reverse Buzzer and Reverse Buzzer Limit Switch See General Warnings on page 1-1. NOTE: Reverse Buzzer: This is a voltage test. A reverse buzzer is mounted on the back side of the instrument panel. On some models, another reverse buzzer is also mounted on a bracket at the left rear of the vehicle.
Page 327 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 16 – Malfunction Indicator Light (MIL) See General Warnings on page 1-1. NOTE: This is a voltage test. If necessary, see Testing Basics. Remove the instrument panel. Make sure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Turn the key switch to ON.
Page 328 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM 3030C Figure 18-16 Battery Test (Under Load) Put the black (–) probe on the negative (–) battery post. Turn the key switch to ON. Make sure that the FNR is in N, and push the accelerator pedal. NOTE: With the accelerator pedal pushed, the battery is under load.
Page 329 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 19 – Fuel Pump See General Warnings on page 1-1. WARNING • To avoid the possibility of fire or explosion, make sure the fuel tank cap is securely in place while performing this test procedure.
Page 330 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM 6.2.2. If there is voltage, check the fuel pump resistance. Fuel Pump Resistance Procedure If necessary, see Testing Basics. Disconnect the battery. Disconnect the fuel pump connector from the top of the fuel pump module. Set the multimeter to 200 Ohms.
Page 331 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Wire Color Description Switched 12V Power Constant 12V Power Open Malfunction Indicator Light (MIL) White Ground Kill Wire Green Low Oil Light Black / White Fuel Pump Open Figure 18-19 ECU Connector 2021 Carryall 300 Maintenance and Service Manual Page 18-33...
Page 332 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 20 – Fuel Level Sending Unit See General Warnings on page 1-1. WARNING • To avoid the possibility of fire or explosion, make sure the fuel tank cap is securely in place while performing this test procedure.
Page 333 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures FLOAT POSITION RESISTANCE READING FUEL GAUGE READINGS Lower position (tank empty) 250 ohms (±10) Empty Center position (tank half full) 141 ohms (±8) Half full Upper position (tank full) 33.3 ohms (±6) Full 5.1.
Page 334 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 21 – Fuel Gauge See General Warnings on page 1-1. NOTE: This is a voltage test. 1. Black 2. Red/White 4. Purple 6. Black 7. White Figure 18-21 Fuel Gauge/Hour Meter If necessary, see Testing Basics.
Page 335 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Put the black (–) probe on terminal 1 of the fuel gauge/hour meter with the black wire (3) connected. Turn the key switch ON. The voltage reading should be the same as the battery voltage reading recorded earlier. 11.1.
Page 336 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 23 – Headlight Switch See General Warnings on page 1-1. NOTE: The headlight circuit is protected by the 20-amp fuse. Check the fuse before this procedure is performed. See Test Procedure 2 – Fuses on page 18-11. This is a voltage test.
Page 337 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 24 – Voltage at Headlight Socket See General Warnings on page 1-1. NOTE: This is a voltage test. If necessary, see Test Basics. Inspect the wires at the light bulb socket. Make sure the wires are securely fastened to the contacts inside the socket and that wires are installed correctly.
Page 338 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 25 – Voltage Limiter See General Warnings on page 1-1. NOTE: This is a diode test. The voltage limiter is a diode. Diodes are designed to conduct current in one direction only. See following NOTE. NOTE: If the voltage limiter conducts current in both directions, the diode has failed closed.
Page 339 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 26 – 4-Pin Connector (for Connected Car Device) See General Warnings on page 1-1. NOTE: This is a voltage and continuity test. The Connected Car Device 4-pin connector is used for Guardian/Visage and is labeled “V3 circuit” on the main wire harness.
Page 340 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM 9.2. If the voltage is incorrect, check the wiring and then the ECU. See following NOTE. NOTE: If pin 4 has no voltage, the ECU LIN (Local Interconnect bus) may have failed. If the vehicle does not use Guardian or Visage, the vehicle can be driven and will not show any symptoms.
Page 341 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 29 – Solenoid - Key-Start Vehicles Only See General Warnings on page 1-1. NOTE: This is a resistance and voltage test. If necessary, see Testing Basics. Remove the electrical component box cover (1) (Figure 18-27). 3025B Figure 18-27 Solenoid Wires Make sure that the wires are connected correctly and are tight.
Page 342 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 3027B Figure 18-28 Solenoid Voltage Test 6.4. With key switch in the OFF and ON positions: The multimeter should read no voltage. 6.4.1.
Page 343 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 30 – Maintenance/Operate Switch – Key-Start Vehicles See General Warnings on page 1-1. NOTE: This is a continuity test. The Maintenance/Operate Switch is also known as the Neutral Lockout Switch. If necessary, see Testing Basics.
Page 344 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM TEST PROCEDURE 31 – Charging Diode (Generator Circuit) – Key-Start Vehicles Only See General Warnings on page 1-1. WARNING • Incorrect wiring could result in severe injury or death. • Diode and solenoid connections must have correct polarity. •...
Page 345 GASOLINE VEHICLE - TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Connect the black (–) multimeter probe to the red lead of the charging diode. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1700-30100-10384 Figure 18-31 Diode Test – Probes Reversed Connect the red (+) multimeter probe to the white lead of the charging diode.
Page 346 GASOLINE VEHICLE - TROUBLESHOOTING Test Procedures AND ELECTRICAL SYSTEM Pagination Page Page 18-48 2021 Carryall 300 Maintenance and Service Manual...
Page 347: Section 19 - Gasoline Vehicle - Electrical Components
SECTION 19 — GASOLINE VEHICLE - ELECTRICAL COMPONENTS DANGER Gasoline Vehicle - Electrical Components • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION WARNING • To prevent damage to the ECU, never mix the black and gray connectors that attach to it. The black connector is tethered to the ECU mounting plate to help prevent accidentally installing it in the gray port.
Page 348: Disassembly Of The Starter/Generator To Service The Brushes
GASOLINE VEHICLE - ELECTRICAL Starter/Generator COMPONENTS 3033C Figure 19-1 Starter/Generator Wiring Loosen the pivot nuts (1) and pivot bolts (2) (Figure 19-2, Page 19-2). 2997B Figure 19-2 Starter/Generator Removal Remove the adjustment nut (3), washer (4) and adjustment bolt (5). Lower the starter/generator and remove the belt (6) from the pulley.
Page 349: Brush Inspection And Replacement
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Starter/Generator NOTE: If the brushes are not removed, contact between the brushes and commutator as the commutator end cover is being removed or installed could damage the brushes. Lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover.
Page 350: Starter/Generator Assembly
GASOLINE VEHICLE - ELECTRICAL Starter/Generator COMPONENTS Install the four brushes (27) into their holders and insert the four brush springs (28) (Figure 19-4, Page 19-3). 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 19-6, Page 19-4).
Page 351: Disassembly Of The Starter/Generator To Service The Armature/Commutator
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Starter/Generator Figure 19-7 Pull Brushes Away From Center of the Commutator End Cover DISASSEMBLY OF THE STARTER/GENERATOR TO SERVICE THE ARMATURE/COMMUTATOR Remove the commutator end cover to prevent damage to the brushes and armature. To separate armature and output end cover assembly from the field coil housing, first remove the two securing bolts (43).
Page 352: Bearing Cleaning And Inspection
GASOLINE VEHICLE - ELECTRICAL Starter/Generator COMPONENTS 1342 Figure 19-8 Output End Cover Assembly, Armature and Housing BEARING CLEANING AND INSPECTION Using a clean cloth, wipe the carbon dust from the two bearings. Inspect bearings by spinning them by hand and checking for both axial (A) and radial (B) play (Figure 19-9, Page 19-6).
Page 353: Bearing Removal
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Starter/Generator BEARING REMOVAL Place the wedge attachment tool between the bearing and the armature. Make sure the wedge attachment tool is supporting the inner race of the bearing. If a press is not available, secure a bearing puller to the wedge attachment tool and pull the bearing off of the end of the armature shaft.
Page 354: Commutator Cleaning And Inspection
GASOLINE VEHICLE - ELECTRICAL Starter/Generator COMPONENTS Figure 19-11 Field Coil Assembly COMMUTATOR CLEANING AND INSPECTION Clean the carbon dust, dirt and oil from the commutator. Visually inspect the commutator for worn, burned or glazed areas. Check for loose or raised commutator bars. Slight roughness of the commutator can be polished away with 400 grit (or finer) sandpaper.
Page 355: Armature Ground Test
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Starter/Generator 1. Measure each position in two places, 90 degrees apart Figure 19-12 Inspect Commutator ARMATURE GROUND TEST CAUTION • Do not submerge armature in solvent. NOTE: Before testing, wipe the armature with a clean cloth and remove carbon dust and metal particles from between commutator bars.
Page 356: Visual Inspection Of Field Coils
GASOLINE VEHICLE - ELECTRICAL Starter/Generator COMPONENTS WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 200 Ohms Setting 2. Commutator 3. Armature Shaft Figure 19-13 Armature Ground Test VISUAL INSPECTION OF FIELD COILS If the insulation on the field coils appears blackened or charred, the serviceability of the coils is questionable. Burned or scorched coil insulation indicates the starter/generator has overheated due to overloads or grounded or shorted coil windings.
Page 357 GASOLINE VEHICLE - ELECTRICAL COMPONENTS Starter/Generator Press a new ball bearing (35) onto the output end of the armature (Figure 19-8, Page 19-6). Press a new ball bearing onto the commutator end of the armature shaft. See following CAUTION. CAUTION •...
Page 358 GASOLINE VEHICLE - ELECTRICAL Starter/Generator COMPONENTS 90° 1. Jumper Wire 2. 1 inch (25.4 mm) Minimum Radius 3. Jumper Wire Not Allowed in this Area. 2687 Figure 19-14 A1 to F1 Terminal Jumper Wire Routing Page 19-12 2021 Carryall 300 Maintenance and Service Manual...
Page 359: Starter/Generator Installation
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Starter/Generator STARTER/GENERATOR INSTALLATION Disable the vehicle. Disconnect the battery and spark plug wire. Install the green wire (1) from the F1 terminal to the A2 terminal on the starter/generator (Figure 19-15). 3033B Figure 19-15 Starter/Generator Green Wire Install a flat washer, lock washer, and nut onto each terminal and tighten to 48 in·lb (5.4 N·m).
Page 360: Belt Tension Inspection For Efi Engines
GASOLINE VEHICLE - ELECTRICAL Starter/Generator COMPONENTS Adjust the belt tension. See Belt Tension Adjustment For EFI Engines. Connect the yellow wire (7) from the voltage regulator to the DF terminal on the starter/generator (Figure 19-17). 3033D Figure 19-17 Starter/Generator Yellow Wire Install a flat washer, lock washer, and nut onto the terminal.
Page 361: Belt Tension Adjustment For Efi Engines
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Starter/Generator Existing Belts Only Disconnect the battery and spark plug wire. Mark a location on belt to repeat tension measurement each time. Use paint pen or permanent marker of light color. Install a Universal Belt Tension Gauge (OTC 6673 recommended) midway between the pulleys.
