Club Car Carryall 550 2015 Maintenance And Service Manual
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Club Car Carryall 550 2015 Maintenance And Service Manual

Club Car Carryall 550 2015 Maintenance And Service Manual

Gasoline vehicle with subaru ex40 engine electric vehicle with quiq charger
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2015 Carryall 550
Maintenance and Service
Manual
Gasoline Vehicle with Subaru EX40 Engine
Electric Vehicle with QuiQ™ ™ ™ Charger
Manual Number 105157206
Edition Code 0714A00000

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Summary of Contents for Club Car Carryall 550 2015

  • Page 1 2015 Carryall 550 Maintenance and Service Manual Gasoline Vehicle with Subaru EX40 Engine Electric Vehicle with QuiQ™ ™ ™ Charger Manual Number 105157206 Edition Code 0714A00000...
  • Page 3 If it appears that a service question is not answered in this manual, please contact your nearest authorized Club Car dealer or distributor for assistance. You may also write to us at: Club Car, LLC, P.O. Box 204658; Augusta, GA 30917-4658 USA, Attention: Technical Services.

  • Page 5: Table Of Contents

    CONTENTS SECTION 1 – SAFETY ............................1-1 Safety Details ..............................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 Disconnecting the Battery – Gasoline Vehicles .................... 1-4 Connecting the Battery –...
  • Page 6 Electric Bed Lift ............................4-19 Electric Bed Lift Removal ......................... 4-20 Electric Bed Lift Installation ........................4-20 Floor Mat ..............................4-22 Floor Mat Removal ..........................4-22 Floor Mat Installation..........................4-22 Trailer Hitch..............................4-22 Trailer Hitch Removal..........................4-22 Trailer Hitch Installation..........................4-22 SECTION 5 –...
  • Page 7 Rack and Pinion Disassembly ........................7-8 Rack and Pinion Assembly ........................7-10 Rack and Pinion Installation – Maintenance-Free Ball Joints............... 7-12 Tie Rod and Drag Link ..........................7-13 Tie Rod and Drag Link Removal – Maintenance-Free Ball Joints ..............7-13 Tie Rod and Drag Link Installation –...
  • Page 8 Protocol Version ............................11-5 Param Block Version..........................11-5 MFG Date Code ............................11-5 OS Version...............................11-5 SM Version ..............................11-6 VCL App Version ............................11-6 Parameters ..............................11-6 Settings ..............................11-6 Amp Hours...............................11-9 Access Codes ............................11-9 Vehicle ID .............................. 11-10 Monitor Menu ............................. 11-10 Speed In ..............................11-10 Throttle % ..............................
  • Page 9 Diagnostics Menu ............................11-18 Present Errors Folder..........................11-18 Fault History Folder ..........................11-18 System Faults ............................11-18 Fault Recovery ............................11-20 Fault Descriptions............................11-21 01 Throttle Fault 1 ..........................11-21 02 Low Battery Voltage ........................... 11-21 03 Overvoltage ............................11-21 04 Thermal Cutback ..........................
  • Page 10 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 ..........................13-1 Key Switch Removal ..........................13-1 Key Switch Installation ..........................13-1 Forward/Reverse Rocker Switch........................
  • Page 11 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 ............................15-2 IP (Ingress Protection) Rating........................15-2 How To Identify Charge Algorithm Number ....................15-2 The Charge Circuit...........................
  • Page 12 Testing Basics ............................18-14 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 – ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE ..........20-1 Starter/Generator............................20-1 Starter/Generator Removal ........................20-1 Disassembly of the Starter/Generator to Service the Brushes ..............
  • Page 13 Fuel Gauge/Hour Meter Installation......................20-24 Fuel Level Sending Unit ..........................20-24 Oil Level Sensor ............................20-24 Oil Level Sensor Removal ........................20-24 Oil Level Sensor Installation ........................20-25 Voltage Limiter ............................20-25 Voltage Limiter Removal .........................20-25 Voltage Limiter Installation........................20-25 Headlight Switch............................20-26 Headlight Switch Removal........................20-26 Headlight Switch installation ........................20-26 Headlights..............................20-27 Headlight Bezel Removal ........................20-27 Headlight Bezel Installation ........................20-27...
  • Page 14 Flywheel Installation ..........................22-11 Oil Level Sensor ............................22-12 Testing the Oil Level Sensor ........................22-12 Oil Level Sensor Removal ........................22-12 Oil Level Sensor Installation ........................22-12 Ignition Coil ..............................22-13 Testing the Ignition Coil ...........................22-13 Ignition Coil Removal ..........................22-13 Ignition Coil Installation ...........................22-13 Snubber ..............................22-14 Snubber Removal...........................22-14 Snubber Installation ..........................22-14...
  • Page 15 Troubleshooting............................25-1 Drive Belt ..............................25-3 Drive Belt Removal ..........................25-3 Drive Belt Installation ..........................25-3 Drive Clutch ..............................25-4 Drive Clutch Removal ..........................25-5 Drive Clutch Cleaning and Inspection......................25-6 Drive Clutch Disassembly......................... 25-6 Inspection of Drive Clutch Parts........................ 25-9 Drive Clutch Assembly ..........................

  • Page 17: Section 1 - Safety

    SECTION 1 – SAFETY SAFETY DETAILS WARNING • This owner’s manual should be read completely before attempting to drive or service the vehicle. Failure to follow the instructions in this manual can result in property damage, severe personal injury, or death. It is important to note that some vital statements throughout this manual and on the decals affixed to the vehicle are preceded by the words 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 Gasoline vehicles only: • To avoid unintentionally starting a gasoline vehicle, disconnect the battery and spark plug wire. See Disconnecting the Battery – Gasoline Vehicles on page 1-4. • Frame ground – Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wiring.

  • 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: 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 22: International Safety Symbols On Batteries

    General Warnings SAFETY INTERNATIONAL SAFETY SYMBOLS ON BATTERIES Anyone using, repairing, or servicing the vehicle must understand and heed the safety symbols on the vehicle battery or batteries. 1. Shield eyes. 3. No smoking, no open flames, no sparks. 5. Battery acid hazard. 2.

  • Page 23: Section 2 - Vehicle Specifications

    SECTION 2 – VEHICLE SPECIFICATIONS VEHICLE SPECIFICATIONS VEHICLE SPECIFICATIONS – ELECTRIC VEHICLES SPECIFICATIONS CARRYALL 550 POWER SOURCE 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 Vehicle Specifications VEHICLE SPECIFICATIONS SPECIFICATIONS CARRYALL 550 POWER SOURCE ELECTRIC Front wheel tread 36.6 in (92.9 cm) Rear wheel tread 39.5 in (100.3 cm) Weight: Standard electric vehicle (curb weight) 1402 lb (636 kg) 15 to 17 mph Maximum forward speed (24 to 27 km/h) Outside clearance circle (diameter) 268 in (680.7 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 550 POWER SOURCE...
  • Page 27 VEHICLE SPECIFICATIONS Vehicle Specifications SPECIFICATIONS CARRYALL 550 POWER SOURCE GASOLINE Front wheel tread 36.6 in (92.9 cm) Rear wheel tread 39.5 in (100.3 cm) Weight: Standard gasoline vehicle (curb weight) 942 lb (427 kg) 15 to 17 mph Maximum forward speed (24 to 27 km/h) Outside clearance circle (diameter) 268 in (680.7 cm)

  • Page 29: Section 3 - General Information

    SECTION 3 – GENERAL INFORMATION DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. This manual features Carryall 550, electric and gasoline vehicle. The Electric Carryall 550, vehicle is equipped with IQ Plus electrical systems and onboard Delta-Q QuiQ™ battery chargers. The Gasoline Carryall 550 vehicle are equipped with Subaru engines and accompanying powertrains and are available with a pedal-start (standard) or key-start (optional) configuration.

  • Page 30: Storage - Electric Vehicles

    Storage – Electric Vehicles GENERAL INFORMATION The two letters (1) at the beginning of the serial number indicate the vehicle model. The following four digits (2) indicate the model year and production week during which the vehicle was built. The six digits (3) following the hyphen represent the unique sequential number assigned to each vehicle built within a given model year.

  • Page 31: Returning The Stored Electric Vehicle To Service

    GENERAL INFORMATION Storage – Electric Vehicles the water with electrolyte. Do NOT water batteries immediately prior to storage because this will not provide sufficient charge time to mix the water with the electrolyte. Freezing can occur when batteries are stored in this condition. Check the water levels in each battery cell.

  • Page 32: Storage - Gasoline Vehicles

    Storage – Gasoline Vehicles GENERAL INFORMATION WARNING • Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the battery. Frozen batteries can explode. Adjust tires to recommended tire pressure. See Vehicle Specifications – Electric Vehicles on page 2-1. Perform the Pre-Operation and Daily Safety Checklist on page 10-1 and the Performance Inspection on page 10-2.

  • Page 33: Returning The Stored Gasoline Vehicle To Service

    GENERAL INFORMATION Storage – Gasoline Vehicles Seal the fuel tank. 3.1. Fill fuel tank, and, following manufacturer’s directions, add a commercially available fuel stabilizer (such as Sta-Bil ® 3.2. Disconnect fuel vent line from fuel tank vent nipple. 3.3. Plug the fuel tank vent nipple so that it is air tight. We recommend using a slip-on vinyl cap. NOTE: It is not necessary to drain the fuel line.

  • Page 35: Section 4 - Body And Trim

    SECTION 4 – BODY AND TRIM DANGER • 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 More Difficult Stains – Perform previous procedure using full-strength bleach, or allow bleach to puddle on affected area for approximately 30 minutes. Rinse with a water dampened cloth to remove any remaining bleach concentration. See following CAUTION. CAUTION •...

