Club Car Carryall 550 2015 Maintenance And Service Manual 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................................................................................................................................... 15-3
Onboard Charger Operation ......................................................................................................................... 15-3
Charger Displays ..................................................................................................................................... 15-5
AC Power Connection.............................................................................................................................. 15-7
Charging Batteries ................................................................................................................................... 15-7
Maintenance ............................................................................................................................................... 15-8
Troubleshooting........................................................................................................................................... 15-9
Test Procedures .........................................................................................................................................15-10
Charger Repairs ......................................................................................................................................... 15-11
Onboard Charger Removal And Installation.................................................................................................. 15-11
Onboard Charger Removal ..................................................................................................................... 15-11
Onboard Charger Installation...................................................................................................................15-12
SECTION 16 - MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES ............................................................... 16-1
General Information ..................................................................................................................................... 16-1
External Motor Testing ................................................................................................................................. 16-1
Motor Removal ............................................................................................................................................ 16-2
Motor Disassembly ...................................................................................................................................... 16-4
Motor Component Testing and Inspection...................................................................................................... 16-7
Armature Inspection and Testing............................................................................................................... 16-7
Motor Frame and Field Windings Inspection .............................................................................................. 16-8
Motor Brush, Spring, and Terminal Insulator Inspection .............................................................................. 16-8
Reconditioning the Motor ............................................................................................................................ 16-11
Motor Specifications ............................................................................................................................... 16-11
Motor Assembly.......................................................................................................................................... 16-11
Motor Installation ........................................................................................................................................16-13
SECTION 17 - TRANSAXLE: ELECTRIC VEHICLES ....................................................................................... 17-1
Lubrication .................................................................................................................................................. 17-1
Axle Bearing and Shaft ................................................................................................................................ 17-1
Axle Shaft ............................................................................................................................................... 17-1
Axle Bearing............................................................................................................................................ 17-4
Transaxle .................................................................................................................................................... 17-5
Transaxle Removal .................................................................................................................................. 17-5
Transaxle Disassembly, Inspection, and Assembly......................................................................................... 17-7
Transaxle Disassembly and Inspection...................................................................................................... 17-7
Transaxle Assembly................................................................................................................................. 17-9
Transaxle Installation .................................................................................................................................. 17-11
SECTION 18 - TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE ................ 18-1
General Information ..................................................................................................................................... 18-1
Accessories............................................................................................................................................. 18-1
Low Oil Warning Light .............................................................................................................................. 18-1
Ground Locations .................................................................................................................................... 18-2
Features of the Electronic Fuel Injection (EFI) System ............................................................................... 18-2
Troubleshooting Guide ................................................................................................................................. 18-2
ECU Error Codes (Displayed by the Low Oil Warning Light) ....................................................................... 18-2
Gasoline Powertrain ................................................................................................................................ 18-3
Wiring Diagrams .......................................................................................................................................... 18-8
Electrical System ........................................................................................................................................18-13
Test Procedures .........................................................................................................................................18-14
2015 Carryall 550 Maintenance and Service Manual Page ix