Page 1 2018 Carryall 300 Maintenance and Service Manual Gasoline Vehicle with Subaru EX40 Engine Electric Vehicle with ERIC Charging System Manual Number 105344220 Edition Code B...
Page 3 To find your local authorized Club Car dealer, visit www.clubcardealer.com, call 1-800-ClubCar (258–2227), or scan this Quick Response (QR) code to be taken to the Club Car dealer locator. Refer to Figure 1. Download a QR code reader such as RedLaser or Barcode Scanner to your cell phone or tablet.
Page 4 Deionizer Filter Replacement Cartridge (non-SPWS) CC PN AM10975 NOTE: This manual represents the most current information at the time of publication. Club Car is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures.
Page 5: Table Of Contents
CONTENTS SECTION 1 — Safety............................1-1 Safety Details ..............................1-1 Personal Safety ............................1-1 Machine Safety............................1-1 Information..............................1-1 General Warnings............................1-1 Disabling the Vehicle..........................1-3 Disconnecting the Battery- Gasoline Vehicles ....................1-3 Connecting the Battery- Gasoline Vehicles ....................1-3 Disconnecting the Batteries –...
Page 6 Rear Fender and Tailskirt Removal ......................4-17 Rear Fender and Tailskirt Installation ......................4-18 Floor Mat ..............................4-18 Floor Mat Removal ..........................4-18 Floor Mat Installation..........................4-18 SECTION 5 — Accelerator and Brake Pedal Group ..................... 5-1 Brake Pedal and Park Brake (Gas and Electric Vehicles).................. 5-1 Brake Pedal Removal (Gas and Electric Vehicles) ..................
Page 7 Kingpin and Steering Spindle Installation – Maintenance-Free Ball Joints............ 7-20 Delta A-Plate Removal..........................7-20 Delta A-Plate Installation .......................... 7-20 Shock Absorber Removal......................... 7-20 Shock Absorber Installation ........................7-20 Front Wheel Bearings and Hubs ........................7-21 Front Wheel Free Play Inspection ......................7-21 Front Hub Removal..........................
Page 8 Vehicle ID ..............................11-9 Monitor Menu ...............................11-9 Batt Voltage............................11-10 V min I ..............................11-10 Signed Battery Current..........................11-10 BDI Percent............................11-10 Speed ..............................11-10 Throttle ..............................11-10 Temperature............................11-10 Arm Current ............................11-10 Field Current ............................11-10 Armature PWM............................11-10 Field PWM .............................
Page 9 Programming ............................. 11-22 Cloning ..............................11-23 Favorites..............................11-23 HHP Settings ............................. 11-23 Plot & Log ..............................11-25 Plot................................ 11-25 Log ................................ 11-25 CDT Troubleshooting ..........................11-26 Connection Tests ............................11-27 SECTION 12 — Excel System Troubleshooting: with ERIC Charging ..............12-1 General Information .............................
Page 10 DC/DC Converter ............................13-10 DC/DC Converter Removal ........................13-10 DC/DC Converter Installation........................13-11 Fuse Block ..............................13-11 Fuse Block Removal ..........................13-11 Fuse Block Installation ..........................13-11 Headlight Switch............................13-12 Headlight Switch Removal........................13-12 Headlight Switch Installation........................13-12 Headlights..............................13-12 Headlight Bezel Removal ........................13-12 Headlight Bezel Installation ........................13-12 Headlight Bulb Removal (Halogen) ......................13-13 Headlight Bulb Installation (Halogen) .......................13-13 Headlight Bulb Removal (LED) ........................13-13...
Page 11 USB Service Port Cleaning and Care .......................15-13 Charger Troubleshooting..........................15-14 Numbering Vehicles and Chargers......................15-14 USB Service Port............................15-14 Incoming AC Service ..........................15-14 Terminal Block Cover ..........................15-15 Resetting Power – External Charger ......................15-15 Resetting Power – Onboard Charger .......................15-15 External Charger Troubleshooting Indicators ....................15-16 Onboard Charger Fault Codes.........................15-18 Test Procedures ............................15-20 External Charger Repairs ..........................15-23...
Page 12 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......................
Page 13 Oil Level Sensor ............................20-28 Oil Level Sensor Removal ........................20-28 Oil Level Sensor Installation ........................20-28 Voltage Limiter ............................20-28 Voltage Limiter Removal .........................20-29 Voltage Limiter Installation........................20-29 Headlight Switch............................20-30 Headlight Switch Removal........................20-30 Headlight Switch installation ........................20-30 Headlights..............................20-30 Headlight Bezel Removal ........................20-30 Headlight Bezel Installation ........................20-30 Headlight Bulb Removal (Halogen) ......................20-31 Headlight Bulb Installation (Halogen) .......................20-31 Headlight Bulb Removal (LED) ........................20-31...
Page 14 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 SECTION 23 — Fuel System: Gasoline Vehicles ....................23-1 General Information ............................. 23-1 EFI System Features/Specifications......................
Page 15 Drive Clutch ..............................25-4 Drive Clutch Removal ..........................25-5 Drive Clutch Cleaning and Inspection......................25-6 Drive Clutch Disassembly......................... 25-7 Inspection of Drive Clutch Parts........................ 25-9 Drive Clutch Assembly ..........................25-10 Drive Clutch Installation .......................... 25-11 Driven Clutch .............................25-12 Driven Clutch Removal ...........................25-13 Driven Clutch Disassembly........................25-13 Driven Clutch Inspection .........................25-14 Driven Clutch Assembly ..........................25-14...
Page 17: Section 1 - Safety
SAFETY DETAILS Safety To ensure the safety of those servicing Club Car vehicles, and to protect the vehicles from possible damage resulting from improper service or maintenance, the procedures in this manual must be followed. It is important to note that throughout this manual there are statements labeled DANGER, WARNING, or CAUTION.
Page 18 • The vehicle will not provide protection from lightning, flying objects, or other storm-related hazards. If caught in a storm while driving a Club Car vehicle, exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location.
Page 19: Disabling The Vehicle
SAFETY General Warnings WARNING • To avoid unintentionally starting an electric vehicle, disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4. Gasoline vehicles only: • To avoid unintentionally starting a gasoline vehicle, disconnect the battery and spark plug wire. See Disconnecting the Battery- Gasoline Vehicles on page 1-3.
Page 20: Disconnecting The Batteries - Electric Vehicles
Please contact your nearest Club Car dealer or distributor for information on how to properly recycle your batteries. Page 1-4...
Page 21: International Safety Symbols On Batteries
SAFETY General Warnings 1403 Figure 1-3 Dispose of Lead-acid Batteries Properly 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.
Page 22 General Warnings SAFETY Pagination Page Page 1-6 2018 Carryall 300 Maintenance and Service Manual...
Page 23 SECTION 2 — VEHICLE SPECIFICATIONS VEHICLE SPECIFICATIONS Vehicle Specifications VEHICLE SPECIFICATIONS – ELECTRIC VEHICLES SPECIFICATIONS CARRYALL 300 POWER SOURCE ELECTRIC Drive motor: Direct drive, 48 volts DC, shunt wound, 3.3 hp ● Transaxle: Double reduction helical gear with 12.3:1 direct drive axle ●...
Page 24: Section 2 - Vehicle Specifications
Vehicle Specifications VEHICLE SPECIFICATIONS SPECIFICATIONS CARRYALL 300 POWER SOURCE ELECTRIC Intersecting aisle clearance 87 in (221 cm) Floorboard height 12.5 in (31.7 cm) Load bed height 29.5 in (74.93 cm) 36.2 x 47.5 x 10.5 in Load bed size: Box bed inside dimensions (91.9 x 120.6 x 26.6 cm) 36.5 x 48.8 in Load bed size: Flat bed inside dimensions...
Page 25: E.r.i.c. Battery Charger Specifications
VEHICLE SPECIFICATIONS Vehicle Specifications E.R.I.C. BATTERY CHARGER SPECIFICATIONS E.R.I.C. BATTERY CHARGER SPECIFICATIONS MODEL NUMBER IC650-048-CC AC INPUT AC voltage 100 to 240 VAC Frequency 50 / 60 Hz POWER CONSUMPTION Maximum AC input current (amps) DC OUTPUT Rated DC voltage (VDC) Maximum DC voltage (VDC) Maximum DC output current (amps) 13.5...
Page 26: Vehicle Specifications - Gasoline Vehicles
Vehicle Specifications VEHICLE SPECIFICATIONS VEHICLE SPECIFICATIONS – GASOLINE VEHICLES NOTE: Engine horsepower and torque specifications are provided by the engine manufacturer. Actual horsepower and torque in use may differ and are dependent on environmental conditions as well as maintenance condition of the engine. SPECIFICATIONS CARRYALL 300 POWER SOURCE...
Page 27 VEHICLE SPECIFICATIONS Vehicle Specifications SPECIFICATIONS CARRYALL 300 POWER SOURCE GASOLINE Rear wheel tread 39.5 in (100.3 cm) Weight: Standard gasoline vehicle (dry fuel tank) 789 lb (357.8 kg) Curb weight 817 lb (370. 5 kg) Maximum forward speed 15 to 17 mph (24 to 27 km/h) Curb clearance circle (diameter) 230.5 in (585.4 cm) Turning radius (per SAE J 695)
Page 28 Vehicle Specifications VEHICLE SPECIFICATIONS Pagination Page Page 2-6 2018 Carryall 300 Maintenance and Service Manual...
Page 29: Section 3 - General Information
SECTION 3 — GENERAL INFORMATION DANGER General Information • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. This manual features Carryall 300 vehicles. The electric Carryall 300 vehicle is equipped with the ERIC (Efficient, Reliable, Intelligent, Connected) battery charging system.
Page 30: Storage - Electric Vehicles
Storage – Electric Vehicles GENERAL INFORMATION 2843 Figure 3-1 Serial Number Decal STORAGE – ELECTRIC VEHICLES See General Warnings on page 1-1. WARNING • Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse handle or switch in the NEUTRAL position during storage.
Page 31: Returning The Stored Electric Vehicle To Service
GENERAL INFORMATION Storage – Electric Vehicles Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse switch in the NEUTRAL position during storage. If so installed, turn off all accessories, including GPS units, fans, etc. Place the Run/Tow switch in the TOW position.
Page 32: Storage - Gasoline Vehicles
Storage – Gasoline Vehicles GENERAL INFORMATION Perform the Pre-Operation and Daily Safety Checklist on page 10-1 and the Performance Inspection on page 10-2. STORAGE – GASOLINE VEHICLES See General Warnings on page 1-1. DANGER • Do not attempt to drain fuel when the engine is hot or while it is running. •...
Page 33: Returning The Stored Gasoline Vehicle To Service
GENERAL INFORMATION Storage – Gasoline Vehicles Disconnect battery and spark plug wire. See Disconnecting the Battery- Gasoline Vehicles on page 1-3. Batteries should be clean and free of corrosion. Wash tops and terminals of batteries with a solution of baking soda and water: use 1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water.
Page 34 Storage – Gasoline Vehicles GENERAL INFORMATION Pagination Page Page 3-6 2018 Carryall 300 Maintenance and Service Manual...
Page 35: Section 4 - Body And Trim
SECTION 4 — BODY AND TRIM DANGER Body and Trim • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. CLEANING THE VEHICLE See General Warnings on page 1-1. CAUTION • Do not use detergents or cleaning solvents that contain ammonia, aromatic solvents, or alkali materials on body panels or seats.
Page 36: Front Body Repair
Front Body Repair BODY AND TRIM CAUTION • To prevent damage to the vehicle when removing difficult stains or heavy soiling, remove the seat from the vehicle first. FRONT BODY REPAIR See General Warnings on page 1-1. LIGHT SCRATCHES Clean entire area to be repaired with clean, clear water. Using 1200 grit sandpaper, water-sand entire area of scratch until original scratch is no longer visible, either with finishing sander or wet sanding block.
Page 37: Front Body
BODY AND TRIM Front Body COLOR CC P/N Dark Gray 105117705 Black 105117706 105117707 Bright Blue 105117708 TITN Silver 105117709 Light Gray 105117710 FRONT BODY See General Warnings on page 1-1. HEAVY DUTY BUMPER REMOVAL Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Disconnecting the Battery- Gasoline Vehicles on page 1-3.
Page 38 Front Body BODY AND TRIM 2986 Figure 4-1 Heavy Duty Bumper Page 4-4 2018 Carryall 300 Maintenance and Service Manual...
Page 39: Cowl Removal
BODY AND TRIM Front Body COWL REMOVAL Park vehicle and chock tires. Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Disconnecting the Battery- Gasoline Vehicles on page 1-3. The cowl is secured by tabs located behind the front fenders (2), and under the lip of the dash (1) (Figure 4-2, Page 4-6).
Page 40: Grille Removal
Front Body BODY AND TRIM 2846 Figure 4-2 Front Cowl GRILLE REMOVAL Park vehicle and chock the tires. Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Disconnecting the Battery- Gasoline Vehicles on page 1-3. Remove HD bumper (if equipped).
Page 41: 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 42 Front Body BODY AND TRIM 2844 Figure 4-3 Front Grille, Bumper, and Side Fenders Page 4-8 2018 Carryall 300 Maintenance and Service Manual...
Page 43: Front Bumper And Side Fender Removal
BODY AND TRIM Front Body FRONT BUMPER AND SIDE FENDER REMOVAL Park the vehicle, chock tires. Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Disconnecting the Battery- Gasoline Vehicles on page 1-3. Remove HD bumper, (if equipped). See Heavy Duty Bumper Removal on page 4-3. Remove the front cowl.
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 on page 1-3. Remove front cowl. See Cowl Removal, Section 4, Page 4-5. 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 on page 1-3. Remove cowl. See Cowl Removal on page 4-5. Remove steering wheel. See Steering Wheel Removal, Section 7, Page 7-1. Disconnect instrument panel wiring.
Page 46 Front Body BODY AND TRIM 2863 Figure 4-5 Dash Assembly Page 4-12 2018 Carryall 300 Maintenance and Service Manual...
Page 47: Tilt Bed
BODY AND TRIM Tilt Bed TILT BED See General Warnings on page 1-1. 2981 Figure 4-6 Tilt Bed Mounting 2018 Carryall 300 Maintenance and Service Manual Page 4-13...
Page 48: Tilt Bed Removal
Tilt Bed BODY AND TRIM TILT BED REMOVAL NOTE: This procedure requires two people. WARNING • Remove all cargo before raising the bed or servicing the vehicle. If the vehicle is equipped with a prop rod, ensure that it is securely engaged while bed is raised. Do not close bed until all persons are clear of cargo bed area.
Page 49: Bed Latch Assembly Removal
BODY AND TRIM Tilt Bed Use a small hammer to lightly tap bolts through hinge assembly (Figure 4-6, Page 4-13). Adjust the striker plates (12), if necessary. Install a locknut (7) on each bolt (6) and tighten to 15 ft·lb (21 N·m). Connect the batteries.