Page 362 GASOLINE VEHICLE - ELECTRICAL Starter/Generator COMPONENTS 2724 Figure 19-20 Belt Tension Gauge Tighten the adjustment nut (1) and pivot nut (2) with your hand (Figure 19-21, Page 19-16) . 2997C Figure 19-21 Starter/Generator Mounting Hardware Install the belt tension tool. Page 19-16 2021 Carryall 300 Maintenance and Service Manual...
Page 363 GASOLINE VEHICLE - ELECTRICAL COMPONENTS Starter/Generator 2725 Figure 19-22 Belt Tensioning Tool Installation 5.1. Carefully insert pry bar between starter/generator and bracket. NOTE: In some cases, the threaded J-bolt of the belt tension tool does not have enough length to consistently fit under the starter/generator mounting ear.
Page 364: Belt Tension Tool Modification
GASOLINE VEHICLE - ELECTRICAL Starter/Generator COMPONENTS Maintain tension and tighten the adjustment nut (1) to 15 to 18 ft·lb (20 to 24.5 N·m). Tighten the pivot nuts (2) to 20 to 25 ft·lb (27 to 34 N·m) (Figure 19-23, Page 19-18). 2997C Figure 19-23 Starter/Generator Mounting Hardware Installation...
Page 365: Voltage Regulator
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Voltage Regulator VOLTAGE REGULATOR VOLTAGE REGULATOR REMOVAL Disconnect the battery and spark plug wire. Remove the electrical component box cover. Disconnect the voltage regulator red wire (1) at the large post on the solenoid (Figure 19-25). 2973B Figure 19-25 Voltage Regulator Disconnect the yellow wire (2) at the bullet connector.
Page 366: Key Switch
GASOLINE VEHICLE - ELECTRICAL Key Switch COMPONENTS KEY SWITCH KEY SWITCH REMOVAL Disconnect the battery and spark plug. Remove the instrument panel. 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.
Page 367: Key Switch Installation
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Key Switch KEY SWITCH INSTALLATION Install the key switch (1) and washer (2) into the instrument panel (Figure 19-27, Page 19-21). 2931C Figure 19-27 Key Switch Installation Install the key switch nut (3). Tighten the nut to 35 to 45 in·lb (4 to 5 N·m). Install key switch cap (4) into instrument panel.
Page 368: Maintenance/Operate Switch
GASOLINE VEHICLE - ELECTRICAL Maintenance/Operate Switch COMPONENTS MAINTENANCE/OPERATE SWITCH MAINTENANCE/OPERATE SWITCH REMOVAL Disconnect the battery and spark plug wire. Remove the boot/hex nut (1) (Figure 19-28). 000755-004 Figure 19-28 Maintenance/Operate Switch Remove the Maintenance/Operate switch (2) from bracket (3). Disconnect the wires and remove Maintenance/Operate switch. MAINTENANCE/OPERATE SWITCH INSTALLATION Connect the wires to the Maintenance/Operate switch.
Page 369: Neutral Lockout Limit Switch
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Neutral Lockout Limit Switch 000755-004 Figure 19-29 Maintenance/Operate Switch Install the boot/hex nut (1). Tighten the boot/hex nut to 16 in·lb (1.8 N·m). Connect the battery. NEUTRAL LOCKOUT LIMIT SWITCH NEUTRAL LOCKOUT LIMIT SWITCH REMOVAL On Transaxle Disable the vehicle.
Page 370 GASOLINE VEHICLE - ELECTRICAL Neutral Lockout Limit Switch COMPONENTS 000999-003 Figure 19-30 Transaxle - Neutral Lockout Limit Switch Remove the nuts (2),washers (3), and bolts (4). Remove the neutral lockout limit switch. On FNR Disable the vehicle. Disconnect the battery and spark plug wire. Remove the instrument panel.
Page 371: Neutral Lockout Limit Switch Installation
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Neutral Lockout Limit Switch NEUTRAL LOCKOUT LIMIT SWITCH INSTALLATION CAUTION • Do not overtighten the retaining nuts. If the nuts are overtightened, limit switches could be damaged. On Transaxle Install the limit switch (1) with the screws (4), washers (3), and nuts (2). Tighten the hardware to 5 in·lb (0.6 N·m) (Figure 19-32).
Page 372: Solenoid
GASOLINE VEHICLE - ELECTRICAL Solenoid COMPONENTS 000999-004 Figure 19-33 FNR - Neutral Lockout Limit Switch Move the Forward/Neutral/Reverse control (FNR) to make sure the switch actuates Connect the 3-wire connector to the neutral lockout limit switch lead. Connect the battery and spark plug wire. Test drive the vehicle in both forward and reverse for proper operation.
Page 373: Solenoid Installation
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Solenoid 3025C Figure 19-34 Solenoid Wires Disconnect the wires from the solenoid (2). Remove the screws (3) from the solenoid (Figure 19-35). 001014-003 Figure 19-35 Solenoid Screws Remove the solenoid. SOLENOID INSTALLATION Install the solenoid in the electrical component box. Install the screws (1) (Figure 19-36).
Page 374: Fuse
GASOLINE VEHICLE - ELECTRICAL Fuse COMPONENTS 001014-004 Figure 19-36 Solenoid Screws Pedal-Start Vehicle: 3.1. Connect the 4 gauge white wire, 18 gauge white wire, and the 18 gauge red wire to the large post. 3.2. Connect the 4-gauge red wire, 10-gauge red wire, and 16-gauge orange wire to the other large post on the solenoid.
Page 375: Fuse Removal
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Fuse FUSE REMOVAL Disconnect the battery. ATC Fuse Only: Remove electrical component box cover cover. ATM Fuse Only: Remove fuse holder cover. Remove the fuse from the fuse block. FUSE INSTALLATION Install the fuse. See following WARNING. WARNING •...
Page 376: Accelerator Pedal Limit Switch
GASOLINE VEHICLE - ELECTRICAL Accelerator Pedal Limit Switch COMPONENTS ACCELERATOR PEDAL LIMIT SWITCH ACCELERATOR PEDAL LIMIT SWITCH REMOVAL Disconnect the battery and spark plug wire. Remove the screw (1) (Figure 19-37). 2948D Figure 19-37 Accelerator Pedal Limit Switch Remove the electrical component box cover (2). Remove the two nuts (3) and washers (4).
Page 377: Kill Limit Switch
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Kill Limit Switch KILL LIMIT SWITCH KILL LIMIT SWITCH REMOVAL Disconnect the battery and spark plug wire. Remove the screw (1) (Figure 19-38). 2948E Figure 19-38 Kill Limit Switch Remove the electrical component box cover (2). Remove the two nuts (3) and washers (4).
Page 378: Reverse Warning Buzzer
GASOLINE VEHICLE - ELECTRICAL Reverse Warning Buzzer COMPONENTS Install the electrical component box cover (2). Be sure to press down firmly all corners. Install the screw (1). Tighten the screw to 18 in·lb (2 N·m). Connect the battery and spark plug wire. REVERSE WARNING BUZZER REVERSE WARNING BUZZER REMOVAL Disconnect the battery and spark plug wire.
Page 379: Reverse Buzzer Limit Switch
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Reverse Buzzer Limit Switch REVERSE BUZZER LIMIT SWITCH REVERSE BUZZER LIMIT SWITCH REMOVAL Disconnect the battery and spark plug wire. Remove the instrument panel. Cut the wire tie that retains the limit switch leads to the instrument panel harness. Remove the nuts (1) and washers (2) (Figure 19-40, Page 19-33).
Page 380: Low Oil Warning Light
GASOLINE VEHICLE - ELECTRICAL Low Oil Warning Light COMPONENTS Connect the battery and spark plug wire. Turn the key switch to the ON position. Set the FNR to R. Make sure that the buzzer sounds. LOW OIL WARNING LIGHT LOW OIL WARNING LIGHT REMOVAL Disconnect the battery and spark plug wire.
Page 381: Malfunction Indicator Light
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Malfunction Indicator Light MALFUNCTION INDICATOR LIGHT MALFUNCTION INDICATOR LIGHT REMOVAL Disconnect the battery and spark plug wire. Remove the instrument panel. Disconnect the malfunction indicator light (1) wires (Figure 19-42, Page 19-35). Do not allow wires to touch. 3003C Figure 19-42 Malfunction Indicator Light Push the retaining tabs and remove the malfunction indicator light from the instrument panel.
Page 382: Fuel Gauge/Hour Meter Removal
GASOLINE VEHICLE - ELECTRICAL Fuel Level Sending Unit COMPONENTS FUEL GAUGE/HOUR METER REMOVAL Disconnect the battery and spark plug wire. Remove the instrument panel. Disconnect the fuel gauge/hour meter (1) wires (Figure 19-43, Page 19-36). Do not allow wires to touch. 3003D Figure 19-43 Fuel Gauge/Hour Meter Alternate pulling the lower and upper tabs away from the gauge housing to remove clip.
Page 383: Voltage Limiter
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Voltage Limiter VOLTAGE LIMITER VOLTAGE LIMITER REMOVAL NOTE: Battery will charge reducing the voltage going to accessories. The voltage limiter is located on the driver side cowl frame. Disable the vehicle. Disconnect the battery and spark plug wire. Remove the cowl.
Page 384: Headlight Switch
GASOLINE VEHICLE - ELECTRICAL Headlight Switch COMPONENTS HEADLIGHT SWITCH HEADLIGHT SWITCH REMOVAL Disconnect the battery and spark plug wire. Remove the instrument panel. Disconnect the wires from the headlight switch (1) (Figure 19-45). 3003E Figure 19-45 Headlight Switch Push the tabs and remove the headlight switch from the instrument panel. HEADLIGHT SWITCH INSTALLATION Connect the wires to the headlight switch (1) (Figure 19-45).
Page 385: Headlights
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Headlights HEADLIGHTS HEADLIGHT BEZEL REMOVAL Disconnect the battery Remove the cowl. Remove the front fender. Disconnect the headlight and turn signal electrical connectors. Remove the bolts (1) (Figure 19-46, Page 19-39). Figure 19-46 Headlight Bezel Remove the headlight bezel (2).
Page 386: Halogen Headlight Bulb Removal
GASOLINE VEHICLE - ELECTRICAL Headlights COMPONENTS HALOGEN HEADLIGHT BULB REMOVAL CAUTION • Do not touch the glass part of the headlight bulb. Oil from fingertips can decrease the life of the headlight bulb. Disconnect the battery Remove the cowl. Lift the tabs on the connector harness to release the electrical connector from the headlight bulb (1) (Figure 19-47, Page 19-40).
Page 387: Halogen Headlight Lens Removal
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Headlights HALOGEN HEADLIGHT LENS REMOVAL CAUTION • Do not touch the glass part of the headlight bulb. Oil from fingertips can decrease the life of the headlight bulb. Disconnect the battery Remove the cowl. Lift the tabs on the connector harness to release the electrical connector from the headlight bulb (1) (Figure 19-48, Page 19-41).