  • Page 37: Touch-Up Paint Color Chart

    BODY AND TRIM Front Body Repair TOUCH-UP PAINT COLOR CHART COLOR CC P/N White 105117701 Classic Blue 105117702 Dark Green 105117703 105117704 Dark Gray 105117705 Black 105117706 105117707 Bright Blue 105117708 TITN Silver 105117709 Light Gray 105117710 2015 Carryall 550 Maintenance and Service Manual Page 4-3...

  • Page 38: Front Body

    Front Body BODY AND TRIM 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 Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4. Loosen and remove screws (1), washers (3), and locknuts (2) that attach heavy duty (HD) bumper mounting bracket (4) to HD bumper weldment (5) (Figure 4-1, Page 4-5).
  • Page 39 BODY AND TRIM Front Body 2986.eps Figure 4-1 Heavy Duty Bumper 2015 Carryall 550 Maintenance and Service Manual Page 4-5...

  • Page 40: Heavy Duty Bumper Installation

    Front Body BODY AND TRIM 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 4-5) Attach plastic bumper (13). Use the existing fastener holes in the mounting bracket and vehicle structure as an alignment guide.

  • Page 41: Grille Removal

    BODY AND TRIM Front Body 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 Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4. Remove HD bumper (if equipped).
  • Page 42 Front Body BODY AND TRIM 2844 Figure 4-3 Front Grille, Bumper, and Side Fenders Page 4-8 2015 Carryall 550 Maintenance and Service Manual...

  • Page 43: Grille Installation

    BODY AND TRIM Front Body 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 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 Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4. Remove front cowl. See Cowl Removal, Section 4, Page 4-6. From the inside of the dash, press upper snap tabs (1) of the instrument panel inward to release from dash.

  • 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 Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4. Remove cowl. See Cowl Removal on page 4-6. Remove steering wheel.
  • Page 46 Front Body BODY AND TRIM 2863.eps Figure 4-5 Dash Assembly Page 4-12 2015 Carryall 550 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.eps Figure 4-6 Tilt Bed Mounting Page 4-14 2015 Carryall 550 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 Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4. Raise bed and secure prop rod (9) in prop rod track (2) (Figure 4-6, Page 4-14).
  • Page 50 Tilt Bed BODY AND TRIM 2982.eps Figure 4-7 Bed Latch Assembly Page 4-16 2015 Carryall 550 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.eps 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 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). Using a 10 mm socket, remove the two M6 screws (2) that attach the tailskirt (3) to the vehicle frame. Remove fenders and tailskirt.

  • Page 53: Electric Bed Lift

    BODY AND TRIM Electric Bed Lift ELECTRIC BED LIFT 2983.eps Figure 4-9 Electric Bed Lift 2015 Carryall 550 Maintenance and Service Manual Page 4-19...

  • Page 54: Electric Bed Lift Removal

    Electric Bed Lift BODY AND TRIM 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 Disconnecting the Battery –...
  • Page 55 BODY AND TRIM Electric Bed Lift Connect actuator wires. Lower bed. Connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. See Connecting the Battery – Gasoline Vehicles on page 1-4. 2015 Carryall 550 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 • 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 1400-18000-10201 Figure 5-1 Brake and Park Brake Pedal Assembly and Mounting Page 5-2 2015 Carryall 550 Maintenance and Service Manual...
  • Page 59 ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake (Gas and Electric Vehicles) 2999.eps Figure 5-2 Brake Pedal Weldment Through Floor Position and attach brake pedal assembly, mounting blocks (26), and washers (27) to vehicle frame as shown. Tighten the bolts (28) and nuts to 95 in·lb (10.7 N·m). Tighten the nut (2) on the equalizer rod (1) so that brake pedal free-play is from 1/4 inch to 1/2 inch (6 mm to 13 mm) (Figure 5-3, Page 5-3).

  • 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 Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4.

  • Page 61: Accelerator Pedal - Gasoline Vehicles

    ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles Install the two bushings (30) in the park brake pedal and position the park brake pedal on the shaft on the brake pedal assembly weldment (10). Then attach the ends of the torsion spring to the park brake pedal and to the brake pedal weldment as shown (Figure 5-5, Page 5-4).

  • Page 62: Accelerator Pedal Installation - Gasoline Vehicles

    Accelerator Pedal – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP 12. 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 2015 Carryall 550 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: Pedal Group Adjustment - Electric Vehicles

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles CAUTION • After accelerator rod adjustment, make sure that approximately the same number of threads are exposed at each end of the accelerator rod. • If the lever on the limit switch in the electrical box is bent, replace the limit switch. •...
  • Page 72 Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP 1400-18100-10209 Figure 5-19 Loosen Rear Brake Equalizer Rod Nuts 2.3. Loosen the brake stop jam nut (31), then relieve pedal pressure on the stop by pushing down slightly on the pedal.
  • Page 73 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles 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 (6.3 mm to 12.7 mm) (Figure 5-3, Page 5-3). 3.3.
  • Page 74 Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP 1. Locked Position 2. Ratchet (B) Tooth Length 3. Make sure pawl (A) engages at least 75% of ratchet tooth length (B). Figure 5-23 Accelerator Pedal Height Measurement Figure 5-24 Ratchet/Pawl Tooth Engagement 4.5.
  • Page 75 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles 1. Accelerator Pedal Adjustment Tool (CC P/N 101871001) 2. Rubber Strap Figure 5-27 Accelerator Pedal Height Adjustment Adjust the brakes. See Brake Adjustment, Section 6, Page 6-6. Connect the battery cables. See Connecting the Battery – Gasoline Vehicles, Section 1, Page 1-4. See Connecting the Batteries –...

  • Page 77: Section 6 - Wheel Brake Assemblies

    SECTION 6 – WHEEL BRAKE ASSEMBLIES DANGER • 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) to each end of both brake shoes and into the slots in the brake shoe mounting block as shown (Figure 6-10, Page 6-4).

  • 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 6-15).

  • 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 2015 Carryall 550 Maintenance and Service Manual...

  • Page 85: Brake Cable Equalization

    WHEEL BRAKE ASSEMBLIES Brake Adjustment TYPICAL 4 PLACES TYPICAL 4 PLACES 2903.eps 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 NOTE: Brake pedal free play is the distance the brake pedal can be pressed before the brake actuator arm (at the brake cluster) moves. 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.
  • Page 88 Brake Cluster Removal and Installation WHEEL BRAKE ASSEMBLIES TYPICAL 4 PLACES 2810 Figure 6-22 Front Spindle Assembly Page 6-12 2015 Carryall 550 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. 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 6-15). Remove E-clip (7) from brake cable housing at the front spindle bracket and remove cable (8) from spindle.
  • Page 91 WHEEL BRAKE ASSEMBLIES Front Brake Cables TYPICAL BOTH SIDES OF VEHICLE 2995.eps Figure 6-23 Front Brake Cables and Equalizer 2015 Carryall 550 Maintenance and Service Manual Page 6-15...

  • Page 92: Rear Brake Cables

    Rear Brake Cables 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 6-24, Page 6-17).
  • Page 93 WHEEL BRAKE ASSEMBLIES Rear Brake Cables BOTTOM VIEW 2996.eps Figure 6-24 Rear Brake Cables and Equalizer 2015 Carryall 550 Maintenance and Service Manual Page 6-17...

  • Page 95: Section 7 - Steering And Front Suspension

    SECTION 7 – STEERING AND FRONT SUSPENSION DANGER • 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 2015 Carryall 550 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 4-6. 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 CAUTION • In step 4, do not press against the outer race of the bearing. If the bearing (9) was removed, press on a new bearing, exerting all pressure on the inner race (grease the bearing before installing it).

  • Page 106: Rack And Pinion Installation - Maintenance-Free Ball Joints

    Rack and Pinion STEERING AND FRONT SUSPENSION Apply a small amount of grease to the rack guide (13) where it comes into contact with the rack (17) (Figure 7-10, Page 7-10). 10. Place a few drops of Loctite ® 222 to the threads of the screw (16) (Figure 7-10, Page 7-10). 11.

  • Page 107: Tie Rod And Drag Link

    STEERING AND FRONT SUSPENSION Tie Rod and Drag Link 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 7-17) and loosen jam nuts (27 and 29) on the drag link (Figure 7-10, Page 7-10).

  • Page 108: Front Suspension

    Front Suspension STEERING AND 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 109 STEERING AND FRONT SUSPENSION Front Suspension After adjusting camber, tighten the four spring retaining nuts (32) (Figure 7-19, Page 7-18) to 23 ft·lb (31 N·m). Then roll the vehicle forward one full tire revolution and recheck the camber. Adjust as required. See also Figure 7-14, Page 7-14.

  • Page 110: Front Suspension Components

    Front Suspension Components STEERING AND FRONT SUSPENSION 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 Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4.
  • Page 111 STEERING AND FRONT SUSPENSION Front Suspension Components 2610 Figure 7-18 Front Suspension – Upper Portion 2015 Carryall 550 Maintenance and Service Manual Page 7-17...
  • Page 112 Front Suspension Components STEERING AND FRONT SUSPENSION 2611 Figure 7-19 Front Suspension – Lower Portion Page 7-18 2015 Carryall 550 Maintenance and Service Manual...

  • Page 113: Kingpin And Steering Spindle Installation - Maintenance-Free Ball Joints

    STEERING AND FRONT SUSPENSION Front Suspension Components 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 7-18).