Page 50 Tilt Bed BODY AND TRIM 2982 Figure 4-7 Bed Latch Assembly Page 4-16 2018 Carryall 300 Maintenance and Service Manual...
Page 51: Rear Fenders And Tailskirt
BODY AND TRIM Rear Fenders and Tailskirt REAR FENDERS AND TAILSKIRT See General Warnings on page 1-1. 2984 Figure 4-8 Rear Fender and Tailskirt REAR FENDER AND TAILSKIRT REMOVAL Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL and set the park brake.
Page 52: Rear Fender And Tailskirt Installation
Floor Mat BODY AND TRIM 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 on page 1-3. Remove the tilt bed.
Page 53: Section 5 - Accelerator And Brake Pedal Group
SECTION 5 — ACCELERATOR AND BRAKE PEDAL GROUP DANGER Accelerator and Brake Pedal Group • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. BRAKE PEDAL AND PARK BRAKE (GAS AND ELECTRIC VEHICLES) See General Warnings on page 1-1. BRAKE PEDAL REMOVAL (GAS AND ELECTRIC VEHICLES) Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s).
Page 54 Brake Pedal and Park Brake (Gas and Electric Vehicles) ACCELERATOR AND BRAKE PEDAL GROUP 3206 Figure 5-1 Brake and Park Brake Pedal Assembly and Mounting Page 5-2 2018 Carryall 300 Maintenance and Service Manual...
Page 55 ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake (Gas and Electric Vehicles) 2999 Figure 5-2 Brake Pedal Weldment Through Floor Position and attach brake pedal assembly, mounting blocks (3 and 7), and washers (9) to vehicle frame as shown. Tighten the bolts (10) and nuts to 95 in·lb (10.7 N·m).
Page 56: 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 on page 1-3.
Page 57: 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 58 Accelerator Pedal – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP Remove the accelerator pedal (1) from the vehicle. Inspect all parts for wear and damage. Replace as necessary. 3000 Figure 5-6 Accelerator Pedal – Gasoline Vehicles Page 5-6 2018 Carryall 300 Maintenance and Service Manual...
Page 59: Accelerator Pedal Installation - Gasoline Vehicles
ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles ACCELERATOR PEDAL INSTALLATION – GASOLINE VEHICLES If the accelerator pivot rod supports were replaced, position the supports (21) on the vehicle frame and install the four bolts (22), flat washers (19), and lock nuts (18). Finger-tighten nuts at this time (Figure 5-6, Page 5-6). Insert the lower end of the accelerator pedal (1) through the floorboard and install the accelerator pivot rod (6) through the uppermost hole in the pedal.
Page 60: Accelerator Pedal - Electric Vehicles
Accelerator Pedal – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP ACCELERATOR PEDAL – ELECTRIC VEHICLES See General Warnings on page 1-1. ACCELERATOR PEDAL REMOVAL – ELECTRIC VEHICLES Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4.
Page 61 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles 2642 Figure 5-8 Accelerator Pedal – Electric Vehicle with MCOR 2018 Carryall 300 Maintenance and Service Manual Page 5-9...
Page 62: 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 63 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 64 Pedal Group Adjustment – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP 3.2. Tighten the nut (2) on the equalizer rod (1) so that the brake pedal free play is 1/4 to 1/2 inch (6 mm to 13 mm) (Figure 5-3, Page 5-3). 3.3.
Page 65 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 66 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 67: 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 68 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 69 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles 3.1. Measure perpendicularly from the floorboard to the back of the brake pedal, then press the brake pedal and measure the distance that the pedal moves before all of the slack is taken out of the brake cables (Figure 5-21, Page 5-16).
Page 70 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 71 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 6-9. Connect the battery cables. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. 2018 Carryall 300 Maintenance and Service Manual Page 5-19...
Page 72 Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP Pagination Page Page 5-20 2018 Carryall 300 Maintenance and Service Manual...
Page 73: Section 6 - Wheel Brake Assemblies
SECTION 6 — WHEEL BRAKE ASSEMBLIES DANGER Wheel Brake Assemblies • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. Asbestos Dust Warning • Some aftermarket brake shoes contain asbestos dust. Asbestos dust is created when these brake mechanisms are handled.
Page 74 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES 1400-18100-10209 1400-18100-10220 Figure 6-1 Loosen Brake Cables Figure 6-2 Shoe Retainer Pins 5.2. Insert a 1/2 inch x 5/8 inch (1.27 x 1.58 cm) cold chisel (1) under the head of each pin (2) and shear them off as illustrated (Figure 6-2, Page 6-2).
Page 75: Brake Shoe Removal
WHEEL BRAKE ASSEMBLIES Brake Shoe Removal 1400-18100-10222 1400-17700-10225 Figure 6-3 Remove Shoe Retainer Clip Figure 6-4 Remove Brake Shoes 1. Slide Figure 6-5 Remove Adjuster Wheel Figure 6-6 Lubricate Slide and Slide Plate 2018 Carryall 300 Maintenance and Service Manual Page 6-3...
Page 76 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES A. Electric Vehicle B. Gasoline Vehicle 2902 Figure 6-7 Self-adjusting Wheel Brake Assembly Page 6-4 2018 Carryall 300 Maintenance and Service Manual...
Page 77: Brake Assembly Cleaning
WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning BRAKE ASSEMBLY CLEANING See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. Carefully clean the brake backing plate and all of its mechanical components. Remove the rubber boot from backing plate and wipe with a clean damp cloth. For vehicles equipped without a slide plate (2), lubricate the backing plate, where the slide operates, with dry moly lubricant (P/N 1012151).
Page 78 Brake Assembly Cleaning WHEEL BRAKE ASSEMBLIES Figure 6-10 Apply Grease To Brake Adjuster Figure 6-11 Install Adjuster Wheel, Trailing Shoe Page 6-6 2018 Carryall 300 Maintenance and Service Manual...
Page 79: Brake Shoe Installation
WHEEL BRAKE ASSEMBLIES Brake Shoe Installation BRAKE SHOE INSTALLATION See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. Turn the adjusting wheel screw so that the shoe slot is vertical, then position the trailing shoe in the slots in the shoe mounting block and adjuster assembly (Figure 6-11, Page 6-6).
Page 80 Brake Shoe Installation WHEEL BRAKE ASSEMBLIES Figure 6-14 Install Leading Shoe Figure 6-15 Check Shoe Positions Place a flatblade screwdriver under the adjusting arm (1) and raise the arm off of the adjusting wheel (2). While holding the arm (1) up, turn the wheel (2) upward until it stops (Figure 6-16, Page 6-8). Arm must engage teeth of the wheel.
Page 81: Brake Adjustment
WHEEL BRAKE ASSEMBLIES Brake Adjustment BRAKE ADJUSTMENT See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. When cleaning or repair on both wheels is complete, and with the brake cable still loose, lower the vehicle to the floor.
Page 82: Brake Assembly Removal And Installation
Brake Assembly Removal and Installation WHEEL BRAKE ASSEMBLIES BRAKE ASSEMBLY REMOVAL AND INSTALLATION See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. BRAKE ASSEMBLY REMOVAL Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s). See Disconnecting the Batteries –...
Page 83: Brake Cable Removal And Installation
WHEEL BRAKE ASSEMBLIES Brake Cable Removal and Installation BRAKE CABLE REMOVAL AND INSTALLATION See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. BRAKE CABLE REMOVAL Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s). See Disconnecting the Batteries –...
Page 84 Brake Cable Removal and Installation WHEEL BRAKE ASSEMBLIES Pagination Page Page 6-12 2018 Carryall 300 Maintenance and Service Manual...
Page 85: Section 7 - Steering And Front Suspension
SECTION 7 — STEERING AND FRONT SUSPENSION DANGER Steering and Front Suspension • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION Steering is controlled through a rack and pinion steering assembly that is connected by a steering column to a steering wheel.
Page 86: 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 87: Steering Column
STEERING AND FRONT SUSPENSION Steering Column STEERING COLUMN See General Warnings on page 1-1. STEERING COLUMN REMOVAL Remove the steering wheel as previously instructed. Remove the front cowl. See Front Body, Section 4, Page 4-3. Remove the grille and bumper. Remove steering column sleeve.
Page 88 Steering Column STEERING AND FRONT SUSPENSION 2609 Figure 7-3 Steering Column Page 7-4 2018 Carryall 300 Maintenance and Service Manual...
Page 89: 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 90: 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 91: 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 92: 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 93 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 94: 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 95 STEERING AND FRONT SUSPENSION Rack and Pinion Apply a light coating of EP grease to the teeth of the rack (17), then slide the rack through the bushing (5) and housing (6). Install the stop washer (18) and retaining ring (19) to the end of the rack (Figure 7-10, Page 7-10). CAUTION •...
Page 96 Rack and Pinion STEERING AND FRONT SUSPENSION 1500-18400-10265 Figure 7-13 Rack and Pinion Resistance Install the internal snap ring (11) (Figure 7-10, Page 7-10). Using an appropriate size deep well socket (1) to apply pressure evenly, press in a new dust seal (2) (Figure 7-11, Page 7-11).
Page 97: Rack And Pinion Installation - Maintenance-Free Ball Joints
STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION INSTALLATION – MAINTENANCE-FREE BALL JOINTS Position the steering gear box assembly on the shock and gear support and install the bolts (30), washers (31), and nuts (32). Do not tighten the mounting bolts (Figure 7-10, Page 7-10). For ease of assembly and to prevent corrosion, apply a light coat of anti-seize and lubricating compound to the splined end of the steering column shaft.
Page 98: Tie Rod And Drag Link
Tie Rod and Drag Link STEERING AND FRONT SUSPENSION TIE ROD AND DRAG LINK See General Warnings on page 1-1. TIE ROD AND DRAG LINK REMOVAL – MAINTENANCE-FREE BALL JOINTS Using locking pliers to hold tie rod and drag link, loosen jam nuts (7 and 12) on tie rod ball joints (Figure 7-18, Page 7-18) and loosen jam nuts (27 and 29) on the drag link (Figure 7-10, Page 7-10).
Page 99: Front Suspension
STEERING AND FRONT SUSPENSION Front Suspension FRONT SUSPENSION See General Warnings on page 1-1. LUBRICATION Two grease fittings (one in each spindle housing) are provided. Lubricate these fittings at the recommended interval with the proper lubricant. See Periodic Lubrication Schedules, Section 10, Page 10-7. WHEEL ALIGNMENT Wheel alignment is limited to equalizing the camber angle of each front wheel and adjusting toe-in of the front wheels.
Page 100 Front Suspension STEERING AND FRONT SUSPENSION Tighten the hex nut (8) on the adjustment eccentric (7) to 23 ft·lb (31 N·m) (Figure 7-19, Page 7-19). See also Figure 7-15, Page 7-15. Toe-in Adjustment On a level surface, roll the vehicle forward, then stop. Make sure the front wheels are pointed straight ahead. Do not turn the steering wheel again during this procedure.
Page 101: Front Suspension Components
STEERING AND FRONT SUSPENSION Front Suspension Components FRONT SUSPENSION COMPONENTS See General Warnings on page 1-1. LEAF SPRING REMOVAL Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s). See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Disconnecting the Battery- Gasoline Vehicles on page 1-3.
Page 102 Front Suspension Components STEERING AND FRONT SUSPENSION 2849 Figure 7-18 Front Suspension – Upper Portion Page 7-18 2018 Carryall 300 Maintenance and Service Manual...
Page 103 STEERING AND FRONT SUSPENSION Front Suspension Components 32 x 4 2847 Figure 7-19 Front Suspension – Lower Portion 2018 Carryall 300 Maintenance and Service Manual Page 7-19...
Page 104: Kingpin And Steering Spindle Installation - Maintenance-Free Ball Joints
Front Suspension Components STEERING AND FRONT SUSPENSION KINGPIN AND STEERING SPINDLE INSTALLATION – MAINTENANCE-FREE BALL JOINTS Inspect all parts and replace them as necessary. Install the kingpin (26) over the leaf spring eye. Insert the bolt (25) and install the nut (14) (Figure 7-19, Page 7-19).
Page 105: Front Wheel Bearings And Hubs
STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs FRONT WHEEL BEARINGS AND HUBS See General Warnings on page 1-1. NOTE: The front wheel bearings are pressed into the spindle and are not serviceable. If excessive free-play is detected the entire hub should be replaced. FRONT WHEEL FREE PLAY INSPECTION Raise the front of the vehicle.
Page 106 Front Wheel Bearings and Hubs STEERING AND FRONT SUSPENSION Pagination Page Page 7-22 2018 Carryall 300 Maintenance and Service Manual...
Page 107: Section 8 - Wheels And Tires
• See General Warnings on page 1-1. GENERAL INFORMATION NOTE: Use only Club Car approved tires when replacing tires. Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care. • Keep tires properly inflated. See Vehicle Specifications on page 2-1.
Page 108: Tires
Tires WHEELS AND TIRES TIRES See General Warnings on page 1-1. TIRE REMOVAL NOTE: Tire must be removed or installed from the valve stem side of the rim. Remove the tire and wheel assembly from the vehicle as instructed above. See Wheel Removal on page 8-1. Remove the valve cap and valve core and allow air to escape from the tire.
Page 109: Tire Installation
WHEELS AND TIRES Tires NOTE: An air leak could be due to a punctured casing, faulty valve core, improperly seated valve stem, or improperly seated tire bead. Small holes in the casing can be plugged using a standard automotive tubeless tire repair kit available at auto supply stores.
Page 110 Tires WHEELS AND TIRES Figure 8-2 Inflate Tire Page 8-4 2018 Carryall 300 Maintenance and Service Manual...
Page 111: Section 9 - Rear Suspension
SECTION 9 — REAR SUSPENSION DANGER Rear Suspension • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION The rear suspension and powertrain of the vehicle move independently from the vehicle frame. The suspension includes three multi-leaf springs controlled by two hydraulic shock absorbers mounted between the spring mounting plate and the frame.
Page 112: Shock Absorber Installation
Multi-Leaf Springs REAR SUSPENSION SHOCK ABSORBER INSTALLATION NOTE: When installing shock absorbers, make sure front shocks have identical part numbers and rear shocks have identical part numbers. NOTE: Tighten 3/8 hex nut at shock absorber until shock absorber cushions are approximately the same diameter as the retainers.
Page 113 REAR SUSPENSION Multi-Leaf Springs 2865 Figure 9-2 Lifting Position Place a floor jack under the transaxle differential casing to support (but not lift) the drivetrain. Raise it just enough to relieve tension on the shock absorbers without compressing them. Remove the tire and wheel assembly on the side from which the spring is to be removed. Thread one lug nut onto a stud on the rear hub.
