Page 1 2019 Carryall 500 and 700 Maintenance and Service Manual Gasoline Vehicle with Kohler ECH440 Engine Electric Vehicle with QuiQ™ ™ ™ Charger Manual Number 105355106 Edition Code A...
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 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 Disable The Vehicle ........................... 1-3 Disconnect the Battery- Gasoline Vehicles ....................1-4 Connect the Battery- Gasoline Vehicles....................... 1-4 Disconnect the Batteries –...
Page 6 Rear Fender and Tailskirt Installation ......................4-17 Electric Bed Lift ............................4-18 Electric Bed Lift Removal ......................... 4-18 Electric Bed Lift Installation ........................4-18 Floor Mat ..............................4-21 Floor Mat Removal ..........................4-21 Floor Mat Installation..........................4-21 Trailer Hitch..............................4-21 Trailer Hitch Removal..........................
Page 7 Rack and Pinion Removal – Maintenance-Free Ball Joints ................7-7 Rack and Pinion Disassembly ........................7-8 Rack and Pinion Assembly ........................7-10 Rack and Pinion Installation – Maintenance-Free Ball Joints............... 7-13 Tie Rod and Drag Link ..........................7-14 Tie Rod and Drag Link Removal – Maintenance-Free Ball Joints ..............7-14 Tie Rod and Drag Link Installation –...
Page 8 Lift The Rear Of The Vehicle ........................10-17 Lower The Front Of The Vehicle ......................10-18 Lower The Rear Of The Vehicle.......................10-19 Spark Plug ..............................10-20 Spark Plug Removal ..........................10-20 Spark Plug Inspection ..........................10-21 Spark Plug Gap ............................10-21 Spark Plug Installation ..........................10-22 Valve Clearance Check and Adjustment.......................10-22 SECTION 11 —...
Page 9 Relay DNC # ............................11-13 Current Sense # ............................. 11-13 M-Shorted # ............................11-13 Relay Coil #............................11-13 Precharge # ............................11-13 FLD Missing # ............................11-13 HW Failsafe #............................11-13 DRVR Overcur #............................. 11-14 RLY DRVR On #............................. 11-14 RLY DRVR Off # .............................
Page 10 Programming ............................. 11-24 Cloning ..............................11-24 Favorites..............................11-24 HHP Settings ............................. 11-25 Plot & Log ..............................11-26 Plot................................ 11-26 Log ................................ 11-26 CDT Troubleshooting ..........................11-27 Connection Tests ............................11-28 SECTION 12 — Electrical System Troubleshooting: IQ Plus Electric Vehicles............12-1 General Information .............................
Page 11 Battery Testing Basics – 6 Volt........................14-2 Observation............................. 14-2 Measuring Voltage of Battery Set......................14-2 Battery Cell Numbering ..........................14-2 Battery Testing – 6 Volt ..........................14-3 Battery Regrouping............................14-3 Battery Replacement ........................... 14-5 Battery Care..............................14-6 Water Quality ............................14-6 Deionizer ..............................
Page 12 Axle Shaft ............................... 17-1 Axle Bearing............................17-4 Transaxle ..............................17-5 Transaxle Removal ..........................17-5 Transaxle Disassembly, Inspection, and Assembly..................17-8 Transaxle Disassembly and Inspection...................... 17-8 Transaxle Assembly..........................17-10 Transaxle Installation ..........................17-12 SECTION 18 — Troubleshooting and Electrical System: Gasoline Vehicles............18-1 General Information .............................
Page 13 Accelerator Pedal Limit Switch ........................19-30 Accelerator Pedal Limit Switch Removal ....................19-30 Accelerator Pedal Limit Switch Installation....................19-30 Kill Limit Switch ............................19-31 Kill Limit Switch Removal ........................19-31 Kill Limit Switch Installation ........................19-31 Reverse Warning Buzzer..........................19-32 Reverse Warning Buzzer Removal ......................19-32 Reverse Warning Buzzer Installation......................19-32 Reverse Buzzer Limit Switch ........................19-33 Reverse Buzzer Limit Switch Removal .....................19-33 Reverse Buzzer Limit Switch Installation ....................19-33...