  • Page 114: Front Wheel Bearings And Hubs

    Front Wheel Bearings and Hubs STEERING AND FRONT SUSPENSION Install the shock absorber by reversing the removal procedure. Tighten the nuts (9 and 38) to 20 ft·lb (27 N·m). FRONT WHEEL BEARINGS AND HUBS See General Warnings on page 1-1. FRONT WHEEL FREE PLAY INSPECTION Raise the front of the vehicle.

  • Page 115: Front Hub And Wheel Bearings Installation

    STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs 1500-18700-10273 Figure 7-20 Front Wheel Bearings and Hub 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).

  • Page 117: Section 8 - Wheels And Tires

    • See General Warnings, Section 1, Page 1-1. GENERAL INFORMATION NOTE: Use only Club Car approved tires when replacing tires. NOTE: Carryall 550 front and rear wheels are NOT interchangeable. The front wheels have no offset, whereas the rear wheels do have an offset. A rectangular sticker on the inside of each wheel designates its correct position on the vehicle as either FRONT (front) or REAR (rear).
  • Page 118 Wheels WHEELS AND TIRES Lower the vehicle and finish tightening the lug nuts, using a crisscross pattern, to 65 ft·lb (88 N·m). Page 8-2 2015 Carryall 550 Maintenance and Service Manual...

  • Page 119: Tires

    WHEELS AND TIRES 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 120: Tire Installation

    Tires WHEELS AND TIRES Small holes in the casing can be plugged using a standard automotive tubeless tire repair kit available at auto supply stores. When the cause of the air leak has been determined, remove tire from the rim and repair as required. See Tire Removal on page 8-3.
  • Page 121 WHEELS AND TIRES Tires Figure 8-2 Inflate Tire 2015 Carryall 550 Maintenance and Service Manual Page 8-5...

  • Page 123: Section 9 - Rear Suspension

    SECTION 9 – REAR SUSPENSION DANGER • See General Warnings, Section 1, Page 1-1. WARNING • See General Warnings, Section 1, Page 1-1. GENERAL INFORMATION The rear suspension and powertrain of the vehicle move independently from the vehicle frame. It consists of three leaf springs controlled by two hydraulic shock absorbers mounted between the springs and the vehicle frame.

  • Page 124: Shock Absorber Installation

    Shock Absorbers REAR SUSPENSION SHOCK ABSORBER INSTALLATION NOTE: When installing shock absorbers, make sure front shocks have identical part numbers and rear shocks have identical part numbers. NOTE: Tighten 3/8 hex nut at shock absorber until shock absorber cushions are approximately the same diameter as the retainers.
  • Page 125 REAR SUSPENSION Shock Absorbers 2988.eps Figure 9-2 Rear Suspension Assembly and Mounting 2015 Carryall 550 Maintenance and Service Manual Page 9-3...

  • Page 126: Multi-Leaf Springs

    Multi-Leaf Springs REAR SUSPENSION MULTI-LEAF SPRINGS See General Warnings on page 1-1. MULTI-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 Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4.

  • Page 127: Multi-Leaf Spring Installation

    REAR SUSPENSION Multi-Leaf Springs 2600-30000-10369 1400-18100-10243 Figure 9-3 Support Vehicle on Jack Stands Figure 9-4 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 129: 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 130: 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 131: 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 132: 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 133 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 134 Periodic Service Schedules PERIODIC MAINTENANCE PERIODIC SERVICE SCHEDULE – GASOLINE VEHICLES REGULAR INTERVAL SERVICE Clean terminals and wash dirt from casing; check Battery electrolyte level . Check and adjust if necessary. Front wheel alignment and camber See Steering and Front Suspension section in the maintenance and service manual.

  • Page 135: 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 136 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 137: Section 11 - Controller Diagnostic Tool (Cdt)

    SECTION 11 – CONTROLLER DIAGNOSTIC TOOL (CDT) DANGER • 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 138: 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 139: 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 140: 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 141: System Info

    CONTROLLER DIAGNOSTIC TOOL (CDT) System Info SYSTEM INFO The System Info menu is accessed by using the arrow keys to highlight System Info and pressing the Select softkey to activate the menu. The System Info selection displays information pertaining to the controller. The information provided from this menu selection includes: MODEL NUMBER Displays the model number of the controller.

  • Page 142: Sm Version

    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 143 CONTROLLER DIAGNOSTIC TOOL (CDT) Parameters increase, even if the accelerator is quickly pressed to the floor. Turn the feature on or off by pressing “+” or “–” on the change value button. M1/M2 Pedal Up Three options exist for M1/M2 pedal up (motor braking). On a level surface, when the accelerator pedal is released, motor braking will slow the vehicle to a stop when pedal up motor braking is enabled (option 1 or 2).
  • Page 144 Parameters CONTROLLER DIAGNOSTIC TOOL (CDT) 6.5 mph (10.5 km/h) 10.5 mph (16.9 km/h) 13.5 mph (21.7 km/h) 15.5 mph (25.0 km/h) 6.4 mph (10.3 km/h) 10.4 mph (16.7 km/h) 13.4 mph (21.6 km/h) 15.4 mph (24.8 km/h) 6.3 mph (10.1 km/h) 10.3 mph (16.6 km/h) 13.3 mph (21.4 km/h) 15.3 mph (24.6 km/h)

  • Page 145: Amp Hours

    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 146: Vehicle Id

    Monitor Menu CONTROLLER DIAGNOSTIC TOOL (CDT) VEHICLE ID 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. MONITOR MENU The Monitor menu is accessed by using the arrow keys to highlight Monitor and pressing the Select softkey to activate the menu.

  • Page 147: Heatsink Temp

    CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu HEATSINK TEMP Displays the temperature (in degrees Celsius) of the speed controller heatsink. During normal operating conditions, the heatsink temperature should be below 85 °C (±5) (185 °F (±9)). See following NOTE. NOTE: Improper brake adjustment can sometimes cause the operating current to be higher than normal. This higher current increases the temperature of the speed controller heatsink.

  • Page 148: Forward Input

    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 149: Thrtl Fault

    CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu THRTL FAULT # Displays the number of times the THRTL fault has been detected. See Fault Descriptions on page 11-21. UNDERVOLTAGE # Displays the number of times the UNDERVOLTAGE fault has been detected. See Fault Descriptions on page 11-21. OVERVOLTAGE # Displays the number of times the OVERVOLTAGE fault has been detected.

  • Page 150: Main Coil Opn

    Monitor Menu CONTROLLER DIAGNOSTIC TOOL (CDT) MAIN COIL OPN # Displays the number of times the MAIN COIL OPN fault has been detected. See Fault Descriptions on page 11-21. MAIN DROPOUT # Displays the number of times the MAIN DROPOUT fault has been detected. See Fault Descriptions on page 11-21. MOTOR STALL # Displays the number of times the MOTOR STALL fault has been detected.

  • Page 151: Fld Missing

    CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu FLD MISSING # Displays the number of times the FLD MISSING fault has been detected. See Fault Descriptions on page 11-21. HW FAILSAFE # Displays the number of times the HW FAILSAFE fault has been detected. See Fault Descriptions on page 11-21. DRVR OVERCUR # Displays the number of times the DRVR OVERCUR fault has been detected.

  • Page 152: Led Driver

    Monitor Menu CONTROLLER DIAGNOSTIC TOOL (CDT) LED DRIVER Displays the present state of pin 11 in the controller 16-pin connector that operates the charge indicator light on the dash. When pin 11 is activated, power is provided to the light and the handset indicates that the LED Driver is ON. When pin 11 is not activated, the handset indicates that the LED Driver is OFF.

  • Page 153: Amp Hours Display

    CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu Completed Charges Displays the number of completed charge cycles. Interrupted Charges Displays the number of interrupted charge cycles. Storage Charges Displays the number of storage charge cycles. AMP HOURS DISPLAY Signed Battery Current While driving the vehicle, this displays either the current being pulled out of the batteries or the current being returned to the batteries during regenerative motor braking.

  • Page 154: Diagnostics Menu

    Diagnostics Menu CONTROLLER DIAGNOSTIC TOOL (CDT) DIAGNOSTICS MENU CAUTION • A failed motor will damage the controller. Always inspect the motor before replacing the controller. See External Motor Testing, Section 16, Page 16-1. NOTE: The software is subject to frequent updates, and this manual may span many versions. Be aware that some faults listed in this manual may not display in the CDT, indicating older software.
  • Page 155 CONTROLLER DIAGNOSTIC TOOL (CDT) Diagnostics Menu menu, the number of fault occurrances are located in the fault counter section of the monitor menu, even if the fault has occurred multiple times. Causes of Faults Some common causes of faults are •...

  • Page 156: Fault Recovery

    Diagnostics Menu CONTROLLER DIAGNOSTIC TOOL (CDT) 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 157: Fault Descriptions

    CONTROLLER DIAGNOSTIC TOOL (CDT) Fault Descriptions 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 158: 09 Speed Sensor

    Fault Descriptions CONTROLLER DIAGNOSTIC TOOL (CDT) 09 SPEED SENSOR If the speed controller does not detect pulses from the speed sensor while the controller outputs power (greater than 75% armature PWM) to the motor, a speed sensor fault is detected. 10 MAIN DRIVER ON If the FET that controls the activation of the solenoid coil is found to be energized when it should not be, a main driver on fault is detected by the speed controller.

  • Page 159: 17 Current Sense

    CONTROLLER DIAGNOSTIC TOOL (CDT) Fault Descriptions 17 CURRENT SENSE If there are problems with the armature current sensor circuitry, a current sense fault is detected. 18 M- SHORTED If an uncontrolled current path is detected from the motor to B- (bypassing the MOSFETs), an M- shorted fault is detected.

