Club Car Carryall 500 2016 Maintenance And Service Manual
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Club Car Carryall 500 2016 Maintenance And Service Manual

Gasoline vehicle with subaru ex40 engine electric vehicle with quiq charger
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2016 Carryall 500 and 700
Maintenance and Service
Manual
Gasoline Vehicle with Subaru EX40 Engine
Electric Vehicle with QuiQ™ ™ ™ Charger
Manual Number 105334704
Edition Code 0515F0616E

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  • Page 1 2016 Carryall 500 and 700 Maintenance and Service Manual Gasoline Vehicle with Subaru EX40 Engine Electric Vehicle with QuiQ™ ™ ™ Charger Manual Number 105334704 Edition Code 0515F0616E...
  • Page 3 To find your local authorized Club Car dealer, visit www.clubcardealer.com, call 1-800-ClubCar (258–2227), or scan this Quick Response (QR) code to be taken to the Club Car dealer locator. Refer to Figure 1. Download a QR code reader such as RedLaser or Barcode Scanner to your cell phone or tablet.
  • Page 4 Deionizer Filter Replacement Cartridge (non-SPWS) CC PN AM10975 NOTE: This manual represents the most current information at the time of publication. Club Car is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures.

  • Page 5: Table Of Contents

    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 Disabling the Vehicle..........................1-4 Disconnecting the Batteries – Electric Vehicles .................... 1-4 Connecting the Batteries – Electric Vehicles ....................1-4 Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles..............
  • Page 6 Bed Latch Assembly Installation ....................... 4-15 Rear Fenders and Tailskirt..........................4-17 Rear Fender and Tailskirt Removal ......................4-17 Rear Fender and Tailskirt Installation ......................4-18 Electric Bed Lift ............................4-19 Electric Bed Lift Removal ......................... 4-19 Electric Bed Lift Installation ........................4-19 Floor Mat ..............................
  • Page 7 Steering Adjustment ............................7-6 Rack and Pinion ............................7-7 Rack and Pinion Inspection ........................7-7 Rack and Pinion Removal – Maintenance-Free Ball Joints ................7-7 Rack and Pinion Disassembly ........................7-8 Rack and Pinion Assembly ........................7-10 Rack and Pinion Installation – Maintenance-Free Ball Joints............... 7-13 Tie Rod and Drag Link ..........................
  • Page 8 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 OS Version...............................11-5 SM Version ..............................11-5 VCL App Version ............................11-5 Parameters ..............................11-5 Settings ..............................11-6 Amp Hours...............................11-9 Access Codes ............................11-9 Vehicle ID ..............................11-9 Monitor Menu .............................
  • Page 9 Battery Monitor ............................11-15 Charging Totals ............................11-15 Amp Hours Display ..........................11-15 LIN ................................ 11-15 Diagnostics Menu ............................11-17 Present Errors Folder..........................11-17 Fault History Folder ..........................11-17 System Faults ............................11-17 Fault Recovery ............................11-19 Fault Descriptions............................11-20 01 Throttle Fault 1 ..........................
  • Page 10 Wiring Diagrams ............................12-4 Troubleshooting............................12-8 Troubleshooting the Vehicle with the CDT ....................12-8 Troubleshooting Guide 1 .......................... 12-9 Troubleshooting Guide 2 .........................12-12 Test Procedures ............................12-14 Testing Basics ............................12-14 SECTION 13 — Electrical Components: IQ Plus Electric Vehicles............... 13-1 Key Switch ..............................13-1 Testing the Key Switch ..........................
  • Page 11 Watering Batteries with the SPWS ......................14-11 Battery Storage ............................14-13 Fleet Rotation.............................14-13 Deep-Discharge ............................14-14 Early Excessive Discharging ........................14-14 SECTION 15 — QuiQ High Frequency Charger ....................15-1 General Information ............................. 15-1 Features ..............................15-1 UL and CSA Listing ..........................15-1 CE Compliance ............................
  • Page 12 Gasoline Powertrain ..........................18-4 Wiring Diagrams ............................18-9 Electrical System ............................18-15 Test Procedures ............................18-16 Testing Basics ............................18-16 SECTION 19 — Troubleshooting and Electrical System: Key-Start Gas Vehicle........... 19-1 General Information ............................. 19-1 Wiring Diagrams ............................19-2 Test Procedures ............................19-6 SECTION 20 —...
  • Page 13 Low Oil Warning Light Removal .......................20-29 Low Oil Warning Light Installation ......................20-29 Fuel Gauge/Hour Meter ..........................20-29 General Information ..........................20-29 Fuel Gauge/Hour Meter Removal ......................20-30 Fuel Gauge/Hour Meter Installation......................20-30 Fuel Level Sending Unit ..........................20-30 Oil Level Sensor ............................20-30 Oil Level Sensor Removal ........................20-30 Oil Level Sensor Installation ........................20-30 Voltage Limiter ............................20-31 Voltage Limiter Removal .........................20-31...
  • Page 14 Valve Clearance Check and Adjustment....................22-7 Engine Removal ............................22-8 Engine Removal to Mid-2016 Model Year ....................22-8 Engine Removal from Mid-2016 Model Year .....................22-10 Engine Installation ............................22-11 Engine Installation to Mid-2016 Model Year ....................22-11 Engine Installation from Mid-2016 Model Year ..................22-12 Flywheel ..............................22-13 Flywheel Removal ..........................22-13 Flywheel Installation ..........................22-14...
  • Page 15 SECTION 24 — Exhaust System: Gasoline Vehicles ..................24-1 Muffler ................................ 24-1 Muffler Removal ............................24-1 Muffler Installation............................ 24-1 SECTION 25 — Clutches: Gasoline Vehicles..................... 25-1 General Information ............................. 25-1 Troubleshooting............................25-1 Drive Belt ..............................25-3 Drive Belt Removal ..........................25-3 Drive Belt Installation ..........................

  • 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 SAFETY General Warnings WARNING • To avoid unintentionally starting an electric vehicle, disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4. Gasoline vehicles only: • To avoid unintentionally starting a gasoline vehicle, disconnect the battery and spark plug wire. See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5.

  • Page 20: Disabling The Vehicle

    General Warnings SAFETY DISABLING THE VEHICLE Engage park brake to lock wheels. Turn the key switch OFF and remove the key. Place the Forward/Reverse control in the NEUTRAL position. In addition, chock the wheels if servicing or repairing the vehicle. DISCONNECTING THE BATTERIES –...

  • Page 21: Side-Post Battery: Disconnecting The Battery-Gasoline Vehicles

    SAFETY General Warnings SIDE-POST BATTERY: DISCONNECTING THE BATTERY-GASOLINE VEHICLES Disable the vehicle. See Disabling the Vehicle on page 1-4. Disconnect the battery cables, negative (–) cable first, as shown (Figure 1-2). Disconnect the spark plug wire(s) from the spark plug(s). SIDE-POST BATTERY: CONNECTING THE BATTERY-GASOLINE VEHICLES Connect the battery cables, positive (+) cable first.

  • Page 22: Recycling Lead-Acid 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 500 CARRYALL 700 POWER SOURCE ELECTRIC ELECTRIC Drive motor: Direct drive, 48 volts DC, shunt wound, 3.7 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 500 CARRYALL 700 POWER SOURCE ELECTRIC ELECTRIC Weight: Standard electric vehicle (curb weight) 1393 lb (632 kg) 1475 lb (669 kg) 15 to 17 mph 15 to 17 mph Maximum forward speed (24 to 27 km/h) (24 to 27 km/h) Outside clearance circle (diameter) 248.5 in (631.1 cm)

  • Page 25: Quiq Battery Charger Specifications

    VEHICLE SPECIFICATIONS Vehicle Specifications QUIQ BATTERY CHARGER SPECIFICATIONS QUIQ BATTERY CHARGER SPECIFICATIONS AC INPUT AC Voltage – range 85 to 265 VAC (acceptable) AC Voltage – nominal 120 to 230 VAC Frequency 45 to 65 Hz AC Power Factor – nominal >0.99 @ 120 VAC / >0.98 @ 230 VAC POWER CONSUMPTION Max:...

  • 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 500 CARRYALL 700...
  • Page 27 VEHICLE SPECIFICATIONS Vehicle Specifications SPECIFICATIONS CARRYALL 500 CARRYALL 700 POWER SOURCE GASOLINE GASOLINE Wheelbase 78.1 in (198.3 cm) 99.1 in (251.7 cm) Ground clearance 5.2 in (13.2 cm) 5.2 in (13.2 cm) Front wheel tread 36.6 in (92.9 cm) 36.6 in (92.9 cm) Rear wheel tread 39.5 in (100.3 cm) 39.5 in (100.3 cm)
  • Page 28 Vehicle Specifications VEHICLE SPECIFICATIONS Pagination Page Page 2-6 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 29: Section 3 - General Information

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

  • Page 30: Storage - Electric Vehicles

    Storage – Electric Vehicles GENERAL INFORMATION SERIAL NUMBER CC5819-123456 BC54679 ASSEMBLED IN USA 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/Reverse handle or switch in the NEUTRAL position during storage.

  • Page 31: Returning The Stored Electric Vehicle To Service

    GENERAL INFORMATION Storage – Electric Vehicles Immediately Prior to Storage, Perform the Following Steps Unload the vehicle so that tires are supporting only the weight of the vehicle. Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse switch in the NEUTRAL position during storage.

  • Page 32: Storage - Gasoline Vehicles

    Storage – Gasoline Vehicles GENERAL INFORMATION 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. • Be sure to clean up any spilled gasoline before operating the vehicle. •...

  • Page 33: Returning The Stored Gasoline Vehicle To Service

    GENERAL INFORMATION Storage – Gasoline Vehicles Batteries should be clean and free of corrosion. Wash tops and terminals of batteries with a solution of baking soda and water: use 1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water. Rinse solution off batteries. Do not allow this solution to enter the batteries.
  • Page 34 Storage – Gasoline Vehicles GENERAL INFORMATION Pagination Page Page 3-6 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • 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 COLOR CC P/N Dark Gray 105117705 Black 105117706 105117707 Bright Blue 105117708 TITN Silver 105117709 Light Gray 105117710 FRONT BODY See General Warnings on page 1-1. HEAVY DUTY BUMPER REMOVAL Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5.
  • Page 38 Front Body BODY AND TRIM 2986 Figure 4-1 Heavy Duty Bumper Page 4-4 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 39: Heavy Duty Bumper Installation

    BODY AND TRIM Front Body HEAVY DUTY BUMPER INSTALLATION Position brush guard mounting bracket (4) onto brush guard weldment (5). Align holes and secure with four screws (1), eight washers (3), and four locknuts (2) (Figure 4-1, Page 4-4) Attach plastic bumper (13). Use the existing fastener holes in the mounting bracket and vehicle structure as an alignment guide.

  • Page 40: Grille Removal

    Front Body BODY AND TRIM 2846 Figure 4-2 Front Cowl GRILLE REMOVAL Park vehicle and chock the tires. Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5. See Top-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5.

  • Page 41: Grille Installation

    BODY AND TRIM Front Body Remove charger receptacle (if equipped) by removing the three screws that attach the receptacle or disconnect connector (quick connect). GRILLE INSTALLATION Connect the charger receptacle or connector (quick connect). Install, but do not tighten upper M6 screws. (Do not tighten screws until plastic bumper is installed). Lower grille holes are shared with the front bumper, ensure lower bumper screws are attached first then install grille.
  • Page 42 Front Body BODY AND TRIM 2844 Figure 4-3 Front Grille, Bumper, and Side Fenders Page 4-8 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 43: Front Bumper And Side Fender Removal

    BODY AND TRIM Front Body FRONT BUMPER AND SIDE FENDER REMOVAL Park the vehicle, chock tires. Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5. See Top-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5.

  • Page 44: Instrument Panel Removal

    Front Body BODY AND TRIM INSTRUMENT PANEL REMOVAL Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5. See Top-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5. Remove front cowl.

  • Page 45: Dash Removal

    BODY AND TRIM Front Body DASH REMOVAL Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5. See Top-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5. Remove cowl.
  • Page 46 Front Body BODY AND TRIM 2863 Figure 4-5 Dash Assembly Page 4-12 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 47: Tilt Bed

    BODY AND TRIM Tilt Bed TILT BED See General Warnings on page 1-1. 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.
  • Page 48 Tilt Bed BODY AND TRIM 2980 Figure 4-6 Tilt Bed Mounting Page 4-14 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 49: Bed Latch Assembly Removal

    BODY AND TRIM Tilt Bed BED LATCH ASSEMBLY REMOVAL NOTE: This procedure requires the aid of an assistant. Park the vehicle and chock the tires. Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5. See Top-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5.
  • Page 50 Tilt Bed BODY AND TRIM 2982 Figure 4-7 Bed Latch Assembly Page 4-16 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 51: Rear Fenders And Tailskirt

    BODY AND TRIM Rear Fenders and Tailskirt 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/Reverse handle in NEUTRAL and set the park brake.

  • Page 52: Rear Fender And Tailskirt Installation

    Rear Fenders and Tailskirt BODY AND TRIM See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5. See Top-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5. Remove the tilt bed. See Tilt Bed Removal on page 4-13. Disconnect the three taillight wires. Using a 10 mm socket, remove the three fasteners (5) that attach the rear fender (4) to vehicle frame (Figure 4-8, Page 4-17).

  • Page 53: Electric Bed Lift

    BODY AND TRIM Electric Bed Lift ELECTRIC BED LIFT ELECTRIC BED LIFT REMOVAL NOTE: For vehicles equipped with an electric bed lift. This procedure requires the aid of an assistant. Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles on page 1-4. See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5.
  • Page 54 Electric Bed Lift BODY AND TRIM 2983 Figure 4-9 Electric Bed Lift Page 4-20 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 55 BODY AND TRIM Electric Bed Lift 2985 Figure 4-10 Electric Bed Mounting 2016 Carryall 500 and 700 Maintenance and Service Manual Page 4-21...

  • Page 56: Floor Mat

    Floor Mat BODY AND TRIM FLOOR MAT See General Warnings on page 1-1. FLOOR MAT REMOVAL Remove the brake and accelerator pedals. See Accelerator and Brake Pedal Group, Section 5, Page 5-1. Remove the top edge of the floor mat from the overlapping flange under the dash. Lift the mat from the vehicle.

  • Page 57: 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(s).
  • Page 58 Brake Pedal and Park Brake (Gas and Electric Vehicles) ACCELERATOR AND BRAKE PEDAL GROUP Carryall 500 and 700 Electric Vehicle shown, (Gasoline Vehicle similar) 3208 Figure 5-1 Brake and Park Brake Pedal Assembly and Mounting Page 5-2 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 59 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 8), and washers (10) to vehicle frame as shown.

  • Page 60: 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(s). See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5.

  • Page 61: Accelerator Pedal - Gasoline Vehicles

    ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles Install the spacer (23) and torsion spring (22) on the park brake pedal shaft on the brake pedal assembly. 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).

