Club Car Carryall 550 2015 Maintenance And Service Manual 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 ..................................................................... 20-1
Brush Inspection and Replacement........................................................................................................... 20-2
Brush Spring Inspection and Replacement ................................................................................................ 20-2
Starter/Generator Assembly ..................................................................................................................... 20-3
Disassembly of the Starter/Generator to Service the Armature/Commutator ................................................ 20-4
Bearing Cleaning and Inspection .............................................................................................................. 20-4
Bearing Removal ..................................................................................................................................... 20-5
Field Coil Removal................................................................................................................................... 20-5
Visual Inspection of Armature ................................................................................................................... 20-6
Commutator Cleaning and Inspection ....................................................................................................... 20-6
Armature Ground Test.............................................................................................................................. 20-7
Visual Inspection of Field Coils ................................................................................................................. 20-8
Starter/Generator Rework ........................................................................................................................ 20-8
Starter/Generator Assembly ..................................................................................................................... 20-8
Starter/Generator Installation.................................................................................................................... 20-9
Belt Tension Adjustment.......................................................................................................................... 20-11
Voltage Regulator .......................................................................................................................................20-12
Voltage Regulator Removal .....................................................................................................................20-12
Voltage Regulator Installation ..................................................................................................................20-12
Engine Control Unit (ECU) ..........................................................................................................................20-13
Engine Control Unit Removal...................................................................................................................20-13
Engine Control Unit Installation................................................................................................................20-13
Key Switch .................................................................................................................................................20-13
Key Switch Removal ...............................................................................................................................20-14
Key Switch Installation ............................................................................................................................20-14
Maintenance/Operate Switch.......................................................................................................................20-15
Maintenance/Operate Switch Removal.....................................................................................................20-15
Maintenance/Operate Switch Installation ..................................................................................................20-15
Neutral Lockout Limit Switch .......................................................................................................................20-15
Neutral Lockout Limit Switch Removal .....................................................................................................20-15
Neutral Lockout Limit Switch Installation...................................................................................................20-16
Solenoid.....................................................................................................................................................20-16
Solenoid Removal ..................................................................................................................................20-16
Solenoid Installation................................................................................................................................20-16
Fuse ..........................................................................................................................................................20-17
Fuse Removal ........................................................................................................................................20-17
Fuse Installation .....................................................................................................................................20-17
Kill Limit Switch ..........................................................................................................................................20-18
Kill Limit Switch Removal ........................................................................................................................20-18
Kill Limit Switch Installation .....................................................................................................................20-18
Reverse Warning Buzzer.............................................................................................................................20-19
Reverse Warning Buzzer Removal ..........................................................................................................20-19
Reverse Warning Buzzer Installation........................................................................................................20-19
Reverse Buzzer Limit Switch .......................................................................................................................20-21
Reverse Buzzer Limit Switch Removal .....................................................................................................20-21
Reverse Buzzer Limit Switch Installation ..................................................................................................20-21
Low Oil Warning Light .................................................................................................................................20-23
Low Oil Warning Light Removal ...............................................................................................................20-23
Low Oil Warning Light Installation ............................................................................................................20-23
Fuel Gauge/Hour Meter ..............................................................................................................................20-23
General Information ................................................................................................................................20-23
Fuel Gauge/Hour Meter Removal ............................................................................................................20-24
Page x 2015 Carryall 550 Maintenance and Service Manual