Page 114 Multi-Leaf Springs REAR SUSPENSION 2861 Figure 9-5 Rear Suspension Assembly and Mounting Page 9-4 2018 Carryall 300 Maintenance and Service Manual...
Page 115: Multi-Leaf Spring Installation
REAR SUSPENSION Jounce Bumpers MULTI-LEAF SPRING INSTALLATION NOTE: When installing rear leaf springs, make sure that both springs have identical part numbers. Tighten flange bolt (19) after clamp from brake cable has been positioned between nut and frame component. Place front of leaf spring (20) into vehicle frame and insert bolt (22) through frame and leaf spring eye (Figure 9-5, Page 9-4).
Page 116 Jounce Bumpers REAR SUSPENSION Pagination Page Page 9-6 2018 Carryall 300 Maintenance and Service Manual...
Page 117: Section 10 - Periodic Maintenance
Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service. PRE-OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new vehicle(s), you should become familiar with its controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery.
Page 118: 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 119: 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 120: 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. • If any problems are found during scheduled inspection or service, do not operate the vehicle until repairs are made.
Page 121 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; Semiannual service by trained technician adjust if necessary.
Page 122 Periodic Service Schedules PERIODIC MAINTENANCE PERIODIC SERVICE SCHEDULE – GASOLINE VEHICLES REGULAR INTERVAL SERVICE See Pre-Operation and Daily Safety Pre-Operation and Daily Safety Checklist Checklist on page 10-1. Daily service by owner Performance Inspection See Performance Inspection on page 10-2. Check engine oil level;...
Page 123: 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) Semiannually by owner or Brake linkage and pivots Dry Moly Lube (CC PN 1012151) trained technician (or every 50 hours of operation, whichever Accelerator pivot rod supports...
Page 124 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 125: Section 11 - Controller Diagnostic Tool (Cdt)
SECTION 11 — CONTROLLER DIAGNOSTIC TOOL (CDT) DANGER Controller Diagnostic Tool (CDT) • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. NOTE: The information presented in this section addresses the following: • The Controller Diagnostic Tool (CDT) handheld programmer which replaced the IQDM series 2 handset. •...
Page 126: 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 127: Plugging The Cdt Into The Vehicle
CONTROLLER DIAGNOSTIC TOOL (CDT) Plugging the CDT into the Vehicle PLUGGING THE CDT INTO THE VEHICLE Figure 11-2 Communication Port Under Instrument Panel Connect one end of the cable to the port located on the bottom of the CDT. Connect the cable adaptor to the CDT cable. Find the communication port on the vehicle (Figure 11-2, Page 11-3).
Page 128: Quick Reference Guide - Excel With Eric Charging System
Quick Reference Guide – Excel with ERIC Charging System CONTROLLER DIAGNOSTIC TOOL (CDT) QUICK REFERENCE GUIDE – EXCEL WITH ERIC CHARGING SYSTEM OPERATION: Change screen contrast for better viewing by selecting the following: HPP Settings, Backlight Preset Favorites: Select a frequently viewed screen, press “Add to” softkey, highlight “Favorites”, press “Select” softkey. CONTROLLER FAULTS: Anti Tamper: If car is not equipped with Visage, make sure Control Main Driver Off: Replace controller.
Page 129: 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 130: Settings
Parameters CONTROLLER DIAGNOSTIC TOOL (CDT) The Parameters menu is where you can view and modify the settings of the controller's adjustable parameters. Navigate through this complex menu using the arrow keys, +/- keys, and softkeys. The parameters displayed will depend on the access level of the handset. Be aware when changing parameter settings, the new values replace the earlier values.
Page 131 CONTROLLER DIAGNOSTIC TOOL (CDT) Parameters PEDAL UP MODE SETTING MODE OPERATION DESCRIPTION Pedal up motor braking is disabled Mild pedal up Mild pedal up motor braking Aggressive pedal up Aggressive pedal up motor braking Speed Cal The speed cal (speed calibration) menu item allows the user to fine tune the vehicle speed. This feature cannot be used to increase the vehicle speed.
Page 132: Amp Hours
15 mph (24.1 km/h). For more information on this feature, contact your local Club Car distributor or dealer. NOTE: If controller is replaced, the information below must be entered into the new controller. See Speed Controller Installation, Section 13, Page 13-8.
Page 133: Vehicle Id
CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu VEHICLE ID S/N ASCII Letter 1 S/N ASCII Letter 2 The two-letter serial number prefix is coded as two separate ASCII characters per the following table. For example, serial number JE1401-000001 would have 74 for S/N ASCII Letter 1 and 69 for S/N ASCII Letter 2. ASCII NUMBER ASCII CHARACTER ASCII NUMBER...
Page 134: Batt Voltage
Monitor Menu CONTROLLER DIAGNOSTIC TOOL (CDT) WARNING • The vehicle operator should not monitor the handset while the vehicle is in motion. A technician can monitor the handset while traveling as a passenger in the vehicle. Failure to heed this warning could result in severe personal injury or death.
Page 135: Field Pwm
CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu FIELD PWM Displays motor field PWM (pulse width modulation). The range of pulse width modulation is 0% to 100%. When the vehicle is in operation, the pulse width modulation will fluctuate in response to the terrain and throttle input. SPEED PULSES The speed pulses menu item displays the activity of the motor speed sensor.
Page 136: Odometer
“private speed mode”. In the event that “private speed mode” is locked out, the controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 11-8.
Page 137: Amp Hours Display
CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu AMP HOURS DISPLAY Signed Battery Current While driving the vehicle, this displays either the current being pulled out of the batteries or the current being returned to the batteries during regenerative motor braking. It has a range from negative (–) 300 amps to positive (+) 300 amps. Amp Hours Displays total accumulated amp hours removed from batteries since initial vehicle start-up.
Page 138: 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 139: Causes Of Faults
CONTROLLER DIAGNOSTIC TOOL (CDT) Diagnostics Menu CAUSES OF FAULTS Some common causes of faults are: • Loose, broken, or disconnected wires or connectors • Failed components • Improper adjustment or installation of electrical or mechanical components (examples: brake adjustment, improper MCOR installation) •...
Page 140 Diagnostics Menu CONTROLLER DIAGNOSTIC TOOL (CDT) CONTROLLER FAULT CONTROLLER RESPONSE VEHICLE RESPONSE HW FAILSAFE A, B, C Vehicle comes to a stop THROTTLE FAULT A, C Vehicle comes to a stop SPEED SENSOR Vehicle runs at slow speed MAIN WELDED Vehicle runs at slow speed MAIN DRIVER ON A, B...
Page 141: Fault Recovery
CONTROLLER DIAGNOSTIC TOOL (CDT) Diagnostics Menu FAULT RECOVERY When a fault is detected by the controller, the controller will attempt to recover from the fault and resume normal operation. In the case of an intermittent problem, such as a loose wiring connection, the controller may be able to recover and operate normally for a while, but the problem should be repaired before placing the vehicle in service.
Page 142: Fault Descriptions
The max password tries fault is declared when the incorrect password fault has been declared several times. In the event that the max password tries fault is indicated, the speed controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 11-8. See also Password Tries (OEM Access Level Only) on page 11-11.
Page 143: Thermal Cutback
CONTROLLER DIAGNOSTIC TOOL (CDT) Fault Descriptions THERMAL CUTBACK If the controller heatsink temperature is found to be in excess of 185 °F (±9) (85 °C (±5)) or below –13 °F (±9) (–25 °C (±5)), the thermal cutback fault is detected. What it means: Heatsink temperature rises above 185 °F (85 °C).
Page 144: Main Welded
Fault Descriptions CONTROLLER DIAGNOSTIC TOOL (CDT) What it means: This is a symptom, not a cause. The controller records the number of times this occurs. What to do: Charge batteries. If fault occurs more frequently than normal, test battery pack. Section 14 — Batteries: Electric Vehicle with ERIC Charging MAIN WELDED If the speed controller detects that the solenoid contacts are welded closed, a main welded fault is detected.
Page 145: Main Dropout (1 Or 2)
CONTROLLER DIAGNOSTIC TOOL (CDT) Fault Descriptions large solenoids should read 180 to 190 ohms; small solenoids 200 to 250 ohms), a broken blue/white wire at the 16-pin controller plug or its terminal is loose in the 16-pin plug. MAIN DROPOUT (1 OR 2) If the controller detects that the solenoid contacts have opened while the vehicle is in operation, a main dropout fault is detected.
Page 146: Fld (Field) Missing
Programming CONTROLLER DIAGNOSTIC TOOL (CDT) FLD (FIELD) MISSING If the speed controller is operating at a duty cycle of greater than 90% (almost full speed) and the field current is less than 3 amps, a field missing fault is detected by the speed controller. CAUTION •...
Page 147: Cloning
CONTROLLER DIAGNOSTIC TOOL (CDT) Favorites CLONING Use the “Restore .cpf File” function to clone a controller with a saved .cpf file stored in the CDT. If using an OEM-level CDT, after you highlight a stored .cpf file and choose “Restore,” a pop-up window will ask whether you want to enable Advanced Cloning (“Yes”/“No”) using the softkeys.
Page 148 HHP Settings CONTROLLER DIAGNOSTIC TOOL (CDT) MENU ITEM DESCRIPTIONS Backlight Here you can set the brightness of the programmer’s LCD display—from 100% to 20%, in 5% increments. Keytone You can choose between several tones to sound each time you press a key, or you can turn the keytone Off for silent programmer operation.
Page 149: Plot & Log
CONTROLLER DIAGNOSTIC TOOL (CDT) Plot & Log PLOT & LOG The Plot & Log menu selection allows the user, with the Plot program, to plot real-time variables on the CDT display screen; or, with the Log program, to create a log file of variable values to view later in a spreadsheet program on a PC. The first step is to add the desired items to the Plot Variable List or the Log Variable List.
Page 150: 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 151: Connection Tests
CONTROLLER DIAGNOSTIC TOOL (CDT) Connection Tests TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Section 12 — Excel System Troubleshooting: Speed controller malfunction with ERIC Charging Disconnect the CDT cord from the vehicle. Handset malfunction Wait a few seconds and reconnect the handset to the vehicle Display screen shows jumbled or Loose connection at CDT port...
Page 152 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 cord with the square plug. Place the black (–) probe on each of the pins, one at a time, on the plug on the other end of the cord. The multimeter should indicate continuity on only one pin.
Page 153 CONTROLLER DIAGNOSTIC TOOL (CDT) Connection Tests 1.3. Connect the handset cord to the handset. 1.4. Connect the other end of the handset cord (without the adapter) to the four-pin connector of the speed controller. 1.5. Connect the vehicle batteries, positive (+) cable first. If the handset does not function during Test Procedure 3A, but does function when connected directly to the speed controller, the handset cord adapter and vehicle wire harness should be thoroughly tested.
Page 154 Connection Tests CONTROLLER DIAGNOSTIC TOOL (CDT) Pagination Page Page 11-30 2018 Carryall 300 Maintenance and Service Manual...
Page 155: Section 12 - Excel System Troubleshooting: With Eric Charging
SECTION 12 — EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING DANGER with ERIC Charging Excel System Troubleshooting: • General Warnings WARNING • General Warnings • Shorting of battery terminals can cause personal injury or death. – Do not place component mounting plate directly on top of batteries when removing or installing plate.
Page 156: Key Differences: Excel With Eric Charging System Vs. Powerdrive Chargers
EXCEL SYSTEM TROUBLESHOOTING: General Information WITH ERIC CHARGING • The Excel minimum motor braking speed has been lowered to almost zero. • Excel has higher energy output during regenerative braking due to the lowered minimum motor braking speed. • The Excel accelerator pedal has more control of downhill speed. •...
Page 157 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING General Information km/h). If the walk away braking function remains engaged for two seconds or more, a warning buzzer will sound to alert the driver that motor braking has been activated. WARNING • Walk Away Braking will not limit vehicle speed to 3 mph (4.8 km/h) on very steep grades. Do not operate vehicle on slopes exceeding 20% grades.
Page 158: Wiring Diagrams
EXCEL SYSTEM TROUBLESHOOTING: Wiring Diagrams WITH ERIC CHARGING WIRING DIAGRAMS WD1050772_L_DGM Figure 12-1 Wiring Diagram – CA300 with ERIC Charging Page 12-4 2018 Carryall 300 Maintenance and Service Manual...
Page 159 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Wiring Diagrams WD1050772_R_DGM Figure 12-2 Wiring Diagram – CA300 with ERIC Charging (Continued) 2018 Carryall 300 Maintenance and Service Manual Page 12-5...
Page 160 EXCEL SYSTEM TROUBLESHOOTING: Wiring Diagrams WITH ERIC CHARGING WD1050821_DGM_C1 Figure 12-3 Wiring Diagram – Instrument Panel Page 12-6 2018 Carryall 300 Maintenance and Service Manual...
Page 161 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Wiring Diagrams WD1050772_2_DGM Figure 12-4 Wiring Diagram – Accessories 2018 Carryall 300 Maintenance and Service Manual Page 12-7...
Page 162 EXCEL SYSTEM TROUBLESHOOTING: Wiring Diagrams WITH ERIC CHARGING 3119 Figure 12-5 Sonic Weld, Diode and 10k Ohm Resistor Locations (Approximate) – CA300 with ERIC Charging Page 12-8 2018 Carryall 300 Maintenance and Service Manual...
Page 163: Troubleshooting
TROUBLESHOOTING THE VEHICLE WITH THE CDT Club Car recommends the use of the CDT handheld programmer for troubleshooting vehicles equipped with the Excel electrical system. Troubleshooting Guide 1 is to be used in conjunction with the CDT handheld programmer. See 11 Controller Diagnostic Tool (CDT)for operating instructions.
Page 164 EXCEL SYSTEM TROUBLESHOOTING: Troubleshooting WITH ERIC CHARGING TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected motor speed sensor Repair and/or connect the three-pin connector or broken wire to the motor speed sensor Monitor Menu – SPEED PULSES menu item indicates that speed pulses are OFF when Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector...
Page 165 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected three-pin connector at Repair and/or connect the three-pin connector the MCOR or broken wire to the MCOR Diagnostic Menu – THROTTLE FAULT fault Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector code...
Page 166: Troubleshooting Guide 2
EXCEL SYSTEM TROUBLESHOOTING: Troubleshooting WITH ERIC CHARGING TROUBLESHOOTING GUIDE 2 In the event that the vehicle is not functioning properly after completing Troubleshooting Guide 1, use Troubleshooting Guide 2. If a CDT handheld programmer is unavailable, use Troubleshooting Guide 2. Page 12-12 2018 Carryall 300 Maintenance and Service Manual...