  • Page 160: 26 Circuit Brkr Open

    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 161: Main Cont Dnc

    CONTROLLER DIAGNOSTIC TOOL (CDT) Fault Descriptions What it means: This is a symptom, not a cause. The controller records the number of times this occurs. What to do: Charge batteries. If fault occurs more frequently than normal, test battery pack. See Section 14 – Batteries: IQ Plus Electric Vehicles.

  • Page 162: Clearing Fault History

    Fault Descriptions CONTROLLER DIAGNOSTIC TOOL (CDT) CLEARING FAULT HISTORY After a repair has been made, the fault history should be cleared. This will enable the trained technician to properly troubleshoot the vehicle in the future, in the event that another problem occurs. If the fault history is not cleared after a repair, a technician may mistakenly replace a new component due to an old fault code.

  • Page 163: Programming

    CONTROLLER DIAGNOSTIC TOOL (CDT) Programming 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 164: Hhp Settings

    HHP Settings CONTROLLER DIAGNOSTIC TOOL (CDT) 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 165: Plot & Log

    CONTROLLER DIAGNOSTIC TOOL (CDT) Plot & Log 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 166: Cdt Troubleshooting

    CDT Troubleshooting CONTROLLER DIAGNOSTIC TOOL (CDT) CDT TROUBLESHOOTING In the event that the handset does not function as described in this manual, the following troubleshooting guide should be studied and the referenced test procedures should be performed to troubleshoot the handset. TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES...

  • Page 167: Connection Tests

    CONTROLLER DIAGNOSTIC TOOL (CDT) Connection Tests TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Disconnect the CDT cord from the vehicle. Handset malfunction Wait a few seconds and reconnect the handset to the vehicle See Section 14 – Batteries: IQ Plus Electric Vehicle batteries –...
  • Page 168 Connection Tests CONTROLLER DIAGNOSTIC TOOL (CDT) Using a multimeter set for 200 ohms, place the red (+) probe into one of the terminals on the end of the adapter with the square plug. Place the black (–) probe on each of the pins, one at a time, on the other plug of the adaptor. The multimeter should indicate continuity on only one pin.
  • Page 169 CONTROLLER DIAGNOSTIC TOOL (CDT) Connection Tests Figure 11-3 Disconnect Four-pin Connector. 2015 Carryall 550 Maintenance and Service Manual Page 11-33...

  • Page 171: Section 12 - Electrical System Troubleshooting: Iq Plus Electric Vehicles

    SECTION 12 – ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES DANGER • 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 172: 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 173 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES General Information • Speed Calibration: This function allows the vehicle’s top speed to be calibrated in 0.1 mph (0.2 km/h) increments. See M1/M2 Speed Cal, Section 11, Page 11-7. • Motor Protection Circuit: The operator should never attempt to hold the vehicle on an incline by pressing the accelerator pedal instead of the brake pedal, as motor overheating could result.

  • Page 174: 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 2015 Carryall 550 Maintenance and Service Manual...
  • Page 175 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Wiring Diagrams WD1050496_R_DGM Figure 12-2 Wiring Diagram (Continued) 2015 Carryall 550 Maintenance and Service Manual Page 12-5...
  • Page 176 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 177 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Wiring Diagrams WD1050496_2_DGM Figure 12-4 Wiring Diagram – Accessories 2015 Carryall 550 Maintenance and Service Manual Page 12-7...

  • Page 178: 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 179: Troubleshooting Guide 1

    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 180 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 181 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 See Section 16 –...

  • Page 182: 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 183 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 184: 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 185 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures 8 – Forward/Reverse Rocker Switch 9 – Solenoid Activating Coil 10 – Solenoid Contacts 11 – Charger Interlock 12 – MCOR Voltage 13 – Motor Speed Sensor 14 – A1 and A2 Motor Voltage 15 –...
  • Page 186 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 2015 Carryall 550 Maintenance and Service Manual...
  • Page 187 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 188 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES A reading of 32 to 42 volts indicates discharged or failed batteries. Each battery should be checked with a multimeter while under load. See following NOTE. NOTE: If a 48-volt set of batteries is down in the 32 to 38 volt range, the discharge machine will activate but it will think it is testing a 36-volt battery set.
  • Page 189 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 190 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES – 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. Probe the wire on each side of the fuse with insulation-piercing probes. 4.2.
  • Page 191 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 192 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 193 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 194 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 195 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 196 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES – If the CDT does not indicate ON, check circuit wiring and DC plug connection. See the following procedure Testing the Interlock Circuit. – If the CDT does indicate ON, but the vehicle can still be driven, replace the controller. See Speed Controller Removal, Section 13, Page 13-9.
  • Page 197 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures 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 198 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES 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. If reading does not increase as the pedal is pressed, check the drive bar for wear. If drive bar is not worn, replace MCOR.
  • Page 199 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures With batteries connected, disconnect the three-pin connector at the motor speed sensor. Check voltage at black/white wire: 3.1. Set a multimeter to 200 volts DC. Place the red (+) probe on the battery no. 1 positive post and place the black (–) probe on the black/white wire terminal socket in the three-pin connector.
  • Page 200 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES 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. The voltage reading should be from 4.60 to 5.00 volts.
  • Page 201 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures 6.2. Replace the speed sensor if – there is no voltage reading. – the voltage reading is not above 3.50. – the voltage reading does not fluctuate as the motor is turned. TEST PROCEDURE 14 –...
  • Page 202 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES Figure 12-15 Test A1 and A2 Motor Voltage TEST PROCEDURE 15 – 24-Pin Connector 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.
  • Page 203 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures SPEED CONTROLLER 24-PIN CONNECTOR WIRE TEST PROCEDURE FOOT INPUT Pin 8 – Green (18-gauge) Pin 9 – Pink (18-gauge) Test continuity of wire Pin 10 – Brown (18-gauge) Pin 11 – Red/Green (18-gauge) Pin 12 –...
  • Page 204 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES CAUTION • Do not fully insert probes into the 24-pin plug. Doing so can result in a poor connection. With the accelerator pedal fully up (not pressed), the multimeter should read approximately 1k ohms. Slowly press the accelerator pedal while monitoring the multimeter.
  • Page 205 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures Set a multimeter to 200 volts DC, insert the red (+) probe of the multimeter into pin 8 (green wire) of the 24-pin connector. See following CAUTION. Connect the black (–) probe to the B– terminal of the speed controller or negative (–) post of battery no.
  • Page 206 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES 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 207 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures 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 208 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES Detail A: Front of 24-Pin Connector Figure 12-19 Test: Pin 10 (Black Wires) Pin 1 See General Warnings on page 1-1. Pin 1 in the 24-pin connector provides a connection point for the key switch to the speed controller. The key switch provides a +48 volt signal to the speed controller through pin 1 (tan wire) when the key switch is in the ON position.
  • Page 209 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures Detail A: Front of 24-Pin Connector Figure 12-20 Test: Pin 1 (Tan Wire) Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. See Connecting the Batteries –...
  • Page 210 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES – Continuity of the wires in the wire harness. – Reverse buzzer for proper operation. See Reverse Buzzer on page 12-40. – Tow/Run switch for proper operation. See Tow/Run Switch on page 12-18. –...
  • Page 211 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Place the Tow/Run switch in the RUN position. Set a multimeter to 200 volts DC.
  • Page 212 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES If charge indicator light does not flash three times, disconnect charger DC cord from vehicle and connect an CDT to the vehicle. Access the Monitor menu and select LED Driver by using the SCROLL DISPLAY buttons. The CDT should indicate OFF.
  • Page 213 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures NOTE: The white/black wire only has voltage with the Run/Tow switch in the RUN position. If pin 4 has no voltage, the controllers LIN (Local Interconnect bus) may have failed. The vehicle can be driven if it is not used with Guardian or Visage and will not show any symptoms.

  • Page 215: Section 13 - Electrical Components: Iq Plus Electric Vehicles

    SECTION 13 – ELECTRICAL COMPONENTS: IQ PLUS ELECTRIC VEHICLES DANGER • 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 – Key Switch and MCOR Limit Switch Circuit on page 12-22. KEY SWITCH REMOVAL Disconnect the batteries and discharge the controller.
  • Page 216 ELECTRICAL COMPONENTS: IQ PLUS Key Switch ELECTRIC VEHICLES Figure 13-1 Key Switch Page 13-2 2015 Carryall 550 Maintenance and Service Manual...

  • Page 217: 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 218: Tow/Run Switch Removal

    ELECTRICAL COMPONENTS: IQ PLUS Circuit Breaker ELECTRIC VEHICLES 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 219 ELECTRICAL COMPONENTS: IQ PLUS ELECTRIC VEHICLES Circuit Breaker Figure 13-2 Circuit Breaker 2015 Carryall 550 Maintenance and Service Manual Page 13-5...

  • Page 220: 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 221: Mcor Installation

    ELECTRICAL COMPONENTS: IQ PLUS ELECTRIC VEHICLES Reverse Buzzer MCOR INSTALLATION Align the two tabs of the MCOR (2) with the slots in the plastic housing (4) on the chassis (Figure 13-3, Page 13-6). Insert the MCOR into the plastic housing (4) until the tabs engage. See following NOTE. NOTE: Rotate the drive bar (5) back and forth if necessary to align the D-shaped end with the MCOR.