  • Page 62: Accelerator Pedal Installation - Gasoline Vehicles

    Accelerator Pedal – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP Inspect the accelerator pivot rod supports (21) for wear and damage and replace if necessary. If the pivot rod supports do not require replacement, loosen, but do not remove, the four bolts (22) and lock nuts (18) to make installation of the pivot rod easier.

  • Page 63: Accelerator Pedal - Electric Vehicles

    ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles 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. Install the plastic spacer (20) on the pivot rod (6). Insert the pivot rod through the pivot rod supports on the vehicle frame.
  • Page 64 Accelerator Pedal – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP 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 65 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles 2642 Figure 5-8 Accelerator Pedal – Electric Vehicle with MCOR 2016 Carryall 500 and 700 Maintenance and Service Manual Page 5-9...

  • Page 66: 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 67 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 68 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 inch to 1/2 inch (6 mm to 13 mm) (Figure 5-3, Page 5-3). 3.3.
  • Page 69 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 70 Pedal Group Adjustment – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP 1. Accelerator Pedal Adjustment Tool (CC P/N 101871001) 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/Reverse handle in the NEUTRAL position.
  • Page 71 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles 0 to 5° Top View of the Electrical Component Box 3016 Figure 5-18 Accelerator Cable CAUTION • After accelerator rod adjustment, make sure that approximately the same number of threads are exposed at each end of the accelerator rod.

  • Page 72: Pedal Group Adjustment - Electric Vehicles

    Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP Connect the battery cables. See Side-Post Battery: Connecting the Battery-Gasoline Vehicles, Section 1, Page 1-5. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. PEDAL GROUP ADJUSTMENT – ELECTRIC VEHICLES See General Warnings on page 1-1.
  • Page 73 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles Correct pedal position is 6 inches (15.2 cm) from floormat to back of brake pedal. 1400-18000-10211 1400-18000-10212 Figure 5-20 Brake Pedal Height Adjustment Figure 5-21 Brake Pedal Height Measurement Adjust brake pedal free play.
  • Page 74 Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP 0.060 inch (1.5 mm) A. Bottom View B. Cutaway Side View 2643 Figure 5-22 Park Brake Ratchet/Pawl Gap Adjustment 4.3. With the park brake unlocked, measure and note the distance from the top of the accelerator pedal to the floorboard, then lock the park brake (Figure 5-23, Page 5-18).
  • Page 75 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles accelerator pedal height closest to the floorboard. Press the accelerator pedal until the end of the tool rests against the floorboard; pedal height should be 5-5/8 inches (14.3 cm). Use a rubber strap to hold pedal in position against the floorboard and then tighten nut to 26 ft·lb (35.3 N·m) (Figure 5-27, Page 5-19).
  • Page 76 Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP Pagination Page Page 5-20 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 77: 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 fiber, and asbestos dust is created when these brake mechanisms are handled.
  • Page 78 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES BRAKE DRUM TWO BRAKE SHOE RETAINER PIN HEADS AXLE TUBE 1/2 INCH X 5/8 INCH COLD CHISEL 2814 2834a Figure 6-1 Loosen Equalizer Nut Figure 6-2 Shoe Retainer Pins 4.2. Insert a 1/2 inch x 5/8 inch cold chisel (1) under the head (2) of each pin and shear them off as illustrated (Figure 6-2, Page 6-2).

  • Page 79: Brake Assembly Cleaning

    WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning 2824 2825 Figure 6-3 Rotate Clip Retainer Figure 6-4 Remove Shoes 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 mechanical components. Remove the rubber boot from backing plate and wipe with a clean damp cloth.
  • Page 80 Brake Assembly Cleaning WHEEL BRAKE ASSEMBLIES Use a small brush to carefully apply a light coat of white lithium NLGI #2 grease (Dow Corning ® BR2-Plus or equivalent) on each of the six raised bosses on brake backing plate (Figure 6-7, Page 6-4). See preceding WARNING.

  • 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. NOTE: Components of the front wheel brake assembly are identical to the rear wheel manually-adjusted brake assembly. The front brake assembly is rotated 90° (when compared to the rear brake assembly) so the adjusting bolt on each assembly is oriented to the rear of the vehicle rather than at the top of the assembly (Figure 6-23, Page 6-14).

  • Page 82: Brake Adjustment

    Brake Adjustment WHEEL BRAKE ASSEMBLIES 2808 2800 Figure 6-13 Insert Shoes Figure 6-14 Position Shoes CAUTION • Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to installing the axle shaft. For electric vehicles: Install the axle shaft.

  • Page 83: Brake Cluster Adjustment

    Figure 6-18 Front Brake Adjustment Bolt Use a torque wrench and a 7 mm 8–point socket or Club Car brake adjustment tool (CC P/N 1013582) to turn the brake adjustment bolt (5) on each brake clockwise until it is tightened to 15 ft·lb (20.3 N·m) then back off 5 clicks.
  • Page 84 Brake Adjustment WHEEL BRAKE ASSEMBLIES 2806 Figure 6-19 Front Manually Adjusted Brake Assembly Page 6-8 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 85: Brake Cable Equalization

    WHEEL BRAKE ASSEMBLIES Brake Adjustment TYPICAL 4 PLACES TYPICAL 4 PLACES 2903 Figure 6-20 Rear Manually-Adjusted Brake Assembly BRAKE CABLE EQUALIZATION Set park brake in the third tooth of the ratchet. Place a wedge between the park brake pedal and brake pedal to prevent the park brake from disengaging while equalizing the brake cables (Figure 6-21, Page 6-10).

  • Page 86: Final Brake Cluster Adjustment

    Brake Adjustment WHEEL BRAKE ASSEMBLIES 2809 Figure 6-21 Set Park Brake and Insert Wedge Equalize the brake cables. 2.1. Tighten the nylon lock nut (6) on the front equalizer rod (2) to 35 in·lb (4 N·m) (Figure 6-16, Page 6-7). 2.2.

  • Page 87: Brake Cluster Removal And Installation

    WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation Test drive vehicle. Be sure the brakes function properly. When brake pedal is fully pressed under moderate pressure, it should not go more than halfway to floor, and the vehicle should come to a smooth, straight stop. If the brake pedal goes more than halfway to the floor, or if the vehicle swerves or fails to stop, check pedal group adjustment, and readjust cable tension and brakes.
  • Page 88 Brake Cluster Removal and Installation WHEEL BRAKE ASSEMBLIES TYPICAL 4 PLACES 2810 Figure 6-22 Front Spindle Assembly Page 6-12 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 89: Rear Brake Cluster Removal

    WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation REAR BRAKE CLUSTER REMOVAL Place chocks at the front wheels, loosen the lug nuts on the rear wheels and lift the rear of the vehicle with a chain hoist or floor jack. Place jack stands under the axle tubes to support the vehicle. Release park brake and loosen equalizer retaining nuts (1 and 5) on equalizer rod (2) to slightly loosen brake cable (Figure 6-15, Page 6-7).

  • Page 90: Front Brake Cables

    Front Brake Cables WHEEL BRAKE ASSEMBLIES FRONT BRAKE CABLES See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. 3189 Figure 6-23 Front Brake Cables and Equalizer Page 6-14 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 91: Front Brake Cable Removal

    WHEEL BRAKE ASSEMBLIES Front Brake Cables FRONT BRAKE CABLE REMOVAL Remove bow-tie pin (9) and clevis pin (6) from brake lever arm on front brake cluster (Figure 6-23, Page 6-14). Remove E-clip (7) from brake cable housing at the front spindle bracket and remove cable (8 or 18) from spindle. Remove bow-tie pin (9), clevis pin (6), and E-clip (7) from brake cable (8 or 18) at equalizer (2).

  • Page 92: Rear Brake Cables

    Rear Brake Cables WHEEL BRAKE ASSEMBLIES REAR BRAKE CABLES 3191 Figure 6-25 Rear Brake Cables and Equalizer Page 6-16 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 93: Rear Brake Cable Removal

    WHEEL BRAKE ASSEMBLIES Rear Brake Cables REAR BRAKE CABLE REMOVAL Chock wheels to keep vehicle from unintentionally moving. Release park brake if latched and loosen equalizer retaining nuts (13 and 14) on equalizer rod (2) to slightly loosen brake cables (7) (Figure 6-25, Page 6-16). Rotate brake cables (7) upward and pull ends through holes in top of equalizer (3).
  • Page 94 Rear Brake Cables WHEEL BRAKE ASSEMBLIES Pagination Page Page 6-18 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 95: 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 96: 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 97: Steering Column

    STEERING AND FRONT SUSPENSION Steering Column STEERING COLUMN See General Warnings on page 1-1. 2609 Figure 7-3 Steering Column 2016 Carryall 500 and 700 Maintenance and Service Manual Page 7-3...

  • Page 98: Steering Column Removal

    Steering Column STEERING AND FRONT SUSPENSION STEERING COLUMN REMOVAL Remove the steering wheel as previously instructed. Remove cowl. See Cowl Removal, Section 4, Page 4-5. Remove the upper bolt (2) and lock washer (3) from the universal joint (Figure 7-3, Page 7-3). Remove the nuts (9), bolts (8 and 10), and washers (7 and 11) from the steering column mount (4 and 5) (Figure 7-3, Page 7-3).

  • Page 99: Steering Column Installation

    STEERING AND FRONT SUSPENSION Steering Column (CC P/N 1014259) (CC P/N 1014264) 2 to 2 1/8 inches (CC P/N 1014264) (5.1 to 5.4 cm) 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 –...

  • Page 100: 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 101: 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 102: 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 103 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 104: 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 105 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 106 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 107: 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 108: 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 109: 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 110 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 111: 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(s). See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5.
  • Page 112 Front Suspension Components STEERING AND FRONT SUSPENSION 2610 Figure 7-18 Front Suspension – Upper Portion Page 7-18 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 113 STEERING AND FRONT SUSPENSION Front Suspension Components 2611 Figure 7-19 Front Suspension – Lower Portion 2016 Carryall 500 and 700 Maintenance and Service Manual Page 7-19...

  • Page 114: 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 115: 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. FRONT WHEEL FREE PLAY INSPECTION Raise the front of the vehicle. Using your hands, attempt to rock the wheel and hub assembly back and forth on the spindle. If there is any observable movement of the wheel and hub on the spindle, remove dust cap (1) and cotter pin (2) and then tighten the spindle nut (3) until the bearing (5) fully seats in the bearing race (7) (Figure 7-20, Page 7-21).

  • Page 116: Front Hub And Wheel Bearings Installation

    Front Wheel Bearings and Hubs STEERING AND FRONT SUSPENSION FRONT HUB AND WHEEL BEARINGS INSTALLATION Pack the wheel bearings (5) and hub cavities, and lubricate cups (7) with wheel bearing grease or chassis lube. Make sure the grease is forced between the rollers (Figure 7-20, Page 7-21). If bearing cups (7) were removed, press new ones in squarely against stops in the hub (Figure 7-20, Page 7-21).

  • Page 117: Section 8 - Wheels And Tires

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

  • Page 118: Tires

    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 119: 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 120 Tires WHEELS AND TIRES Figure 8-2 Inflate Tire Page 8-4 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 121: 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. It consists of two leaf springs controlled by two shock absorbers mounted between the springs and the vehicle frame.

  • Page 122: Multi-Leaf Springs

    Multi-Leaf Springs REAR SUSPENSION NOTE: Tighten 3/8 hex nut at shock absorber until shock absorber cushions are approximately the same diameter as the retainers. Do not over tighten. On the upper and lower shock absorber mounting stems, tighten the nut (1) until the rubber bushing (3) expands to the size of the cup washer (4).

  • Page 123: Multi-Leaf Spring Installation

    REAR SUSPENSION Multi-Leaf Springs 2600-30000-10369 1400-18100-10243 Figure 9-2 Support Vehicle on Jack Stands Figure 9-3 Disconnect Brake Cable MULTI-LEAF SPRING INSTALLATION NOTE: Tighten bolt (11) after clamp from brake cable has been positioned between nut and frame component. Install the bushings and spacers in the spring eyes. See following CAUTION. CAUTION •...
  • Page 124 Multi-Leaf Springs REAR SUSPENSION 2987 Figure 9-4 Rear Suspension Assembly and Mounting Page 9-4 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 125: Section 10 - Periodic Maintenance

    Contact your local authorized distributor/dealer to perform all repairs and semiannual and annual periodic service. PRE-OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new vehicle(s), you should become familiar with its controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery.

  • Page 126: Performance Inspection

    Club Car vehicles operate at reduced speed in reverse. When the pedal is released, it should return to the original position and the motor should rotate freely or go into motor braking mode. See Pedal Up Motor Braking below.

  • Page 127: Maintenance

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

  • Page 128: Periodic Service Schedules

    Periodic Service Schedules PERIODIC MAINTENANCE PERIODIC SERVICE SCHEDULES See General Warnings on page 1-1. WARNING • Service, repairs, and adjustments must be made per instructions in the maintenance and service manual. NOTE: If the vehicle is constantly hauling heavy loads or hauling a trailer, these preventive maintenance procedures should be performed more often than recommended in the Periodic Service Schedule.
  • Page 129 PERIODIC MAINTENANCE Periodic Service Schedules PERIODIC SERVICE SCHEDULE – ELECTRIC VEHICLES REGULAR INTERVAL SERVICE Check brake shoes; replace if necessary or adjust as required. Check brake cables for damage; replace if Brake system necessary. Check brake cable equalizer adjustment; adjust if Semiannual service by trained technician necessary.
  • Page 130 Periodic Service Schedules PERIODIC MAINTENANCE PERIODIC SERVICE SCHEDULE – GASOLINE VEHICLES REGULAR INTERVAL SERVICE Clean terminals and wash dirt from casing; For Battery side-post battery, check electrolyte level. (Figure 18-8) Check and adjust if necessary. Front wheel alignment and camber See Steering and Front Suspension section in the maintenance and service manual.

  • Page 131: 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 (CC PN 1012151) Brake linkage and pivots Dry Moly Lube (CC PN 1012151) Semiannually by owner or trained technician (or every 50 Accelerator pivot rod supports...
  • Page 132 Periodic Lubrication Schedules PERIODIC MAINTENANCE PERIODIC LUBRICATION SCHEDULE – GASOLINE VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Brake pedal shaft bearings Dry Moly Lube (CC PN 1012151) Brake linkage and pivots Dry Moly Lube (CC PN 1012151) Semiannually by owner or trained technician (or every 50 Accelerator pivot rod supports and Dry Moly Lube (CC PN 1012151)

  • Page 133: 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 134: 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 135: Introductory Display

    CONTROLLER DIAGNOSTIC TOOL (CDT) Plugging the CDT into the Vehicle 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 11-2). Remove the dust cap from the communication port.