Page 167 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Troubleshooting TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Batteries – batteries discharged Charge batteries Check vehicle wiring. See Wiring Diagrams Batteries – battery connections on page 12-4. Battery charger is connected to the vehicle Disconnect the battery charger from the –...
Page 168 EXCEL SYSTEM TROUBLESHOOTING: Troubleshooting WITH ERIC CHARGING TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Procedure 12 – Motor Speed Sensor on Speed sensor disconnected or failed page 12-30 To change the programmed top speed of Incorrect speed setting the vehicle, an OEM-level CDT handheld programmer must be used Check vehicle wiring.
Page 169: Test Procedures
EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures TEST PROCEDURES Using the following procedures, the entire electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
Page 170 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING CAUTION • Be careful not to damage the wire or terminal when back-probing. • When testing voltage, the batteries must remain connected. • When testing voltage, unless specifically directed to do otherwise in a procedure, connect the black (–) probe of the multimeter to the negative post of battery no.
Page 171 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures TEST PROCEDURE 1 – Batteries / Voltage Check (BPV) See General Warnings on page 1-1. NOTE: This is a voltage test. The batteries must be properly maintained and fully charged in order to perform the following test procedures. Battery maintenance procedures, including watering information and allowable mineral content, can be found in the Battery section of this manual.
Page 172 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING 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 12-15. Be sure the batteries are fully charged and that the electrolyte level is correct in all cells. Connect the tester leads to the positive (+) post of battery no.1 and negative (–) post of battery no.6 (Figure 12-7, Page 12-18).
Page 173 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures If no voltage is coming to the Run/Tow Switch, inspect the red-to-pink wire spade connection at the solenoid. Run/Tow Switch Test with the CDT Handset With the Run/Tow switch in the RUN position, connect the CDT to the vehicle. Immediately after the CDT is connected to the vehicle, the screen should display a copyright notice and the CDT model number.
Page 174 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING 2976 Figure 12-8 Testing the Fuse If necessary, see Testing Basics on page 12-15. Access the fuses but do not remove them. Fuses are found at the following locations: – On Controller Mounting Plate: 15-amp fuse to DC/DC converter, 2-amp fuse to connected car device (Guardian/Visage V3 Circuit), and 15-amp fuse to electric powertrain –...
Page 175 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures 20-Amp ATC Fuse Near MCOR and ATM Fuses Under Front Cowl: With the batteries connected, key switch ON and DC/DC converter operating: NOTE: For these fuses only, connect the black probe of the meter to the 12 volt ground terminal block located under the front cowl.
Page 176 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING TEST PROCEDURE 5 – Key Switch and MCOR Limit Switch Circuit See General Warnings on page 1-1. NOTE: This is a voltage test. The MCOR provides FOOT INPUT to the controller. The key switch provides KEY INPUT to the controller. Key Switch and MCOR Limit Switch Circuit Test with the CDT Handset Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack.
Page 177 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures 4.2. With the key switch in the OFF position and the accelerator pedal at rest, the green wire should show zero (0) volts. 4.3. With the key switch in the ON position and the accelerator pedal pressed, the green wire should show BPV which is FOOT INPUT to controller.
Page 178 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING 4.2. Place the Forward/Reverse switch in the REVERSE position. The CDT should indicate that REVERSE INPUT is ON. If the CDT indicates any other reading, check vehicle wiring. See Wiring Diagrams on page 12-4.
Page 179 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures TEST PROCEDURE 7 – Solenoid Activating Coil See General Warnings on page 1-1. NOTE: This is a resistance test. Be aware that one of two different solenoids may be found on the vehicle. Visually, the production solenoid is smaller than the service replacement.
Page 180 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING Measure resistance between the two large posts of the solenoid. The reading should be approximately 250 ohms. If not, remove pre-charge resistor, with pre-charge resistor removed, if it does not read approximately 250 ohms and is not discolored, replace.Solenoid Removal on page 13-6.
Page 181 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures WARNING • Keep people and equipment clear from rotating rear wheels. Do not allow persons under the car. Contact with rotating rear wheels could result in serious personal injury. Change the multimeter to measure resistance. Place the Run/Tow switch in the RUN position, turn the key switch to the ON position, place the Forward/Reverse rocker switch in the FORWARD position, and press the accelerator pedal.
Page 182 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING Check continuity: Set multimeter to Continuity test. With the red (+) probe (with insulation-piercing probe) still on the light blue wire (pin 5 of the 16-pin connector), place the black (–) probe in the blue wire terminal of the charger receptacle.
Page 183 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures MCOR Voltage Test without the CDT Handset Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame rails just forward of each spring mount. See WARNING “Lift only one end...” in General Warnings.
Page 184 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING TEST PROCEDURE 12 – Motor Speed Sensor See General Warnings on page 1-1. Motor Speed Sensor Test without any Tool CAUTION • Perform the following procedure only on a level surface. To avoid injury or property damage, ensure that the path of the vehicle is clear before pushing vehicle.
Page 185 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures 4.1. With Run/Tow switch in the RUN position and using a multimeter set to 20 volts DC, place the black (–) probe on the battery no. 6 (6 x 8-Volt battery set) negative post and place red (+) probe on red wire terminal socket in three-pin connector.
Page 186 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING As the accelerator pedal is pressed, the voltage reading should increase from approximately 5 volts RMS when the MCOR limit switch closes, to approximately 48 volts RMS with the accelerator pedal fully pressed. See following NOTE.
Page 187 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures TEST PROCEDURE 15 – 16-Pin Connector See General Warnings on page 1-1. Pin 1 – White Pin 5 – Light Blue Pin 9 – Gray Pin 13 – White/Black Pin 2 – Yellow Pin 6 –...
Page 188 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING If 16-pin must be disconnected: Keep the 16-pin connector disconnected from the controller. With Run/Tow switch in the TOW position, reconnect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. Place the Run/Tow switch in the RUN position and then check the appropriate wires.
Page 189 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures PERFORM TEST WITH 16-PIN CONTROLLER INPUTS CONNECTED TO CONTROLLER? (IF TEST PROCEDURE YES, BACK-PROBE TO TEST) FORWARD INPUT BPV from Forward/Reverse switch in FWD Pin 8 – Brown (Key switch either ON or OFF) B+ INPUT Pin 9 –...
Page 190 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING If necessary, see Testing Basics on page 12-15. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4. Remove the instrument panel. See Instrument Panel Removal, Section 4, Page 4-10. Disconnect the orange/white and pink wires from the reverse buzzer.
Page 191 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures – Condition of the 9-pin connector behind instrument panel. – Condition of the yellow/green wire terminal in the instrument panel wire harness. – Continuity of the wires in the wire harnesses. If no problems exist in the above items, replace the charge indicator light. TEST PROCEDURE 18 –...
Page 192 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING Pagination Page Page 12-38 2018 Carryall 300 Maintenance and Service Manual...
Page 193: Section 13 - Electrical Components: Electric Vehicles
SECTION 13 — ELECTRICAL COMPONENTS: ELECTRIC VEHICLES DANGER Electrical Components: Electric Vehicles • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. KEY SWITCH See General Warnings on page 1-1. TESTING THE KEY SWITCH See Test Procedure 5 – Key Switch and MCOR Limit Switch Circuit on page 12-22. KEY SWITCH REMOVAL Disconnect the batteries and discharge the controller.
Page 194: Forward/Reverse Rocker Switch
ELECTRICAL COMPONENTS: ELECTRIC Forward/Reverse Rocker Switch VEHICLES Figure 13-1 Key Switch FORWARD/REVERSE ROCKER SWITCH See General Warnings on page 1-1. TESTING THE FORWARD/REVERSE ROCKER SWITCH See Test Procedure 6 – Forward/Reverse Rocker Switch on page 12-23. FORWARD/REVERSE ROCKER SWITCH REMOVAL Disconnect the batteries and discharge the controller.
Page 195: Run/Tow Switch
ELECTRICAL COMPONENTS: ELECTRIC VEHICLES Run/Tow Switch WARNING • Make sure that the vehicle operates in the forward direction when the Forward/Reverse switch is in the FORWARD position. • Make sure that the vehicle operates in the reverse direction when the Forward/Reverse switch is in the REVERSE position.
Page 196: Motor Controller Output Regulator (Mcor)
ELECTRICAL COMPONENTS: ELECTRIC Motor Controller Output Regulator (MCOR) VEHICLES MOTOR CONTROLLER OUTPUT REGULATOR (MCOR) See General Warnings on page 1-1. TESTING THE MCOR 11 – MCOR Voltage MCOR REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4.
Page 197: Reverse Buzzer
ELECTRICAL COMPONENTS: ELECTRIC VEHICLES Reverse Buzzer NOTE: Rotate the drive bar (5) back and forth if necessary to align the D-shaped end with the MCOR. Secure the MCOR (2) to the plastic housing (4) with two torx screws (3). Tighten screws to 12 in·lb (1.4 N·m). Connect the two-pin and three-pin connectors (1) from the wire harness to the MCOR (2).
Page 198: Solenoid
ELECTRICAL COMPONENTS: ELECTRIC Solenoid VEHICLES SOLENOID See General Warnings on page 1-1. The solenoid is located on the driver side of the electrical component mounting plate. TESTING THE SOLENOID 7 – Solenoid Activating Coil SOLENOID REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4.
Page 199: Speed Controller
ELECTRICAL COMPONENTS: ELECTRIC VEHICLES Speed Controller SPEED CONTROLLER See General Warnings on page 1-1. TESTING THE SOLID STATE SPEED CONTROLLER See Test Procedure 13 – A1 and A2 Motor Voltage on page 12-31. SPEED CONTROLLER REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4.
Page 200: Speed Controller Installation
ELECTRICAL COMPONENTS: ELECTRIC Speed Controller VEHICLES 2901 Figure 13-6 Speed Controller SPEED CONTROLLER INSTALLATION Install controller (6) on the two self-tapping screws (3). Install third self-tapping screw (3) and tighten to 5.5 ft·lb (7.5 N·m) (Figure 13-6, Page 13-8). Connect the 16-pin connector, 4-pin connector, and spade connectors to the controller (6). Connect the the heavy gauge wires to the controller (6) per the electrical schematics.
Page 201: Charger Receptacle
VEHICLES Charger Receptacle 7.7. Select Information, Software Version and verify the value is 13 or higher. If not, contact a Club Car Technical Representative. 7.8. Place the Run/Tow switch in the TOW position for 30 seconds. Then return it to RUN.
Page 202: Charger Receptacle Installation
ELECTRICAL COMPONENTS: ELECTRIC Charge Indicator Light VEHICLES CHARGER RECEPTACLE INSTALLATION Insert receptacle assembly into grille. Install the three screws (1) that secure the receptacle to the grille. Tighten screws to 16 in·lb (1.8 N·m). Connect three-pin connector. Install cowl. See Cowl Installation on page 4-5. Place the Run/Tow switch in the TOW position and connect the batteries.
Page 203: Dc/Dc Converter Installation
ELECTRICAL COMPONENTS: ELECTRIC VEHICLES Fuse Block DC/DC CONVERTER INSTALLATION Install the DC/DC converter (5) to the frame and secure with new locknuts (4). Tighten locknuts (4) to 75 in·lb (8.5 N·m). Connect the three pin (1) and the two pin plugs (2) of the wire harness (3) to the DC/DC converter (5) leads. Connect the batteries.
Page 204: Headlight Switch
ELECTRICAL COMPONENTS: ELECTRIC Headlight Switch VEHICLES 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 Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4.
Page 205: Headlight Bulb Removal (Halogen)
ELECTRICAL COMPONENTS: ELECTRIC VEHICLES Headlights HEADLIGHT BULB REMOVAL (HALOGEN) Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Remove cowl. See Cowl Removal, Section 4, Page 4-5. Remove front fenders. See Front Bumper and Side Fender Removal, Section 4, Page 4-9. Rotate (but do not touch) bulb (4) in a 90°...
Page 206 ELECTRICAL COMPONENTS: ELECTRIC Headlights VEHICLES 2993 Figure 13-7 Headlight Assembly Page 13-14 2018 Carryall 300 Maintenance and Service Manual...
Page 207: Section 14 - Batteries: Electric Vehicle With Eric Charging
SECTION 14 — BATTERIES: ELECTRIC VEHICLE WITH ERIC CHARGING DANGER Batteries: Electric Vehicle with ERIC Charging • 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 208: Battery Testing Basics - 8 Volt
BATTERIES: ELECTRIC VEHICLE WITH Battery Testing Basics – 8 Volt ERIC CHARGING BATTERY TESTING BASICS – 8 VOLT See General Warnings on page 1-1. OBSERVATION Inspect the battery compartment for the following items: • Rusted, corroded, or broken battery posts •...
Page 209: Battery Testing - 8 Volt
Regrouping is now Club Car’s standard battery replacement method. Regrouping is the practice of placing batteries of similar condition together in one vehicle. For example, if there was an issue with the batteries in two cars and the battery test indicated three failed batteries in each car, after removing the failed batteries, there will be six good batteries remaining.
Page 210 BATTERIES: ELECTRIC VEHICLE WITH Battery Regrouping ERIC CHARGING 3104 Figure 14-2 Battery Regrouping Process Flow Page 14-4 2018 Carryall 300 Maintenance and Service Manual...
Page 211: Battery Replacement
BATTERIES: ELECTRIC VEHICLE WITH ERIC CHARGING 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 212: 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 213: 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 214: Battery Care - Vehicles Equipped With The Single-Point Watering System (Spws)
BATTERIES: ELECTRIC VEHICLE WITH Battery Care ERIC CHARGING 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 215: 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 216: Self-Discharge
BATTERIES: ELECTRIC VEHICLE WITH Battery Care ERIC CHARGING WARNING • If battery wire terminals are damaged or corroded, replace or clean them as necessary. Failure to do so may cause them to overheat during operation and can result in fire, property damage, or personal injury.
Page 217: Vibration Damage
BATTERIES: ELECTRIC VEHICLE WITH ERIC CHARGING Single Point Watering System (SPWS) CAUTION 1. Level Indicator 2. Cap 3. Plates Maintain electrolyte level from at least 1/2 inch (13 mm) above plates to 1/4 inch (6 mm) below level indicator. Figure 14-4 Electric Battery Electrolyte Level Add water only after charging unless the electrolyte is below the level of the plates.
Page 218: Initial Maintenance Of The Spws
A deionizer for vehicles with SPWS, Club Car Part Number 105166801 is available from Service Parts (DC powered water quality indicator light). Replacement cartridge: 104005901. Bottled distilled water, with hand pump, Club Car Part Number 104006101, is recommended for private consumer applications.
Page 219 BATTERIES: ELECTRIC VEHICLE WITH ERIC CHARGING Single Point Watering System (SPWS) 3083 Figure 14-5 Connecting Hose with Filter to Water Source Figure 14-6 Checking the Water Flow Rate Completely open the water faucet until the water flows out of the hose-end assembly (3), and note the movement of the red flow indicator balls (6).