  • Page 222: Installing The Speed Controller Cover

    ELECTRICAL COMPONENTS: IQ PLUS Solenoid ELECTRIC VEHICLES INSTALLING THE SPEED CONTROLLER COVER Place the curved edges on the bottom of the speed controller cover into the slots on the component mounting plate. Press the speed controller cover onto the component mounting plate over the speed controller and other electrical components.

  • Page 223: Speed Controller

    ELECTRICAL COMPONENTS: IQ PLUS ELECTRIC VEHICLES Speed Controller Using the wiring diagram, install the wires, washers, and nuts onto the large mounting posts. Tighten nuts to 77 in·lb (8.7 N·m). See Wiring Diagrams, Section 12, Page 12-4. Install the blue/white and light blue wires onto the small terminals of the solenoid (Figure 13-4, Page 13-8). Install speed controller cover.
  • Page 224 ELECTRICAL COMPONENTS: IQ PLUS Speed Controller ELECTRIC VEHICLES 2998 Figure 13-5 Speed Controller Page 13-10 2015 Carryall 550 Maintenance and Service Manual...

  • Page 225: 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 227: Section 14 - Batteries: Iq Plus Electric Vehicles

    SECTION 14 – BATTERIES: IQ PLUS ELECTRIC VEHICLES DANGER • 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 228: 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 229: 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 230 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 231: 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 232: 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 233: 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 234: 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 235: 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 236: Self-Discharge

    Battery Care BATTERIES: IQ PLUS ELECTRIC VEHICLES WARNING • If battery wire terminals are damaged or corroded, replace or clean them as necessary. Failure to do so can cause them to overheat during operation and can result in fire, property damage, or personal injury.

  • Page 237: 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 238 Single Point Watering System (SPWS) BATTERIES: IQ PLUS ELECTRIC VEHICLES CAUTION • Make sure the screen filter is clean. • 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.

  • Page 239: 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 240: 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 241: 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 242: Ce Compliance

    General Information QUIQ HIGH FREQUENCY CHARGER CE COMPLIANCE This battery charger is compliant with the EU EMC Directive 2004/108/EC. IP (INGRESS PROTECTION) RATING The enclosure of the charger has been tested successfully to EN60529, meeting IP66. The AC supply inlet is rated to IP20, which is suitable for indoor use only.

  • Page 243: The Charge Circuit

    QUIQ HIGH FREQUENCY CHARGER Onboard Charger Operation Battery Charger Algorithms CHARGER MODEL (PART NUMBER) ALGORITHM BATTERY TYPE 912–4854–04 algorithm # 72 912–4854–04 algorithm # 3 Trojan THE CHARGE CIRCUIT The charge circuit consists of the onboard charger, batteries and charger information light (Figure 15-2, Page 15-3). B–...
  • Page 244 – 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 245: Charger Displays

    QUIQ HIGH FREQUENCY CHARGER Onboard Charger Operation WARNING – Install surge arrestors on incoming AC power lines. Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightening strikes – Ensure battery connections are clean and properly tightened. –...
  • Page 246 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 247: 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 248: 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 249: 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 250: 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 251: 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 252: Onboard Charger Installation

    Onboard Charger Removal And Installation QUIQ HIGH FREQUENCY CHARGER Remove four lock nuts (5) securing charger to charger mounting plate. 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.

  • Page 253: 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 254: Motor Removal

    MOTOR (MODEL DA5-4006): ELECTRIC Motor Removal VEHICLES TEST PROCEDURE 2 – Armature Circuit Open 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. 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 255 MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor Removal 1. Position floor jack under hitch bracket or frame. 2. Carryall 700 (shown) 2867.eps 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 256: 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 257 MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor Disassembly CAUTION • The motor housing will drop when the bolts are removed. Do not put fingers under the motor housing when removing bolts. Remove the end cap and armature from the motor frame (Figure 16-5, Page 16-4). Inspect the brush springs for proper tension.
  • Page 258 MOTOR (MODEL DA5-4006): ELECTRIC Motor Disassembly VEHICLES Figure 16-8 Brush Rigging Removal Figure 16-9 Retaining Ring Removal Page 16-6 2015 Carryall 550 Maintenance and Service Manual...

  • Page 259: 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 260: 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 261 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 262 MOTOR (MODEL DA5-4006): ELECTRIC Motor Component Testing and Inspection VEHICLES Figure 16-13 Motor Page 16-10 2015 Carryall 550 Maintenance and Service Manual...

  • Page 263: 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 264 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 265: 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 266 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 267 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 268 MOTOR (MODEL DA5-4006): ELECTRIC Motor Installation VEHICLES Viewed From Driver Side Figure 16-21 Motor Tightening Sequence Page 16-16 2015 Carryall 550 Maintenance and Service Manual...

  • Page 269: Section 17 - Transaxle: Electric Vehicles

    SECTION 17 – TRANSAXLE: ELECTRIC VEHICLES DANGER • 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 270 Axle Bearing and Shaft TRANSAXLE: ELECTRIC VEHICLES CAUTION • Do not scar or damage the inside surfaces of the tube when removing the oil seal and adapter ring. A damaged tube might have to be replaced. NOTE: Do not discard the adapter ring. If the adapter ring is lost or damaged, the axle tube will have to be replaced. 6.2.
  • Page 271 TRANSAXLE: ELECTRIC VEHICLES Axle Bearing and Shaft Figure 17-5 Transaxle – Type G 2015 Carryall 550 Maintenance and Service Manual Page 17-3...

  • Page 272: 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 273: 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 274 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 275: Transaxle Disassembly, Inspection, And Assembly

    TRANSAXLE: ELECTRIC VEHICLES Transaxle Disassembly, Inspection, and Assembly 11. 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. See preceding WARNING. 12.
  • Page 276 Transaxle Disassembly, Inspection, and Assembly TRANSAXLE: ELECTRIC VEHICLES CAUTION • Do not damage gears. Use extreme care when handling them. Use a bearing puller or arbor press to remove bearings (16) from the input pinion gear. If the oil seal (10) is damaged, replace it (Figure 17-5, Page 17-3).

  • Page 277: Transaxle Assembly

    TRANSAXLE: ELECTRIC VEHICLES Transaxle Disassembly, Inspection, and Assembly 8.5. Remove the idler gears (1 and 2) and thrust plates (3 and 4) (Figure 17-16, Page 17-9). Figure 17-15 Differential Pin Figure 17-16 Left Differential 8.6. Remove the differential gears (5 and 6) and thrust plates (7 and 8). 8.7.
  • Page 278 Transaxle Disassembly, Inspection, and Assembly TRANSAXLE: ELECTRIC VEHICLES Install both dowel pins (25) in the transaxle housing (20) (Figure 17-5, Page 17-3). Install left half of transaxle housing: 8.1. Place a 1/8-inch (3 mm) bead of Three Bond liquid gasket on mating surface of housing. 8.2.

  • Page 279: Transaxle Installation

    TRANSAXLE: ELECTRIC VEHICLES Transaxle Installation 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 281: Section 18 - Troubleshooting And Electrical System: Pedal-Start Gas Vehicle

    SECTION 18 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE DANGER • 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 282: Ground Locations

    TROUBLESHOOTING AND ELECTRICAL SYSTEM: Troubleshooting Guide PEDAL-START GAS VEHICLE GROUND LOCATIONS Electrical grounds are located at the following areas: • Below the Battery: The battery, starter/generator, voltage regulator and main wire harness are all grounded to the chassis on the frame rail below the battery. •...

  • Page 283: Gasoline Powertrain

    TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Troubleshooting Guide Failure Mode Table – After Ignition Has Been In ON Position (i.e. During Use of Vehicle) DISPLAY MODE CONDITION LAMP CONTROL Blink Code No Failure Step 1: Lamp OFF Detect Failure Step 1: Lamp OFF Four Seconds Step 2: Display Blink Code Error Codes –...
  • Page 284 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Troubleshooting Guide PEDAL-START GAS VEHICLE TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Water or dirt in the fuel system and/or throttle See Section 23 – Fuel System: Gasoline body/fuel injector; dirty or clogged fuel filter Vehicles. Clean or adjust.
  • Page 285 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Fan screen is partially blocked or plugged See Section 22 – Engine (Subaru EX40). See Section 23 – Fuel System: Gasoline Governor is improperly adjusted Vehicles.
  • Page 286 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Troubleshooting Guide PEDAL-START GAS VEHICLE TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Neutral lockout switch is in the MAINTENANCE Place switch in the OPERATE position. position Fuse is blown Test Procedure 2 – Fuses Battery is dead Test Procedure 1 –...
  • Page 287 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Engine mounting nuts or bolts are loose See Section 22 – Engine (Subaru EX40). Snubber on frame is worn or damaged See Section 22 – Engine (Subaru EX40). See Section 24 –...