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

    Quick Reference Guide – IQ Plus with Quiq Charger CONTROLLER DIAGNOSTIC TOOL (CDT) QUICK REFERENCE GUIDE – IQ PLUS WITH QUIQ CHARGER 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 not equipped with Visage, make sure Control Mode Main Weld: Replace solenoid, if it doesn’t correct fault of car running at...
  • Page 137 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 138 A vehicle programmed for speed setting 4 does not conform to ANSI Z130.1 – American National Standard for Golf Cars – Safety and Performance Specifications because it is capable of speeds in excess of 15 mph (24.1 km/h). For more information on this feature, contact your local Club Car distributor or dealer. M1/M2 Fast Accel M1/M2 fast accel (fast acceleration) is an option that can be enabled or disabled.
  • Page 139 CONTROLLER DIAGNOSTIC TOOL (CDT) Parameters M1/M2 PEDAL UP 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 M1/M2 Speed Cal The M1/M2 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 140 Parameters CONTROLLER DIAGNOSTIC TOOL (CDT) 5.7 mph (9.2 km/h) 9.7 mph (15.6 km/h) 12.7 mph (20.4 km/h) 14.7 mph (23.7 km/h) 5.6 mph (9.0 km/h) 9.6 mph (15.4 km/h) 12.6 mph (20.3 km/h) 14.6 mph (23.5 km/h) 5.5 mph (8.9 km/h) 9.5 mph (15.3 km/h) 12.5 mph (20.1 km/h) 14.5 mph (23.3 km/h)
  • Page 141 Once activated, Mode 2 settings can be programmed using the same procedures as Mode 1 settings. This allows the vehicle to be customized to perform according to which mode it is operated in. For more information on this feature, contact your local Club Car distributor or dealer. To activate Mode 2: Enter Code A, Code B, and Code C.
  • Page 142 Monitor Menu CONTROLLER DIAGNOSTIC TOOL (CDT) ASCII NUMBER ASCII CHARACTER ASCII NUMBER ASCII CHARACTER Vehicle Date of Manufacture Four digit number programmed by vehicle manufacturer. Example: 1401 represents Model Year 2014, week 1. Vehicle S/N Six digit number programmed by vehicle manufacturer. Vehicle Decal Decal number ranging from 0 to 999 and programmed by vehicle manufacturer.
  • Page 143 CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu THROTTLE % Indicates the position of the accelerator pedal from 0% (pedal not pressed) to 95% and 100% (pedal fully pressed). This item can be monitored when the key switch is in the ON or OFF position. BATT VOLTAGE Displays the current battery voltage at the speed controller.
  • Page 144 Mode 2. If repeated attempts are unsuccessful, the speed controller will permanently lock out access to Mode 2. In the event that Mode 2 is locked out, the controller must be removed and shipped to Club Car before Mode 2 can be activated.
  • Page 145 CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu RELAY WELDED # Displays the number of times the RELAY WELDED fault has been detected. See Fault Descriptions on page 11-20. SPD SENSOR # Displays the number of times the SPD SENSOR fault has been detected. See Fault Descriptions on page 11-20. MAIN DRV ON # Displays the number of times the MAIN DRV ON fault has been detected.
  • Page 146 Monitor Menu CONTROLLER DIAGNOSTIC TOOL (CDT) DRVR OVERCUR # Displays the number of times the DRVR OVERCUR fault has been detected. See Fault Descriptions on page 11-20. RLY DRVR ON # Displays the number of times the RLY DRVR ON fault has been detected. See Fault Descriptions on page 11-20. RLY DRVR OFF # Displays the number of times the RLY DRVR OFF fault has been detected.

  • Page 147: Battery Monitor

    CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu Open Circuit SOC Start Open Circuit SOC Start is the estimated state of charge following a cycle of the Run/Tow switch or coming out of sleep mode. BATTERY MONITOR These menu items reset every time the vehicle is charged. Lowest Battery Voltage Displays the lowest battery pack voltage reached since the last charge.
  • Page 148 Monitor Menu CONTROLLER DIAGNOSTIC TOOL (CDT) Charger Additional Page 11-16 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 149: Diagnostics Menu

    CONTROLLER DIAGNOSTIC TOOL (CDT) Diagnostics Menu 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 150 Diagnostics Menu CONTROLLER DIAGNOSTIC TOOL (CDT) 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 151: Fault Recovery

    CONTROLLER DIAGNOSTIC TOOL (CDT) Diagnostics Menu FAULT RECOVERY When a fault is detected by the speed controller, the speed 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 152: Fault Descriptions

    Fault Descriptions CONTROLLER DIAGNOSTIC TOOL (CDT) FAULT DESCRIPTIONS The following faults can be detected by the IQ Plus controller and seen under both the Monitor Menu and Diagnostics Menu: 01 THROTTLE FAULT 1 If the MCOR (Motor Controller Output Regulator) voltage is less than 0.20 volts or greater than 4.80 volts, the controller detects a throttle fault.

  • Page 153: 12 Main Dropout

    CONTROLLER DIAGNOSTIC TOOL (CDT) Fault Descriptions 12 MAIN DROPOUT If the controller detects that the solenoid contacts have opened while the vehicle is in operation, a main dropout fault is detected. 13 MOTOR STALL If the motor current is high and there is no movement of the vehicle wheels for a short period of time, a motor stall is detected by the speed controller.

  • Page 154: 25 Incorrect Password

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

  • Page 155: Main Cont Dnc

    CONTROLLER DIAGNOSTIC TOOL (CDT) Fault Descriptions What to do: Charge batteries. If fault occurs more frequently than normal, test battery pack. Section 14 — Batteries: IQ Plus Electric Vehicles MAIN CONT DNC The main cont dnc (main contactor (solenoid) did not close) fault is detected when the speed controller has sent voltage to the solenoid activating coil but the solenoid contacts are not closed.

  • Page 156: Programming

    Programming CONTROLLER DIAGNOSTIC TOOL (CDT) PROGRAMMING The Programming menu is accessed by using the arrow keys to highlight Programming and pressing the Select softkey to activate the menu. The Programming menu selection allows the user to save and restore parameter settings files (.cpf files). These files contain controller information and are saved to the internal memory or SD card.

  • Page 157: Hhp Settings

    CONTROLLER DIAGNOSTIC TOOL (CDT) HHP Settings HHP SETTINGS The HHP Settings menu is accessed by using the arrow keys to highlight HHP Settings and pressing the Select softkey to activate the menu. The HHP Settings menu selection allows the user to adjust the appearance of the screen displays, adjust several aspects of the handheld programmer’s functionality, and displays information pertaining to the handset.

  • Page 158: Plot & Log

    Plot & Log CONTROLLER DIAGNOSTIC TOOL (CDT) MENU ITEM DESCRIPTIONS Remember Last View When set to On, when you select a menu from the Main Menu screen, you will be returned to the screen you were on before you last exited that menu. When set to Off, each time you select a menu from the Main Menu screen, you will go to the selected root menu.

  • Page 159: Cdt Troubleshooting

    CONTROLLER DIAGNOSTIC TOOL (CDT) CDT Troubleshooting 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 160: Connection Tests

    Connection Tests CONTROLLER DIAGNOSTIC TOOL (CDT) TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Section 12 — Electrical System Speed controller malfunction Troubleshooting: IQ Plus Electric Vehicles Disconnect the CDT cord from the vehicle. Handset malfunction Wait a few seconds and reconnect the handset to the vehicle Display screen shows jumbled or Loose connection at CDT port...
  • Page 161 CONTROLLER DIAGNOSTIC TOOL (CDT) Connection Tests Using a multimeter set for 200 ohms, place the red (+) probe into one of the terminals on the end of the cord with the square plug. Place the black (–) probe on each of the pins, one at a time, on the plug on the other end of the cord. The multimeter should indicate continuity on only one pin.
  • Page 162 Connection Tests CONTROLLER DIAGNOSTIC TOOL (CDT) 1.3. Connect the handset cord to the handset. 1.4. Connect the other end of the handset cord (without the adapter) to the four-pin connector of the speed controller. 1.5. Connect the vehicle batteries, positive (+) cable first. If the handset does not function during Test Procedure 3A, but does function when connected directly to the speed controller, the handset cord adapter and vehicle wire harness should be thoroughly tested.

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

    SECTION 12 — ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES DANGER Electrical System Troubleshooting: IQ Plus Electric Vehicles • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION The IQ Plus vehicle uses a 48-volt electrical system with a shunt-wound, 3.7 hp motor that is powered by eight 6-Volt, lead-acid batteries and charged by a high-frequency charger.

  • Page 164: Features

    Contact your Club Car dealer/distributor to inquire about this programmable feature. • Regenerative Braking: When motor braking is activated, the vehicle motor acts as a generator, slowing the vehicle as it creates energy that is used to charge the batteries.
  • Page 165 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES General Information If either situation arises, an HPD fault is recorded by the speed controller and will be displayed on an CDT handset in the Diagnostic History menu. See CDT Troubleshooting, Section 11, Page 11-27. 2016 Carryall 500 and 700 Maintenance and Service Manual Page 12-3...

  • Page 166: Wiring Diagrams

    ELECTRICAL SYSTEM TROUBLESHOOTING: Wiring Diagrams IQ PLUS ELECTRIC VEHICLES WIRING DIAGRAMS ONBOARD BATTERY CHARGER WD1050496_L_DGM Figure 12-1 Wiring Diagram Page 12-4 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 167 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Wiring Diagrams WD1050496_R_DGM Figure 12-2 Wiring Diagram (Continued) 2016 Carryall 500 and 700 Maintenance and Service Manual Page 12-5...
  • Page 168 ELECTRICAL SYSTEM TROUBLESHOOTING: Wiring Diagrams IQ PLUS ELECTRIC VEHICLES REVERS E BUZZER W08 18 _BLU_YEL SW_ 2 W10 18 _BLK W09 16 _BLK_YEL W11 16_B LK_YEL S W_1 W04 18 _RED W03 16 _GRN W02 16 _G RN_RED W17 18 _WHT_BLK W16 18 _P UR W07 16 _BLU W15 18 _RE D_G RN...
  • Page 169 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Wiring Diagrams WD1050496_2_DGM Figure 12-4 Wiring Diagram – Accessories 2016 Carryall 500 and 700 Maintenance and Service Manual Page 12-7...

  • Page 170: Troubleshooting

    TROUBLESHOOTING THE VEHICLE WITH THE CDT Club Car recommends the use of the CDT handset for troubleshooting vehicles equipped with the IQ Plus electrical system. Troubleshooting Guide 1 is to be used in conjunction with the CDT handset. Refer to the CDT Owner’s Manual for operating instructions.
  • Page 171 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Troubleshooting TROUBLESHOOTING GUIDE 1 The following troubleshooting guide is intended for use with an CDT handset. For CDT operating instructions, refer to the CDT Owner’s Manual. See following NOTE. NOTE: Before troubleshooting the vehicle, check the diagnostic history from the Special Diagnostics Menu. Note any fault codes.
  • Page 172 ELECTRICAL SYSTEM TROUBLESHOOTING: Troubleshooting IQ PLUS ELECTRIC VEHICLES TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Speed controller logic malfunction Disconnect the batteries and allow the speed controller capacitors to discharge. See WARNING “To avoid unintentionally starting...” in See General Warnings Failed controller FET (that powers up Monitor Menu –...
  • Page 173 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected motor field coil wires at motor or speed controller or Repair and/or connect the field coil wires broken wire Diagnostic Menu – FIELD MISSING fault code Failure of the motor field windings Section 16 —...

  • Page 174: Troubleshooting Guide 2

    ELECTRICAL SYSTEM TROUBLESHOOTING: Troubleshooting IQ PLUS ELECTRIC VEHICLES TROUBLESHOOTING GUIDE 2 TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Batteries discharged Charge batteries Check vehicle wiring. See Wiring Diagrams Improper or poor battery connections beginning on page 12-4 Battery charger is connected to the vehicle – Disconnect the battery charger from the vehicle Solenoid lockout feature has disabled the vehicle Check for loose or disconnected wires at key...
  • Page 175 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Troubleshooting TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Procedure 13 – Motor Speed Sensor on page Speed sensor disconnected or failed 12-28 To change the programmed top speed of the Incorrect speed setting vehicle, an CDT handset must be used Check vehicle wiring.