Page 220: Battery Storage
BATTERIES: ELECTRIC VEHICLE WITH Battery Storage ERIC CHARGING CAUTION • If at any time water overflows from the batteries, immediately stop the refill process, disconnect the pressure regulator from the battery fill coupling, and call for service. When the red flow indicator balls stop moving, immediately press the grey button to disconnect the hose-end assembly from the battery fill coupling (9), and squeeze the dust cover (10) to lightly secure it to the male connector of the battery fill coupling (Figure 14-7).
Page 221: Section 15 - Battery Charger: For Eric Charging System
WARNING • Only trained technicians should repair or service the charger. Contact your nearest Club Car distributor/dealer. • This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.
Page 222: General Information
This section includes information, troubleshooting and service procedures pertaining to the external high-frequency battery charger (model number IC0650-048-CC). Do not attempt to service a battery charger that has not been properly identified. If a charger cannot be properly identified, contact your local Club Car dealer or distributor. COV-1481 Figure 15-1 High-Frequency Battery Charger –...
Page 223: Usb Service Port
USB SERVICE PORT The ERIC charger has a USB port for use by Club Car authorized technicians for data transfer, reconfiguration, and updates. Keep the USB port cover in place when the port is not in use. See USB Service Port Cleaning and Care on page 15-13.
Page 224: Ac Input Voltage Detection
BATTERY CHARGER: FOR ERIC General Information CHARGING SYSTEM Onboard Charger: While the charger AC cord is plugged into an electrical outlet, the vehicle control circuit is locked out, preventing operation of the vehicle, as well as the possibility of consequent damage to the charger and the vehicle. AC INPUT VOLTAGE DETECTION The high-frequency charger automatically detects the AC input voltage and will operate at full power if the voltage is within the 100 to 240 VAC range.
Page 225: Onboard Charger Status Indicators
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM General Information Solid green Charging is complete. Battery pack is fully charged. Solid green Flashing green Charging is in progress. Battery pack has reached a high state of charge. Solid green Charging is in progress. Battery pack has NOT reached a high state of charge. Flashing green AC power to charger is present.
Page 226: Long-Term Storage
BATTERY CHARGER: FOR ERIC General Information CHARGING SYSTEM Solid green Charging is complete. Battery pack is fully charged. Solid green Flashing green Charging is in progress. Battery pack has reached a high state of charge. Solid green Charging is in progress. Battery pack has NOT reached a high state of charge. Flashing green AC power to charger is present.
Page 227: External Charger Mounting
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM External Charger Mounting EXTERNAL CHARGER MOUNTING WARNING • Make sure the charger is securely mounted. Do not hang the charger by its handle. • Place all cords so they will not be stepped on, tripped over, or otherwise subjected to damage or stress. CAUTION •...
Page 228: Ac Power Connection
BATTERY CHARGER: FOR ERIC AC Power Connection CHARGING SYSTEM 1. AC Cord 2. Wire Tie 2758 Figure 15-4 AC Cord Drip-Loop Example AC POWER CONNECTION WARNING • Install surge arrestors on incoming AC power lines. Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightning strikes.
Page 229: The Charge Circuit
NOTE: Make sure that the AC cord provided with your charger has the proper AC plug for your location. If it does not, contact your Club Car representative to obtain the proper cord or plug. Two of these high-frequency chargers can be used on a dedicated 15 or 20 ampere, single-phase branch circuit. This high-frequency charger caps current draw at 6 amps and will operate at full power if the voltage is within the 100 to 240 VAC and 50 to 60 Hz ranges.
Page 230: Charger Operation
(or) the vehicle receptacle. • 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 231 Vehicles should be restricted to 40 to 50 amp hours of discharge between charges until the batteries have been properly seasoned (50 to 70 charge cycles). For maximum battery life, Club Car recommends that electric vehicles always be recharged after 40 to 50 amp hours of discharge or each night in order to avoid deeply discharging the batteries.
Page 232 If the charger does not seem to be operating properly, or if the batteries seem weak, see Charger Troubleshooting on page 15-14. If troubleshooting does not solve the issue, contact your local Club Car distributor/dealer. 2795...
Page 233: Charger Maintenance
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM Charger Maintenance CHARGER MAINTENANCE See General Warnings on page 1-1. To ensure trouble-free performance, it is very important to follow an established preventive maintenance program. Regular and consistent maintenance can prevent vehicle downtime and expensive repairs that can result from neglect. Any charger not functioning correctly should be removed from use until it is properly repaired.
Page 234: Charger Troubleshooting
BATTERY CHARGER: FOR ERIC Charger Troubleshooting CHARGING SYSTEM CHARGER TROUBLESHOOTING See General Warnings on page 1-1. DANGER • Do not touch any wire or component in the battery charger while AC power is present. Failure to heed this warning will result in an electric shock. WARNING •...
Page 235: Terminal Block Cover
When the blue AC status indicator light comes on, reconnect the DC cord under the rear-facing seat. If the triangular status indicator light comes on, contact your Club Car dealer. If the light does not come back on, attempt to charge the vehicle as usual.
Page 236: External Charger Troubleshooting Indicators
BATTERY CHARGER: FOR ERIC Charger Troubleshooting CHARGING SYSTEM EXTERNAL CHARGER TROUBLESHOOTING INDICATORS If a fault occurs, count the number of red flashes (on the charger or dash) between pauses and refer to the table below: EXTERNAL CHARGER TROUBLESHOOTING GUIDE CHECK STATUS STATUS POSSIBLE CAUSES STATUS...
Page 237 BATTERY CHARGER: FOR ERIC CHARGING SYSTEM Charger Troubleshooting EXTERNAL CHARGER TROUBLESHOOTING GUIDE 1. Erroneous event (an unknown variable; Reset charger power. See Resetting Power – External something occurred to Charger on page 15-15. Reconnect DC cord to vehicle. the charger or vehicle that If status goes away, continue using charger.
Page 238: Onboard Charger Fault Codes
BATTERY CHARGER: FOR ERIC Charger Troubleshooting CHARGING SYSTEM ONBOARD CHARGER FAULT CODES The “E” and “F” codes will appear in the display panel followed by three numbers and a period to indicate the different conditions. ONBOARD CHARGER FAULT CODES FAULT CODE DESCRIPTION SOLUTIONS F-0-0-1...
Page 239 BATTERY CHARGER: FOR ERIC CHARGING SYSTEM Charger Troubleshooting ONBOARD CHARGER FAULT CODES Possible causes: Poor battery health, discharged battery, battery not connected correctly, and/or high parasitic loads on the battery while it is charging. • Replace the battery pack. E-0-0-7 Battery amp hour limit reached •...
Page 240: Test Procedures
BATTERY CHARGER: FOR ERIC Test Procedures CHARGING SYSTEM ONBOARD CHARGER FAULT CODES There has been a problem connecting or disconnect- ing the USB flash drive. • Disconnect and reconnect the USB flash drive. E-0-1-7 USB error • If the problem persists, remove AC and battery for E-0-2-7 minimum 30 seconds and retry charger.
Page 241 BATTERY CHARGER: FOR ERIC CHARGING SYSTEM Test Procedures 3.1. Verify that the 10-gauge red wire from the charger receptacle is connected to the large post of solenoid with 6-gauge red wire (Figure 15-5, Page 15-10). 3.2. Verify that the 10-gauge black wire from the charger receptacle is connected to the B- terminal of controller. 3.3.
Page 242 BATTERY CHARGER: FOR ERIC Test Procedures CHARGING SYSTEM With a multimeter set to 500 volts AC, check incoming AC voltage. Insert multimeter test probes into AC wall outlet; voltage should be between 85 and 270 volts. See AC Input Voltage Detection on page 15-4. If proper voltage is not present, have building wiring checked by a licensed electrical contractor.
Page 243: External Charger Repairs
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM External Charger Repairs EXTERNAL CHARGER REPAIRS See General Warnings on page 1-1. WARNING • Knowledge of battery charger wiring and component terminology is required before attempting any repair (Figure 15-5, Page 15-10). • Prior to servicing the charger, disconnect the DC plug from the vehicle charger receptacle and the AC cord from the AC outlet.
Page 244: Terminal Block Cover Installation
BATTERY CHARGER: FOR ERIC External Charger Repairs CHARGING SYSTEM 2791 Figure 15-9 Terminal Block Cover Mounting Tabs TERMINAL BLOCK COVER INSTALLATION WARNING • The terminal block cover (3) on the DC terminal block (4) must be installed properly to comply with UL code.
Page 245: Handle Installation
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM External Charger Repairs HANDLE INSTALLATION Place handle (9) onto charger and seat it onto mounting bosses of charger. See following NOTE. NOTE: The handle (9) features locating tabs to aid installation. Secure handle (9) to charger with two torx screws (8). Tighten screws (8) to 39.8 in·lb (4.5 N·m). FOOT REMOVAL Disconnect DC cord (1) from vehicle.
Page 246 BATTERY CHARGER: FOR ERIC External Charger Repairs CHARGING SYSTEM Pagination Page Page 15-26 2018 Carryall 300 Maintenance and Service Manual...
Page 247: Section 16 - Motor (Model Ej8-4001A): Electric Vehicle
The vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. The shunt-wound motor is designed for use in Excel System vehicles. Club Car recommends that motors requiring major repair be sent to a qualified motor repair shop; however, there are many relatively simple tasks that can be performed by a technician with general knowledge and experience in electric motor repair.
Page 248 MOTOR (MODEL EJ8-4001A): ELECTRIC External Motor Testing VEHICLE MOTOR TERMINALS CONTINUITY TEST RESULT A1 to A2 Continuity F1 to F2 A1 to F1 No Continuity A1 to F2 A2 to F1 No Continuity A2 to F2 A1 to Ground No Continuity A2 to Ground F1 to Ground No Continuity...
Page 249 MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE External Motor Testing 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 250: Motor Removal
MOTOR (MODEL EJ8-4001A): ELECTRIC Motor Removal VEHICLE MOTOR REMOVAL 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 terminals on the motor using two wrenches to prevent posts from turning. Label the wires to ensure proper reconnection.
Page 251 MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Motor Removal Figure 16-3 Lower Axle Remove the bolts and lock washers that secure the motor to the transaxle (Figure 16-25, Page 16-18). See following CAUTION. CAUTION • Do not position fingers under motor when sliding motor off of the input shaft in step 9. Fingers may get pinched when motor disengages.
Page 252: Motor Disassembly
MOTOR (MODEL EJ8-4001A): ELECTRIC Motor Disassembly VEHICLE MOTOR DISASSEMBLY Before beginning disassembly, place match marks on the motor end cap and motor frame. Remove speed sensor and magnet. 2.1. Remove the two screws (25) and clamp that secure the speed sensor (10) to the end cap (11) (Figure 16-15, Page 16-12).
Page 253 MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Motor Disassembly CAUTION • Removing the armature from the end cap requires two people: one to operate the press, and another to hold the armature. Failure to heed this CAUTION could result in personal injury and/or damage to the armature resulting from an unsupported armature falling after it becomes disengaged from the end cap bearing.
Page 254: Motor Component Testing And Inspection
MOTOR (MODEL EJ8-4001A): ELECTRIC Motor Component Testing and Inspection VEHICLE Figure 16-10 Brush Rigging Figure 16-11 Bearing Retaining Ring MOTOR COMPONENT TESTING AND INSPECTION See General Warnings on page 1-1. ARMATURE INSPECTION AND TESTING Remove the motor from the vehicle. See Motor Removal on page 16-4. Remove the end cap and armature by performing steps 1 through 7 of Motor Disassembly on page 16-6.
Page 255 MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Motor Component Testing and Inspection CAUTION • Do not use emery cloth to polish the commutator. Particles of emery are conductive and may short-circuit the commutator bars. Do not use oil or lubricants on the commutator or brushes. NOTE: Oil on the commutator may indicate a faulty transaxle input shaft oil seal.
Page 256: Motor Frame And Field Windings Inspection
MOTOR (MODEL EJ8-4001A): ELECTRIC Motor Component Testing and Inspection VEHICLE MOTOR FRAME AND FIELD WINDINGS INSPECTION Remove the motor from the vehicle. See Motor Removal on page 16-4. Remove the and cap and armature by performing steps 1 through 7 of Motor Disassembly on page 16-6. Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings.
Page 257 MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Motor Component Testing and Inspection Bearing Inspection NOTE: Replacement of the end cap bearing is highly-recommended if the end cap is removed from the motor. The following procedure is provided as a guideline for determining general bearing failure. Remove the motor from the vehicle.
Page 258 MOTOR (MODEL EJ8-4001A): ELECTRIC Motor Component Testing and Inspection VEHICLE 2613 Figure 16-15 Electric Motor (EJ8-4001A) Page 16-12 2018 Carryall 300 Maintenance and Service Manual...
Page 259: Reconditioning The Motor
MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE 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 260 MOTOR (MODEL EJ8-4001A): ELECTRIC Motor Assembly VEHICLE Figure 16-16 Brush Rigging Figure 16-17 Retracted Brushes Figure 16-18 Armature Installation Figure 16-19 Brush Setting With the brushes retracted, use an arbor press to press the armature shaft into the end cap bearing (Figure 16-18, Page 16-14).
Page 261: Motor Installation
MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Motor Installation Install clamp (3) onto sensor wires (4) and secure with other screw (5) finger-tight. Ensure clamp (3) and wires (4) are oriented as shown (Figure 16-20, Page 16-15). Tighten both screws (2 and 5) to 20 in·lb (2.2 N·m). Make sure the armature turns freely.
Page 262 MOTOR (MODEL EJ8-4001A): ELECTRIC Motor Installation VEHICLE inch inch 1/8 INCH 3/8 INCH (9.5 MM) (3.1 MM) Figure 16-21 Grease on Putty Knife Figure 16-22 Application of grease to Input Shaft Grooves 2.6. Check the chamfer (1) and end (2) of the input shaft to ensure these areas are completely clean of grease as shown (Figure 16-23, Page 16-17).
Page 263 MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Motor Installation 1/16 INCH (1.6 MM) Figure 16-23 Clean Chamfer and Input Shaft End Figure 16-24 Gap at Motor and Transaxle 4.2. Loosely install the three bolts and lock washers that secure the motor to the transaxle (Figure 16-25, Page 16-18).
Page 264 MOTOR (MODEL EJ8-4001A): ELECTRIC Motor Installation VEHICLE Insert the mounting bolts through the spring shackles and the bushings in the leaf spring eyes and install lock nuts. Tighten the bolts to 23 ft·lb (31 N·m). See Multi-Leaf Spring Installation, Section 9, Page 9-5. Install the shock absorbers.