  • Page 288: Wiring Diagrams

    TROUBLESHOOTING AND ELECTRICAL SYSTEM: Wiring Diagrams PEDAL-START GAS VEHICLE WIRING DIAGRAMS FUS ES WD1050077_DGM_D-L Figure 18-1 Wiring Diagram for Pedal-Start Gasoline Vehicle Page 18-8 2015 Carryall 550 Maintenance and Service Manual...
  • Page 289 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Wiring Diagrams TO ECU (BLACK 18-PIN) NEUTRAL LOCKOUT SW ITCH WD1050077_DGM_D-R Figure 18-2 Wiring Diagram for Pedal-Start Gasoline Vehicle – Continued 2015 Carryall 550 Maintenance and Service Manual Page 18-9...
  • Page 290 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Wiring Diagrams PEDAL-START GAS VEHICLE FNR Harness Instrument Panel Harness BRAKE LIGHT RELAY SPST WD1050951_DGM_A Figure 18-3 Wiring Diagram – Instrument Panel and FNR Shifter Page 18-10 2015 Carryall 550 Maintenance and Service Manual...
  • Page 291 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-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 292 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Wiring Diagrams PEDAL-START GAS VEHICLE 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 293: Electrical System

    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 294: Test Procedures

    TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures 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 295 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures Index of Test Procedures 1 – Battery 2 – Fuses 3 – Ground Cables 4 – EFI System (ECU and Sensors) 5 – Key Switch (Start Circuit) 6 – Key Switch (Engine Kill Circuit) 7 –...
  • Page 296 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE TEST PROCEDURE 1 – Battery See General Warnings on page 1-1. DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working near a battery.
  • Page 297 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 298 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE NOTE: A fully charged battery that is in good condition should have a specific gravity of at least 1.225 in all cells, and the difference in the specific gravity of any two cells should be less than 50 points. Open circuit voltage should be at least 12.4 volts.
  • Page 299 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 300 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE 4.1. Probe the two, small metal contacts on the top of the fuse (Figure 18-8, Page 18-19). 4.2. Each contact should show battery voltage. 4.3. If only one side shows battery voltage, replace fuse. 4.4.
  • Page 301 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 302 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE 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 18-14. 18-PIN CONNECTOR (GRAY AND BLACK): A.
  • Page 303 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 Continuity: ECU Gray Pin 17 (Black/Yellow) and Ground Meter should beep Key OFF Gray MAP Sensor Ground Voltage: ECU Gray Pin 17 (Black/Yellow) and Battery...
  • Page 304 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures 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 18-14.
  • Page 305 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 18-14. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4.
  • Page 306 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE 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 307 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures 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 18-14.
  • Page 308 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE 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 309 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures 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 18-14. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position.
  • Page 310 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE • Scrape a small amount of paint from starter/generator housing (ground) and use this location when testing motor terminals to electrical ground. MOTOR TERMINALS CONTINUITY TEST RESULT A1 to A2 Continuity F1 to F2 A1 to F1 No Continuity...
  • Page 311 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures 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 18-14. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position.
  • Page 312 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE 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 313 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures 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 18-14. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position.
  • Page 314 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE 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 315 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures 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 316 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE 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 18-14.
  • Page 317 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures 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 318 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE 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. See Fuel Pump Module Removal on page 23-18. 4.2.
  • Page 319 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures 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 18-21 Fuel Gauge/Hour Meter If necessary, see Testing Basics on page 18-14.
  • Page 320 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE 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 18-22 Fuel Gauge Voltage Test - Terminal 2 Figure 18-23 Fuel Gauge Voltage Test - Terminal 4 TEST PROCEDURE 24 –...
  • Page 321 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures 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 18-19. This is a voltage test.
  • Page 322 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE 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 323 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures 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 325: Section 19 - Troubleshooting And Electrical System: Key-Start Gas Vehicle

    SECTION 19 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START GAS VEHICLE DANGER • 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 326: Wiring Diagrams

    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 2015 Carryall 550 Maintenance and Service Manual...
  • Page 327 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 2015 Carryall 550 Maintenance and Service Manual Page 19-3...
  • Page 328 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 2015 Carryall 550 Maintenance and Service Manual...
  • Page 329 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 330: Test Procedures

    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 331 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 18-14.
  • Page 332 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 333 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 18-14.
  • Page 334 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 335: Section 20 - Electrical Components: Pedal-Start Gas Vehicle

    SECTION 20 – ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE DANGER • 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 18-29. See Test Procedure 11 –...

  • Page 336: Brush Inspection And Replacement

    ELECTRICAL COMPONENTS: PEDAL- Starter/Generator START GAS VEHICLE NOTE: To clean and inspect the armature/commutator and the bearings, see Disassembly of the Starter/Generator to Service the Armature/Commutator on page 20-4. Figure 20-1 Commutator End Cover Figure 20-2 Brush Covers and Brushes BRUSH INSPECTION AND REPLACEMENT Visually inspect brushes.

  • Page 337: Starter/Generator Assembly

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator CAUTION Figure 20-4 Brush Spring Tension Test STARTER/GENERATOR ASSEMBLY Connect the brush wires to the holders using four lock washers (26) and four screws (25), making sure the crossover leads are connected also. Tighten the screws to 31 in·lb (3.5 N·m) (Figure 20-2, Page 20-2). To prevent contact between the brushes and commutator as the commutator is installed, and possible damage to the brushes, lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover.

  • Page 338: Disassembly Of The Starter/Generator To Service The Armature/Commutator

    ELECTRICAL COMPONENTS: PEDAL- Starter/Generator START GAS VEHICLE 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. 1.1.

  • Page 339: Bearing Removal

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator Figure 20-7 Bearing Play Inspection BEARING REMOVAL Place the wedge attachment tool (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 (CC P/N 1012811) to the wedge attachment tool and pull the bearing off of the end of the armature shaft.

  • Page 340: Visual Inspection Of Armature

    ELECTRICAL COMPONENTS: PEDAL- Starter/Generator START GAS VEHICLE VISUAL INSPECTION OF ARMATURE Obvious defects can be seen by examining the armature. If an armature has frayed or charred insulation, broken wires or thrown solder, it is obvious without testing that it should be replaced. Faults seen during the visual inspection can aid in diagnosing the original cause of the failure.

  • Page 341: Armature Ground Test

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator 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 342: Visual Inspection Of Field Coils

    ELECTRICAL COMPONENTS: PEDAL- Starter/Generator START GAS VEHICLE 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 343: Starter/Generator Installation

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator Install the output end cover (36) onto the armature. Secure the bearing retainer (32) to the cover and tighten the screws (43) to 39 in·lb (4.4 N·m) (Figure 20-6, Page 20-4). Slide the housing with field coils over the armature. Use the locating pin to align housing to the cover. NOTE: The terminal insulators should be on the commutator end of the housing.
  • Page 344 ELECTRICAL COMPONENTS: PEDAL- Starter/Generator START GAS VEHICLE Install the green wire (1) from the F1 terminal to the A2 terminal on the starter/generator (Figure 20-13, Page 20-10). 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 345: Belt Tension Adjustment

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator BELT TENSION ADJUSTMENT Belt tension should be checked periodically. If the belt slips when starter/generator motor operates, adjust belt to correct tension. Belt Tension Gauge 2. End View Figure 20-14 Belt Tension Gauge Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4.

  • Page 346: Voltage Regulator

    ELECTRICAL COMPONENTS: PEDAL- Voltage Regulator START GAS VEHICLE VOLTAGE REGULATOR See General Warnings on page 1-1. TESTING THE VOLTAGE REGULATOR See Test Procedure 13 – Voltage Regulator on page 18-31. VOLTAGE REGULATOR REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4.

  • Page 347: Engine Control Unit (Ecu)

    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 348: Key Switch Removal

    ELECTRICAL COMPONENTS: PEDAL- Key Switch START GAS VEHICLE KEY SWITCH REMOVAL Disconnect the batteries and spark plug. See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4. Remove instrument panel. See Instrument Panel Removal on page 4-10. NOTE: Take care to prevent key switch terminals and wires from touching the metal frame around the dash. Disconnect the wires from the key switch.

  • Page 349: Maintenance/Operate Switch

    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 18-27. MAINTENANCE/OPERATE SWITCH REMOVAL Disconnect the battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-4.

  • Page 350: Neutral Lockout Limit Switch Installation

    ELECTRICAL COMPONENTS: PEDAL- Solenoid START GAS VEHICLE NEUTRAL LOCKOUT LIMIT SWITCH INSTALLATION Install the limit switch (1) with washers (4) and nuts (3) and tighten to 5 in·lb (0.6 N·m). Move the Forward/Reverse handle to make sure the switch actuates. See following CAUTION. CAUTION •...

  • Page 351: Fuse

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Fuse Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 1, Page 1-4. 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.

  • Page 352: Kill Limit Switch

    ELECTRICAL COMPONENTS: PEDAL- Kill Limit Switch START 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 18-32. KILL LIMIT SWITCH REMOVAL Disconnect battery and spark plug wire(s).

  • Page 353: Reverse Warning Buzzer

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Reverse Warning Buzzer 2948.eps Figure 20-17 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 18-35. REVERSE WARNING BUZZER REMOVAL Disconnect battery and spark plug wire(s).
  • Page 354 ELECTRICAL COMPONENTS: PEDAL- Reverse Warning Buzzer START GAS VEHICLE 3003.eps Figure 20-18 Instrument Panel Switches Page 20-20 2015 Carryall 550 Maintenance and Service Manual...

  • Page 355: Reverse Buzzer Limit Switch

    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 18-35. REVERSE BUZZER LIMIT SWITCH REMOVAL Disconnect battery and spark plug wire(s).
  • Page 356 ELECTRICAL COMPONENTS: PEDAL- Reverse Buzzer Limit Switch START GAS VEHICLE 3001.eps Figure 20-19 Forward/Reverse Assembly Switches Page 20-22 2015 Carryall 550 Maintenance and Service Manual...

  • Page 357: Low Oil Warning Light

    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 18-35. LOW OIL WARNING LIGHT REMOVAL Disconnect battery and spark plug wire(s).

  • Page 358: Fuel Gauge/Hour Meter Removal

    ELECTRICAL COMPONENTS: PEDAL- Fuel Level Sending Unit START GAS VEHICLE FUEL GAUGE/HOUR METER REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4. Remove the instrument panel. See Instrument Panel Removal, Section 4, Page 4-10. Disconnect the wires from the fuel gauge/hour meter (6).