  • Page 176: Test Procedures

    ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES TEST PROCEDURES Using the following procedures, the entire IQ Plus electrical system can be tested without major disassembly of the vehicle. See following WARNING. 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 177 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures 11 – Charger Interlock 12 – MCOR Voltage 13 – Motor Speed Sensor 14 – A1 and A2 Motor Voltage 15 – 24-Pin Connector 16 – Reverse Buzzer 17 – Walk Away Braking Relay 18 –...
  • Page 178 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES (Viewed from driver side of vehicle) 1. RED probe to battery no. 1 (+). 2. BLACK probe to battery no. 6 (-). 3072 Figure 12-5 Battery Voltage Test – 500/550/700 Page 12-16 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 179 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES 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 12-14. 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.
  • Page 180 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES A fully charged set of batteries in good condition should read between 47 and 49 volts while under load. A reading of 32 to 42 volts indicates discharged or failed batteries. Each battery should be checked with a multimeter while under load.
  • Page 181 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures TEST PROCEDURE 4 – 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 AGC-style glass fuse is used for the charger interlock circuit.
  • Page 182 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES – For one of the 15-amp ATC fuses, check Tow/Run switch to make sure it is in RUN position. – Check if 12 gauge red wire is coming off large post on solenoid. 1-amp AGC Glass Fuse Only: With the Tow/Run switch in the RUN position: 4.1.
  • Page 183 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures TEST PROCEDURE 6 – Wire Harness Diodes See General Warnings on page 1-1. A diode is designed to conduct current in one direction only. Depending on the application, diodes are used in the vehicle to control electrical system logic, or to help protect relay and switch contacts from excessive arcing.
  • Page 184 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES TEST PROCEDURE 7 – 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.
  • Page 185 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures 4.1. Locate and connect an insulation-piercing probe to the pin 1 tan wire in the 24-pin connector. 4.2. With the key switch in the OFF position and the accelerator pedal at rest, the tan wire should show zero (0) volts.
  • Page 186 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES 4.1. Access the Monitor menu and select REVERSE INPUT by using the SCROLL DISPLAY buttons. The CDT should indicate OFF when the Forward/Reverse switch is in the NEUTRAL or FORWARD position. 4.2.
  • Page 187 See General Warnings on page 1-1. NOTE: Unlike other controllers used by Club Car, the pre-charge resistor is internal to the IQ Plus controller. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame crossmember between the spring mount and side stringer, just forward of each rear wheel.
  • Page 188 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES Insert the onboard charger AC plug into an AC outlet. In a few seconds, the CDT should indicate ON and the vehicle can no longer be driven. If not, check the KEY, FORWARD, REVERSE and FOOT INPUTS to the controller.
  • Page 189 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures MCOR Voltage 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. Position jack stands under the frame crossmember between the spring mount and side stringer, just forward of each rear wheel. See WARNING “Lift only one end...”...
  • Page 190 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES at the MCOR. The reading should be zero (0) volts with the pedal up. Slowly press the accelerator pedal and note the readings on the multimeter. As the pedal is pressed, the reading should increase until it reaches approximately 4.65 volts when the pedal is fully pressed.
  • Page 191 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures Turn the key switch to the OFF position and place the Forward/Reverse switch in the NEUTRAL position. With batteries connected, disconnect the three-pin connector at the motor speed sensor. Check voltage at black/white wire: 3.1.
  • Page 192 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES Figure 12-12 Test 13: Speed Sensor Red Wire Check voltage at the light green wire: 5.1. Set a multimeter to 20 volts DC. Place the black (–) probe on the battery no. 8 negative post and place the red (+) probe on the light green wire female terminal in the three-pin connector at the motor speed sensor.
  • Page 193 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures Figure 12-14 Test 13: Speed Sensor Green Wire 6.1. Raise one rear wheel off ground. Slowly turn the rear wheel to rotate the motor armature. As the armature rotates, the voltage reading should alternate from zero to approximately 4.85 volts. The voltage reading will fluctuate from zero to 4.85 volts and back to zero four times for each revolution of the motor armature.
  • Page 194 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES NOTE: Voltage can vary depending on controller speed setting as well as which zone a Guardian equipped vehicle is located. Example: Speed setting 1 may only read 30 volts. 4.1. If there is no voltage reading or if there is no increase in voltage as the pedal is pressed, check the MCOR. See MCOR Voltage on page 12-26.
  • Page 195 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures If the results of any of the referenced procedures are different from those described in the procedure, check the continuity of the wires in the wire harness and test the connected components with the appropriate test procedures. (See Index of Test Procedures on page 12-14).
  • Page 196 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame crossmember between the spring mount and side stringer, just forward of each rear wheel.
  • Page 197 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures Pin 8 See General Warnings on page 1-1. Pin 8 in the 24-pin connector provides a connection point for the MCOR limit switch to the speed controller. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4.
  • Page 198 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES – Tow/Run switch for proper operation. See Tow/Run Switch on page 12-18. – Key switch and MCOR limit switch for proper operation. See Key Switch and MCOR Limit Switch Circuit on page 12-22. –...
  • Page 199 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures Detail A: Front of 24-Pin Connector Figure 12-18 Test: Pin 19 (Orange/White Wire) Pins 10 and 11 See General Warnings on page 1-1. Pins 10 and 11 in the 24-pin connector provide a connection point for the Forward/Reverse rocker switch to the speed controller.
  • Page 200 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES Place the Forward/Reverse switch in the FORWARD position. The multimeter should indicate full battery voltage (approximately 48 volts). Insert the red (+) probe of the multimeter into pin 11 (blue wire) of the 24-pin connector. Leave the black (–) probe (alligator clip) connected to the B–...
  • Page 201 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures With a multimeter set for 200 volts DC, insert the red (+) probe of the multimeter into pin 1 (tan wire) of the 24-pin connector. See following CAUTION. With an alligator clip, connect the black (–) probe to the B– terminal of the speed controller (Figure 12-20, Page 12-39).
  • Page 202 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES Set a multimeter to 200 volts DC. Use an alligator clip to connect the red (+) probe to the positive terminal on battery no. 1. With an insulation-piercing probe, connect the black (–) probe to the blue/white wire attached to pin 17 of the 24-pin connector.
  • Page 203 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures TEST PROCEDURE 16 – Reverse Buzzer See General Warnings on page 1-1. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Remove the instrument panel. See Instrument Panel Removal, Section 4, Page 4-10. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first.
  • Page 204 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES With batteries connected, Tow/Run switch in the RUN position and the key switch in the OFF position, connect charger DC cord to vehicle. In a few seconds, the light will flash three times and the reverse buzzer simultaneously will sound three times to indicate charging has begun.
  • Page 205 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures Check for continuity between pin 1 (yellow/black wire) (Figure 12-21, Page 12-42) and pin 3 (purple/white wire) of the 16-pin connector. It should indicate continuity. If not, check sonic welds no. 1 and no. 2. Probe pin 2 (red/white wire).
  • Page 206 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES Pagination Page Page 12-44 2016 Carryall 500 and 700 Maintenance and Service Manual...

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

    SECTION 13 — ELECTRICAL COMPONENTS: IQ PLUS ELECTRIC VEHICLES DANGER Electrical Components: IQ Plus Electric Vehicles • 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 7 –...
  • Page 208 ELECTRICAL COMPONENTS: IQ PLUS Key Switch ELECTRIC VEHICLES Figure 13-1 Key Switch Page 13-2 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 209: Forward/Reverse Rocker Switch

    ELECTRICAL COMPONENTS: IQ PLUS ELECTRIC VEHICLES Forward/Reverse Rocker Switch FORWARD/REVERSE ROCKER SWITCH See General Warnings on page 1-1. TESTING THE FORWARD/REVERSE ROCKER SWITCH See Test Procedure 8 – Forward/Reverse Rocker Switch on page 12-23. FORWARD/REVERSE ROCKER SWITCH REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4.

  • Page 210: Tow/Run Switch Removal

    ELECTRICAL COMPONENTS: IQ PLUS Circuit Breaker ELECTRIC VEHICLES See Test Procedure 3 – Tow/Run Switch on page 12-18. TOW/RUN SWITCH REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Using a 5/8 in (16 mm) socket, remove Tow/Run switch boot/hex nut (6). Remove Tow/Run switch (10) and nut (9) from bracket (5).
  • Page 211 ELECTRICAL COMPONENTS: IQ PLUS ELECTRIC VEHICLES Circuit Breaker Figure 13-2 Circuit Breaker 2016 Carryall 500 and 700 Maintenance and Service Manual Page 13-5...

  • Page 212: Motor Controller Output Regulator (Mcor)

    ELECTRICAL COMPONENTS: IQ PLUS Motor Controller Output Regulator (MCOR) ELECTRIC VEHICLES MOTOR CONTROLLER OUTPUT REGULATOR (MCOR) See General Warnings on page 1-1. TESTING THE MCOR See Test Procedure 12 – MCOR Voltage on page 12-26 and Test Procedure 7 – Key Switch and MCOR Limit Switch Circuit on page 12-22.

  • Page 213: Reverse Buzzer

    ELECTRICAL COMPONENTS: IQ PLUS ELECTRIC VEHICLES Reverse Buzzer NOTE: Rotate the drive bar (5) back and forth if necessary to align the D-shaped end with the MCOR. Secure the MCOR (2) to the plastic housing (4) with two torx screws (3). Tighten screws to 12 in·lb (1.4 N·m). Connect the two-pin and three-pin connectors (1) from the wire harness to the MCOR (2).

  • Page 214: Solenoid

    ELECTRICAL COMPONENTS: IQ PLUS Solenoid ELECTRIC VEHICLES SOLENOID See General Warnings on page 1-1. The solenoid is located on the passenger side of the electrical component mounting plate. TESTING THE SOLENOID See Test Procedure 9 – Solenoid Activating Coil on page 12-24 and Test Procedure 10 – Solenoid Contacts on page 12-25.

  • Page 215: Speed Controller

    ELECTRICAL COMPONENTS: IQ PLUS ELECTRIC VEHICLES Speed Controller SPEED CONTROLLER See General Warnings on page 1-1. TESTING THE SPEED CONTROLLER See Test Procedure 14 – A1 and A2 Motor Voltage on page 12-31. SPEED CONTROLLER REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4.
  • Page 216 ELECTRICAL COMPONENTS: IQ PLUS Speed Controller ELECTRIC VEHICLES 2998 Figure 13-5 Speed Controller Page 13-10 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 217: Charge Indicator Light

    ELECTRICAL COMPONENTS: IQ PLUS ELECTRIC VEHICLES Charge Indicator Light CHARGE INDICATOR LIGHT See General Warnings on page 1-1. TESTING THE CHARGE INDICATOR LIGHT See Test Procedure 18 – Charge Indicator Light on page 12-41. CHARGE INDICATOR LIGHT REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4.
  • Page 218 ELECTRICAL COMPONENTS: IQ PLUS Charge Indicator Light ELECTRIC VEHICLES Pagination Page Page 13-12 2016 Carryall 500 and 700 Maintenance and Service Manual...

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

    SECTION 14 — BATTERIES: IQ PLUS ELECTRIC VEHICLES DANGER Batteries: IQ Plus Electric Vehicles • 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 220: Battery Testing Basics - 6 Volt

    Battery Testing Basics – 6 Volt BATTERIES: IQ PLUS ELECTRIC VEHICLES BATTERY TESTING BASICS – 6 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 221: Battery Testing - 6 Volt

    Regrouping is now Club Car’s standard battery replacement method. Regrouping is the practice of placing batteries of similar condition together in one vehicle. For example, if there was an issue with the batteries in two cars and the battery test indicated three failed batteries in each car, after removing the failed batteries, there will be six good batteries remaining.
  • Page 222 Battery Regrouping BATTERIES: IQ PLUS ELECTRIC VEHICLES BATTERY REGROUPING PROCESS FLOW (6 volt, 8 volt, and 12 volt batteries) CAUTION: To prevent degradation of battery perform a n c e a n d life , n e ve r m ix b a tte rie s o f d iffe re n t p a rt n u m b e rs o r b r a n d s / m o d e l n u m b e r s .

  • Page 223: Battery Replacement

    BATTERIES: IQ PLUS ELECTRIC VEHICLES 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°...

  • Page 224: Battery Care

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

  • Page 225: Deionizer

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

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

    Battery Care BATTERIES: IQ PLUS ELECTRIC VEHICLES Log. Use these decals to record filter replacement activity and fleet inspection activity. For convenience, both decals have a QR code for ordering replacement filters. Seasonal Maintenance Water supplies must be drained and stored in an empty state if they will be exposed to freezing temperatures. Failure to do so can cause permanent damage.

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

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

  • Page 228: Self-Discharge

    Battery Care BATTERIES: IQ PLUS ELECTRIC VEHICLES After use, charge the batteries. The batteries should never be left discharged any longer than absolutely necessary (do not leave discharged overnight). 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.

  • Page 229: Vibration Damage

    A deionizer for vehicles with SPWS, Club Car Part Number 105166801 is available from Service Parts (DC powered water quality indicator light). Replacement cartridge: 104005901. Bottled distilled water, with hand pump, Club Car Part Number 104006101, is recommended for private consumer applications.
  • Page 230 Single Point Watering System (SPWS) BATTERIES: IQ PLUS ELECTRIC VEHICLES • Do not use a longer garden hose than provided with the System (20 feet or 6 meters), as a decrease in water pressure can overfill the batteries and damage the refill system. Before screwing the hose-end assembly (3) onto the opposite end of the water hose, check the screen filter (4) inside the end of the assembly to make sure it is clean (Figure 14-4).

  • Page 231: Battery Storage

    BATTERIES: IQ PLUS ELECTRIC VEHICLES Battery Storage 2829 2830 Figure 14-6 Dust Cap Figure 14-7 Connecting Hose-end Assembly to Battery Fill Connector The red flow indicator balls should swirl, indicating that the batteries are being filled. See following CAUTION. CAUTION •...

  • Page 232: Deep-Discharge

    Deep-Discharge BATTERIES: IQ PLUS ELECTRIC VEHICLES DEEP-DISCHARGE Never discharge batteries to the point the vehicle will no longer operate. This will considerably shorten the cycle life of the batteries, and may permanently damage the batteries. It is possible the batteries will not accept a charge if they are completely discharged.

  • Page 233: Section 15 - Quiq High Frequency Charger

    If a charger cannot be properly identified, contact your local authorized Club Car dealer or distributor. The High Frequency Battery Charger functions as an integral part of the vehicles' electrical system and will not work with other electric vehicles.

  • Page 234: How To Identify Charge Algorithm Number

    General Information QUIQ HIGH FREQUENCY CHARGER HOW TO IDENTIFY CHARGE ALGORITHM NUMBER The algorithm numbers offered can be found in See Battery Charger Algorithms on page 15-2. The charger can display its algorithm number by initiating Algorithm Display Mode. To enter Algorithm Display Mode, do the following: Unplug the AC power supply cord from the wall outlet.

  • Page 235: The Charge Circuit

    QUIQ HIGH FREQUENCY CHARGER Onboard Charger Operation THE CHARGE CIRCUIT The charge circuit consists of the onboard charger, batteries and charger information light (Figure 15-2, Page 15-3). B– SOLID STATE SPEED CONTROLLER TERMINAL 14 GA. BLACK To Main 6 GA. RED Vehicle Harness Gray...
  • Page 236 – Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the battery in accordance with all environmental laws or return to an authorized Club Car dealer. Frozen batteries can explode.

  • Page 237: Charger Displays

    QUIQ HIGH FREQUENCY CHARGER Onboard Charger Operation WARNING – Wear safety glasses or approved eye protection when servicing the vehicle or battery charger. Wear a full face shield and rubber gloves when working on or near batteries. – Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the vehicle or battery charger.
  • Page 238 Onboard Charger Operation QUIQ HIGH FREQUENCY CHARGER Icon Indication (following LED Color STATUS EXPLANATION “Power-On Self Test”) Solid: Displays approximate scale of current output during bulk phase. Flashing: High internal charger temperature. Output reduced. Also displays algorithm Ammeter (Amber) #1 through # 6 for 11 seconds if no battery is connected. 80% Charge Solid: Bulk charge phase complete, 80% charged.

  • Page 239: Ac Power Connection

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

  • Page 240: Maintenance

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

  • Page 241: Troubleshooting

    QUIQ HIGH FREQUENCY CHARGER Troubleshooting 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 242: Test Procedures

    Test Procedures QUIQ HIGH FREQUENCY CHARGER TEST PROCEDURES See General Warnings, Section 1, Page 1-1. Index of Test Procedures 1 – Battery Voltage Using Multimeter 2 – Battery Condition Using Charger – All Batteries 3 – On-Charge Battery Voltage Using Charger And Multimeter 4 –...

  • Page 243: Charger Repairs

    QUIQ HIGH FREQUENCY CHARGER Charger Repairs TEST PROCEDURE 4 – AC Power and Continuity Test of AC Circuit Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle. Check the AC line fuse or circuit breaker in the storage facility. With a multimeter set to 500 volts AC, check incoming AC voltage.

  • Page 244: Onboard Charger Installation

    Onboard Charger Removal And Installation QUIQ HIGH FREQUENCY CHARGER Remove charger from vehicle. ONBOARD CHARGER INSTALLATION Install charger onto vehicle. Install the four lock nuts (5) securing charger to charger mounting plate. Tighten to 40 in·lb (5.4 N·m). Connect the AC and DC connector. Connect 8-pin grey connector.