Page 388: Led Headlight Removal
GASOLINE VEHICLE - ELECTRICAL Battery COMPONENTS LED HEADLIGHT REMOVAL Disconnect the battery. Remove the cowl. Lift the tabs on the connector harness to release the electrical connector from the LED headlight (1) (Figure 19-49, Page 19-42). 2993E Figure 19-49 LED Headlight Remove the screws (2).
Page 389: General Information
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Battery DANGER • Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or clothing. Antidotes: – External: Flush with water. Call a physician immediately. – Internal: Drink large quantities of milk or water followed with milk of magnesia or vegetable oil.
Page 390: Vibration Damage
GASOLINE VEHICLE - ELECTRICAL Battery COMPONENTS VIBRATION DAMAGE The battery hold-down clamp should always be tight enough to keep the battery from bouncing. Battery life may be severely shortened if the clamp is too loose. Excessive vibration shortens the life of the battery. It may also cause acid to leak out of the vent caps and corrosion to build up on surrounding metal parts.
Page 391: Battery Storage
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Battery Connect the battery and spark plug wire. BATTERY STORAGE See General Warnings on page 1-1. Also see DANGER at beginning of Battery topic. Keep the battery clean and free of corrosion. The battery cables should be disconnected from the battery so the battery can be connected to the charger. The battery can be left in the vehicle.
Page 392: Oxygen Sensor
GASOLINE VEHICLE - ELECTRICAL Oxygen Sensor COMPONENTS OXYGEN SENSOR OXYGEN SENSOR REMOVAL Disconnect the battery. Disconnect the oxygen sensor connector from the engine wire harness (1) (Figure 19-50, Page 19-46). Figure 19-50 Oxygen Sensor Remove the oxygen sensor (2). OXYGEN SENSOR INSTALLATION Install the oxygen sensor (2) into the muffler tube (Figure 19-50, Page 19-46).
Page 393: Charging Dioded (Key-Start Only)
GASOLINE VEHICLE - ELECTRICAL COMPONENTS Charging Dioded (Key-Start Only) CHARGING DIODED (KEY-START ONLY) See General Warnings on page 1-1. CHARGING DIODE REMOVAL Disable the vehicle. Disconnect the battery and spark plug wire. Remove the screw (1) (Figure 19-51, Page 19-47) 2978Beps Figure 19-51 Charging Diode Remove the electrical component box cover (2).
Page 394: Charging Diode Installation
GASOLINE VEHICLE - ELECTRICAL Charging Dioded (Key-Start Only) COMPONENTS CHARGING DIODE INSTALLATION CAUTION • Be sure to remove and discard the protective film from both sides of the thermal pad before installing it. If not removed, the film will reduce the thermal heat transfer and therefore reduce the power handling capability of the diode, causing it to overheat and damage the electrical system.
Page 395: Usb Receptacle
GASOLINE VEHICLE - ELECTRICAL COMPONENTS USB Receptacle USB RECEPTACLE The 5-volt, 2.1 amp USB receptacle supplies electricity to power and charge portable devices. The USB receptacle is not for movement of data. The USB receptacle will only operate when a shielded USB cord is connected. When the USB receptacle is not in use, remove the shielded USB cord to prevent battery drain.
Page 396 GASOLINE VEHICLE - ELECTRICAL USB Receptacle COMPONENTS Connect the USB black wire to the jumper wire (3). Connect the USB red wire to the main harness red wire (2) and the 12V power point (1). Install the cowl. Connect the battery. Page 19-50 2021 Carryall 300 Maintenance and Service Manual...
Page 397: Section 20 - Gasoline Vehicle - Engine
SECTION 20 — GASOLINE VEHICLE - ENGINE DANGER Gasoline Vehicle - Engine • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION See General Warnings on page 1-1. This vehicle is powered by a Kohler, high-compression, chain driven, overhead valve engine (OHV). See following NOTE.
Page 398: Louver Arm
Louver Arm GASOLINE VEHICLE - ENGINE LOUVER ARM The louver assembly is installed with the Kit Instruction TPCC040401EB019 ECH440 Engine Oil Dilution Prevention. Move the louver arm (1) up or down to open or close the louver assembly. The close position will increase the engine temperature faster. Figure 20-1 Set the louver arm to close for short trip operation.
Page 399: Engine Removal
GASOLINE VEHICLE - ENGINE Engine Removal ENGINE REMOVAL See General Warnings on page 1-1. CAUTION • Before removal and disassembly, clean the engine. Disconnect the battery. Disconnect the spark plug wire. For some vehicles, the engine can be removed by lifting it up and out of the chassis. For other vehicles, it is easier to remove the entire powertrain assembly first.
Page 400 Engine Removal GASOLINE VEHICLE - ENGINE Remove the bolts (5 and 6) (Figure 20-3, Page 20-4). Figure 20-3 Clutch Plate Removal Remove the clutch plate (7). Remove the bolts (8) (Figure 20-4, Page 20-4). Figure 20-4 Exhaust Weldment Removal Remove the exhaust weldment (9). Page 20-4 2021 Carryall 300 Maintenance and Service Manual...
Page 401 GASOLINE VEHICLE - ENGINE Engine Removal Remove the bolts (10), washers (11), and nuts (12) (Figure 20-5, Page 20-5). Figure 20-5 Engine Pan Removal Lift the engine from engine pan (13). See following NOTE. NOTE: The engine weighs approximately 54 lb (24.5 kg). Remove the oil drain plug and drain all oil from crankcase.
Page 402: Engine Installation
Engine Installation GASOLINE VEHICLE - ENGINE ENGINE INSTALLATION See General Warnings on page 1-1. If replacing engine, install starter/generator mounting weldment on engine with the screws. Tighten the screws to 17 ft·lb (23 N·m). Install oil drain plug and tighten to 13 ft·lb (18 N·m). Place the engine onto the engine pan (13) and secure with mounting hardware (10, 11, and 12) (Figure 20-6, Page 20-6).
Page 403 GASOLINE VEHICLE - ENGINE Engine Installation Install the clutch plate (7) with bolts (5 and 6) (Figure 20-8, Page 20-7). Tighten the bolts (5) to 27 ft·lb (36 N·m). Tighten the bolts (6) to 50 ft·lb (68 N·m). Figure 20-8 Clutch Plate Installation Install the drive clutch.
Page 404 Engine Installation GASOLINE VEHICLE - ENGINE Connect the ground cable to the engine (4) (Figure 20-9, Page 20-8). Figure 20-9 Governor Cover and Ground Cable Installation Route the vent line (3) through the governor cover (2). Connect the vent line. Install the governor cover with the screw (1).
Page 405: Snubber
GASOLINE VEHICLE - ENGINE Snubber SNUBBER See General Warnings on page 1-1. NOTE: The snubber is installed on the gasoline vehicle only. SNUBBER REMOVAL Support the powertrain with a floor jack under the engine pan (1) so that the snubber (2) is raised slightly and does not rest on the vehicle frame (Figure 20-10, Page 20-9).
Page 406 Snubber GASOLINE VEHICLE - ENGINE Pagination Page Page 20-10 2021 Carryall 300 Maintenance and Service Manual...
Page 407: Section 21 - Gasoline Vehicle - Fuel System
SECTION 21 — GASOLINE VEHICLE - FUEL SYSTEM DANGER Gasoline Vehicle - Fuel System • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. • Fuel may be under pressure. Use extreme caution when disconnecting fuel line to prevent the spray of fuel onto hot engine.
Page 408: General Information
Engine Control Linkages GASOLINE VEHICLE - FUEL SYSTEM DANGER • To ensure the vehicle does not run over you while you disconnect or adjust the accelerator push rod, do the following: – Turn key switch OFF and remove key, place Forward/Reverse handle in the NEUTRAL position, and chock the wheels prior to servicing the vehicle.
Page 409 GASOLINE VEHICLE - FUEL SYSTEM Engine Control Linkages 1345 Figure 21-1 Accelerator Rod Figure 21-2 Accelerator Rod – Pull Spring Release to Attach (Bottom View) Accelerator Rod Installation and Adjustment Before installing the accelerator rod, adjust accelerator pedal position. See Pedal Group Adjustment – Gasoline Vehicles in the Accelerator and Brake Pedal Group Section.
Page 410 Engine Control Linkages GASOLINE VEHICLE - FUEL SYSTEM 3113 Figure 21-3 Accelerator Cable Cam Position – 7° (Top View) Before tightening the jam nuts (3), set the park brake to the first latch and pawl position and check for proper activation of switches.
Page 411: Governor Cable
GASOLINE VEHICLE - FUEL SYSTEM Engine Control Linkages GOVERNOR CABLE Governor Cable Removal Turn the key switch to the OFF position and remove the key, place the Forward/Neutral/Reverse control (FNR) in the NEUTRAL position, and chock the wheels. Disconnect battery and spark plug wire. At engine: 3.1.
Page 412 Engine Control Linkages GASOLINE VEHICLE - FUEL SYSTEM Governor Cable Installation and Adjustment At engine: 1.1. Snap governor cable into throttle body bracket (4) (Figure 21-6, Page 21-6). Figure 21-6 Governor Cable Installation - Throttle Body 1.2. Connect the governor cable fitting (1) to throttle lever (2). 1.3.
Page 413: Accelerator Cable
GASOLINE VEHICLE - FUEL SYSTEM Engine Control Linkages Loosen adjustment screw jam nut (4) and back off throttle stop screw (5) several turns (Figure 21-8, Page 21-7). A = 0.055 in. ± 0.039 (1.4 mm ± 1) 3111B Figure 21-8 Throttle Stop Screw Gap Rotate governor arm counterclockwise until it stops and hold in this position.
Page 414 Engine Control Linkages GASOLINE VEHICLE - FUEL SYSTEM At transaxle: 3.1. Unhook spring fitting of accelerator cable (1) from governor arm (2) (Figure 21-9, Page 21-8). 3110D Figure 21-9 Accelerator Cable Removal - Governor Arm 3.2. Unsnap accelerator cable from FNR/accelerator cable bracket (3). At electrical component box: 4.1.
Page 415 GASOLINE VEHICLE - FUEL SYSTEM Engine Control Linkages 3110C Figure 21-11 Accelerator Cable Installation - Governor 1.2. Snap accelerator cable into FNR/accelerator cable bracket (3). 1.3. Push dust shield (4) onto end of cable housing. At electrical component box: 2.1. Insert barrel fitting (5) of accelerator cable (6) into cam (7) in electrical component box (Figure 21-12, Page 21-9).
Page 416: Closed Throttle Or Idle Adjustment - Pedal-Start Vehicles
Engine Control Linkages GASOLINE VEHICLE - FUEL SYSTEM CLOSED THROTTLE OR IDLE ADJUSTMENT – PEDAL-START VEHICLES To adjust the idle, see ECU Reset Procedure and TPS Learn Procedure for Pedal Start Applications in the Kohler Service Manual. CLOSED THROTTLE OR IDLE ADJUSTMENT – KEY-START VEHICLES To adjust the idle, see ECU Reset Procedure and TPS Learn Procedure for Key Start Applications in the Kohler Service Manual.