Page 265: Section 17 - Transaxle (Type G): Electric Vehicles
SECTION 17 — TRANSAXLE (TYPE G): ELECTRIC VEHICLES DANGER Transaxle (Type G): Electric Vehicles • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. LUBRICATION See General Warnings on page 1-1. There are two plugs located on the lower half of the transaxle housing. The upper plug (21) (as viewed when the vehicle is on a level surface) is used as a lubricant level indicator (Figure 17-5, Page 17-3).
Page 266 Axle Bearing and Shaft TRANSAXLE (TYPE G): ELECTRIC VEHICLES 6.2. Use a press to separate the axle oil seal (15) from the adapter ring (39) (Figure 17-3, Page 17-2). Retain the adapter ring and discard the oil seal. Inspect the axle shaft assembly to be sure the bearing and collar have not slipped and are still seated against the shoulder on the axle shaft.
Page 267 TRANSAXLE (TYPE G): ELECTRIC VEHICLES Axle Bearing and Shaft Figure 17-5 Transaxle – Type G 2018 Carryall 300 Maintenance and Service Manual Page 17-3...
Page 268: Axle Bearing
Axle Bearing and Shaft TRANSAXLE (TYPE G): 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 269: Transaxle
TRANSAXLE (TYPE G): 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 270 Transaxle TRANSAXLE (TYPE G): 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 271 TRANSAXLE (TYPE G): ELECTRIC VEHICLES Transaxle CAUTION 1. Motor Mounting Bolts 2. Input Pinion Gear 3. Intermediate Gear Assembly 4. Differential Gear Case 2639 Figure 17-11 Motor Mounting Bolts and Gear Assembly Figure 17-10 Detach Axle From Leaf Springs Carefully remove the motor from the transaxle. Slide the motor away from the transaxle until the motor spline becomes disengaged from the input shaft, then lift motor out.
Page 272: Transaxle Disassembly, Inspection, And Assembly
Transaxle Disassembly, Inspection, and Assembly TRANSAXLE (TYPE G): ELECTRIC VEHICLES TRANSAXLE DISASSEMBLY, INSPECTION, AND ASSEMBLY See General Warnings on page 1-1. TRANSAXLE DISASSEMBLY AND INSPECTION To detach axle tubes (14 and 35) from the transaxle housing, remove the bolts (8) (Figure 17-5, Page 17-3). Remove 11 bolts (24) that hold housing together.
Page 273 TRANSAXLE (TYPE G): ELECTRIC VEHICLES Transaxle Disassembly, Inspection, and Assembly Disassemble the differential gear case: 8.1. Remove the hex bolts (33) and the ring gear (32) from the differential case (Figure 17-5, Page 17-3). 8.2. Remove the ring gear. 8.3. Separate the differential gear case housing.
Page 274: Transaxle Assembly
Transaxle Disassembly, Inspection, and Assembly TRANSAXLE (TYPE G): ELECTRIC VEHICLES NOTE: Damaged or worn gears should be replaced as sets. TRANSAXLE ASSEMBLY CAUTION • Do not press against the bearing outer race. • The housing and all parts must be wiped clean and dry before reassembly. If bearings (13) were removed during disassembly, install new bearings using an arbor press (Figure 17-5, Page 17-3).
Page 275 TRANSAXLE (TYPE G): ELECTRIC VEHICLES Transaxle Disassembly, Inspection, and Assembly WARNING • Be sure retaining ring is properly seated in its groove. If ring is not properly installed, the axle assembly will separate from the transaxle and damage the axle assembly and other components. Loss of vehicle control could result in severe personal injury or death.
Page 276: Transaxle Installation
Transaxle Installation TRANSAXLE (TYPE G): ELECTRIC VEHICLES TRANSAXLE INSTALLATION See General Warnings on page 1-1. If using a chain hoist, raise the vehicle and place transaxle in position on the jack stands. If using a floor jack, lower the jack stands to their lowest settings and place the transaxle in position on the jack stands. Align the center hole in the saddle of the transaxle with the pilot bolt in the leaf spring assembly.
Page 277: Section 18 - Troubleshooting And Electrical System: Pedal-Start Gas Vehicle
SECTION 18 — TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE DANGER Troubleshooting and Electrical System: Pedal-Start Gas Vehicle • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION WARNING • To prevent damage to the ECU, never mix the black and gray connectors that attach to it. The black connector is tethered to the ECU mounting plate to help avoid installing it in the gray port.
Page 278: Features Of The Electronic Fuel Injection (Efi) System
TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: PEDAL-START GAS VEHICLE • Top of Fuel Tank: The fuel tank is grounded to the chassis through the main wire harness. FEATURES OF THE ELECTRONIC FUEL INJECTION (EFI) SYSTEM • Open-loop system (i.e. oxygen sensor not used) •...
Page 279 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Troubleshooting Guide Error Codes – ECU BLINK CODE CODE DESCRIPTION CORRECTIVE ACTION Check battery voltage. Charge/replace battery Low Battery Voltage as necessary. Check connector at ECU & Throttle module. MAP Sensor: Open or Shorted Connection If connection is made and no corrosion is present, replace ECU and Throttle Module.
Page 280: Gasoline Powertrain
TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: PEDAL-START GAS VEHICLE GASOLINE POWERTRAIN TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Spark plug is partially fouled or in poor Clean or replace condition Spark plug is damaged or loose Replace or tighten Incorrect spark plug gap Adjust gap Spark plug wire is damaged or loose Replace or reconnect...
Page 281 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Fuel tank is empty Section 23 — Fuel System: Gasoline Vehicles Fuel line or filter clogged Section 23 — Fuel System: Gasoline Vehicles Fouled spark plug Section 22 —...
Page 282 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: PEDAL-START GAS VEHICLE TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Incorrect plug Section 22 — Engine (Subaru EX40) Spark plug wire is damaged Section 22 — Engine (Subaru EX40) Unsuitable fuel, or incorrect (rich) fuel mixture Section 23 —...
Page 283 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Transmission shifter linkage is binding or is Section 26 — Transaxle (ED65): Gasoline out of adjustment Vehicles Insufficient (low) level of lubricant or wrong Section 26 —...
Page 284: Wiring Diagrams
TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM: PEDAL-START GAS VEHICLE WIRING DIAGRAMS WD1050077_DGM_D-L Figure 18-1 Wiring Diagram for Pedal-Start Gasoline Vehicle Page 18-8 2018 Carryall 300 Maintenance and Service Manual...
Page 285 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Wiring Diagrams WD1050077_DGM_D-R Figure 18-2 Wiring Diagram for Pedal-Start Gasoline Vehicle – Continued 2018 Carryall 300 Maintenance and Service Manual Page 18-9...
Page 286 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM: PEDAL-START GAS VEHICLE WD1050951_DGM_A Figure 18-3 Wiring Diagram – Instrument Panel and FNR Shifter Page 18-10 2018 Carryall 300 Maintenance and Service Manual...
Page 287 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Wiring Diagrams WD1050081_DGM_D Figure 18-4 Wiring Diagram – EFI and Engine 2018 Carryall 300 Maintenance and Service Manual Page 18-11...
Page 288 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM: PEDAL-START GAS VEHICLE 3021 Figure 18-5 Sonic Weld and Diode Locations (Approximate) – CA300 Page 18-12 2018 Carryall 300 Maintenance and Service Manual...
Page 289: 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 290: Test Procedures
TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURES Using the following procedures, the entire electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
Page 291 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures 2 – Fuses 3 – Ground Cables 4 – EFI System (ECU and Sensors) 5 – Key Switch (Start Circuit) 6 – Key Switch (Engine Kill Circuit) 7 – Accelerator Pedal Limit Switch – Pedal-Start Vehicles Only 8 –...
Page 292 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: 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 293 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures IF TEMPERATURE IS MINIMUM CRANKING VOLTAGE 70 °F (20 °C and above) 9.6 V 60 °F (16 °C) 9.5 V 50 °F (10 °C) 9.4 V 40 °F (4 °C) 9.3 V 30 °F (-1 °C) 9.1 V 20 °F (-7 °C)
Page 294 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE 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 295 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures 5-amp ATM Fuse Only: With the key switch in the ON position: 4.1. Probe the two, small metal contacts on the top of the fuse (Figure 18-6, Page 18-18). 4.2. Each contact should show battery voltage. 4.3.
Page 296 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE 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 297 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 4 – EFI System (ECU and Sensors) See General Warnings on page 1-1. WARNING • This procedure involves testing voltage, resistance and continuity. If necessary, see Testing Basics on page 18-14. 2018 Carryall 300 Maintenance and Service Manual Page 18-21...
Page 298 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE 18-PIN CONNECTOR (GRAY AND BLACK): A. ECU SIDE OF CONNECTOR B. WIRE ENTRY SIDE OF CONNECTOR CONNECTOR FUNCTION TEST TYPE & PROBE BETWEEN LOCATIONS TEST RESULT CONDITION I.D. COLOR Resistance: ECU Gray Pin 1 (Black/White) and ECU Approx.
Page 299 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures 18-PIN CONNECTOR (GRAY AND BLACK): A. ECU SIDE OF CONNECTOR B. WIRE ENTRY SIDE OF CONNECTOR CONNECTOR FUNCTION TEST TYPE & PROBE BETWEEN LOCATIONS TEST RESULT CONDITION I.D. COLOR Meter should beep Key OFF Black Ignition OFF Input...
Page 300 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 5 – Key Switch (Start Circuit) See General Warnings on page 1-1. NOTE: This is a voltage test. The key switch provides power and KEY INPUT to the ECU. If necessary, see Testing Basics on page 18-14.
Page 301 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 6 – Key Switch (Engine Kill Circuit) See General Warnings on page 1-1. NOTE: This is a continuity test. If necessary, see Testing Basics on page 18-14. Disconnect battery and spark plug wire(s). See Disconnecting the Battery- Gasoline Vehicles on page 1-3. Remove the instrument panel.
Page 302 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: 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 303 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 304 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: 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 305 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 306 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE • When disconnecting wires from starter/generator terminals, use a second wrench on the lower nut of the terminal post to hold post steady. • Scrape a small amount of paint from starter/generator housing (ground) and use this location when testing motor terminals to electrical ground.
Page 307 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 308 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: 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 309 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 310 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: 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 311 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 312 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: 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 313 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 314 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE Probe between pin (1) and pin (2) terminals in module (Figure 18-18, Page 18-37). 4.1. The reading should be approximately 2 to 5 ohms. If the reading indicates no resistance, the fuel pump has failed and the fuel pump module must be replaced.
Page 315 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 18-19 Fuel Gauge/Hour Meter If necessary, see Testing Basics on page 18-14.
Page 316 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: 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 18-20 Fuel Gauge Voltage Test - Terminal 2 Figure 18-21 Fuel Gauge Voltage Test - Terminal 4 TEST PROCEDURE 24 –...
Page 317 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 18-18. This is a voltage test.
Page 318 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: 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 319 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 320 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE Pagination Page Page 18-44 2018 Carryall 300 Maintenance and Service Manual...
Page 321: Section 19 - Troubleshooting And Electrical System: Key-Start Gas Vehicle
SECTION 19 — TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START GAS VEHICLE DANGER Troubleshooting and Electrical System: Key-Start Gas Vehicle • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION WARNING • To prevent damage to the ECU, never mix the black and gray connectors that attach to it. The black connector is tethered to the ECU mounting plate to help prevent accidentally installing it in the gray port.
Page 322: Wiring Diagrams
TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM: KEY-START GAS VEHICLE WIRING DIAGRAMS WD1050080_DGM_B-L Figure 19-1 Wiring Diagram for Key-Start Gasoline Vehicle Page 19-2 2018 Carryall 300 Maintenance and Service Manual...
Page 323 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START GAS VEHICLE Wiring Diagrams WD1050080_DGM_B-R Figure 19-2 Wiring Diagram for Key-Start Gasoline Vehicle – Continued 2018 Carryall 300 Maintenance and Service Manual Page 19-3...
Page 324 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM: KEY-START GAS VEHICLE WD1050951_DGM_A Figure 19-3 Wiring Diagram – Instrument Panel and FNR Shifter Page 19-4 2018 Carryall 300 Maintenance and Service Manual...
Page 325 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START GAS VEHICLE Wiring Diagrams WD1050081_DGM_D Figure 19-4 Wiring Diagram – EFI and Engine 2018 Carryall 300 Maintenance and Service Manual Page 19-5...
Page 326: 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 327 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START GAS VEHICLE Test Procedures TEST PROCEDURE 2 – Key Switch (ON Position) See General Warnings on page 1-1. NOTE: This is a voltage test. The key switch ON position provides power and KEY INPUT to the ECU. If necessary, see Testing Basics on page 18-14.
Page 328 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: KEY-START GAS VEHICLE TEST PROCEDURE 4 – Solenoid See General Warnings on page 1-1. NOTE: This is a resistance and voltage test. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. Cover 2. Electrical Component Box 3. 6 Ga. White Wire 4. 18 Ga. White Wire 5.
Page 329 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START GAS VEHICLE Test Procedures TEST PROCEDURE 5 – Maintenance/Operate Switch – Key-Start Vehicles See General Warnings on page 1-1. NOTE: This is a continuity test. The Maintenance/Operate Switch is also known as the Neutral Lockout Switch. If necessary, see Testing Basics on page 18-14.
Page 330 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: KEY-START GAS VEHICLE TEST PROCEDURE 6 – Charging Diode (Generator Circuit) – Key-Start Vehicles Only See General Warnings on page 1-1. WAVETEK 1000 WAVETEK 1000 2000 200k 2000 200k 200nA 200nA 1000 --- FUSED 750V 1000 --- FUSED...
Page 331 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START GAS VEHICLE Test Procedures WARNING • Diode and solenoid connections must have correct polarity. • Keep all persons clear of engine belts when making final connections. 2018 Carryall 300 Maintenance and Service Manual Page 19-11...
Page 332 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: KEY-START GAS VEHICLE Pagination Page Page 19-12 2018 Carryall 300 Maintenance and Service Manual...
Page 333: Section 20 - Electrical Components: Pedal-Start Gas Vehicle
SECTION 20 — ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE DANGER Electrical Components: Pedal-Start Gas Vehicle • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. STARTER/GENERATOR See General Warnings on page 1-1. TESTING THE STARTER/GENERATOR See Test Procedure 12 – Starter/Generator (Starter Function) on page 18-29. See Test Procedure 11 –...
Page 334: Brush Inspection And Replacement
ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE Figure 20-2 Brush Covers and Brushes Figure 20-1 Commutator End Cover BRUSH INSPECTION AND REPLACEMENT Visually inspect brushes. Replace brushes that are cracked or severely chipped. Measure the length of each brush. Replace the brush set if a brush is less than 0.375 inch (9.5 mm) (Figure 20-3, Page 20-2).