  • Page 245: Section 16 - Motor (Model Da5-4006): Electric Vehicles

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

  • Page 246: Motor Removal

    MOTOR (MODEL DA5-4006): ELECTRIC Motor Removal VEHICLES Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. 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 247 MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor Removal 1. Position floor jack under hitch bracket or frame. 2. Carryall 700 (shown) 2867 Figure 16-2 Vehicle Supported on Jack Stands Figure 16-1 Lift Vehicle with Floor Jack Remove both rear wheels. Remove the nut, cup washer, and bushing from the bottom side of the shock absorber. Compress the shock absorber (pushing upwards) to move it out of the way (Figure 16-3, Page 16-3).

  • Page 248: Motor Disassembly

    MOTOR (MODEL DA5-4006): ELECTRIC Motor Disassembly VEHICLES Figure 16-4 Speed Sensor Magnet Figure 16-5 End Cap Removal MOTOR DISASSEMBLY Release the clasp and remove the headband assembly (21) from the motor. Visually inspect brushes and springs. (Figure 16-13, Page 16-10). Before continuing disassembly, place match marks on the motor end cap (20) and motor frame (14).
  • Page 249 MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor Disassembly Remove the four end cap bolts. The weight of the motor housing will cause it to drop when the bolts are removed. See following CAUTION. CAUTION • The motor housing will drop when the bolts are removed. Do not put fingers under the motor housing when removing bolts.
  • Page 250 MOTOR (MODEL DA5-4006): ELECTRIC Motor Disassembly VEHICLES Figure 16-8 Brush Rigging Removal Figure 16-9 Retaining Ring Removal Page 16-6 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 251: Motor Component Testing And Inspection

    MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor Component Testing and Inspection 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, Section 16, Page 16-2. Remove the end cap and armature by performing steps 1 through 6 of Motor Disassembly on page 16-4. Visual Inspection •...

  • Page 252: Motor Frame And Field Windings Inspection

    MOTOR (MODEL DA5-4006): ELECTRIC Motor Component Testing and Inspection VEHICLES Figure 16-10 Armature Test MOTOR FRAME AND FIELD WINDINGS INSPECTION Remove the motor from the vehicle. See Motor Removal, Section 16, Page 16-2. Remove the end cap and armature by performing steps 1 through 6 of Motor Disassembly on page 16-4. Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings.
  • Page 253 MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor Component Testing and Inspection Install the brushes in the same rigging 180° apart from each other. Brush Inspection Remove the motor from the vehicle. See Motor Removal, Section 16, Page 16-2. Release the clasp and remove the headband from the motor. Inspect the brushes (16) for damage or excessive wear (Figure 16-13, Page 16-10).
  • Page 254 MOTOR (MODEL DA5-4006): ELECTRIC Motor Component Testing and Inspection VEHICLES Figure 16-13 Motor Page 16-10 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 255: Reconditioning The Motor

    MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES 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 256 MOTOR (MODEL DA5-4006): ELECTRIC Motor Assembly VEHICLES Figure 16-14 Retracted Brushes Figure 16-15 Armature Installation With the brushes retracted, use an arbor press to press the armature shaft into the end cap bearing (Figure 16-15, Page 16-12). See following CAUTION. CAUTION •...

  • Page 257: Motor Installation

    MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor Installation A. End View B. Side View 3066 Figure 16-16 Speed Sensor Clamp MOTOR INSTALLATION See General Warnings on page 1-1. Clean the transaxle input shaft. 1.1. Spray the input shaft thoroughly with CRC ®...
  • Page 258 MOTOR (MODEL DA5-4006): ELECTRIC Motor Installation VEHICLES inch inch 1/8 INCH 3/8 INCH (9.5 MM) (3.1 MM) Figure 16-17 Grease on Putty Knife Figure 16-18 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 16-19, Page 16-15).
  • Page 259 MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor Installation 1/16 INCH (1.6 MM) Figure 16-19 Clean Chamfer and Input Shaft End Figure 16-20 Gap at Motor and Transaxle If using a chain hoist, lower the vehicle and guide the leaf springs into the shackles. If using a floor jack, raise the transaxle until the leaf springs can be guided into the shackles.
  • Page 260 MOTOR (MODEL DA5-4006): ELECTRIC Motor Installation VEHICLES Viewed From Driver Side Figure 16-21 Motor Tightening Sequence Page 16-16 2016 Carryall 500 and 700 Maintenance and Service Manual...

  • Page 261: Section 17 - Transaxle: Electric Vehicles

    SECTION 17 — TRANSAXLE: ELECTRIC VEHICLES DANGER Transaxle: Electric Vehicles • 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 262 Axle Bearing and Shaft TRANSAXLE: ELECTRIC VEHICLES 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. Inspect bearing (5) (Figure 17-5, Page 17-3). If the bearing in a Type G transaxle is worn or damaged, the entire axle shaft assembly (1 or 2) must be replaced.
  • Page 263 TRANSAXLE: ELECTRIC VEHICLES Axle Bearing and Shaft Figure 17-5 Transaxle – Type G 2016 Carryall 500 and 700 Maintenance and Service Manual Page 17-3...

  • Page 264: Axle Bearing

    Axle Bearing and Shaft TRANSAXLE: ELECTRIC VEHICLES 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 265: Transaxle

    TRANSAXLE: ELECTRIC VEHICLES Transaxle TRANSAXLE See General Warnings on page 1-1. TRANSAXLE REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. 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 266 Transaxle TRANSAXLE: ELECTRIC VEHICLES 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 267 TRANSAXLE: ELECTRIC VEHICLES 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 268: Transaxle Disassembly, Inspection, And Assembly

    Transaxle Disassembly, Inspection, and Assembly TRANSAXLE: ELECTRIC VEHICLES 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 269 TRANSAXLE: ELECTRIC VEHICLES 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 270: Transaxle Assembly

    Transaxle Disassembly, Inspection, and Assembly TRANSAXLE: ELECTRIC VEHICLES 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 271 TRANSAXLE: ELECTRIC VEHICLES 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 272: Transaxle Installation

    Transaxle Installation TRANSAXLE: ELECTRIC VEHICLES 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 273: Section 18 - Troubleshooting And Electrical System: Pedal-Start Gas Vehicle

    SECTION 18 — TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE DANGER Troubleshooting and Electrical System: Pedal-Start Gas Vehicle • 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 274: Features Of The Electronic Fuel Injection (Efi) System

    TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: PEDAL-START GAS VEHICLE • Top of Fuel Tank: The fuel tank is grounded to the chassis through the main wire harness. FEATURES OF THE ELECTRONIC FUEL INJECTION (EFI) SYSTEM • Open-loop system (i.e. oxygen sensor not used) •...
  • Page 275 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Troubleshooting Guide Error Codes – ECU BLINK CODE CODE DESCRIPTION CORRECTIVE ACTION Check battery voltage. Charge/replace battery Low Battery Voltage as necessary. Check connector at ECU & Throttle module. MAP Sensor: Open or Shorted Connection If connection is made and no corrosion is present, replace ECU and Throttle Module.
  • Page 276 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: PEDAL-START GAS VEHICLE GASOLINE POWERTRAIN TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Spark plug is partially fouled or in poor Clean or replace condition Spark plug is damaged or loose Replace or tighten Incorrect spark plug gap Adjust gap Spark plug wire is damaged or loose Replace or reconnect...
  • Page 277 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Fuel tank is empty Section 23 — Fuel System: Gasoline Vehicles Fuel line or filter clogged Section 23 — Fuel System: Gasoline Vehicles Fouled spark plug Section 22 —...
  • Page 278 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: PEDAL-START GAS VEHICLE TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Incorrect plug Section 22 — Engine (Subaru EX40) Spark plug wire is damaged Section 22 — Engine (Subaru EX40) Unsuitable fuel, or incorrect (rich) fuel mixture Section 23 —...
  • Page 279 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or broken wire in the starter/ generator Test Procedure 11 – Starter/Generator circuit (Generator Function) Test Procedure 11 – Starter/Generator Generator field coil is shorted (Generator Function) Section 20 —...
  • Page 280 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: PEDAL-START GAS VEHICLE TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Kill circuit wire is disconnected from the Test Procedure 14 – Kill Limit Switch – ignition coil Pedal-Start Vehicles Only Accelerator pedal linkage out of adjustment Section 23 —...
  • Page 281 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Wiring Diagrams WIRING DIAGRAMS FUS ES WD1050077_DGM_D-L Figure 18-1 Wiring Diagram for Pedal-Start Gasoline Vehicle 2016 Carryall 500 and 700 Maintenance and Service Manual Page 18-9...
  • Page 282 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM: PEDAL-START GAS VEHICLE TO ECU (BLACK 18-PIN) NEUTRAL LOCKOUT SW ITCH WD1050077_DGM_D-R Figure 18-2 Wiring Diagram for Pedal-Start Gasoline Vehicle – Continued Page 18-10 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 283 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Wiring Diagrams FNR Harness Instrument Panel Harness BRAKE LIGHT RELAY SPST WD1050951_DGM_A Figure 18-3 Wiring Diagram – Instrument Panel and FNR Shifter 2016 Carryall 500 and 700 Maintenance and Service Manual Page 18-11...
  • Page 284 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM: PEDAL-START GAS VEHICLE MAP SENSOR W05 18 BLK_YEL PIN 1 - S ENS OR GND PIN 2 - S ENS OR S IGNAL W07 18 GRN_YEL PIN 3 - S ENS OR +5V W06 18 RED_YEL TEMPERATURE SENSOR W04 18 ORG_BLU...
  • Page 285 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Wiring Diagrams Sonic We ld Sonic We ld Sonic Sonic We ld We ld Sonic We ld Sonic We ld Sonic We ld To ECU Diode Sonic We ld Sonic Diode We ld Sonic Sonic We ld...
  • Page 286 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM: PEDAL-START GAS VEHICLE Sonic We ld Sonic We ld Sonic We ld Sonic Sonic We ld We ld Sonic We ld Sonic We ld Sonic We ld Sonic We ld Diode Sonic Diode We ld To ECU Sonic Sonic...
  • Page 287 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE 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 288 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE 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 289 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures 2 – Fuses 3 – Ground Cables 4 – EFI System (ECU and Sensors) 5 – Key Switch (Start Circuit) 6 – Key Switch (Engine Kill Circuit) 7 – Accelerator Pedal Limit Switch – Pedal-Start Vehicles Only 8 –...
  • Page 290 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 1 – Battery (Side-Post Battery Only) 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 291 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures When the float rises off the bottom, adjust the electrolyte level so that the float rides free of the bottom but does not strike the bottom of the rubber bulb. Remove the hydrometer from the cell and release the pressure from the bulb. Hold the hydrometer vertically, ensuring that the float is not contacting the sides of the glass tube.
  • Page 292 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE Voltage Test Take a voltage reading with a multimeter set to 20 VDC by placing the red (+) probe on the positive (+) battery post and the black (–) probe on the negative (–) battery post. If it shows less than 12.4 volts, or if the lowest specific gravity reading from the Hydrometer Test is less than 1.225, recharge the battery.
  • Page 293 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE 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 294 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE 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 18-9, Page 18-21). 4.2. Each contact should show battery voltage. 4.3.
  • Page 295 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE 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(s) of the vehicle. An additional ground wire is located on top of the fuel tank.
  • Page 296 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE 1. Battery Ground 2. Main Wire Harness Ground 3. Engine Ground Cable 4. Starter/Generator Ground (from A1 Terminal) 5. Voltage Regulator Ground Wire (from electrical component box) 3023 Figure 18-10 Ground Wires and Cables Page 18-24 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 297 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 4 – EFI System (ECU and Sensors) See General Warnings on page 1-1. WARNING • This procedure involves testing voltage, resistance and continuity. If necessary, see Testing Basics on page 18-16. 2016 Carryall 500 and 700 Maintenance and Service Manual Page 18-25...
  • Page 298 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE 18-PIN CONNECTOR (GRAY AND BLACK): A. ECU SIDE OF CONNECTOR B. WIRE ENTRY SIDE OF CONNECTOR CONNECTOR FUNCTION TEST TYPE & PROBE BETWEEN LOCATIONS TEST RESULT CONDITION I.D. COLOR Resistance: ECU Gray Pin 1 (Black/White) and ECU Approx.
  • Page 299 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures 18-PIN CONNECTOR (GRAY AND BLACK): A. ECU SIDE OF CONNECTOR B. WIRE ENTRY SIDE OF CONNECTOR CONNECTOR FUNCTION TEST TYPE & PROBE BETWEEN LOCATIONS TEST RESULT CONDITION I.D. COLOR Meter should beep Key OFF Black Ignition OFF Input...
  • Page 300 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 5 – Key Switch (Start Circuit) 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 on page 18-16.
  • Page 301 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 6 – Key Switch (Engine Kill Circuit) See General Warnings on page 1-1. NOTE: This is a continuity test. If necessary, see Testing Basics on page 18-16. Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5.
  • Page 302 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE Make sure the battery is disconnected. With the key switch in the OFF position, the Forward/Reverse handle in NEUTRAL, and the accelerator pedal in the UP position, the reading should be no continuity. With the accelerator pedal pressed, the reading should be continuity.
  • Page 303 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 8 – Solenoid See General Warnings on page 1-1. NOTE: This is a resistance and voltage test. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. Cover 2. Electrical Component Box 3. 6 Ga. White Wire 4. 18 Ga. White Wire 5.
  • Page 304 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 9 – 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 on page 18-16.
  • Page 305 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 10 – 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 306 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 11 – Starter/Generator (Generator Function) See General Warnings on page 1-1. NOTE: This is a voltage test. If necessary, see Testing Basics on page 18-16. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position.
  • Page 307 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures • When disconnecting wires from starter/generator terminals, use a second wrench on the lower nut of the terminal post to hold post steady. • Scrape a small amount of paint from starter/generator housing (ground) and use this location when testing motor terminals to electrical ground.
  • Page 308 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE 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 on page 18-16. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position.
  • Page 309 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 14 – Kill Limit Switch – Pedal-Start Vehicles Only See General Warnings on page 1-1. NOTE: This is a continuity test. The kill limit switch is the lower of the two limit switches located in the electrical component box. There is a white/black wire and a blue wire connected to this limit switch.
  • Page 310 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 15 – Ignition Spark See General Warnings on page 1-1. NOTE: Keep the battery connected while performing this test procedure. If necessary, see Testing Basics on page 18-16. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position.
  • Page 311 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 16 – Ignition Coil See General Warnings on page 1-1. NOTE: This is a resistance test. The following test procedures will properly detect a coil that has failed in most cases; however, in rare cases, some ignition coils can fail to operate at normal (warmer) operating temperatures.
  • Page 312 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 17 – Reverse Buzzer and Reverse Buzzer Limit Switch See General Warnings on page 1-1. NOTE: Reverse Buzzer: This is a voltage test. Reverse Buzzer Limit Switch: This is a continuity test. A reverse buzzer is mounted on the back side of the instrument panel.
  • Page 313 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 19 – Oil Level Sensor See General Warnings on page 1-1. NOTE: Keep the battery connected while performing this test procedure. This procedure requires the oil to be drained from the engine. If necessary, see Testing Basics on page 18-16.
  • Page 314 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 21 – 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 315 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures Disconnect the 5-pin connector from the top of the fuel pump module. Probe between pin (1) and pin (2) terminals in module (Figure 18-21, Page 18-42). 4.1. The reading should be approximately 2 to 5 ohms. If the reading indicates no resistance, the fuel pump has failed and the fuel pump module must be replaced.
  • Page 316 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 23 – 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 18-22 Fuel Gauge/Hour Meter If necessary, see Testing Basics on page 18-16.
  • Page 317 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures WAVETEK WAVETEK 1000 1000 2000 2000 200k 200k 200nA 200nA 1000 --- FUSED 750V 1000 --- FUSED 750V 1. 20 VDC Setting 2. Purple 3. Black 4. White 5. Red/White 1. 20 VDC Setting 2. Purple Figure 18-23 Fuel Gauge Voltage Test - Terminal 2 Figure 18-24 Fuel Gauge Voltage Test - Terminal 4 TEST PROCEDURE 24 –...
  • Page 318 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 25 – Light 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 18-21. This is a voltage test.
  • Page 319 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 27 – 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 320 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 28 – 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 321 SECTION 19 — TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START GAS VEHICLE DANGER Troubleshooting and Electrical System: Key-Start Gas Vehicle • 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 322 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM: KEY-START GAS VEHICLE WIRING DIAGRAMS FUS ES WD1050080_DGM_B-L Figure 19-1 Wiring Diagram for Key-Start Gasoline Vehicle Page 19-2 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 323 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START GAS VEHICLE Wiring Diagrams TO ECU (BLACK 18-PIN) NEUTRAL LOCKOUT SW ITCH WD1050080_DGM_B-R Figure 19-2 Wiring Diagram for Key-Start Gasoline Vehicle – Continued 2016 Carryall 500 and 700 Maintenance and Service Manual Page 19-3...
  • Page 324 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM: KEY-START GAS VEHICLE FNR Harness Instrument Panel Harness BRAKE LIGHT RELAY SPST WD1050951_DGM_A Figure 19-3 Wiring Diagram – Instrument Panel and FNR Shifter Page 19-4 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 325 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START GAS VEHICLE Wiring Diagrams MAP SENSOR W05 18 BLK_YEL PIN 1 - S ENS OR GND PIN 2 - S ENS OR S IGNAL W07 18 GRN_YEL PIN 3 - S ENS OR +5V W06 18 RED_YEL TEMPERATURE SENSOR W04 18 ORG_BLU...
  • Page 326 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: KEY-START GAS VEHICLE 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 327 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START GAS VEHICLE Test Procedures TEST PROCEDURE 2 – Key Switch (ON Position) See General Warnings on page 1-1. NOTE: This is a voltage test. The key switch ON position provides power and KEY INPUT to the ECU. If necessary, see Testing Basics on page 18-16.
  • Page 328 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: KEY-START GAS VEHICLE TEST PROCEDURE 4 – Solenoid See General Warnings on page 1-1. NOTE: This is a resistance and voltage test. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. Cover 2. Electrical Component Box 3. 6 Ga. White Wire 4. 18 Ga. White Wire 5.
  • Page 329 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START GAS VEHICLE Test Procedures TEST PROCEDURE 5 – 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 on page 18-16.
  • Page 330 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: KEY-START GAS VEHICLE TEST PROCEDURE 6 – Charging Diode (Generator Circuit) – Key-Start Vehicles Only See General Warnings on page 1-1. WAVETEK 1000 WAVETEK 1000 2000 200k 2000 200k 200nA 200nA 1000 --- FUSED 750V 1000 --- FUSED...
  • Page 331 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START GAS VEHICLE Test Procedures WARNING • Incorrect wiring could result in severe injury or death. • Diode and solenoid connections must have correct polarity. • Keep all persons clear of engine belts when making final connections. 2016 Carryall 500 and 700 Maintenance and Service Manual Page 19-11...
  • Page 332 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: KEY-START GAS VEHICLE Pagination Page Page 19-12 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 333 SECTION 20 — ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE DANGER Electrical Components: Pedal-Start Gas Vehicle • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. STARTER/GENERATOR See General Warnings on page 1-1. TESTING THE STARTER/GENERATOR See Test Procedure 12 – Starter/Generator (Starter Function) on page 18-34. See Test Procedure 11 –...
  • Page 334 ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE Figure 20-2 Brush Covers and Brushes Figure 20-1 Commutator End Cover BRUSH INSPECTION AND REPLACEMENT Visually inspect brushes. Replace brushes that are cracked or severely chipped. Measure the length of each brush. Replace the brush set if a brush is less than 0.375 inch (9.5 mm) (Figure 20-3, Page 20-2).
  • Page 335 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator CAUTION • When checking brush spring tension, do not push springs beyond the point they would normally be if there were new brushes installed. Exerting excessive force or pushing brush springs beyond their normal maximum extension point will damage springs. Figure 20-4 Brush Spring Tension Test STARTER/GENERATOR ASSEMBLY Install the brushes (27) into the holders.
  • Page 336 ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE Figure 20-5 Pull Brushes Away From Center of the Commutator End Cover DISASSEMBLY OF THE STARTER/GENERATOR TO SERVICE THE ARMATURE/COMMUTATOR 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.
  • Page 337 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator Figure 20-6 Armature and Output End Cover Assembly 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 20-7, Page 20-5). Replace the bearing if it is noisy, does not spin smoothly, or has excessive play.
  • Page 338 ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE BEARING REMOVAL Place the wedge attachment tool (1) (CC P/N 1012812) 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 (2) (CC P/N 1012811) to the wedge attachment tool and pull the bearing off of the end of the armature shaft.
  • Page 339 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator • Worn armature bearing or shaft • Dirty or oily commutator Figure 20-9 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.
  • Page 340 ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE Figure 20-10 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 341 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 20-11 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 342 ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE STARTER/GENERATOR ASSEMBLY Place the field coil into the housing. The two insulators that look alike fit into the slots next to the F1 and F2 markings on the outside of the housing. The insulator that looks different slides into the slot next to the DF marking. After the insulators are seated in the slots, install the threaded terminals through the wire connectors and then through the insulators.
  • Page 343 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator STARTER/GENERATOR INSTALLATION 2997 Figure 20-12 Starter/Generator Installation Install the green wire (1) from the F1 terminal to the A2 terminal on the starter/generator (Figure 20-13, Page 20-12). Install a flat washer, lock washer, and nut onto each terminal and tighten to 48 in·lb (5.4 N·m). Position the starter/generator over the mounting bracket so that the bolts will go through the starter/generator before going through the bracket.