Page 417 GASOLINE VEHICLE - FUEL SYSTEM Engine Control Linkages 5.3. Be sure both jam nuts are locked against the electrical component box and check ground speed again. If ground speed needs to be adjusted, repeat previous step. See following NOTE. NOTE: If more adjustment is required than the cable housing will allow, make sure the spring fitting on the other end of the accelerator cable is properly installed.
Page 418: Air Intake System
Air Intake System GASOLINE VEHICLE - FUEL SYSTEM AIR INTAKE SYSTEM See General Warnings on page 1-1. 3048 Figure 21-13 Air Intake System – CA 300 Page 21-12 2021 Carryall 300 Maintenance and Service Manual...
Page 419: Air Cleaner Removal
GASOLINE VEHICLE - FUEL SYSTEM Air Intake System AIR CLEANER REMOVAL Turn key switch to the OFF position and remove key, place Forward/Neutral/Reverse control (FNR) in the NEUTRAL position, and chock the wheels. Disconnect battery and spark plug wire. See Disconnect the Battery- Gasoline Vehicles on page 1-4. Remove clamp (5) and disconnect air intake hose (6) from air cleaner (3) (Figure 21-13, Page 21-12).
Page 420: Relieving Fuel Pressure
CAUTION • This EFI gasoline vehicle is equipped with 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 421: Fuel Line Removal
GASOLINE VEHICLE - FUEL SYSTEM Fuel Line FUEL LINE REMOVAL WARNING • Fuel may be under pressure. Use extreme caution when disconnecting fuel line to prevent the spray of fuel onto hot engine. See Relieving Fuel Pressure. • Carefully drain any fuel into an approved container. Add drained fuel back into fuel tank or dispose of properly.
Page 422: Fuel Line Installation
Fuel Line GASOLINE VEHICLE - FUEL SYSTEM 5.2. Pull out the locking clip (4) (Figure 21-15, Page 21-16). Figure 21-15 Fuel Line Connector – Disconnect 5.3. Push in and hold the release tab (5). 5.4. Remove the fuel line from the throttle body. 5.5.
Page 423 GASOLINE VEHICLE - FUEL SYSTEM Fuel Line Figure 21-16 Carbon Canister Bracket 1.2. Install the P-clamp (2) and bolt onto the fuel line support bracket (3) (Figure 21-17, Page 21-17). Tighten the bolt to 93 to 111 in·lb (10.5 to 12.5 N·m). Figure 21-17 Fuel Line Support Bracket - Connect 1.3.
Page 424: Fuel Pump Module
Fuel Pump Module GASOLINE VEHICLE - FUEL SYSTEM Figure 21-18 Fuel Line Connector – Connect 1.5. Push in the locking clip (4) until it is fully seated. DANGER • Ensure line is connected properly to avoid a leak that can cause a fire. Clean spilled and remove any drained gasoline from the area.
Page 425: Fuel Pump Module Removal
GASOLINE VEHICLE - FUEL SYSTEM Fuel Pump Module FUEL PUMP MODULE REMOVAL 3052B Figure 21-19 Fuel Pump Module Removal 2021 Carryall 300 Maintenance and Service Manual Page 21-19...
Page 426: Fuel Pump Module Installation
Fuel Pump Module GASOLINE VEHICLE - FUEL SYSTEM Disable the vehicle. Disconnect the battery. Clean the top of the fuel tank (1) and fuel pump module (2) (Figure 21-19, Page 21-19). With a marker pen, make a mark across the top of the fuel pump module and onto the tank to note orientation before removal.
Page 427: Fuel Tank
SAEJ30R9 1/4 in (6.3 mm) fuel vent hose and 3/16 in (4.78 mm) fuel vent hose. To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car fuel vent hoses or equivalent. 2021 Carryall 300 Maintenance and Service Manual...
Page 428: Fuel Tank Removal
Fuel Tank GASOLINE VEHICLE - FUEL SYSTEM FUEL TANK REMOVAL 3052D Figure 21-20 Fuel Tank Removal Page 21-22 2021 Carryall 300 Maintenance and Service Manual...
Page 429: Fuel Tank Disposal
GASOLINE VEHICLE - FUEL SYSTEM Fuel Tank Disable the vehicle. Set the Maintenance/Operate switch to MAINTENANCE. Disconnect the battery. Clean the top of the fuel tank (1) and fuel pump module (2) (Figure 21-20, Page 21-22). Remove gas cap and siphon all fuel from tank into an approved container. See following DANGER and WARNING.
Page 430: Fuel Tank Installation
SAEJ30R9 1/4 in (6.3 mm) fuel vent hose and 3/16 in (4.78 mm) fuel vent hose. To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car fuel vent hoses or equivalent. Place fuel tank (1) in vehicle (Figure 21-20, Page 21-22).
Page 431: Fuel Filter
GASOLINE VEHICLE - FUEL SYSTEM Fuel Filter FUEL FILTER See General Warnings on page 1-1. GENERAL INFORMATION The fuel filter is located in the fuel tank. It is part of the fuel pump module assembly and should last the life of the vehicle;...
Page 432 Fuel Filter GASOLINE VEHICLE - FUEL SYSTEM 3052E Figure 21-22 Fuel Filter Installation Connect flex hoses (2 and 3) to the fuel filter. 2.1. Orient flex hoses with matching port in filter and push each hose end straight into filter until fully seated. 2.2.
Page 433: Section 22 - Gasoline Vehicle - Exhaust System
SECTION 22 — GASOLINE VEHICLE - EXHAUST SYSTEM DANGER Gasoline Vehicle - Exhaust System • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. MUFFLER MUFFLER REMOVAL Disconnect the battery and spark plug wire. If necessary, remove the oxygen sensor (1) from the muffler (2) (Figure 22-1, Page 22-1). See Oxygen Sensor Removal.
Page 434: Muffler Installation
Muffler GASOLINE VEHICLE - EXHAUST SYSTEM MUFFLER INSTALLATION Install the new exhaust gasket (7) on the exhaust port studs (Figure 22-2, Page 22-2). Figure 22-2 Muffler Installation Put the muffler (2) into position on the engine. Install the nuts (3), bolt (4), washer (5), and bolts (6). Tighten the hardware by hand. Tighten the hardware in the following order: 4.1.
Page 435: Section 23 - Gasoline Vehicle - Clutches
SECTION 23 — GASOLINE VEHICLE - CLUTCHES DANGER Gasoline Vehicle - Clutches • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION The torque converter consists of a drive clutch, a driven clutch, and a drive belt. The drive clutch, which is mounted to the engine, is in the open position when the engine is at idle.
Page 436 Troubleshooting GASOLINE VEHICLE - CLUTCHES Maintaining proper adjustment of the engine and governor, as well as the torque converter, is essential to the troubleshooting process. If these adjustments are within specifications and, when climbing a steep hill, the engine begins to lose RPM before the drive belt reaches the top of the driven clutch, there is a torque converter problem. If the torque converter is not operating properly, perform the following steps: Check the governor and throttle settings.
Page 437: Drive Belt
GASOLINE VEHICLE - CLUTCHES Drive Belt DRIVE BELT See General Warnings on page 1-1. The drive belt should be inspected semiannually for wear and (or) glazing. If it is excessively worn, frayed, or glazed, replace the belt. As the drive belt wears, the engine RPM will increase to compensate for the change in torque converter ratio. This will keep the vehicle’s maximum ground speed correct.
Page 438: Drive Clutch
Drive Clutch GASOLINE VEHICLE - CLUTCHES DRIVE CLUTCH See General Warnings on page 1-1. 1. Screw, 3/8-24 x 5.75, Patch 10. Retainer 2. Washer, Hard, M10 11. Ring, Spiral Backup 3. Washer, 3/8, Type A, Flat 12. Bushing, Split, Drive Clutch 4.
Page 439: Drive Clutch Removal
GASOLINE VEHICLE - CLUTCHES Drive Clutch 8. Drive Clutch Weight 17. Spacer, Idler, Drive 9. Thrust Washer 18. Sheave, Fixed, Drive 2960 Figure 23-2 Drive Clutch – Exploded View CAUTION • Be very careful when handling the clutches. A clutch that has been dropped will not be properly balanced.
Page 440: Drive Clutch Cleaning And Inspection
Drive Clutch GASOLINE VEHICLE - CLUTCHES WARNING • Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold vehicle in raised position.
Page 441: Drive Clutch Disassembly
GASOLINE VEHICLE - CLUTCHES Drive Clutch DRIVE CLUTCH DISASSEMBLY CAUTION • The drive clutch is balanced as an assembly. Before disassembly, make match marks on the drive clutch hub and on the moveable sheave so they can be reassembled in the same positions (Figure 23-5, Page 23-7).
Page 442 Drive Clutch GASOLINE VEHICLE - CLUTCHES 3053 Figure 23-7 Drive Button Mounting Figure 23-8 Weight Position Remove the clutch weights: 5.1. Remove the screws (1) and flat washers (2) attaching the weights (3) as shown (Figure 23-8, Page 23-8). 5.2. Pull the weight assemblies (3), with pins, from slots (4) in the clutch.
Page 443: Inspection Of Drive Clutch Parts
GASOLINE VEHICLE - CLUTCHES Drive Clutch Figure 23-9 Primary and Secondary Weights, Wave Washer and Pin Remove the retaining ring (6) from the shaft of the fixed sheave (18) and slide the moveable sheave (13) off the shaft (Figure 23-2, Page 23-4). See following NOTE. NOTE: If the moveable sheave is removed from the hub of the fixed sheave, the spiral back-up rings (11) must be replaced with new rings (Figure 23-2, Page 23-4).
Page 444: Drive Clutch Assembly
Drive Clutch GASOLINE VEHICLE - CLUTCHES Inspect the primary weights (8) and the hub casting for wear. If the primary weights show signs they are touching the casting, the tips of the weights have worn beyond specification and they must be replaced. Inspect the pins on the primary weights (8).
Page 445: Drive Clutch Installation
GASOLINE VEHICLE - CLUTCHES Drive Clutch NOTE: Make sure there is at least a (minimum) gap of 0.020 in. (0.51 mm) between each end of the mounting pin and the mounting bolt. Install three drive button take-up springs. 11.1. Install each spring on right-hand side of the three button mounting posts (when looking into the interior of the clutch drive hub, and with the rib at a twelve o’clock position) as shown (Figure 23-12, Page 23-11).
Page 446: Driven Clutch
Driven Clutch GASOLINE VEHICLE - CLUTCHES DRIVEN CLUTCH See General Warnings on page 1-1. 1. Screw, 5/16-18 X 3/4 Hex-Head with Patch 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.
Page 447: Driven Clutch Removal
GASOLINE VEHICLE - CLUTCHES Driven Clutch 5. Cam, Driven Clutch 11. Sheave, Fixed, Driven 6. Spring, Driven Clutch, CCW, Red 12. Key, 3/16 in. (4.7 mm) Square X 1.50 in. (38 mm) Long 2961 Figure 23-13 Driven Clutch – Exploded View DRIVEN CLUTCH REMOVAL Remove the drive belt as instructed.