  • Page 359: Oil Level Sensor Installation

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Voltage Limiter OIL LEVEL SENSOR INSTALLATION See Oil Level Sensor Installation on page 22-12. VOLTAGE LIMITER See General Warnings on page 1-1. TESTING THE VOLTAGE LIMITER See Test Procedure 27 – Voltage Limiter on page 18-42. VOLTAGE LIMITER REMOVAL NOTE: Battery will charge reducing the voltage going to accessories.

  • Page 360: Headlight Switch

    ELECTRICAL COMPONENTS: PEDAL- Headlight Switch START GAS VEHICLE 3002.eps Figure 20-20 Voltage Limiter HEADLIGHT SWITCH See General Warnings on page 1-1. TESTING THE LIGHT SWITCH See Test Procedure 25 – Light Switch on page 18-41. 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 20-18, Page 20-20).

  • Page 361: Headlights

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Headlights HEADLIGHTS See General Warnings on page 1-1. TESTING THE HEADLIGHT SOCKET See Test Procedure 26 – Voltage at Headlight Socket on page 18-41. HEADLIGHT BEZEL REMOVAL Disconnect the batteries and discharge the controller. Disconnecting the Batteries – Electric Vehicles on page 1-4 Remove the cowl.

  • Page 362: Headlight Bulb Removal (Led)

    ELECTRICAL COMPONENTS: PEDAL- Headlights START GAS VEHICLE HEADLIGHT BULB REMOVAL (LED) Disconnect the batteries. Remove cowl. See Cowl Removal, Section 4, Page 4-6. 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 20-21, Page 20-29) HEADLIGHT BULB INSTALLATION (LED) Install bulb assembly (6) into bezel (1) and secure with screws (2).
  • Page 363 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Headlights 2993.eps Figure 20-21 Headlight Assembly 2015 Carryall 550 Maintenance and Service Manual Page 20-29...

  • Page 364: Battery

    ELECTRICAL COMPONENTS: PEDAL- Battery START 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 365: Preventive Maintenance

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Battery PREVENTIVE MAINTENANCE To keep the battery in good operating condition, remove any corrosion immediately. Post connections should be clean and tight. Any frayed or worn wires should be replaced. After all cables have been connected and properly tightened to 144 in·lb (16 N·m), coat terminals with Battery Terminal Protector Spray (CC P/N 1014305) to prevent future corrosion.

  • Page 366: Vibration Damage

    ELECTRICAL COMPONENTS: PEDAL- Battery START GAS VEHICLE Hot weather also has an effect on a battery’s self-discharge rate. The higher the temperature, the quicker a battery will discharge. In hotter climates, therefore, the battery should be checked more often. When storing the battery, keep in a cool place.
  • Page 367 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 368: Battery Removal

    ELECTRICAL COMPONENTS: PEDAL- Battery START 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.

  • Page 369: Battery Storage

    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 20-31. 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 371: Section 21 - Electrical Components: Key-Start Gas Vehicle

    SECTION 21 – ELECTRICAL COMPONENTS: KEY-START GAS VEHICLE DANGER • 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 372: Key Switch Removal

    ELECTRICAL COMPONENTS: KEY-START Key Switch GAS VEHICLE KEY SWITCH REMOVAL Disconnect the batteries and spark plug. See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4. Remove instrument panel. See Instrument Panel Removal on page 4-10. NOTE: Take care to prevent key switch terminals and wires from touching the metal frame around the dash. Disconnect the wires from the key switch.

  • Page 373: Maintenance/Operate Switch

    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 Disconnecting the Battery – Gasoline Vehicles on page 1-4.

  • Page 374: Charging Diode

    ELECTRICAL COMPONENTS: KEY-START Charging Diode GAS VEHICLE Connect all wires as indicated. See Wiring Diagrams on page 19-2. 2.1. Connect the 4-gauge white wire from the starter/generator, the 18-gauge white wire from the fuel gauge/hour meter, the 18-gauge red wire from the voltage regulator, and the 10-gauge white wire from the charging diode to the large post on the solenoid.

  • Page 375: Charging Diode Installation

    ELECTRICAL COMPONENTS: KEY-START GAS VEHICLE Charging Diode FRONT OF VEHICLE Some wires omitted for clarity. 2978.eps 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 376 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 377: Section 22 - Engine (Subaru Ex40)

    SECTION 22 – ENGINE (SUBARU EX40) DANGER • 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 378: Torque Specifications

    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 379 ENGINE (SUBARU EX40) General Information CAUTION • Do not remove dipstick while engine is running. 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 380 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 381: Spark Plug

    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 Connecting the Battery – Gasoline Vehicles on page 1-4. 10. 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 382: Breather

    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 383: Valve Clearance Check And Adjustment

    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 384: Engine Removal

    Engine Removal ENGINE (SUBARU EX40) ENGINE REMOVAL See General Warnings on page 1-1. CAUTION • Before removal and disassembly, clean the engine. Utility/T ransportation Orientation Precedent Orientation 3036 Figure 22-7 EX40 Engine and Mounting Brackets Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4.

  • Page 385: Engine Installation

    ENGINE (SUBARU EX40) Engine Installation 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. If removing powertrain, see Transaxle Removal on page 26-9.

  • Page 386: Flywheel

    Flywheel ENGINE (SUBARU EX40) CAUTION • Do not overfill with oil. 15. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 1, Page 1-4. 16. Adjust the engine RPM setting. See Engine RPM Adjustment on page 23-13. 17.

  • Page 387: Flywheel Installation

    ENGINE (SUBARU EX40) Flywheel 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 388: Oil Level Sensor

    Oil Level Sensor ENGINE (SUBARU EX40) OIL LEVEL SENSOR TESTING THE OIL LEVEL SENSOR See Oil Level Sensor on page 18-36. 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 22-10. Remove bolt (1) securing oil sensor wire clamp (2) to engine.

  • Page 389: Ignition Coil

    ENGINE (SUBARU EX40) Ignition Coil IGNITION COIL See General Warnings on page 1-1. TESTING THE IGNITION COIL See Test Procedure 15 – Ignition Spark on page 18-33 and Test Procedure 16 – Ignition Coil on page 18-34. IGNITION COIL REMOVAL Remove screws (1) and fan housing (2) (Figure 22-8, Page 22-10).

  • Page 390: Snubber

    Snubber ENGINE (SUBARU EX40) 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 22-14, Page 22-14).

  • Page 391: Section 23 - Fuel System: Gasoline Vehicles

    SECTION 23 – FUEL SYSTEM: GASOLINE VEHICLES DANGER • 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 392: Relieving Fuel Pressure

    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 393: Throttle Body

    FUEL SYSTEM: GASOLINE VEHICLES Throttle Body 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. Check the following items: •...

  • Page 394: Throttle Body Installation

    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 395 FUEL SYSTEM: GASOLINE VEHICLES Throttle Body 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 23-22. If equipped, install air deflector on top of engine. 10.

  • Page 396: Engine Control Linkages

    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 397: Ground Speed

    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 23-13.
  • Page 398 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 399: Governor Cable

    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 Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4.
  • Page 400 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 2015 Carryall 550 Maintenance and Service Manual...

  • Page 401: Accelerator Cable

    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 Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4.

  • Page 402: Closed Throttle Or Idle Adjustment - Pedal-Start Vehicles

    Engine Control Linkages FUEL SYSTEM: GASOLINE VEHICLES 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 23-12).

  • Page 403: How To Measure Ground Speed

    FUEL SYSTEM: GASOLINE VEHICLES Engine Control Linkages 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 404: Air Intake System

    Air Intake System FUEL SYSTEM: GASOLINE VEHICLES AIR INTAKE SYSTEM See General Warnings on page 1-1. 3048 Figure 23-12 Air Intake System – CA 500/550/700/TRANSPORTER/Cafe Express AIR FILTER The air filter should be inspected periodically and replaced when necessary. Filter changes should not exceed the recommended interval.

  • Page 405: Air Cleaner Removal

    • 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 406: Fuel Line

    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 407: Fuel Line Installation

    FUEL SYSTEM: GASOLINE VEHICLES Fuel Line 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 408: Fuel Pump Module

    Fuel Pump Module FUEL SYSTEM: GASOLINE VEHICLES 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 409 FUEL SYSTEM: GASOLINE VEHICLES Fuel Pump Module 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 410 Fuel Pump Module FUEL SYSTEM: GASOLINE VEHICLES 3052 Figure 23-15 Fuel System (Side-Fill) – Exploded View Page 23-20 2015 Carryall 550 Maintenance and Service Manual...

  • Page 411: Fuel Tank

    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 412: Fuel Tank Disposal

    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 413: Fuel Filter

    FUEL SYSTEM: GASOLINE VEHICLES Fuel Filter WARNING • Always install ground wires during reassembly. Connect fuel line (3) to fuel pump module (1). See Fuel Line Installation on page 23-17. 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 414: Fuel Filter Installation

    Fueling Instructions – Gasoline Vehicle FUEL SYSTEM: GASOLINE VEHICLES 4.2. Pull flex hoses (12 and 13) straight out of filter inlet and outlet. Remove filter (14) from module (1) and dispose of properly. 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.
  • Page 415 FUEL SYSTEM: GASOLINE VEHICLES Fueling Instructions – Gasoline Vehicle 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 417: Section 24 - Exhaust System: Gasoline Vehicles

    SECTION 24 – EXHAUST SYSTEM: GASOLINE VEHICLES DANGER • 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 Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4.
  • Page 418 Muffler EXHAUST SYSTEM: GASOLINE VEHICLES 3112 Figure 24-1 Exhaust System Page 24-2 2015 Carryall 550 Maintenance and Service Manual...