Page 335: Starter/Generator Assembly
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator CAUTION • When checking brush spring tension, do not push springs beyond the point they would normally be if there were new brushes installed. Exerting excessive force or pushing brush springs beyond their normal maximum extension point will damage springs. Figure 20-4 Brush Spring Tension Test STARTER/GENERATOR ASSEMBLY Install the brushes (27) into the holders.
Page 336: Disassembly Of The Starter/Generator To Service The Armature/Commutator
ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE Figure 20-5 Pull Brushes Away From Center of the Commutator End Cover DISASSEMBLY OF THE STARTER/GENERATOR TO SERVICE THE ARMATURE/COMMUTATOR Remove the commutator end cover to prevent damage to the brushes and armature. To separate armature and output end cover assembly from the field coil housing, first remove the two securing bolts (43).
Page 337: Bearing Cleaning And Inspection
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator 1342 Figure 20-6 Output End Cover Assembly, Armature and Housing BEARING CLEANING AND INSPECTION Using a clean cloth, wipe the carbon dust from the two bearings. Inspect bearings by spinning them by hand and checking for both axial (A) and radial (B) play (Figure 20-7, Page 20-5).
Page 338: Bearing Removal
ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE BEARING REMOVAL Place the wedge attachment tool (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 (P/N 1012811) to the wedge attachment tool and pull the bearing off of the end of the armature shaft.
Page 339: Commutator Cleaning And Inspection
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator Figure 20-9 Field Coil Assembly COMMUTATOR CLEANING AND INSPECTION Clean the carbon dust, dirt and oil from the commutator. Visually inspect the commutator for worn, burned or glazed areas. Check for loose or raised commutator bars. Slight roughness of the commutator can be polished away with 400 grit (or finer) sandpaper.
Page 340: Armature Ground Test
ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE 1. Measure each position in two places, 90 degrees apart Figure 20-10 Inspect Commutator ARMATURE GROUND TEST CAUTION • Do not submerge armature in solvent. NOTE: Before testing, wipe the armature with a clean cloth and remove carbon dust and metal particles from between commutator bars.
Page 341: Visual Inspection Of Field Coils
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 200 Ohms Setting 2. Commutator 3. Armature Shaft Figure 20-11 Armature Ground Test VISUAL INSPECTION OF FIELD COILS If the insulation on the field coils appears blackened or charred, the serviceability of the coils is questionable. Burned or scorched coil insulation indicates the starter/generator has overheated due to overloads or grounded or shorted coil windings.
Page 342 ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE Press a new ball bearing (35) onto the output end of the armature (Figure 20-6, Page 20-5). Press a new ball bearing onto the commutator end of the armature shaft. See following CAUTION. CAUTION •...
Page 343 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator 90° 1. Jumper Wire 2. 1 inch (25.4 mm) Minimum Radius 3. Jumper Wire Not Allowed in this Area. 2687 Figure 20-12 A1 to F1 Terminal Jumper Wire Routing 2018 Carryall 300 Maintenance and Service Manual Page 20-11...
Page 344: Starter/Generator Installation
ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE STARTER/GENERATOR INSTALLATION 2997 Figure 20-13 Starter/Generator Installation Install the green wire (1) from the F1 terminal to the A2 terminal on the starter/generator (Figure 20-14, Page 20-13). 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 For Efi Engines
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator 3033 Figure 20-14 Starter/Generator Wiring BELT TENSION ADJUSTMENT FOR EFI ENGINES NOTE: To prevent belt slipping while starting an EFI engine, follow procedure outlined below which is best performed by two people to expedite the process, but can be performed by a single individual if required. The amount a starter/generator belt is tensioned varies between a used and new belt.
Page 346 ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE – Use combination of above methods. Mark a location on belt to repeat tension measurement each time. Use paint pen or permanent marker of light color. For Existing Belts Only: Verify current belt tension using Universal Belt Tension Gauge (OTC 6673 ®...
Page 347: Voltage Regulator
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Voltage Regulator 7.1. Tighten nut on belt tension tool 1/2 turn and check belt tension with gauge (Figure 20-15, Page 20-13). NOTE: To prevent errors in measurement caused by residual tension, ensure to loosen, then reapply, the Universal Belt Tension gauge between measurements.
Page 348: Voltage Regulator Installation
ELECTRICAL COMPONENTS: PEDAL-START Voltage Regulator GAS VEHICLE 1. Red wire to solenoid. 2. To kill limit switch. 3. To frame ground. 4. To bullet connector. 2973 Figure 20-18 Voltage Regulator VOLTAGE REGULATOR INSTALLATION Position the voltage regulator (9) in the electrical component box and install the mounting screw (8) (Figure 20-18, Page 20-16).
Page 349: 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 350: Key Switch
ELECTRICAL COMPONENTS: PEDAL-START Key Switch GAS VEHICLE KEY SWITCH See General Warnings on page 1-1. TESTING THE KEY SWITCH See Test Procedure 5 – Key Switch (Start Circuit) on page 18-24. See Test Procedure 6 – Key Switch (Engine Kill Circuit) on page 18-25. KEY SWITCH REMOVAL Disconnect the batteries and spark plug.
Page 351: 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 1-3. Using a 5/8 inch (16 mm) wrench, remove maintenance/operate boot/hex nut.
Page 352: Solenoid
ELECTRICAL COMPONENTS: PEDAL-START Solenoid GAS VEHICLE Connect the 3-wire connector to the neutral lockout limit switch lead. Connect battery and spark plug wire(s). See Connecting the Battery- Gasoline Vehicles on page 1-3. Test drive the vehicle in both forward and reverse for proper operation. SOLENOID See General Warnings on page 1-1.
Page 353: Fuse Removal
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Fuse TESTING THE FUSE See Test Procedure 2 – Fuses on page 18-18. FUSE REMOVAL Disconnect battery. See Disconnecting the Battery- Gasoline Vehicles on page 1-3. ATC Fuse Only: Remove electrical component box cover cover. ATM Fuse Only: Remove fuse holder cover.
Page 354: Kill Limit Switch
ELECTRICAL COMPONENTS: PEDAL-START Kill Limit Switch GAS VEHICLE KILL LIMIT SWITCH See General Warnings on page 1-1. TESTING THE KILL LIMIT SWITCH See Test Procedure 14 – Kill Limit Switch – Pedal-Start Vehicles Only on page 18-32. KILL LIMIT SWITCH REMOVAL Disconnect battery and spark plug wire(s).
Page 355: Reverse Warning Buzzer
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Reverse Warning Buzzer 2948 Figure 20-20 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 356 ELECTRICAL COMPONENTS: PEDAL-START Reverse Warning Buzzer GAS VEHICLE 3003 Figure 20-21 Instrument Panel Switches Page 20-24 2018 Carryall 300 Maintenance and Service Manual...
Page 357: 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 358: Reverse Buzzer Limit Switch Removal
ELECTRICAL COMPONENTS: PEDAL-START Reverse Buzzer Limit Switch GAS VEHICLE 3001 Figure 20-22 Forward/Reverse Assembly Switches Page 20-26 2018 Carryall 300 Maintenance and Service Manual...
Page 359: 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 360: Fuel Gauge/Hour Meter Installation
ELECTRICAL COMPONENTS: PEDAL-START Fuel Level Sending Unit GAS VEHICLE Alternate pulling the lower and upper tabs away from the gauge housing to remove clip. Pull gauge/meter from the instrument panel. FUEL GAUGE/HOUR METER INSTALLATION Install a new fuel gauge/hour meter (6) into the hole in the instrument panel until the flange seats against the instrument panel (Figure 20-21, Page 20-24).
Page 361: Voltage Limiter Removal
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE 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. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.
Page 362: Headlight Switch
ELECTRICAL COMPONENTS: PEDAL-START Headlight Switch GAS VEHICLE 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 Disconnect battery and spark plug wire(s). See Disconnecting the Battery- Gasoline Vehicles on page 1-3. Remove the instrument panel.
Page 363: Headlight Bulb Removal (Halogen)
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Headlights HEADLIGHT BULB REMOVAL (HALOGEN) Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Remove cowl. See Cowl Removal, Section 4, Page 4-5. Remove front fenders. See Front Bumper and Side Fender Removal, Section 4, Page 4-9. Rotate the bulb (4) (but do not touch) in a 90–degree angle and pull out of lens assembly (5).
Page 364 ELECTRICAL COMPONENTS: PEDAL-START Headlights GAS VEHICLE 2993 Figure 20-24 Headlight Assembly Page 20-32 2018 Carryall 300 Maintenance and Service Manual...
Page 365: Battery
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Battery 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 366: Self-Discharge
ELECTRICAL COMPONENTS: PEDAL-START Battery GAS VEHICLE tightened to 41 in·lb (4.3 N·m), coat terminals with Battery Terminal Protector Spray (CC P/N 1014305) to prevent future corrosion. See preceding WARNINGS and following CAUTION. CAUTION • If battery wire terminals are damaged or corroded, replace or clean them as necessary. Failure to do so may cause them to overheat during operation and could result in a fire, property damage, or personal injury.
Page 367: Battery Removal
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Battery BATTERY REMOVAL See General Warnings on page 1-1. Also see DANGER at beginning of Battery topic. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels. Disconnect battery and spark plug wire(s).
Page 368: Battery Storage
ELECTRICAL COMPONENTS: PEDAL-START Ground Cables GAS VEHICLE 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 20-33. 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 369: Section 21 - Electrical Components: Key-Start Gas Vehicle
SECTION 21 — ELECTRICAL COMPONENTS: KEY-START GAS VEHICLE DANGER Electrical Components: Key-Start Gas Vehicle • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION WARNING • To prevent damage to the ECU, never mix the black and gray connectors that attach to it. The black connector is tethered to the ECU mounting plate to help prevent accidentally installing it in the gray port.
Page 370: Key Switch Installation
ELECTRICAL COMPONENTS: KEY-START Key Switch GAS VEHICLE From the back of the instrument panel, push down on the retaining tabs surrounding the key switch (3) and remove the key switch cap (6). Using a 1-inch socket, hold the key switch (3) and remove the switch retaining nut (5) from the outside of the instrument panel (Figure 21-1, Page 21-2).
Page 371: 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 1-3. Using a 5/8 inch (16 mm) wrench, remove maintenance/operation boot/hex nut.
Page 372: Charging Diode
ELECTRICAL COMPONENTS: KEY-START Charging Diode GAS VEHICLE 2.3. Connect the 18-gauge orange wire from accelerator pedal limit switch to small post on the solenoid. 2.4. Connect the 18-gauge blue wire from the key switch to the other small post on the solenoid. Tighten the hex nuts on the large solenoid posts to 60 in·lb (6.8 N·m).
Page 373 ELECTRICAL COMPONENTS: KEY-START GAS VEHICLE Charging Diode FRONT OF VEHICLE Some wires omitted for clarity. 2978 Figure 21-2 Charging Diode CHARGING DIODE INSTALLATION Thoroughly clean and dry the area of the chassis where the new charging diode (6) is to be attached. Peel the protective film from both sides of the new thermal pad (12) (Figure 21-2, Page 21-5).
Page 374: Charging Diode Removal
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 375: Section 22 - Engine (Subaru Ex40)
SECTION 22 — ENGINE (SUBARU EX40) DANGER Engine (Subaru EX40) • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION See General Warnings on page 1-1. This vehicle is powered by a Subaru EX40, high-compression, chain driven, overhead cam engine. The engine offers a heavy-duty construction featuring cast iron cylinder liner for longer life, dual ball bearing crankshaft support, low oil level sensor and heavy-duty air cleaner system, to name a few characteristics.
Page 376: 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 377 ENGINE (SUBARU EX40) General Information Check oil by fully inserting the dipstick into the oil filler tube and immediately removing it. If the oil level is at or below the low level mark on the dipstick gauge, add oil until the level is between low and full levels (safe level).
Page 378 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 379: Spark Plug
ENGINE (SUBARU EX40) General Information Figure 22-3 Oil Viscosity Chart Connect battery and spark plug wire. See Connecting the Battery- Gasoline Vehicles on page 1-3. 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 380: 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 381: 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 382: Engine Removal
Engine Removal ENGINE (SUBARU EX40) ENGINE REMOVAL See General Warnings on page 1-1. 3036a Figure 22-7 EX40 Engine and Mounting Brackets CAUTION • Before removal and disassembly, clean the engine. Disconnect battery and spark plug wire(s). See Disconnecting the Battery- Gasoline Vehicles on page 1-3. Page 22-8 2018 Carryall 300 Maintenance and Service Manual...
Page 383: 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 384: Flywheel
Flywheel ENGINE (SUBARU EX40) Check all hardware for proper torque/tightness. Fill engine to proper level with correct type of oil. See Engine Oil – Gasoline Vehicle, Section 22, Page 22-2. CAUTION • Do not overfill with oil. Connect battery and spark plug wire(s). See Connecting the Battery- Gasoline Vehicles on page 1-3. Adjust the engine RPM setting.
Page 385: Flywheel Installation
ENGINE (SUBARU EX40) Flywheel Hold flywheel (4) only, not fan (7), with strap wrench (5) and use a 24 mm socket to remove flywheel nut (8) and flat washer (9) by turning it counterclockwise (Figure 22-9, Page 22-11). See following CAUTION. CAUTION •...
Page 386: 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 387: 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 388: 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 389: Section 23 - Fuel System: Gasoline Vehicles
SECTION 23 — FUEL SYSTEM: GASOLINE VEHICLES DANGER Fuel System: Gasoline Vehicles • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. • Fuel may be under pressure. Use extreme caution when disconnecting fuel line to prevent the spray of fuel onto hot engine.
Page 390: 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 391: Throttle Body
FUEL SYSTEM: GASOLINE VEHICLES Throttle Body NOTE: To absorb any residual fuel the may be present in the fuel hose, place a rag or towel around the hose at the end being disconnected. THROTTLE BODY See General Warnings on page 1-1. Before suspecting the throttle body as the cause of poor engine performance, make sure the fuel and ignition systems are in proper operating condition.
Page 392: 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 393 FUEL SYSTEM: GASOLINE VEHICLES Throttle Body Connect governor cable to bracket (4). Connect breather hose (2) to air intake adapter (3). Connect air intake hose and secure with hose clamp. If removed, install fuel tank. See Fuel Tank Installation, Section 23, Page 23-21. If equipped, install air deflector on top of engine.
Page 394: 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 395: 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 23-12.
Page 396 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 397: 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 on page 1-3. At engine: 3.1.
Page 398: Accelerator Cable
Engine Control Linkages FUEL SYSTEM: GASOLINE VEHICLES Adjust governor cable jam nuts until throttle lever (2) is at “wide open throttle” (WOT) (Figure 23-7, Page 23-8) and tighten the governor cable jam nuts to 36 in·lb (4.0 N·m). Release governor arm (4) to return to “idle” position. Adjust gap (A) between governor arm (4) and throttle stop screw (7) to 0.055 in.