Page 448 Driven Clutch GASOLINE VEHICLE - CLUTCHES Slide the threaded bolt assembly through the clutch body until the threaded bolt and thrust collar are against the fixed sheave. Install the cam press plate (5), thrust washer (6), thrust bearing (7), thrust washer (8), and nut (9) onto the threaded bolt.
Page 449 GASOLINE VEHICLE - CLUTCHES Driven Clutch 609B Figure 23-16 Cam Removal Use a driven clutch cam puller (12) to remove the cam (13) from the fixed sheave. Remove the spring (14) (Figure 23-17, Page 23-15). 2961B Figure 23-17 Driven Clutch Disassembly Inspect the key (15) for damage.
Page 450: Driven Clutch Inspection
Driven Clutch GASOLINE VEHICLE - CLUTCHES Slide the moveable sheave (16) off the fixed sheave (17). DRIVEN CLUTCH INSPECTION Inspect the cam for excessive wear. Replace it if necessary. Inspect the drive buttons (2) for excessive wear (Figure 23-18, Page 23-16). Replace if necessary. To remove the drive buttons, remove the socket-head cap screws (1) and then the buttons.
Page 451 GASOLINE VEHICLE - CLUTCHES Driven Clutch 2961C Figure 23-19 Drive Button Installation Slide the acetal washer (3) and moveable sheave (4) onto the fixed sheave (5) (Figure 23-20, Page 23-17). 2961D Figure 23-20 Driven Clutch Assembly Place the end of the spring (6) into the hole in the moveable sheave (9). Install the key (7) into the keyway of the fixed sheave shaft.
Page 452 Driven Clutch GASOLINE VEHICLE - CLUTCHES Figure 23-21 Driven Clutch Tool - Assembly Assemble the threaded bolt (10) through the washer (11) and thrust collar (12). NOTE: It is very important that the bolt, washers, and thrust bearing assembly be assembled in the order described and shown.
Page 453: Driven Clutch Installation
GASOLINE VEHICLE - CLUTCHES Driven Clutch 608C Figure 23-22 Install Retaining Ring Remove the driven clutch tool. DRIVEN CLUTCH INSTALLATION To install the driven clutch, reverse the removal procedure. Make sure that the washer (2) is mounted with the flat portion of the washer against the driven clutch (Figure 23-13, Page 23-12).
Page 454 Driven Clutch GASOLINE VEHICLE - CLUTCHES Pagination Page Page 23-20 2021 Carryall 300 Maintenance and Service Manual...
Page 455: Section 24 - Gasoline Vehicle - Transaxle
SECTION 24 — GASOLINE VEHICLE - TRANSAXLE DANGER Gasoline Vehicle - Transaxle • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION The vehicles addressed in this manual are equipped with heavy-duty transaxles. The transaxle utilizes internal gearing to change vehicle direction.
Page 456: Governor System
General Information GASOLINE VEHICLE - TRANSAXLE WARNING • With the switch in the MAINTENANCE position and the engine running, the vehicle may move suddenly if the Forward/Neutral/Reverse control (FNR) is shifted or accidentally bumped. To prevent this, chock the front and rear wheels and firmly set the park brake before servicing or leaving the vehicle. NOTE: Be sure to return the switch to the OPERATE position after servicing the vehicle, or it will not run with the Forward/Reverse handle in either the F or REVERSE position.
Page 457: Tools Required For This Section
GASOLINE VEHICLE - TRANSAXLE General Information Use a funnel when filling the transaxle through the lubricant level indicator hole. Fill with 67.6 fl-oz (2 L) 80-90 WT. API class GL or 80-90 WT. AGMA class 5 EP gear lubricant (or until lubricant begins to run out of the level indicator hole).
Page 458: Rear Hubs
Rear Hubs GASOLINE VEHICLE - TRANSAXLE REAR HUBS REAR HUB REMOVAL Turn the key switch to the OFF position and remove the key, and place the Forward/Neutral/Reverse control (FNR) in the NEUTRAL position. Disconnect battery and spark plug wire. See Disconnect the Battery- Gasoline Vehicles on page 1-4. Place chocks at the front wheels and loosen lug nuts on both rear wheels.
Page 459 GASOLINE VEHICLE - TRANSAXLE Rear Hubs CAUTION • Do not allow anti-seize compound to contact the brake drum or shoes. Slide hub (6) onto axle shaft (Figure 24-3, Page 24-4). Install the large flat washer (5) onto the threaded portion of the axle. Install hub nut (4) and advance the nut to the large flat washer.
Page 460: Axle Tubes, Axle Shafts, Differential Guard, And Wheel Bearings
Axle Tubes, Axle Shafts, Differential Guard, and Wheel Bearings GASOLINE VEHICLE - TRANSAXLE AXLE TUBES, AXLE SHAFTS, DIFFERENTIAL GUARD, AND WHEEL BEARINGS Removal of the transaxle is not required for servicing or replacing axle shafts, axle bearings, or axle shaft oil seals. If the transaxle is to be removed from the vehicle, do not remove the wheels, axle shafts, or axle tubes first.
Page 461: Axle Tube And Axle Shaft Removal
Axle Tubes, Axle Shafts, Differential Guard, GASOLINE VEHICLE - TRANSAXLE and Wheel Bearings Figure 24-6 Differential Guard Installation AXLE TUBE AND AXLE SHAFT REMOVAL See General Warnings, Section 1, Page 1-1. The transaxle has two axle shafts. If only a tube or shaft is to be serviced, it can be done one side at a time without removing the transaxle.
Page 462: Axle Tube And Axle Shaft Installation
Axle Tubes, Axle Shafts, Differential Guard, and Wheel Bearings GASOLINE VEHICLE - TRANSAXLE 3058 Figure 24-7 Axle Tube, Shaft, Bearing and Oil Seal AXLE TUBE AND AXLE SHAFT INSTALLATION Clean mating surfaces of axle tube (2) flange and transaxle gearcase (4). Also clean the threads of the five axle tube mounting holes in the gearcase.
Page 463: Rear Wheel Bearing Installation
Axle Tubes, Axle Shafts, Differential Guard, GASOLINE VEHICLE - TRANSAXLE and Wheel Bearings Drive axle shaft (3) and bearing (6) from outer end of axle tube (2) as an assembly. Use a puller to remove bearing (6) from axle shaft (3). See following CAUTION. CAUTION •...
Page 464: Transaxle Removal
Transaxle Removal GASOLINE VEHICLE - TRANSAXLE TRANSAXLE REMOVAL See General Warnings on page 1-1. Turn the key switch to the OFF position and remove the key, and place the Forward/Neutral/Reverse control (FNR) in the NEUTRAL position. Disconnect battery and spark plug wire. See Disconnect the Battery- Gasoline Vehicles on page 1-4. Place chocks at the front wheels and loosen lug nuts on both rear wheels.
Page 465 GASOLINE VEHICLE - TRANSAXLE Transaxle Removal Figure 24-10 Disconnect Rear Shackles Figure 24-11 Disconnect Front of Leaf Spring Position floor jack under rear crossmember of chassis or trailer hitch mount (if equipped) (Figure 24-12, Page 24-11). See WARNING “Lift only one end of the vehicle...” in General Warnings on page 1-1. Raise vehicle just enough to relieve weight on leaf springs, then remove bolts securing leaf springs to shackles (Figure 24-10, Page 24-11).
Page 466 Transaxle Removal GASOLINE VEHICLE - TRANSAXLE Roll powertrain out from under vehicle. Place blocks under the engine pan so they will completely support the engine and keep it level to the floor (Figure 24-13, Page 24-12). See following NOTE. NOTE: Place the blocks so they will support the engine when the transaxle is detached and moved away from the powertrain.
Page 467 GASOLINE VEHICLE - TRANSAXLE Transaxle Removal 3063 Figure 24-14 Transaxle Mounting Bolts 2021 Carryall 300 Maintenance and Service Manual Page 24-13...
Page 468: Transaxle Installation
Transaxle Installation GASOLINE VEHICLE - TRANSAXLE TRANSAXLE INSTALLATION See General Warnings on page 1-1. Installation is reverse of removal procedure. When attaching transaxle to powertrain, initially install the eight bolts (1) finger-tight (Figure 24-14, Page 24-13). Then, tighten fasteners in the following order: 1.1.
Page 469: Shifter Cable Installation
GASOLINE VEHICLE - TRANSAXLE Shifter Cable Loosen jam nuts (1) securing shifter cable (2) to FNR/accelerator cable bracket (3) (Figure 24-16, Page 24-15). Then, remove bowtie clip (3) to disconnect shifter cable end (4) from transaxle shift lever (5). Cut wire ties securing shifter cable to chassis. Make note of cable routing, then remove shifter cable from vehicle.
Page 470 Shifter Cable GASOLINE VEHICLE - TRANSAXLE Pagination Page Page 24-16 2021 Carryall 300 Maintenance and Service Manual...
Page 471 SECTION 25 — KOHLER ENGINE SERVICE MANUAL Kohler Engine Service Manual 2021 Carryall 300 Maintenance and Service Manual Page 25-1...
Page 472 ECH440 for CLUB CAR Service Manual IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating instruction of equipment that this engine powers. Ensure engine is stopped and level before performing any maintenance or service. Safety Maintenance Speciﬁ...
Page 473 Safety SAFETY PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property damage. NOTE: is used to notify people of important installation, operation, or maintenance information. CAUTION WARNING WARNING...
Page 474 Maintenance MAINTENANCE INSTRUCTIONS WARNING Before working on engine or equipment, disable engine as Accidental Starts can cause severe injury or follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing.
Page 475 Maintenance OIL RECOMMENDATIONS STORAGE If engine will be out of service for 2 months or more We recommend use of Kohler oils for best performance. follow procedure below. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ 1.
Page 476 Speciﬁ cations Engine Dimensions-Flywheel Side 214.1 mm (8.43 in.) 164.3 mm (6.47 in.) 138.6 mm (5.46 in.) 2 X 112.1 mm Throttle Body Throttle Cable Throttle Cable (4.42 in.) Evap Fitting Mount Face Center Line 239.0 mm (9.41 in.) 116.4 mm (4.58 in.) Oil Fill Plug Oil Drain Plug Throttle Body...
Page 477 Speciﬁ cations Engine Dimensions-Top Side 164.5 mm (6.48 in.) 288.2 mm (11.35 in.) 472.4 mm (18.60 in.) 155.1 mm (6.11 in.) Oxygen Sensor Fuel Injector Cap Bracket 155.8 mm (6.13 in.) M8 X 1.25-6H Tap Oxygen Sensor 64.1 mm (2.53 in.) 19.0 mm (0.75 78.6 mm (3.09) in.) Harness Clip...
Page 478 Speciﬁ cations Engine Dimensions-PTO Side 6 X M8 X 1.25-6H 202.7 mm (7.98 in.) Dipstick and 188.2 mm (7.41 in.) 18.00 mm Exhaust Port Oil Fill Tube (0.71 in.) Deep 300.9 mm (11.85 in.) 218.6 mm (8.61 in.) Oxygen Sensor 35.0 mm (1.38 in.) 32.4 mm (1.28 in.) Exhaust Port...