  • Page 419: Section 25 - Clutches: Gasoline Vehicles

    SECTION 25 – CLUTCHES: GASOLINE VEHICLES DANGER • 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 420: Troubleshooting

    Troubleshooting CLUTCHES: GASOLINE VEHICLES Inspect the driven clutch for dirt and dust buildup on its component parts. Clean the driven clutch with water to remove any dust or dirt, then drive the vehicle and check for proper operation. If cleaning the driven clutch does not solve the problem, disassemble and thoroughly clean all parts of the drive clutch.

  • Page 421: Drive Belt

    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 422: Drive Clutch

    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 423: Drive Clutch Removal

    CLUTCHES: GASOLINE VEHICLES Drive Clutch CAUTION • Be very careful when handling the clutches. A clutch that has been dropped will not be properly balanced. If either clutch is dropped, assume that it is damaged and replace it. DRIVE CLUTCH REMOVAL Remove the drive belt as instructed.

  • Page 424: Drive Clutch Cleaning And Inspection

    Drive Clutch CLUTCHES: GASOLINE VEHICLES Remove the drive clutch retaining bolt (1) and mounting washers (2 and 3) (Figure 25-3, Page 25-4). See also Figure 25-4, Page 25-5. See following NOTE. NOTE: The drive clutch mounting bolt has right-hand threads. The crankshaft has right-hand threads at the clutch mounting hole.
  • Page 425 CLUTCHES: GASOLINE VEHICLES Drive Clutch 2.2. Thread the center bolt of the Drive Clutch Hub Puller (1) (CC P/N 1014497) into clutch until the stop nut touches the clutch, then back the bolt out one-half turn (Figure 25-7, Page 25-7). 2.3.
  • Page 426 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 25-8).

  • Page 427: Inspection Of Drive Clutch Parts

    CLUTCHES: GASOLINE VEHICLES Drive Clutch 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 428 Drive Clutch CLUTCHES: GASOLINE VEHICLES CAUTION • To avoid damaging the spiral back-up rings, be very careful when installing the moveable sheave. 4.1. Rotate the moveable sheave clockwise while installing it onto the shaft. 4.2. Install the retaining ring (6) (Figure 25-3, Page 25-4). Install the primary weights (3) on the mounting pins (4) (Figure 25-10, Page 25-8).

  • Page 429: Drive Clutch Installation

    CLUTCHES: GASOLINE VEHICLES Drive Clutch 3054 Figure 25-13 Correct Orientation of Drive Button Take-up Springs DRIVE CLUTCH INSTALLATION Place the drive clutch assembly on the crankshaft taper. Position the mounting washers (2 and 3) on the bolt (1) and start the bolt into the crankshaft (Figure 25-3, Page 25-4). See following NOTE. NOTE: The drive clutch retaining bolt has right-hand threads.

  • Page 430: Driven Clutch

    Driven Clutch CLUTCHES: GASOLINE VEHICLES 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 431: Driven Clutch Removal

    CLUTCHES: GASOLINE VEHICLES Driven Clutch DRIVEN CLUTCH REMOVAL Remove the drive belt as instructed. See Drive Belt Removal on page 25-3. Remove the bolt (1) and mounting washer (2) from the transaxle input shaft (Figure 25-14, Page 25-12). Grasp the driven clutch assembly and slide it off the shaft. Leave the key (12) in the keyway.

  • Page 432: Driven Clutch Inspection

    Driven Clutch CLUTCHES: GASOLINE VEHICLES 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 25-12). 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 433 CLUTCHES: GASOLINE VEHICLES Driven Clutch 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 25-15). The match marks made before disassembly should now align. 5.1.3.

  • Page 434: Driven Clutch Installation

    Driven Clutch CLUTCHES: GASOLINE VEHICLES 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 25-15). 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 435: Section 26 - Transaxle (Ed65): Gasoline Vehicles

    SECTION 26 – TRANSAXLE (ED65): GASOLINE VEHICLES DANGER • 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 436: Governor System

    General Information TRANSAXLE (ED65): GASOLINE VEHICLES When the switch is in the MAINTENANCE position, it will allow the technician to run the engine in the NEUTRAL position to perform certain maintenance and/or repair functions. With the switch in this position, the vehicle will not operate if the Forward/Reverse handle is placed in either the FORWARD or REVERSE position.

  • Page 437: Tools Required For This Section

    TRANSAXLE (ED65): GASOLINE VEHICLES General Information Oil Change – Transaxle When draining transaxle oil, remove both plugs to allow the oil to drain faster. Clean and reinstall the drain plug and gasket before filling the transaxle with new lubricant. Tighten drain plug to 17 ft·lb (23 N·m).

  • Page 438: Rear Hubs

    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 Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4.
  • Page 439 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 440: Axle Tubes, Axle Shafts And Wheel Bearings

    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 441: Axle Tube And Axle Shaft Installation

    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 442: Axle Shaft Oil Seal Removal

    Axle Tubes, Axle Shafts and Wheel Bearings TRANSAXLE (ED65): GASOLINE VEHICLES AXLE SHAFT OIL SEAL REMOVAL The rear axle tubes (2) must be unbolted from the transaxle to replace oil seals (7) (Figure 26-5, Page 26-6). Clean debris from drain plug and area around it at the bottom of the transaxle. Drain oil. Install plug after draining. Remove axle tube (2) from gearcase (4) (Figure 26-5, Page 26-6).

  • Page 443: Transaxle Removal

    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 Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4.
  • Page 444 Transaxle Removal TRANSAXLE (ED65): GASOLINE VEHICLES Figure 26-8 Disconnect Rear Shackles Figure 26-9 Disconnect Front of Leaf Spring 14. 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. 15.
  • Page 445 TRANSAXLE (ED65): GASOLINE VEHICLES Transaxle Removal 21. 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 446: Transaxle Installation

    Transaxle Installation TRANSAXLE (ED65): GASOLINE VEHICLES 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 26-11). Then, tighten fasteners in the following order: 1.1.

  • Page 447: Shifter Cable Installation

    TRANSAXLE (ED65): GASOLINE VEHICLES Shifter Cable Loosen jam nuts (1) securing shifter cable (2) to FNR/accelerator cable bracket (3) (Figure 26-14, Page 26-13). Then, remove bowtie clip (3) to disconnect shifter cable end (4) from transaxle shift lever (5). Cut wire ties securing shifter cable to chassis. Make note of cable routing, then remove shifter cable from vehicle.
  • Page 449 INDEX testing ............18-16 testing under load........18-18, 18-36 AC power and circuit voltage test ............. 18-17 testing (QuiQ charger) ........15-11 bearing, axle accelerator see transaxle, type g, axle bearing ..... 17-4 cable bearing, motor installation ............23-11 see motor, bearing..........16-9 removal ............23-11 bed, tilt pedal (electric)
  • Page 450 INDEX favorites............11-27 cowl general info............11-2 installation handheld programmer ........11-2 gas ..............4-6 handset cord ............11-31 removal handset cord adaptor........11-31 gas ..............4-6 HHP settings............11-28 introductory display ........... 11-3 M1/M2 Fast Accel ..........11-6 M1/M2 Pedal Up ..........11-7 dash panel M1/M2 Speed ...........
  • Page 451 INDEX gasoline vehicle ..........18-13 fuel pump module ..........23-18 testing circuits ..........12-14 installation ............23-18 engine ..............22-1 removal ............23-18 adjustments and settings ........22-2 fuel pump testing ..........18-37 breather............22-6 fuel tank ............. 23-21 installation ............22-9 disposal ............
  • Page 452 INDEX drive clutch parts..........25-9 driven clutch ........... 25-14 magnet, motor speed sensor front wheel free play .......... 7-20 see motor, speed sensor magnet......16-9 motor maintenance/operate switch armature ground test ........16-7 testing ............ 18-27, 19-9 armature inspection........16-7 MAP sensor bearing............
  • Page 453 INDEX removal ............7-19 single point watering system (SPWS)....14-11 oil level sensor solenoid installation ............22-12 installation ........13-8, 20-16, 21-3 removal ............22-12 removal ......... 13-8, 20-16, 21-3 testing ............18-36 testing ......... 12-25, 18-26, 19-8 oil seal solenoid activating coil installation ............
  • Page 454 INDEX disassembly............7-4 wire harness diodes......... 12-21 installation ............7-5 test procedures, index of removal .............. 7-4 key-start gasoline vehicle........19-6 steering wheel pedal-start gasoline vehicle......18-14 installation ............7-2 test procedures, key-start gasoline vehicle removal .............. 7-1 18-pin connector ..........19-6 suspension, front charging diode ..........
  • Page 455 INDEX armature ground test (starter/genera- installation ............20-12 tor) ..............20-7 removal ............20-12 spark plug............22-6 testing ............18-31 throttle body ..........23-1, 23-3 installation ............23-4 removal ............23-3 tie rod and drag link installation ............7-13 walk away braking ..........12-2 removal ............
  • Page 456 NOTES...
  • Page 457 5. If you are reviewing a Kit Instruction, were all indicated parts included in your kit? Yes / No Your Comments and Suggestions: Please send a copy of this page to: Fax: (706) 228-2662 or Thank You! E-mail: Tech_Pubs@clubcar.com Club Car’s Technical Publications Department 2015 Carryall 550 Maintenance and Service Manual...
  • Page 458 NOTES...

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