Page 399: Closed Throttle Or Idle Adjustment - Pedal-Start Vehicles
FUEL SYSTEM: GASOLINE VEHICLES Engine Control Linkages 2.2. Separate jam nuts (10) on cable and place threaded end into slot of electrical component box. Tighten jam nuts (10) finger-tight. 2.3. Before tightening the cable jam nuts (10), make sure the engine RPM adjustment is correct. See Engine RPM Adjustment on page 23-12.
Page 400: How To Measure Ground Speed
Engine Control Linkages FUEL SYSTEM: GASOLINE VEHICLES HOW TO MEASURE GROUND SPEED Best Method An easy way to check ground speed is by using a GPS device or smartphone application (app). If these are not available, use the alternate method below. Alternate Method (Calculated) Ground speed is easily determined by a known distance travelled, divided by the amount of time it took to travel that known distance (Rate = Distance/Time).
Page 401: Air Intake System
FUEL SYSTEM: GASOLINE VEHICLES Air Intake System AIR INTAKE SYSTEM See General Warnings on page 1-1. 3048 Figure 23-12 Air Intake System – CA 300 2018 Carryall 300 Maintenance and Service Manual Page 23-13...
Page 402: Air Filter
• Engine damage will occur if the air cleaner cap is not properly secured. • If air cleaner is extremely dirty, remove air cleaner from vehicle and clean thoroughly. • Use only Club Car replacement air filters. The use of other air filters could result in engine damage and void the warranty.
Page 403: 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 404: Fuel Line Installation
Fuel Line FUEL SYSTEM: GASOLINE VEHICLES 1. Push fuel line onto nipple until it locks into place. 2. Push in locking clip until fully seated. 1. Pull out locking clip. 2. Push in on release tab. 3. While pushing in on release tab, pull fuel line off nipple. 3050 3051 Figure 23-13 Fuel Line Connector –...
Page 405: Fuel Pump Module
FUEL SYSTEM: GASOLINE VEHICLES Fuel Pump Module FUEL PUMP MODULE See General Warnings on page 1-1. GENERAL INFORMATION NOTE: The fuel pump and fuel level sending unit themselves are not replaceable. If necessary, the fuel pump module must be replaced as an assembly. The fuel pump module can be disassembled to replace the fuel filter.
Page 406 Fuel Pump Module FUEL SYSTEM: GASOLINE VEHICLES 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 407 FUEL SYSTEM: GASOLINE VEHICLES Fuel Pump Module 3052 Figure 23-15 Fuel System (Side-Fill) – Exploded View 2018 Carryall 300 Maintenance and Service Manual Page 23-19...
Page 408: 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 409: 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 410: Fuel Filter
Fuel Filter FUEL SYSTEM: GASOLINE VEHICLES Connect fuel line (3) to fuel pump module (1). See Fuel Line Installation on page 23-16. 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 411: Fuel Filter Installation
FUEL SYSTEM: GASOLINE VEHICLES Fueling Instructions – Gasoline Vehicle FUEL FILTER INSTALLATION CAUTION • Fuel filter flex hoses are keyed to aid proper installation into fuel pump module. NOTE: The fuel filter is keyed to the fuel pump module to prevent incorrect assembly. The inlet and outlet flex hoses are keyed to the fuel filter ports to prevent incorrect assembly.
Page 412 Fueling Instructions – Gasoline Vehicle FUEL SYSTEM: GASOLINE VEHICLES CAUTION • Use unleaded gasoline only. • Whenever possible, avoid using oxygenated and blended fuels. • Do not use any fuel with an alcohol content that exceeds 10% by volume (such as E15 and E85). Ethanol is an alcohol that readily absorbs moisture, causing corrosion of fuel system components.
Page 413: Section 24 - Exhaust System: Gasoline Vehicles
SECTION 24 — EXHAUST SYSTEM: GASOLINE VEHICLES DANGER Exhaust System: Gasoline Vehicles • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. MUFFLER MUFFLER REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery- Gasoline Vehicles on page 1-3. If equipped, remove air deflector from top of engine.
Page 414 Muffler EXHAUST SYSTEM: GASOLINE VEHICLES 3112a Figure 24-1 Exhaust System Page 24-2 2018 Carryall 300 Maintenance and Service Manual...
Page 415: Section 25 - Clutches: Gasoline Vehicles
SECTION 25 — CLUTCHES: GASOLINE VEHICLES DANGER Clutches: Gasoline Vehicles • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION The torque converter consists of a drive clutch, a driven clutch, and a drive belt. The drive clutch, which is mounted to the engine, is in the open position when the engine is at idle.
Page 416: Troubleshooting
Troubleshooting CLUTCHES: GASOLINE VEHICLES If cleaning the driven clutch does not solve the problem, disassemble and thoroughly clean all parts of the drive clutch. Be sure to clean the plastic drive buttons (7) (Figure 25-3, Page 25-4). (CC P/N 101809101) (CC P/N 1014497) (CC P/N 1014508) (CC P/N 1014507)
Page 417: 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 418: 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 419 CLUTCHES: GASOLINE VEHICLES Drive Clutch 8. Drive Clutch Weight 17. Spacer, Idler, Drive 9. Thrust Washer 18. Sheave, Fixed, Drive 2960 Figure 25-3 Drive Clutch – Exploded View CAUTION • Be very careful when handling the clutches. A clutch that has been dropped will not be properly balanced.
Page 420 Drive Clutch CLUTCHES: GASOLINE VEHICLES WARNING • Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold vehicle in raised position.
Page 421 CLUTCHES: GASOLINE VEHICLES Drive Clutch DRIVE CLUTCH DISASSEMBLY CAUTION • The drive clutch is balanced as an assembly. Before disassembly, make match marks on the drive clutch hub and on the moveable sheave so they can be reassembled in the same positions (Figure 25-6, Page 25-7).
Page 422: Drive Clutch Removal
Drive Clutch CLUTCHES: GASOLINE VEHICLES 3053 Figure 25-8 Drive Button Mounting Figure 25-9 Weight Position Remove the clutch weights: 5.1. Remove the screws (1) and flat washers (2) attaching the weights (3) as shown (Figure 25-9, Page 25-8). 5.2. Pull the weight assemblies (3), with pins, from slots (4) in the clutch. See following NOTE. NOTE: Before removing, note the orientation of the wave washer (1) and secondary weight (2) on the primary weight (3) (Figure 25-10, Page 25-9).
Page 423: Inspection Of Drive Clutch Parts
CLUTCHES: GASOLINE VEHICLES Drive Clutch Figure 25-10 Primary and Secondary Weights, Wave Washer and Pin Remove the retaining ring (6) from the shaft of the fixed sheave (18) and slide the moveable sheave (13) off the shaft (Figure 25-3, Page 25-4). See following NOTE. NOTE: If the moveable sheave is removed from the hub of the fixed sheave, the spiral back-up rings (11) must be replaced with new rings (Figure 25-3, Page 25-4).
Page 424: Drive Clutch Assembly
Drive Clutch CLUTCHES: GASOLINE VEHICLES Inspect the primary weights (8) and the hub casting for wear. If the primary weights show signs they are touching the casting, the tips of the weights have worn beyond specification and they must be replaced. Inspect the pins on the primary weights (8).
Page 425: Drive Clutch Installation
CLUTCHES: GASOLINE VEHICLES Drive Clutch NOTE: Make sure there is at least a (minimum) gap of 0.020 in. (0.51 mm) between each end of the mounting pin and the mounting bolt. Install three drive button take-up springs. 11.1. Install each spring on right-hand side of the three button mounting posts (when looking into the interior of the clutch drive hub, and with the rib at a twelve o’clock position) as shown (Figure 25-13, Page 25-11).
Page 426: 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 427: Driven Clutch Removal
CLUTCHES: GASOLINE VEHICLES Driven Clutch 5. Cam, Driven Clutch 11. Sheave, Fixed, Driven 6. Spring, Driven Clutch, 55 Degree 12. Key, 3/16 in. (4.7 mm) Square X 1.50 in. (38 mm) Long 2961 Figure 25-14 Driven Clutch – Exploded View DRIVEN CLUTCH REMOVAL Remove the drive belt as instructed.
Page 428: 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 429 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 430: 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 431: Section 26 - Transaxle (Ed65): Gasoline Vehicles
SECTION 26 — TRANSAXLE (ED65): GASOLINE VEHICLES DANGER Transaxle (ED65): Gasoline Vehicles • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION The vehicles addressed in this manual are equipped with heavy-duty transaxles. The transaxle utilizes internal gearing to change vehicle direction.
Page 432: Governor System
General Information TRANSAXLE (ED65): GASOLINE VEHICLES WARNING • With the switch in the MAINTENANCE position and the engine running, the vehicle may move suddenly if the Forward/Reverse handle is shifted or accidentally bumped. To prevent this, chock the front and rear wheels and firmly set the park brake before servicing or leaving the vehicle.
Page 433: Tools Required For This Section
TRANSAXLE (ED65): GASOLINE VEHICLES General Information Use a funnel when filling the transaxle through the lubricant level indicator hole. Fill with 67.6 fl-oz (2 L) 80-90 WT. API class GL or 80-90 WT. AGMA class 5 EP gear lubricant (or until lubricant begins to run out of the level indicator hole).
Page 434: 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 on page 1-3. Place chocks at the front wheels and loosen lug nuts on both rear wheels.
Page 435 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 436: 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 437: 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 438: Axle Shaft Oil Seal Installation
Axle Tubes, Axle Shafts and Wheel Bearings TRANSAXLE (ED65): GASOLINE VEHICLES Remove axle tube (2) from gearcase (4) (Figure 26-5, Page 26-6). See Axle Tube and Axle Shaft Removal on page 26-6. Pull oil seal (7) from gearcase (4). AXLE SHAFT OIL SEAL INSTALLATION Clean bore in gearcase (4) where new oil seal (7) will sit (Figure 26-5, Page 26-6).
Page 439: 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 on page 1-3. Place chocks at the front wheels and loosen lug nuts on both rear wheels.
Page 440 Transaxle Removal TRANSAXLE (ED65): GASOLINE VEHICLES Figure 26-8 Disconnect Rear Shackles Figure 26-9 Disconnect Front of Leaf Spring Position floor jack under rear crossmember of chassis or trailer hitch mount (if equipped) (Figure 26-10, Page 26-10). See WARNING “Lift only one end of the vehicle...” in General Warnings on page 1-1. Raise vehicle just enough to relieve weight on leaf springs, then remove bolts securing leaf springs to shackles (Figure 26-8, Page 26-10).
Page 441 TRANSAXLE (ED65): GASOLINE VEHICLES Transaxle Removal Roll powertrain out from under vehicle. Place blocks under the engine pan so they will completely support the engine and keep it level to the floor (Figure 26-11, Page 26-11). See following NOTE. NOTE: Place the blocks so they will support the engine when the transaxle is detached and moved away from the powertrain.
Page 442 Transaxle Removal TRANSAXLE (ED65): GASOLINE VEHICLES 3063 Figure 26-12 Transaxle Mounting Bolts Page 26-12 2018 Carryall 300 Maintenance and Service Manual...
Page 443: Transaxle Installation
TRANSAXLE (ED65): GASOLINE VEHICLES Transaxle Installation TRANSAXLE INSTALLATION See General Warnings on page 1-1. Installation is reverse of removal procedure. When attaching transaxle to powertrain, initially install the eight bolts (1) finger-tight (Figure 26-12, Page 26-12). Then, tighten fasteners in the following order: 1.1.
Page 444: Shifter Cable Installation
Shifter Cable TRANSAXLE (ED65): GASOLINE VEHICLES Cut wire ties securing shifter cable to chassis. Make note of cable routing, then remove shifter cable from vehicle. 3064 3065 Figure 26-13 Shifter Cable at FNR Handle Figure 26-14 Shifter Cable at Transaxle SHIFTER CABLE INSTALLATION Install shifter cable (2), routing it exactly as it was originally, from instrument panel to transaxle.
Page 445: Index
Index Index battery Index installation ............20-35 AC power and circuit storage ............20-36 testing (ERIC charger) ........15-21 testing ............. 18-16 accelerator testing under load........18-16, 18-36 cable voltage test ............18-16 installation ............ 23-10 battery charger (ERIC) ........... 15-1 removal ............
Page 446 INDEX brake assembly............ 6-5 amp hours ............11-8 vehicle body............4-1 anti-tamper speed ..........11-7 clutch (torque converter) troubleshooting....25-1 audible charging indicator ........11-8 clutch, drive battery type............11-8 see drive clutch ..........25-4 code a, code b, and code c ......... 11-8 clutch, driven connection tests ..........11-27 see driven clutch ..........
Page 447 INDEX see transaxle ............. 26-9 Forward/Reverse switch driven clutch installation ............13-2 assembly ............25-14 removal ............. 13-2 disassembly............. 25-13 fuel inspection ............25-14 relieving pressure ..........23-2 installation ............25-16 fuel filter removal ............25-13 installation ............23-23 removal ............23-22 fuel gauge/hour meter ..........
Page 448 INDEX testing ............. 12-22 testing (key-start) ..........19-7 headlight switch kill circuit, engine installation ..........13-12, 20-30 testing ............. 18-32 removal ..........13-12, 20-30 kill limit switch headlights installation ............20-22 see also lighting circuit........18-41 removal ............20-22 testing ............. 18-41 kill limit switch, engine high pedal detect ...........
Page 449 INDEX testing ............. 12-31 rear wheel bearing see test procedures, motor ......16-1 see wheel bearing ..........26-7 walk away braking ..........12-2 receptacle motor braking see charger receptacle ........13-9 see regenerative braking ........12-3 regenerative braking ..........12-3 motor controller output regulator (MCOR) reverse buzzer installation ............
Page 450 INDEX bearing shock absorber cleaning ..........20-5–20-6 inspection and removal........9-1 inspection..........20-5–20-6 installation ............9-2 removal ............20-6 belt tension adjustment ........20-13 brush spring inspection............20-2 replacement ........... 20-2 test procedures, CDT connection......11-27 brushes ............. 20-1 test procedures, charger inspection............20-2 AC power and continuity test of AC circuit...
Page 451 INDEX test procedures, pedal-start gasoline vehicle lubrication ............26-2 18-pin connector ..........18-21 removal ............. 26-9 4-pin connector ..........18-43 service............... 26-2 accelerator pedal limit switch......18-25 transaxle, type g battery ............. 18-16 assembly ............17-10 battery load test ..........18-36 axle bearing ............
Page 452 NOTES...
Page 453 NOTES...
Page 454 NOTES...

Club Car Carryall 300 2018 Maintenance And Service Manual

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