Page 479 Speciﬁ cations Engine Dimensions-Opposite Cylinder Head Side 229.8 mm (9.05 in.) 2 X M8 X 1.25-6H Throttle Cable 105.0 mm (4.13 in.) 56.6 mm (2.23 in.) Tap 22.0 mm Mount Face (0.87 in.) Deep M6 X 1.0-6H 14.5 mm Min. Primary Mounting 29.1 mm (1.14 in.) Full Thread...
Page 480 Speciﬁ cations Engine Dimensions-Bottom Side 195.5 mm ± 0.50 mm 2 X Ø 11.25 mm ± 2 X 94.5 mm ± 0.75 (7.70 in. ± 0.02 90.5 mm (3.56 in.) 0.25 mm (0.44 mm (3.72 in. ± in.) Machined in. ± 0.01 in.) 0.03 in.) Holes Distance 195.5 mm ±...
Page 481 Year Manufactured Code Factory Code Code Year 2018 2019 2020 GENERAL SPECIFICATIONS ECH440 for Club Car Bore 89 mm (3.5 in.) Stroke 69 mm (2.7 in.) Displacement 429 cc (26.2 cu. in.) Oil Capacity (reﬁ ll) 1.1 L (1.16 U.S. qt.) Maximum Angle of Operation (@ full oil level) 25°...
Page 482 Speciﬁ cations TORQUE SPECIFICATIONS ECH440 for Club Car Air Cleaner (OEM Supplied) Air Inlet Elbow Mounting Nuts 8.0 N·m (71 in. lb.) Blower Housing and Sheet Metal M6 Screw 10 N·m (89 in. lb.) Cylinder Shield to Cylinder Head Ground Stud and Screw 8.0 N·m (71 in.
Page 483 Speciﬁ cations TORQUE SPECIFICATIONS ECH440 for Club Car Throttle Body Studs 10 N·m (89 in. lb.) Primary Mounting Nuts 8.0 N·m (71 in. lb.) Temperature/Manifold Absolute Pressure (TMAP) Sensor Fastener 7.3 N·m (65 in. lb.) Throttle Position Sensor (TPS) Fastener 1.3 N·m (11.5 in.
Page 484 Speciﬁ cations CLEARANCE SPECIFICATIONS ECH440 for Club Car Crankshaft End Play (free) 0.0508/0.254 mm (0.002/0.010 in.) Ball Bearing Internal Clearance 0.006/0.020 mm (0.0002/0.0008 in.) Crankshaft O.D. (new) PTO end 34.975/34.989 mm (1.3770/1.3775 in.) 35.009/35.027 mm (1.3783/1.3790 in.) Flywheel end Connecting Rod Journal O.D.
Page 485 Speciﬁ cations CLEARANCE SPECIFICATIONS ECH440 for Club Car Piston, Piston Rings, and Piston Pin Piston-to-Piston Pin Running Clearance 0.002/0.016 mm (0.0001/0.0006 in.) Piston Pin Bore I.D. 20.000/20.008 mm (0.7874/0.7877 in.) Max. Wear Limit 20.05 mm (0.7894 in.) Piston Pin O.D.
Page 486 Speciﬁ cations GENERAL TORQUE VALUES English Fastener Torque Recommendations for Standard Applications Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners Into Aluminum Size Grade 2 Grade 5 Grade 8 Tightening Torque: N·m (in. lb.) ± 20% 8-32 2.3 (20) 2.8 (25)
Page 487 Tools and Aids Certain quality tools are designed to help you perform speciﬁ c disassembly, repair, and reassembly procedures. By using these tools, you can properly service engines easier, faster, and safer! In addition, you’ll increase your service capabilities and customer satisfaction by decreasing engine downtime. Here is a list of tools and their source.
Page 488 Tools and Aids TOOLS Description Source/Part No. Flywheel Puller SE Tools KLR-82408 For properly removing ﬂ ywheel from engine. Hose Removal Tool, Dual Size/End (also available in EFI Service Kit) Kohler 25 455 20-S Used to properly remove fuel hose from engine components. Hydraulic Valve Lifter Tool Kohler 25 761 38-S For removing and installing hydraulic lifters.
Page 489 Tools and Aids FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A ﬂ ywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft ﬂ ywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.
Page 490 Troubleshooting TROUBLESHOOTING GUIDE When troubles occur, be sure to check simple causes which, at ﬁ rst, may seem too obvious to be considered. For example, a starting problem could be caused by an empty fuel tank. NOTE: An EFI engine will not operate without a battery connected to system. Some general common causes of EFI engine troubles are listed below and vary by engine speciﬁ...
Page 491 Troubleshooting ● Check air cleaner element (OEM supplied). Look for Engine Loses Power holes, tears, cracked or damaged sealing surfaces, or ● Dirty air cleaner element (OEM supplied). other damage that could allow unﬁ ltered air into ● Engine overheated. engine.
Page 492 Troubleshooting CRANKCASE VACUUM TEST WARNING WARNING Carbon Monoxide can cause severe nausea, Rotating Parts can cause severe injury. fainting or death. Stay away while engine is in operation. Avoid inhaling exhaust fumes. Engine exhaust gases contain poisonous carbon Keep hands, feet, hair, and clothing away from all monoxide.
Page 493 Troubleshooting COMPRESSION TEST This engine is equipped with an automatic compression release (ACR) mechanism. It is diﬃ cult to obtain an accurate compression reading because of ACR mechanism. As an alternative, use cylinder leakdown test described below. CYLINDER LEAKDOWN TEST A cylinder leakdown test can be a valuable alternative to a compression test.
Page 494 Air Cleaner/Intake BREATHER TUBE AIR CLEANER (OEM Supplied) Ensure both ends of breather tube are properly These systems are CARB/EPA certiﬁ ed and components connected. should not be altered or modiﬁ ed in any way. AIR COOLING Refer to operating instructions of equipment this engine powers for speciﬁ...
Page 495 EFI SYSTEM An in-tank fuel pump is used to move fuel from tank WARNING through a fuel ﬁ lter and fuel line. Fuel pump regulates fuel pressure to a system operating pressure of 50 psi. Explosive Fuel can cause ﬁ res and severe Fuel is delivered through high pressure fuel line into burns.
Page 496 EFI SYSTEM ECU continually performs a diagnostic check of itself, Crankshaft position sensor is essential to engine each sensor, and system performance. If a fault is operation; constantly monitoring rotation and speed detected, ECU can turn on a Malfunction Indicator Light (RPM) of crankshaft.
Page 497 EFI SYSTEM Purpose of sensing air temperature is to help ECU Injector has sequential fueling that opens and closes calculate air density. Higher air temperature less dense once every other crankshaft revolution. Amount of fuel air becomes. As air becomes less dense ECU knows injected is controlled by ECU and determined by length that it needs to lessen fuel ﬂ...
Page 498 EFI SYSTEM EFI engines have no carburetor, so throttle function IMPORTANT NOTES! (regulate incoming combustion airﬂ ow) is achieved with ● Cleanliness is essential and must be maintained at all a throttle valve in a separate throttle body attached to times when servicing or working on EFI system.
Page 499 EFI SYSTEM ELECTRICAL COMPONENTS Grey Connector Side Electronic Control Unit (ECU) Pin # Description Pinout of ECU Not Used Black Connector Side Not Used Pin # Function Malfunction Indicator Light (MIL) Ground Ignition Coil Ground Not Used Battery Ground Not Used Diagnostic Communication Line Not Used Speed Sensor input...
Page 500 EFI SYSTEM Never attempt to disassemble ECU. It is sealed to TPS Learn Procedure for Pedal Start Applications prevent damage to internal components. Warranty is NOTE: Refer to equipment manufacturer's manual for void if case is opened or tampered with in any way. details on throttle body cover and throttle cable removal/reinstallation.
Page 501 EFI SYSTEM KohlerEngines.com 17 690 15 Rev. --...
Page 502 EFI SYSTEM Since there is no longer any wear elements inside Crankshaft Position Sensor sensor, most likely faults will be in electrical connections A sealed, non-serviceable assembly. If fault code P0337 between sensor and wire harness and wire harness to is present and engine does not start/run, proceed to step ECU.
Page 503 EFI SYSTEM 4. With throttle blade in full open position (WOT), press Temperature/Manifold Absolute Pressure (TMAP) magnet assembly fully on to throttle shaft. Full Sensor insertion can be checked by measuring height from A sealed non-serviceable integrated sensor that checks throttle body sensor mounting face to end of magnet both intake air temperature and manifold absolute assembly.
Page 504 EFI SYSTEM It is advisable to use an electronic meter such as a Oxygen Sensor (O2) digital voltmeter. Simple mechanical meters may place Detail a heavy electrical load on sensor and cause inaccurate readings. Since resistance of sensor is highest at low temperatures, such meters will cause largest inaccuracies when sensor is in a cool exhaust.
Page 505 EFI SYSTEM Sensor Signal Observation Removal Inspection NOTE: Apply anti-seize compound only to threads. Engine Harness O2 Sensor Connector Plug Detail Anti-seize compound will aﬀ ect sensor performance if it gets into lower shield of sensor. 1. If sensor has heavy deposits on lower shield, engine, oil, or fuel may be source.
Page 506 EFI SYSTEM Troubleshooting-Oxygen (O2) Sensor Condition Possible Cause Conclusion Continuous low voltage output (less Shorted sensor or sensor circuit. Replace sensor or replace and than 400mV) observed with throttle properly route wiring. Shorted lead wire. openings of 38-50% or more. Wiring shorted to ground.
Page 507 EFI SYSTEM Injector clogging is usually caused by a buildup of Fuel Injector deposits on director plate, restricting ﬂ ow of fuel, resulting in a poor spray pattern. Some contributing WARNING factors to injector clogging include higher than normal operating temperatures, short operating intervals, and Explosive Fuel can cause ﬁ...
Page 508 EFI SYSTEM 6. Pull retaining clip to separate fuel injector cap/ FUEL COMPONENTS bracket assembly from injector. Remove screw holding fuel injector cap/bracket assembly to throttle WARNING body. Lift injector from throttle body. Explosive Fuel can cause ﬁ res and severe 7.
Page 509 EFI SYSTEM 4. Check that hook is in upper 1/3 to 1/2 of window in Throttle Body Assembly throttle lever. If hook is further down in window, wire NOTE: ECU Reset is required if throttle body is is bound and steps 2 and 3 should be repeated. replaced.
Page 510 EFI SYSTEM TROUBLESHOOTING Troubleshooting Guide Condition Possible Cause Fuel pump not running. Empty fuel tank. Faulty spark plug. Old/stale fuel. Incorrect fuel pressure. Crankshaft position sensor loose or faulty. Engine Starts Hard TPS set incorrect (ECU Reset and TPS Learn). or Fails to Start TPS faulty.