  • Page 344 ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE 3033 Figure 20-13 Starter/Generator Wiring BELT TENSION ADJUSTMENT FOR EFI ENGINES WITH P/N 105205401 BELT NOTE: This tension adjustment procedure is only for belts with part number 105205401. Locate and confirm part number on belt before proceeding. For belt with part number 47539338001, see Belt Tension Adjustment for EFI Engines with P/N 47539338001 Belt on page 20-15.
  • Page 345 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5. See Top-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5. Access engine compartment. – Remove seat and rear access panel (if equipped). –...
  • Page 346 ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE A. Remove 3/8 to 1/2 inch (9.5 to 12.7 mm) 1. Before 2. After 2726 Figure 20-16 Belt Tension Tool Modification (If Necessary) Tension belt. 7.1. Tighten nut on belt tension tool 1/2 turn and check belt tension with gauge(Figure 20-14, Page 20-12). NOTE: To prevent errors in measurement caused by residual tension, ensure to loosen, then reapply, the Universal Belt Tension gauge between measurements.
  • Page 347 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator BELT TENSION ADJUSTMENT FOR EFI ENGINES WITH P/N 47539338001 BELT NOTE: This tension adjustment procedure is only for belts with part number 47539338001. Locate and confirm part number on belt before proceeding. For belt with part number 105205401, see Belt Tension Adjustment for EFI Engines with P/N 105205401 Belt on page 20-12.
  • Page 348 ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE Tighten starter/generator mounting hardware (4 and 7) finger-tight (Figure 20-12, Page 20-11). Install belt tension tool (P/N 102570401). 6.1. Carefully insert pry bar between starter/generator and bracket. 6.2. Carefully lift starter up until tension tool can be installed as shown over the slotted adjustment bracket (Figure 20-15, Page 20-12).
  • Page 349 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Voltage Regulator 8.3. Connect battery only. DO NOT CONNECT SPARK PLUG WIRE. See Side-Post Battery: Connecting the Battery-Gasoline Vehicles on page 1-5. See Top-Post Battery: Connecting the Battery-Gasoline Vehicles on page 1-5. See following WARNING. WARNING •...
  • Page 350 ELECTRICAL COMPONENTS: PEDAL-START Voltage Regulator GAS VEHICLE 1. Red wire to solenoid. 2. To kill limit switch. 3. To frame ground. 4. To bullet connector. 2973 Figure 20-20 Voltage Regulator VOLTAGE REGULATOR INSTALLATION Position the voltage regulator (9) in the electrical component box and install the mounting screw (8) (Figure 20-20, Page 20-18).
  • Page 351 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Engine Control Unit (ECU) ENGINE CONTROL UNIT (ECU) CAUTION • The Engine Control Unit (ECU) and Throttle Body are to be purchased as one unit. They are matched pairs with matching serial numbers. Do not mix an ECU with another Throttle Body of a different serial number.
  • Page 352 ELECTRICAL COMPONENTS: PEDAL-START Key Switch GAS VEHICLE KEY SWITCH See General Warnings on page 1-1. TESTING THE KEY SWITCH See Test Procedure 5 – Key Switch (Start Circuit) on page 18-28. See Test Procedure 6 – Key Switch (Engine Kill Circuit) on page 18-29. KEY SWITCH REMOVAL Disconnect the batteries and spark plug.
  • Page 353 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Maintenance/Operate Switch MAINTENANCE/OPERATE SWITCH TESTING THE MAINTENANCE/OPERATE SWITCH See Test Procedure 9 – Maintenance/Operate Switch – Pedal-Start Vehicles on page 18-32. MAINTENANCE/OPERATE SWITCH REMOVAL Disconnect the battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5.
  • Page 354 ELECTRICAL COMPONENTS: PEDAL-START Solenoid GAS VEHICLE CAUTION • Do not overtighten the retaining nuts. If the nuts are overtightened, limit switches could be damaged. Connect the 3-wire connector to the neutral lockout limit switch lead. Connect battery and spark plug wire(s). See Side-Post Battery: Connecting the Battery-Gasoline Vehicles on page 1-5.
  • Page 355 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Fuse FUSE See General Warnings on page 1-1. ATC-style fuses are located inside the electrical component box near the battery. ATM-style fuses are located on the main wire harness in front of the engine. TESTING THE FUSE See Test Procedure 2 –...
  • Page 356 ELECTRICAL COMPONENTS: PEDAL-START Kill Limit Switch GAS VEHICLE KILL LIMIT SWITCH See General Warnings on page 1-1. TESTING THE KILL LIMIT SWITCH See Test Procedure 14 – Kill Limit Switch – Pedal-Start Vehicles Only on page 18-37. KILL LIMIT SWITCH REMOVAL Disconnect battery and spark plug wire(s).
  • Page 357 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Reverse Warning Buzzer 2948 Figure 20-22 Accelerator Starter and Kill Limit Switches REVERSE WARNING BUZZER See General Warnings on page 1-1. TESTING THE REVERSE WARNING BUZZER See Test Procedure 17 – Reverse Buzzer and Reverse Buzzer Limit Switch on page 18-40. REVERSE WARNING BUZZER REMOVAL Disconnect battery and spark plug wire(s).
  • Page 358 ELECTRICAL COMPONENTS: PEDAL-START Reverse Warning Buzzer GAS VEHICLE 3003 Figure 20-23 Instrument Panel Switches Page 20-26 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 359 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Reverse Buzzer Limit Switch REVERSE BUZZER LIMIT SWITCH See General Warnings on page 1-1. TESTING THE REVERSE BUZZER LIMIT SWITCH See Test Procedure 17 – Reverse Buzzer and Reverse Buzzer Limit Switch on page 18-40. REVERSE BUZZER LIMIT SWITCH REMOVAL Disconnect battery and spark plug wire(s).
  • Page 360 ELECTRICAL COMPONENTS: PEDAL-START Reverse Buzzer Limit Switch GAS VEHICLE 3001 Figure 20-24 Forward/Reverse Assembly Switches Page 20-28 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 361 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Low Oil Warning Light LOW OIL WARNING LIGHT See General Warnings on page 1-1. TESTING THE LOW OIL WARNING LIGHT See Test Procedure 18 – Low Oil Warning Light (LED) on page 18-40. LOW OIL WARNING LIGHT REMOVAL Disconnect battery and spark plug wire(s).
  • Page 362 ELECTRICAL COMPONENTS: PEDAL-START Fuel Level Sending Unit GAS VEHICLE FUEL GAUGE/HOUR METER REMOVAL Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5. See Top-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5. Remove the instrument panel. See Instrument Panel Removal, Section 4, Page 4-10. Disconnect the wires from the fuel gauge/hour meter (6).
  • Page 363 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Voltage Limiter VOLTAGE LIMITER See General Warnings on page 1-1. TESTING THE VOLTAGE LIMITER See Test Procedure 27 – Voltage Limiter on page 18-47. VOLTAGE LIMITER REMOVAL NOTE: Battery will charge reducing the voltage going to accessories. Turn the key switch OFF and remove the key.
  • Page 364 ELECTRICAL COMPONENTS: PEDAL-START Headlight Switch GAS VEHICLE 3002 Figure 20-25 Voltage Limiter HEADLIGHT SWITCH See General Warnings on page 1-1. TESTING THE LIGHT SWITCH See Test Procedure 25 – Light Switch on page 18-46. HEADLIGHT SWITCH REMOVAL Remove the instrument panel. See Instrument Panel Removal, Section 4, Page 4-10. Disconnect the wires from the light switch (4 and 9) (Figure 20-23, Page 20-26).
  • Page 365 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Headlights Connect battery and spark plug wire(s). See Side-Post Battery: Connecting the Battery-Gasoline Vehicles on page 1-5. See Top-Post Battery: Connecting the Battery-Gasoline Vehicles on page 1-5. HEADLIGHTS See General Warnings on page 1-1. TESTING THE HEADLIGHT SOCKET See Test Procedure 26 –...
  • Page 366 ELECTRICAL COMPONENTS: PEDAL-START Headlights GAS VEHICLE Remove cowl. See Cowl Removal, Section 4, Page 4-5. Remove front fenders. See Front Bumper and Side Fender Removal, Section 4, Page 4-9. Remove the three screws (2) and pull bulb assembly (6) out of bezel (1). (Figure 20-26, Page 20-35) HEADLIGHT BULB INSTALLATION (LED) Install bulb assembly (6) into bezel (1) and secure with screws (2).
  • Page 367 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Headlights 2993 Figure 20-26 Headlight Assembly 2016 Carryall 500 and 700 Maintenance and Service Manual Page 20-35...
  • Page 368 ELECTRICAL COMPONENTS: PEDAL-START Battery GAS VEHICLE 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 on or near batteries. • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area.
  • Page 369 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Battery TESTING THE BATTERY See Test Procedure 1 – Battery (Side-Post Battery Only) on page 18-18. See Test Procedure 20 – Battery Test (Under Load) on page 18-41. PREVENTIVE MAINTENANCE To keep the battery in good operating condition, remove any corrosion immediately. Post connections should be clean and tight.
  • Page 370 ELECTRICAL COMPONENTS: PEDAL-START Battery GAS VEHICLE SELF-DISCHARGE Dirt and battery acid can provide a path for a small current draw that slowly discharges the battery. To prevent self-discharge, the battery should always be kept clean. Hot weather also has an effect on a battery’s self-discharge rate. The higher the temperature, the quicker a battery will discharge.
  • Page 371 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Battery ALLOWABLE CONTENT IMPURITY EFFECTS OF IMPURITY (PARTS PER MILLION) Suspended matter Trace — Total solids 100.0 — Calcium 40.0 Increase of positive shedding Magnesium 40.0 Reduced life Increased self-discharge at both plates, Iron lower on-charge voltage Ammonia Slight self-discharge of both plates Organic matter...
  • Page 372 ELECTRICAL COMPONENTS: PEDAL-START Battery GAS VEHICLE BATTERY REMOVAL See General Warnings on page 1-1. Also see DANGER at beginning of Battery topic. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels. Disconnect battery and spark plug wire(s).
  • Page 373 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Ground Cables 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. See Preventive Maintenance on page 20-37. 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 374 ELECTRICAL COMPONENTS: PEDAL-START Ground Cables GAS VEHICLE Pagination Page Page 20-42 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 375 SECTION 21 — ELECTRICAL COMPONENTS: KEY-START GAS VEHICLE DANGER Electrical Components: Key-Start Gas Vehicle • 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 376 ELECTRICAL COMPONENTS: KEY-START Key Switch GAS VEHICLE Disconnect the wires from the key switch. Do not allow wires to touch. From the back of the instrument panel, push down on the retaining tabs surrounding the key switch (3) and remove the key switch cap (6). Using a 1-inch socket, hold the key switch (3) and remove the switch retaining nut (5) from the outside of the instrument panel (Figure 21-1, Page 21-2).
  • Page 377 ELECTRICAL COMPONENTS: KEY-START GAS VEHICLE Maintenance/Operate Switch MAINTENANCE/OPERATE SWITCH TESTING THE MAINTENANCE/OPERATE SWITCH See Test Procedure 5 – Maintenance/Operate Switch – Key-Start Vehicles on page 19-9. MAINTENANCE/ OPERATE SWITCH REMOVAL Disconnect the battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5.
  • Page 378 ELECTRICAL COMPONENTS: KEY-START Charging Diode GAS VEHICLE 2.2. Connect the 4-gauge red wire from the positive (+) battery terminal, the 10-gauge red wire and 16-gauge orange wire from the fuse blocks, and the 10-gauge red wire from the charging diode to the other large post on the solenoid.
  • Page 379 ELECTRICAL COMPONENTS: KEY-START GAS VEHICLE Charging Diode FRONT OF VEHICLE Some wires omitted for clarity. 2978 Figure 21-2 Charging Diode CHARGING DIODE INSTALLATION Thoroughly clean and dry the area of the chassis where the new charging diode (6) is to be attached. Peel the protective film from both sides of the new thermal pad (12) (Figure 21-2, Page 21-5).
  • Page 380 ELECTRICAL COMPONENTS: KEY-START Charging Diode GAS VEHICLE 4.2. Connect the 10-gauge white wire (5) to the other large solenoid post, along with the red wire (9) from the voltage regulator and white wire (10) from the starter/generator. Tighten nut (3) to 55 in·lb (6.2 N·m). Replace the electrical component box cover (2) and screw (1) and tighten the screw to 18 in·lb (2.0 N·m).
  • Page 381 SECTION 22 — ENGINE (SUBARU EX40) DANGER Engine (Subaru EX40) • 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 Subaru EX40, high-compression, chain driven, overhead cam engine. The engine offers a heavy-duty construction featuring cast iron cylinder liner for longer life, dual ball bearing crankshaft support, low oil level sensor and heavy-duty air cleaner system, to name a few characteristics.
  • Page 382 General Information ENGINE (SUBARU EX40) TORQUE SPECIFICATIONS ITEM SIZE TORQUE Flywheel retaining nut 80 ft·lb (110 N·m) Crankcase cover to block bolts 250 in·lb (28.3 N·m) Step Step New head and bolts: New head and bolts: 159 in·lb (18 N·m) 336 in·lb (38 N·m) Cylinder head bolts Used head and bolts:...
  • Page 383 ENGINE (SUBARU EX40) General Information Check oil by fully inserting the dipstick into the oil filler tube and immediately removing it. If the oil level is at or below the low level mark on the dipstick gauge, add oil until the level is between low and full levels (safe level).
  • Page 384 General Information ENGINE (SUBARU EX40) 1. Drain pan 2. Drain plug 2667 Figure 22-2 Engine Oil Drain Plug and Pan Use a 14 mm socket or wrench to remove the drain plug, turning it counterclockwise, and allow the engine oil to drain into the pan. See following WARNING. WARNING •...
  • Page 385 ENGINE (SUBARU EX40) General Information SAE 30 SAE 10W-30/ SAE 10W-40 SAE 5 W-30 Figure 22-3 Oil Viscosity Chart Connect battery and spark plug wire. See Side-Post Battery: Connecting the Battery-Gasoline Vehicles on page 1-5. See Top-Post Battery: Connecting the Battery-Gasoline Vehicles on page 1-5. With the Forward/Reverse handle in the NEUTRAL position and the Maintenance/Operate switch in the OPERATE position, start and run the engine for a few minutes.
  • Page 386 General Information ENGINE (SUBARU EX40) Figure 22-4 Spark Plug Testing the Spark Plug Check the sparking ability of a cleaned and properly gapped plug on a sparking comparator if possible. Spark should be blue and strong and able to jump a 5/16-in. (8 mm) gap. Setting the Spark Gap Pass a contact point file between the electrodes to produce flat, parallel surfaces to facilitate accurate gauging.
  • Page 387 ENGINE (SUBARU EX40) General Information VALVE CLEARANCE CHECK AND ADJUSTMENT NOTE: Check and adjust clearance when the engine is cold. If equipped, remove air deflector from top of engine. Remove rocker cover. Turn the crankshaft until the piston is at top dead center of the compression stroke (Figure 22-5, Page 22-7). Using a feeler gauge (1), measure the clearance between the adjuster screw (3) and the top of the valve stem (Figure 22-6, Page 22-7).
  • Page 388 Engine Removal ENGINE (SUBARU EX40) ENGINE REMOVAL See General Warnings on page 1-1. ENGINE REMOVAL TO MID-2016 MODEL YEAR Utility/T ransportation Orientation Precedent Orientation 3036 Figure 22-7 EX40 Engine and Mounting Brackets Page 22-8 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 389 ENGINE (SUBARU EX40) Engine Removal CAUTION • Before removal and disassembly, clean the engine. Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles, Section 1, Page 1-5. See Top-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5. For some vehicles, the engine (1) can be removed by lifting it up and out of the chassis.
  • Page 390 Engine Removal ENGINE (SUBARU EX40) ENGINE REMOVAL FROM MID-2016 MODEL YEAR Utility/T ransportation Orientation Precedent Orientation 3036a Figure 22-8 EX40 Engine and Mounting Brackets CAUTION • Before removal and disassembly, clean the engine. Page 22-10 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 391 ENGINE (SUBARU EX40) Engine Installation Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles, Section 1, Page 1-5. See Top-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5. For some vehicles, the engine (1) 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 392 Engine Installation ENGINE (SUBARU EX40) Connect air intake hose, fuel line, wire harness connectors, ground cable and governor cable. See Fuel System: Gasoline Vehicles, Section 23, Page 23-1. If equipped, install air deflector on top of engine. Secure accelerator cable and governor cable P-clamps to engine. Tighten P-clamp bolts to 36 in·lb (4.0 N·m). Check all hardware for proper torque/tightness.
  • Page 393 ENGINE (SUBARU EX40) Flywheel CAUTION • Do not overfill with oil. Connect battery and spark plug wire(s). See Side-Post Battery: Connecting the Battery-Gasoline Vehicles, Section 1, Page 1-5. See Top-Post Battery: Connecting the Battery-Gasoline Vehicles on page 1-5. Adjust the engine RPM setting. See Engine RPM Adjustment on page 23-14. Test-drive vehicle to ensure all systems are functional and correctly adjusted.
  • Page 394 Flywheel ENGINE (SUBARU EX40) CAUTION • The flywheel nut has right-hand threads. Turn it clockwise to tighten, or counterclockwise to loosen. • Do not damage the fan blades with the strap wrench. Do not place screwdriver or pry bar in the fan blades.
  • Page 395 ENGINE (SUBARU EX40) Oil Level Sensor OIL LEVEL SENSOR TESTING THE OIL LEVEL SENSOR See Oil Level Sensor on page 18-41. OIL LEVEL SENSOR REMOVAL Drain oil from engine. See Engine Oil – Gasoline Vehicle, Section 22, Page 22-2. Remove flywheel. See Flywheel Removal on page 22-13. Remove bolt (1) securing oil sensor wire clamp (2) to engine.
  • Page 396 Ignition Coil ENGINE (SUBARU EX40) IGNITION COIL See General Warnings on page 1-1. TESTING THE IGNITION COIL See Test Procedure 15 – Ignition Spark on page 18-38 and Test Procedure 16 – Ignition Coil on page 18-39. IGNITION COIL REMOVAL Remove screws (1) and fan housing (2) (Figure 22-9, Page 22-13).
  • Page 397 ENGINE (SUBARU EX40) 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 22-15, Page 22-17).
  • Page 398 Snubber ENGINE (SUBARU EX40) Pagination Page Page 22-18 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 399 SECTION 23 — FUEL SYSTEM: GASOLINE VEHICLES DANGER Fuel System: Gasoline Vehicles • 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 400 Relieving Fuel Pressure FUEL SYSTEM: GASOLINE VEHICLES 1. ECU 2. Fuel Pump 3. Fuel Tank 4. Fuel Injector 5. MAP Sensor 6. Engine Temperature Sensor 7. CDI Ignition Unit 3040 Figure 23-1 EFI System Components RELIEVING FUEL PRESSURE In the event that servicing the EFI fuel system necessitates removal of the fuel delivery hose, extreme caution must be exercised.