Page 511 EFI SYSTEM Troubleshooting Guide Condition Possible Cause Faulty/malfunctioning ignition system. Dirty air ﬁ lter. Insuﬃ cient fuel delivery. Improper governor adjustment. Low Power Plugged/restricted exhaust. Basic engine problem exists. TPS faulty or mounting exists. Throttle plate in throttle body not fully opening to WOT stop (if equipped). Function Test Fault Codes Example of Diagnostic Display...
Page 512 EFI SYSTEM Diagnostic Fault Code Summary Fault Code Connection or Failure Description 0031 Oxygen Sensor Heater Circuit Low Voltage 0032 Oxygen Sensor Heater Circuit High Voltage 0107 Manifold Absolute Pressure (TMAP) Circuit Low Voltage or Open 0108 Manifold Absolute Pressure (TMAP) Circuit High Voltage 0112 Intake Air Temperature (TMAP) Circuit Low Voltage 0113...
Page 513 EFI SYSTEM Diagnostic Code Summary Code 0107 Code 0031 Component: Manifold Absolute Pressure (TMAP) NOTE: Codes 0031 and 0032 may have been Fault: MAP Circuit Low Voltage or Open mistakenly activated by turning key ON with Condition: Throttle body leak, open connection or oxygen sensor disconnected.
Page 514 EFI SYSTEM Code 0112 Code 0117 Component: Intake Air Temperature (TMAP) Component: Engine Temperature Sensor Fault: Intake Air Temperature Sensor Circuit Fault: Engine Temperature Sensor Circuit Low Low Voltage Voltage Condition: Shorted connection, faulty sensor or Condition: Shorted connection, faulty sensor or shorted wire.
Page 515 EFI SYSTEM Code 0122 Code 0131 Component: Throttle Position Sensor (TPS) Component: Oxygen Sensor Fault: TPS Circuit Low Voltage or Open Fault: O2S 1 Circuit Low Voltage Condition: Open connection, broken wire or faulty Condition: Open connection, broken wire or faulty sensor.
Page 516 EFI SYSTEM Code 0171 Code 0172 Component: Fuel System Component: Fuel System Fault: Maximum adaptation limit exceeded Fault: Minimum adaptation limit exceeded Condition: Fuel inlet screen/ﬁ lter plugged, low Condition: Too high pressure at high pressure fuel pressure at high pressure fuel line, TPS line, TPS malfunction, shorted malfunction, shorted connection, faulty connection, faulty sensor or fuel pump...
Page 517 EFI SYSTEM Code 0174 Code 0230 Component: Fuel System Component: Fuel Pump Relay Fault: Lean fuel condition Fault: Circuit Low Voltage or Open Condition: Fuel inlet screen/ﬁ lter plugged, low Condition: Shorted or open connection. pressure at high pressure fuel line, TPS Conclusion: Fuel Pump Relay Related malfunction, shorted connection or faulty ●...
Page 518 EFI SYSTEM Code 0336 Code 0337 NOTE: If fault code P0337 is present and engine does Component: Crankshaft Position Sensor not start/run, proceed to step 1 of Crankshaft Fault: Crankshaft Position Sensor Noisy Signal Position Sensor earlier in this section. If P0337 is present and engine operates, clear codes and Condition: Loose sensor, faulty/bad battery, shorted...
Page 519 EFI SYSTEM Code 0351 Code 0650 Component: Ignition Coil Component: MIL Circuit Fault: Ignition Coil Malfunction Fault: MIL Circuit Malfunction Condition: Broken wire in harness (may not be Condition: Failure in MIL circuit detected. visible), shorted connection or faulty Conclusion: Bad Connection. sensor.
Page 520 EFI SYSTEM EFI Diagnostic Flow Diagram START OF TEST PROCEED TO START OF TEST FOR RETEST KEY ON MALFUNCTION REFER TO DIAGNOSTIC AID #1 INDICATOR LIGHT SYSTEM POWER REFER TO ARE FAULT CODES DIAGNOSTIC FAULT CODE SUMMARY PRESENT? CLEAR CODES REFER TO DIAGNOSTIC AID #3 DOES ENGINE START? MIL GOES OFF?
Page 521 EFI SYSTEM Flow Chart Diagnostic Aids Diagnostic Aid #5 FUEL PUMP (fuel pump not turning on) Diagnostic Aid #1 SYSTEM POWER Condition (MIL does not illuminate for 3 seconds when key is ﬁ rst ● Inspect fuse(s) turned ON) ● Fuel pump relay circuit problem, pin circuits Black 9 NOTE: MIL is installed by vehicle OEM.
Page 522 Governor System GOVERNOR (OEM Supplied) Refer to operating instructions of equipment this engine powers for speciﬁ c governor instructions. 17 690 15 Rev. -- KohlerEngines.com...
Page 523 Lubrication System These engines use a splash lubrication system, supplying necessary lubrication to crankshaft, camshaft, connecting rod and valve train components. Lubrication Components Dipstick Tube Oil Drain Plug Oil Fill Plug Filler Neck OIL RECOMMENDATIONS WINTER LUBRICATION Refer to Maintenance. If engine is frequently used for short periods of time in ambient temperatures below 4°C (40°F), reduce oil CHECK OIL LEVEL...
Page 524 Lubrication System 4. Fill crankcase with new oil, up to point of overﬂ owing ﬁ ller neck. 5. Reinstall oil ﬁ ll plug/dipstick and tighten securely. 6. Dispose of used oil in accordance with local ordinances. OIL SENTRY (if equipped) ™...
Page 525 Electrical System BATTERY CHARGING SYSTEM (OEM Supplied) 5. Insert fuse into fuse holder until it is seated properly. Install fuse cover. 6. If replacement fuse fails, there is a problem within CAUTION circuit. Diagnostics are required. Identify which Electrical Shock can cause injury. circuit is aﬀ...
Page 526 Electrical System Carbon Fouled Inspection Inspect spark plug as it is removed from cylinder head. Deposits on tip are an indication of general condition of piston rings, valves, and fuel mixture. Normal and fouled plugs are shown in following photos: Normal Soft, sooty, black deposits indicate incomplete combustion caused by a restricted air cleaner, over rich...
Page 527 Electrical System Troubleshooting Guide Test Ignition System Isolate and verify trouble is within engine. 1. If Kohler diagnostic software is available, review "Safety System Active" status in Data Display screen. If yes is displayed, equipment safety circuit is active (Refer to equipment manufacturer's manual for safety system information).
Page 528 Starter System Starter (OEM Supplied) Refer to operating instructions of equipment this engine powers for speciﬁ c starter system instructions. 17 690 15 Rev. -- KohlerEngines.com...
Page 529 Disassembly/Inspection and Service WARNING Before working on engine or equipment, disable engine as Accidental Starts can cause severe injury or follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing.
Page 530 Disassembly/Inspection and Service Remove Throttle Body Assembly Remove Fuel Injector NOTE: Unless fuel injector is damaged or malfunctioning, disassembly from throttle body is unnecessary. NOTE: Make note of fuel injector position before removing. NOTE: Unless fuel injector cap is damaged, removing retainer securing cap to injector is unnecessary.
Page 531 Disassembly/Inspection and Service Fuses and ECU Components Blower Housing Components Fuses/Fuse Holders Screw Cable Clip Ignition Coil Blower Housing Screw Remove Fuses Screen Remove fuses from holders located on lower shield. Screw Blower Housing Clamp Remove Electronic Control Unit (ECU) 1.
Page 532 Disassembly/Inspection and Service Remove Crankshaft Position Sensor Remove Valve Cover NOTE: Do not remove sensor from bracket unless sensor is being replaced. 1. Unplug crankshaft position sensor electrical connector. 2. Remove upper screw securing crankshaft position sensor bracket to crankcase post. 3.
Page 533 Disassembly/Inspection and Service Cylinder Head Components Rocker Arm Pivot Hex Jam Nut Rocker Arm Rocker Arm Stud Adjuster Valve Spring Push Rod Guide Push Rod Valve Spring Retainer Valve Stem Seal Cylinder Head Screw Spark Plug Cylinder Head Cylinder Head Valve Dowel Pin Gasket...
Page 534 Disassembly/Inspection and Service Valve Guides If a valve guide is worn beyond speciﬁ cations, it will not guide valve in a straight line. This may result in burnt valve faces or seats, loss of compression, and excessive oil consumption. To check valve guide-to-valve stem clearance, thoroughly clean valve guide and, using a split-ball gauge, measure inside diameter of guide.
Page 535 Disassembly/Inspection and Service Crankcase/Crankshaft/Camshaft/Closure Plate Components Closure Plate Oil Seal Closure Plate Screw Closure Plate Bearing Closure Plate Balance Closure Plate Gasket Wave Spring Balance Shaft Shaft Bearing Crankcase Balance Connector Rod Crankshaft Connector Rod Shaft Bearing End Cap Piston Piston Pin Retainer Piston Pin Piston Ring Set...
Page 536 Disassembly/Inspection and Service Automatic Compression Release (ACR) Remove Oil Fill Tube ACR Operation Details Details Oil Fill Tube Oil Fill Tube Bracket Bracket Screw NOTE: Unless oil ﬁ ll tube is damaged, disassembly from closure plate is unnecessary. Camshaft Exhaust Cam Lobe 1.
Page 537 Disassembly/Inspection and Service Inspection and Service Dimension C Dimension A Camshaft Journal Speciﬁ cations Cam Lobe Dimension C Limit 32.286 mm 32.032 mm 15.900 mm INTAKE 15.975 mm (0.6289 in.) (1.271 in.) (1.261 in.) (0.6260 in.) 32.506 mm 32.252 mm EXHAUST (1.280 in.) (1.270 in.)
Page 538 Disassembly/Inspection and Service Some important points to remember when servicing Piston and Rings Inspection piston rings: Scuﬃ ng and scoring of piston and cylinder wall occurs 1. Cylinder bore must be deglazed before service ring when internal engine temperatures approach welding sets are used.
Page 539 Disassembly/Inspection and Service NOTE: Rings must be installed correctly. Use a piston 3. Remove oil seal from closure plate. ring expander to install rings. Install bottom (oil 4. Using a suitable press, push crankshaft bearing from control) ring ﬁ rst and top compression ring last. closure plate.
Page 540 Disassembly/Inspection and Service Honing Clean Cylinder Bore After Honing Proper cleaning of cylinder walls following boring and/ Crosshatch Detail or honing is very critical to a successful overhaul. Machining grit left in cylinder bore can destroy an engine in less than one hour of operation after a rebuild. Final cleaning operation should always be a thorough scrubbing with a brush and hot, soapy water.
Page 541 Reassembly Crankcase/Crankshaft/Camshaft/Closure Plate Components Closure Plate Oil Seal Closure Plate Screw Closure Plate Bearing Closure Plate Balance Closure Plate Gasket Wave Spring Balance Shaft Shaft Bearing Crankcase Balance Connector Rod Crankshaft Connector Rod Shaft Bearing End Cap Piston Piston Pin Retainer Piston Pin Piston Ring Set Oil Sentry...
Page 542 Reassembly Install Crankcase Bearings and Oil Seals Install Crankshaft Carefully slide ﬂ ywheel end of crankshaft through main Details ball bearing and seal. Install Connecting Rod with Piston and Rings Connecting Rod Details Outer Surface Seal Depth NOTE: Oil bearings liberally with engine oil when installing.
Page 543 Reassembly Install Balance Shaft Install Valve Tappets and Camshaft Timing Mark Detail Timing Mark Detail Camshaft Drive Balance Shaft Drive Camshaft Gear Balance Shaft Gear on Crankshaft Gear on Crankshaft Timing Mark Timing Mark Timing Mark Timing Mark 1. Lubricate face and stem of each tappet with engine 1.
Page 544 Reassembly Install Oil Fill Tube Install Closure Plate Details Torque Sequence Oil Fill Tube Oil Fill Tube Bracket 1. Check to make sure sealing surfaces of crankcase Bracket Screw and closure plate are clean and free of nicks/burrs. 1. If oil ﬁ ll tube was removed from closure plate, apply 2.
Page 545 Reassembly Cylinder Head Components Rocker Arm Pivot Hex Jam Nut Rocker Arm Rocker Arm Stud Adjuster Valve Spring Push Rod Guide Push Rod Valve Spring Retainer Valve Stem Seal Cylinder Head Screw Spark Plug Cylinder Head Cylinder Head Valve Dowel Pin Torque Sequence Gasket Assemble Cylinder Head...
Page 546 Reassembly Install Push Rods and Rocker Arms Flywheel Components NOTE: Push rods should always be installed in original location. 1. Identify proper position of each push rod. Dip ends of push rods in engine oil and install them in their respective locations, seating each into tappet socket.
Page 547 Reassembly Install Crankshaft Position Sensor Install Cylinder Shield NOTE: Ensure all parts are clean, undamaged and free of debris and make sure electrical connectors have seal in place. NOTE: When mounting ground wire on bottom screw of bracket, ensure ground wire is routed outside and away from ﬂ...
Page 548 Reassembly Install Upper Heat Shield and Engine Temperature Install Fuel Injector and TMAP Sensor Engine Temperature Upper Heat Shield Sensor Dipstick Tube Screw Bracket Oxygen Sensor Fuel Injector Cap Screw Clip Connector Metal Retaining Clip Fuel Injector 1. Position upper heat shield on crankcase and start 2 screws securing to crankcase.
Page 549 Reassembly Install Throttle Body Assembly Install Air Inlet Elbow Throttle Body Fuel Injector Throttle Position TMAP Air Inlet Elbow Sensor (TPS) Breather Hose with Insulator to Throttle Clamp Insulator Sleeve Body Gasket Throttle Body Gasket Governor Bracket Insulator to Cylinder Intake Studs Head Gasket Throttle Body...
Page 550 Reassembly External Engine Components Oil Fill Plug Dipstick Spark Plug Lead Oil Drain Plug Connect Spark Plug Lead Connect lead to spark plug. Secure lead to dipstick tube with a new wire tie. Prepare Engine for Operation NOTE: If ECU, throttle body, TPS, or fuel pump were replaced, an ECU Reset and TPS Learn is required.
Page 552 Shifter Cable KOHLER ENGINE SERVICE MANUAL Pagination Page Page 25-2 2021 Carryall 300 Maintenance and Service Manual...
Page 553 SECTION 26 — WIRING DIAGRAMS GENERAL INFORMATION Wiring Diagrams Wire Description EXAMPLE: 18_GRN_RED • 18 = 18 gauge wire • GRN_RED = Green wire with red stripe Wire Colors NOTE: The following colors will represented as a black wire in the wiring diagrams: •...
Page 554 Pedal-Start Connector Pinouts WIRING DIAGRAMS GRN_WHT Green with White Stripe ORG_BLK Orange with Black Stripe ORG_WHT Orange with White Stripe PUR_WHT Purple with White Stripe RED_GRN Red with Green Stripe RED_WHT Red with White Stripe RED_YEL Red with Yellow Stripe WHT_BLK White with Black Stripe PEDAL-START CONNECTOR PINOUTS...
Page 555 WIRING DIAGRAMS Pedal-Start Connector Pinouts To Engine Harness Wire Color Description Switched 12V Power Constant 12V Power OPEN OPEN Malfunction Indicator Light (MIL) White Ground Kill Wire Green Low Oil Light Black / White Fuel Pump OPEN OPEN To Instrument Panel (IP) Harness Wire Color Description Green / White...
Page 556 Pedal-Start Connector Pinouts WIRING DIAGRAMS Orange / Black Fuel Sending Unit Input White Hour Meter Input Green Low Oil Light To FNR Harness Wire Color Black / Yellow Orange Purple / White Black / Light Blue Blue / White Yellow To Accessories Wire Color Description...
Page 557 WIRING DIAGRAMS Pedal-Start Connector Pinouts To Brake Light Relay Wire Color Description Black Ground White / Black Power Gray / Black To Accessories Pin 3 To Fuel Pump Wire Color Description Open Open Orange/Black Sending Unit Positive (+) Black Sending Unit Negative (-) Black/White Fuel Pump Negative (-) Red/White...
Page 558 Pedal-Start Connector Pinouts WIRING DIAGRAMS Black/White Red/White Open Fuse Holder Wire Color Red/Black Orange/White Orange Fuse Connector Wire Color Pink Page 26-6 2021 Carryall 300 Maintenance and Service Manual...
Page 559 WIRING DIAGRAMS Key-Start Connector Pinouts KEY-START CONNECTOR PINOUTS KEY-START MAIN HARNESS CONNECTOR PINOUTS To Connected Car Wire Color Description Power Black Ground OPEN OPEN OPEN OPEN To Engine Harness Wire Color Description Switched 12V Power Constant 12V Power OPEN OPEN Malfunction Indicator Light (MIL) White...
Page 560 Key-Start Connector Pinouts WIRING DIAGRAMS To Instrument Panel (IP) Harness Wire Color Description Green / White Headlights / Taillights Green / Red Headlight Switch Power Red / Yellow To Key Switch (M+) OPEN OPEN Orange / White Reverse Buzzer Power Blue / White Power Black / White...
Page 561 WIRING DIAGRAMS Key-Start Connector Pinouts To Accessories Wire Color Description Blue Horn Power Gray To Rear Lights Gray / Black Brake Light Relay White To Rear Lights OPEN OPEN Black Ground Brown Power Right Turn Signal Power Green Left Turn Signal Power To Brake Light Relay Wire Color Description...
Page 562 Key-Start Connector Pinouts WIRING DIAGRAMS To Fuel Pump Wire Color Description Open Open Orange/Black Sending Unit Positive (+) Black Sending Unit Negative (-) Black/White Fuel Pump Negative (-) Red/White Fuel Pump Positive (+) Fuel Pump Relay Wire Color Green Black/White Red/White Open Page 26-10...
Page 563 WIRING DIAGRAMS Key-Start Connector Pinouts Fuse Holder Wire Color Red/Black Orange/White Orange Fuse Connector Wire Color Pink 2021 Carryall 300 Maintenance and Service Manual Page 26-11...
Page 564 Engine Harness Wiring Diagram Table WIRING DIAGRAMS ENGINE HARNESS WIRING DIAGRAM TABLE Callout Description Red/Black Red/White Yellow Light Green Dark Green Dark Blue Purple Pink White Grey Black To Main Harness Oil Level Switch 10-amp Fuse (Ignition Switch) 10-amp Fuse (Battery Power) Black Connector Grey Connector Fuel Injector...
Page 565 Wiring Diagrams Gasoline: Engine Harness GASOLINE: ENGINE HARNESS...
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Page 567 Wiring Diagrams Gasoline: Key-Start Main Harness GASOLINE: KEY-START MAIN HARNESS...
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Page 569 Wiring Diagrams Gasoline: Pedal-Start Main Harness GASOLINE: PEDAL-START MAIN HARNESS...
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Page 571 Wiring Diagrams Gasoline: Instrument Panel Harness GASOLINE: INSTRUMENT PANEL HARNESS...
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Page 573 Wiring Diagrams Gasoline: FNR Harness GASOLINE: FNR HARNESS...
Page 574 (Page intentionally left blank.)
Page 575 Wiring Diagrams Electric: Main Harness ELECTRIC: MAIN HARNESS...
Page 576 (Page intentionally left blank.)
Page 577 Wiring Diagrams Electric: Instrument Panel Harness ELECTRIC: INSTRUMENT PANEL HARNESS...
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Page 579 Wiring Diagrams Electric: Accessories Harness ELECTRIC: ACCESSORIES HARNESS...
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Page 581 Index Index self-discharge ..........14-10 Index storage ............14-14 AC power and circuit testing ............... 14-3 testing (ERIC charger) ........15-30 basics ............14-2 accelerator voltage test........... 12-14 cable voltage test (under load) ........ 12-15 installation ............21-8 vibration damage..........14-11 removal ............
Page 582 INDEX installation ............19-48 removal ............19-47 carburetor charging diode (key-start) closed throttle or idle adjustment ....... 21-10 testing ............. 18-46 CAUTION charging system definition of ............1-1 test procedures ..........15-29 cleaning amp hours ............11-8 brake assembly............ 6-5 anti-tamper speed ..........
Page 583 INDEX drive clutch relieving pressure ..........21-14 assembly ............23-10 fuel filter cleaning and inspection ......23-6, 23-9 installation ............21-25 disassembly............23-7 removal ............21-25 installation ............23-11 fuel gauge/hour meter .......... 19-35 removal ............. 23-5 fuel gauge circuit drive motor testing ............
Page 584 INDEX removal ..........13-12, 19-38 testing ............. 18-38 headlights low oil warning light see also lighting circuit........18-39 installation ............19-34 testing ............. 18-39 removal ............19-34 high pedal detect ........... 12-3 testing ............. 18-29 hubs lubrication hub, rear front suspension..........7-15 installation ............
Page 585 INDEX installation ............22-2 regenerative braking ..........12-3 removal ............. 22-1 resistor see also exhaust system........22-1 location.............. 12-4 reverse buzzer installation ..........13-5, 19-32 limit switch installation ............ 19-33 neutral lockout removal ............19-33 limit switch testing ............18-28 installation ............
Page 586 INDEX belt tension inspection ........19-14 brush spring test procedures, CDT connection......11-27 inspection............19-3 test procedures, charger replacement ........... 19-3 AC power and continuity test of AC circuit... 15-30 brushes ............. 19-2 battery condition using charger......15-30 inspection............19-3 battery voltage using multimeter ......15-29 replacement ...........
Page 587 INDEX neutral lockout limit switch (pedal-start)....18-20 reverse buzzer ..........18-28 usb receptacle reverse buzzer limit switch ........ 18-28 installation ..........13-15, 19-49 solenoid (key-start)........... 18-43 removal ..........13-15, 19-49 solenoid (pedal-start) ........18-17 starter/generator........18-22–18-23 voltage limiter........... 18-40 voltage regulator ..........18-26 test procedures, index of gasoline vehicle ..........
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Club Car Carryall 300 2021 Maintenance And Service Manual

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