  • Page 401 FUEL SYSTEM: GASOLINE VEHICLES Throttle Body NOTE: To absorb any residual fuel the may be present in the fuel hose, place a rag or towel around the hose at the end being disconnected. THROTTLE BODY See General Warnings on page 1-1. Before suspecting the throttle body as the cause of poor engine performance, make sure the fuel and ignition systems are in proper operating condition.
  • Page 402 Throttle Body FUEL SYSTEM: GASOLINE VEHICLES 3041 Figure 23-2 Throttle Body – Exploded View THROTTLE BODY INSTALLATION See General Warnings on page 1-1. Install throttle body (1) and its related components onto threaded studs in order as shown (Figure 23-2, Page 23-4).
  • Page 403 FUEL SYSTEM: GASOLINE VEHICLES Throttle Body Connect governor cable to bracket (4). Connect breather hose (2) to air intake adapter (3). Connect air intake hose and secure with hose clamp. If removed, install fuel tank. See Fuel Tank Installation, Section 23, Page 23-23. If equipped, install air deflector on top of engine.
  • Page 404 Engine Control Linkages FUEL SYSTEM: GASOLINE VEHICLES ENGINE CONTROL LINKAGES See General Warnings on page 1-1. 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 405 FUEL SYSTEM: GASOLINE VEHICLES Engine Control Linkages GROUND SPEED NOTE: If possible, the manufacturer recommends measuring ground speed when setting engine RPM. This vehicle should reach the forward ground speed specified in Section 2 – Vehicle Specifications. See How to Measure Ground Speed on page 23-14.
  • Page 406 Engine Control Linkages FUEL SYSTEM: GASOLINE VEHICLES CAUTION • Inspect the limit switches inside the electrical component box. If a limit switch lever is bent, replace the switch. 3113 3043 Figure 23-6 Accelerator Cable Cam Position – 7° (Top Figure 23-7 Governor Cable At Throttle Body 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 407 FUEL SYSTEM: GASOLINE VEHICLES Engine Control Linkages GOVERNOR CABLE Governor Cable Removal Turn the key switch to the OFF position and remove the key, place the Forward/Reverse handle in the NEUTRAL position, and chock the wheels. Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5.
  • Page 408 Engine Control Linkages FUEL SYSTEM: GASOLINE VEHICLES A = 0.055 in. ± 0.039 (1.4 mm ± 1) 3110 3111 Figure 23-8 Governor and Accelerator Cables At Governor Figure 23-9 Throttle Stop Screw Gap Page 23-10 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 409 FUEL SYSTEM: GASOLINE VEHICLES Engine Control Linkages ACCELERATOR CABLE Accelerator Cable Removal Turn the key switch to the OFF position and remove the key, place the Forward/Reverse handle in the NEUTRAL position, and chock the wheels. Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5.
  • Page 410 Engine Control Linkages FUEL SYSTEM: GASOLINE VEHICLES Connect battery and spark plug wire(s). See Side-Post Battery: Connecting the Battery-Gasoline Vehicles on page 1-5. See Top-Post Battery: Connecting the Battery-Gasoline Vehicles on page 1-5. Page 23-12 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 411 FUEL SYSTEM: GASOLINE VEHICLES Engine Control Linkages CLOSED THROTTLE OR IDLE ADJUSTMENT – PEDAL-START VEHICLES When the accelerator pedal is released, the engine will stop. Therefore, it is not possible to measure or set idling speed under normal vehicle operating conditions. Set throttle valve as follows: Loosen the throttle body idle screw so that it is not touching the throttle lever (Figure 23-11, Page 23-13).
  • Page 412 Engine Control Linkages FUEL SYSTEM: GASOLINE VEHICLES HOW TO MEASURE GROUND SPEED Best Method An easy way to check ground speed is by using a GPS device or smartphone application (app). If these are not available, use the alternate method below. Alternate Method (Calculated) Ground speed is easily determined by a known distance travelled, divided by the amount of time it took to travel that known distance (Rate = Distance/Time).
  • Page 413 FUEL SYSTEM: GASOLINE VEHICLES Air Intake System AIR INTAKE SYSTEM See General Warnings on page 1-1. 3048 Figure 23-12 Air Intake System – CA 500/550/700/TRANSPORTER/Cafe Express 2016 Carryall 500 and 700 Maintenance and Service Manual Page 23-15...
  • Page 414 • 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 415 NOTE: This EFI gasoline vehicle is equipped with SAEJ30R9 fuel hose rated for high-pressure systems. Always replace the fuel line on this vehicle with approved Club Car replacement part. Do not attempt to repair, patch or splice the fuel line.
  • Page 416 Fuel Line FUEL SYSTEM: GASOLINE VEHICLES 1. Push fuel line onto nipple until it locks into place. 2. Push in locking clip until fully seated. 1. Pull out locking clip. 2. Push in on release tab. 3. While pushing in on release tab, pull fuel line off nipple. 3050 3051 Figure 23-13 Fuel Line Connector –...
  • Page 417 FUEL SYSTEM: GASOLINE VEHICLES Fuel Pump Module FUEL PUMP MODULE See General Warnings on page 1-1. GENERAL INFORMATION NOTE: The fuel pump and fuel level sending unit themselves are not replaceable. If necessary, the fuel pump module must be replaced as an assembly. The fuel pump module can be disassembled to replace the fuel filter.
  • Page 418 Fuel Pump Module FUEL SYSTEM: GASOLINE VEHICLES NOTE: If equipped with a fuel level sending unit, carefully maneuver module so as to avoid damaging the float arm mechanism. CAUTION • Ensure o-ring stays seated in place during fuel pump module installation. Install hold down ring (6) and ground wire (7) with hardware (5) and tighten in a crisscross pattern to 66 in·lb (7.5 N·m).
  • Page 419 FUEL SYSTEM: GASOLINE VEHICLES Fuel Pump Module 3052 Figure 23-15 Fuel System (Side-Fill) – Exploded View 2016 Carryall 500 and 700 Maintenance and Service Manual Page 23-21...
  • Page 420 SAEJ30R9 1/4 in (6.3 mm) fuel vent hose (CC P/N 102865101) and 3/16 in (4.78 mm) fuel vent hose (CC P/N 1015137). To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car P/N's 102865101, 1015137, or equivalent. FUEL TANK REMOVAL Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels, and the neutral lockout switch in the MAINTENANCE position.
  • Page 421 3/16 in (4.78 mm) fuel vent hose (CC P/N 1015137). To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car P/N's 102865101, 1015137, or equivalent. Place fuel tank (10) in vehicle.
  • Page 422 Fuel Filter FUEL SYSTEM: GASOLINE VEHICLES Connect fuel line (3) to fuel pump module (1). See Fuel Line Installation on page 23-18. See following DANGER. DANGER • Ensure line is connected properly to avoid a leak that can cause a fire. Connect wire harness plug (2) to fuel pump module (1).
  • Page 423 FUEL SYSTEM: GASOLINE VEHICLES Fueling Instructions – Gasoline Vehicle FUEL FILTER INSTALLATION CAUTION • Fuel filter flex hoses are keyed to aid proper installation into fuel pump module. NOTE: The fuel filter is keyed to the fuel pump module to prevent incorrect assembly. The inlet and outlet flex hoses are keyed to the fuel filter ports to prevent incorrect assembly.
  • Page 424 Fueling Instructions – Gasoline Vehicle FUEL SYSTEM: GASOLINE VEHICLES DANGER • If the vehicle has an all-weather enclosure installed, be sure the fuel tank is properly vented as shown in Figure 23-16. • To avoid the possibility of fire, clean up any spilled fuel before operating the vehicle. CAUTION •...
  • Page 425 SECTION 24 — EXHAUST SYSTEM: GASOLINE VEHICLES DANGER Exhaust System: Gasoline Vehicles • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. MUFFLER MUFFLER REMOVAL Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5.
  • Page 426 Muffler EXHAUST SYSTEM: GASOLINE VEHICLES DANGER • Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. 3112a Figure 24-1 Exhaust System Page 24-2 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 427 SECTION 25 — CLUTCHES: GASOLINE VEHICLES DANGER Clutches: Gasoline Vehicles • 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 428 Troubleshooting CLUTCHES: GASOLINE VEHICLES If cleaning the driven clutch does not solve the problem, disassemble and thoroughly clean all parts of the drive clutch. Be sure to clean the plastic drive buttons (7) (Figure 25-3, Page 25-4). (CC P/N 101809101) (CC P/N 1014497) (CC P/N 1014508) (CC P/N 1014507)
  • Page 429 CLUTCHES: GASOLINE VEHICLES 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 430 Drive Clutch CLUTCHES: GASOLINE VEHICLES 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 431 CLUTCHES: GASOLINE VEHICLES Drive Clutch 8. Drive Clutch Weight 17. Spacer, Idler, Drive 9. Thrust Washer 18. Sheave, Fixed, Drive 2960 Figure 25-3 Drive Clutch – Exploded View CAUTION • Be very careful when handling the clutches. A clutch that has been dropped will not be properly balanced.
  • Page 432 Drive Clutch CLUTCHES: GASOLINE VEHICLES 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 433 CLUTCHES: GASOLINE VEHICLES 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 25-6, Page 25-7).
  • Page 434 Drive Clutch CLUTCHES: GASOLINE VEHICLES 3053 Figure 25-8 Drive Button Mounting Figure 25-9 Weight Position Remove the clutch weights: 5.1. Remove the screws (1) and flat washers (2) attaching the weights (3) as shown (Figure 25-9, Page 25-8). 5.2. Pull the weight assemblies (3), with pins, from slots (4) in the clutch. See following NOTE. NOTE: Before removing, note the orientation of the wave washer (1) and secondary weight (2) on the primary weight (3) (Figure 25-10, Page 25-9).
  • Page 435 CLUTCHES: GASOLINE VEHICLES Drive Clutch Figure 25-10 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 25-3, Page 25-4). 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 25-3, Page 25-4).
  • Page 436 Drive Clutch CLUTCHES: GASOLINE VEHICLES 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 437 CLUTCHES: GASOLINE VEHICLES 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 25-13, Page 25-11).
  • Page 438 Drive Clutch CLUTCHES: GASOLINE VEHICLES Connect battery and spark plug wire(s). See Side-Post Battery: Connecting the Battery-Gasoline Vehicles on page 1-5. See Top-Post Battery: Connecting the Battery-Gasoline Vehicles on page 1-5. Drive the vehicle and check for proper operation. Page 25-12 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 439 CLUTCHES: GASOLINE VEHICLES Driven Clutch 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 440 Driven Clutch CLUTCHES: GASOLINE VEHICLES 5. Cam, Driven Clutch 11. Sheave, Fixed, Driven 6. Spring, Driven Clutch, 55 Degree 12. Key, 3/16 in. (4.7 mm) Square X 1.50 in. (38 mm) Long 2961 Figure 25-14 Driven Clutch – Exploded View DRIVEN CLUTCH REMOVAL Remove the drive belt as instructed.
  • Page 441 CLUTCHES: GASOLINE VEHICLES Driven Clutch Figure 25-15 Remove Retaining Ring Figure 25-16 Driven Clutch Disassembly DRIVEN CLUTCH INSPECTION Inspect the cam (5) for excessive wear (Figure 25-14, Page 25-13). Replace it if necessary. Inspect the drive buttons (8) for excessive wear. Replace if necessary. To remove the drive buttons (8), remove the socket-head cap screws (7) and then the buttons.
  • Page 442 Driven Clutch CLUTCHES: GASOLINE VEHICLES 5.1.2. Hold the fixed sheave (3) and rotate the moveable sheave (1) one-third turn counterclockwise, then press the cam (2) onto the fixed sheave (Figure 25-17, Page 25-16). The match marks made before disassembly should now align. 5.1.3.
  • Page 443 CLUTCHES: GASOLINE VEHICLES Driven Clutch 5.2.6. Hold the fixed sheave of the clutch (5) and rotate the moveable sheave of the clutch one-third turn counterclockwise (Figure 25-18, Page 25-16). The match marks made before disassembly should now align. 5.2.7. Use two wrenches and hold the bolt head (1) while tightening the cam press hub (6) to press the cam onto the keyed shaft.
  • Page 444 Driven Clutch CLUTCHES: GASOLINE VEHICLES Pagination Page Page 25-18 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 445 SECTION 26 — TRANSAXLE (ED65): GASOLINE VEHICLES DANGER Transaxle (ED65): Gasoline Vehicles • 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 446 General Information TRANSAXLE (ED65): GASOLINE VEHICLES WARNING • With the switch in the MAINTENANCE position and the engine running, the vehicle may move suddenly if the Forward/Reverse handle 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.
  • Page 447 TRANSAXLE (ED65): GASOLINE VEHICLES 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 448 Rear Hubs TRANSAXLE (ED65): GASOLINE VEHICLES REAR HUBS REAR HUB REMOVAL Turn the key switch to the OFF position and remove the key, and place the Forward/Reverse handle in the NEUTRAL position. Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5.
  • Page 449 TRANSAXLE (ED65): GASOLINE VEHICLES Rear Hubs CAUTION • Do not allow anti-seize compound to contact the brake drum or shoes. Slide hub (6) onto axle shaft (Figure 26-3, Page 26-4). 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 450 Axle Tubes, Axle Shafts and Wheel Bearings TRANSAXLE (ED65): GASOLINE VEHICLES AXLE TUBES, AXLE SHAFTS 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. Instructions for removing the transaxle from the vehicle begin on page 26-9.
  • Page 451 TRANSAXLE (ED65): GASOLINE VEHICLES Axle Tubes, Axle Shafts and Wheel Bearings 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. See following CAUTION. CAUTION •...
  • Page 452 Axle Tubes, Axle Shafts and Wheel Bearings TRANSAXLE (ED65): GASOLINE VEHICLES Remove axle tube (2) from gearcase (4) (Figure 26-5, Page 26-6). See Axle Tube and Axle Shaft Removal on page 26-6. Pull oil seal (7) from gearcase (4). AXLE SHAFT OIL SEAL INSTALLATION Clean bore in gearcase (4) where new oil seal (7) will sit (Figure 26-5, Page 26-6).
  • Page 453 TRANSAXLE (ED65): GASOLINE VEHICLES Transaxle Removal 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/Reverse handle in the NEUTRAL position. Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles on page 1-5.
  • Page 454 Transaxle Removal TRANSAXLE (ED65): GASOLINE VEHICLES Figure 26-8 Disconnect Rear Shackles Figure 26-9 Disconnect Front of Leaf Spring Position floor jack under rear crossmember of chassis or trailer hitch mount (if equipped) (Figure 26-10, Page 26-10). 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 26-8, Page 26-10).
  • Page 455 TRANSAXLE (ED65): GASOLINE VEHICLES Transaxle Removal 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 26-11, Page 26-11). 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 456 Transaxle Removal TRANSAXLE (ED65): GASOLINE VEHICLES 3063 Figure 26-12 Transaxle Mounting Bolts Page 26-12 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 457 TRANSAXLE (ED65): GASOLINE VEHICLES Transaxle Installation 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 26-12, Page 26-12). Then, tighten fasteners in the following order: 1.1.
  • Page 458 Shifter Cable TRANSAXLE (ED65): GASOLINE VEHICLES Push the cable end socket (1) off the stud (3) on the Forward/Reverse shifter handle (Figure 26-13, Page 26-14). Press in tangs (4) anchoring shifter cable (2) to chassis and push out of mounting hole. Loosen jam nuts (1) securing shifter cable (2) to FNR/accelerator cable bracket (3) (Figure 26-14, Page 26-14).
  • Page 459 TRANSAXLE (ED65): GASOLINE VEHICLES Shifter Cable To adjust, the jam nuts (6) at the FNR/accelerator cable bracket must be loosened and moved forward or backward as required (Figure 26-14, Page 26-14). Tighten jam nuts (6) to 22 ft·lb (29.8 N·m). 2016 Carryall 500 and 700 Maintenance and Service Manual Page 26-15...
  • Page 460 Shifter Cable TRANSAXLE (ED65): GASOLINE VEHICLES Pagination Page Page 26-16 2016 Carryall 500 and 700 Maintenance and Service Manual...
  • Page 461 Index Index installation ............20-40 Index storage ............20-41 AC power and circuit testing ............. 18-18 testing (QuiQ charger) ........15-11 testing under load........18-20, 18-41 accelerator voltage test ............18-20 cable bearing, axle installation .............23-11 see transaxle, type g, axle bearing ...... 17-4 removal ............23-11 bearing, motor pedal (electric)
  • Page 462 INDEX connection tests ..........11-28 see test procedures ........18-25, 19-6 control mode ............11-8 connector, 24-pin deterrent demo speed......... 11-8 see test procedures .......... 12-32 diagnostics ............11-1 connector, 4-pin diagnostics menu ..........11-17 see test procedures ........ 12-42, 18-48 fault history folder ..........11-17 Controller Diagnostic Tool (CDT) favorites............11-24 diagnostics ............
  • Page 463 INDEX removal ............20-19 installation ............20-30 testing ............. 18-25, 19-6 removal ............20-30 electric bed lift fuel gauge/hour meter (gasoline vehicles) installation ............4-19 operation ............20-29 removal ............. 4-19 fuel injector electric motor testing ............. 18-25, 19-6 see motor ............16-1 fuel level sending unit ..........
  • Page 464 INDEX hydrometer test ........... 18-18 leaf spring see suspension, front and suspension, rear ... 9-2 light switch testing ............. 18-46 ignition low oil warning light testing spark ............ 18-38 installation ............20-29 ignition coil removal ............20-29 installation ............22-16 testing .............
  • Page 465 INDEX motor controller output regulator 3 (MCOR) testing ............18-40 installation ............13-6 removal ........... 13-7, 20-25 removal ............. 13-6 testing ........... 12-41, 18-40 muffler RPM adjustment .......... 23-7, 23-14 installation ............24-1 removal ............. 24-1 see also exhaust system........24-1 safety..............
  • Page 466 INDEX commutator............20-4 test procedures, electric vehicle armature replacement ........20-7 15-amp fuse............. 12-19 cleaning ............20-7 24-pin connector ..........12-32 inspection............20-7 4-pin connector ..........12-42 disassembly..........20-1, 20-4 batteries/voltage check ........12-15 field coil battery pack voltage (under load) ...... 12-17 inspection............
  • Page 467 INDEX hour meter ............18-45 oil seal ignition coil............18-39 installation ............17-4 iignition spark........... 18-38 removal ............17-1 key switch removal ............. 17-5 starter circuit (pedal-start) ......18-28 troubleshooting............12-8 key switch (engine kill circuit) ......18-29 CDT handheld programmer........11-27 kill limit switch ..........
  • Page 468 NOTES...
  • Page 469 NOTES...
  • Page 470 NOTES...

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