Page 14 Snubber Installation ..........................20-8 SECTION 21 — Fuel System: Gasoline Vehicles ....................21-1 General Information ............................. 21-1 EFI System Features/Specifications......................21-1 Engine Control Linkages ..........................21-1 General Information ..........................21-2 Ground Speed............................21-2 Accelerator Rod............................21-2 Governor Cable ............................21-5 Accelerator Cable ............................
Page 15 Driven Clutch Installation.........................23-19 SECTION 24 — Transaxle (ED65): Gasoline Vehicles..................24-1 General Information ............................. 24-1 Forward/Neutral/Reverse control (FNR) ....................24-1 Maintenance/Operate Switch........................24-1 Governor System............................. 24-2 Transaxle Service ............................ 24-2 Lubrication .............................. 24-2 Tools Required For This Section ....................... 24-3 Rear Hubs..............................
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: Disable The Vehicle
SAFETY General Warnings WARNING Gasoline vehicles only: • To avoid unintentionally starting a gasoline vehicle, disconnect the battery and spark plug wire. • Frame ground – Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wiring.
Page 20: Disconnect The Battery- Gasoline Vehicles
General Warnings SAFETY DISCONNECT THE BATTERY- GASOLINE VEHICLES Disable the vehicle. Remove positive terminal cover. Disconnect the negative (-) cable (1) (Figure 1-1, Page 1-4). Figure 1-1 Battery - Gasoline Vehicles Disconnect the positive (+) cable (2). CONNECT THE BATTERY- GASOLINE VEHICLES Connect the positive (+) cable (2) (Figure 1-1, Page 1-4).
Page 21: Disconnect The Batteries - Electric Vehicles
SAFETY General Warnings DISCONNECT THE BATTERIES – ELECTRIC VEHICLES WARNING • Place Run/Tow switch in the TOW position before disconnecting or connecting the batteries. Failure to heed this warning can result in a battery explosion or severe personal injury. Disable the vehicle. Set the Run/Tow switch to TOW.
Page 22: International Safety Symbols On Batteries
Responsibility for environmental protection must be shared, not only by the manufacturers of the batteries, but by people who use the batteries as well. Please contact your nearest Club Car dealer or distributor for information on how to properly recycle your batteries. 1403...
Page 23 SECTION 2 — VEHICLE SPECIFICATIONS VEHICLE SPECIFICATIONS Vehicle Specifications VEHICLE SPECIFICATIONS – ELECTRIC VEHICLES SPECIFICATIONS CARRYALL 500 CARRYALL 700 POWER SOURCE ELECTRIC ELECTRIC Drive motor: Direct drive, 48 volts DC, shunt wound, 3.7 hp ● ● Transaxle: Double reduction helical gear with 12.3:1 direct drive axle ●...
Page 24: Section 2 - Vehicle Specifications
Vehicle Specifications VEHICLE SPECIFICATIONS SPECIFICATIONS CARRYALL 500 CARRYALL 700 POWER SOURCE ELECTRIC ELECTRIC Weight: Standard electric vehicle (curb weight) 1393 lb (632 kg) 1475 lb (669 kg) 15 to 17 mph 15 to 17 mph Maximum forward speed (24 to 27 km/h) (24 to 27 km/h) Outside clearance circle (diameter) 248.5 in (631.1 cm)
Page 25: Quiq Battery Charger Specifications
VEHICLE SPECIFICATIONS Vehicle Specifications QUIQ BATTERY CHARGER SPECIFICATIONS QUIQ BATTERY CHARGER SPECIFICATIONS AC INPUT AC Voltage – range 85 to 265 VAC (acceptable) AC Voltage – nominal 120 to 230 VAC Frequency 45 to 65 Hz AC Power Factor – nominal >0.99 @ 120 VAC / >0.98 @ 230 VAC POWER CONSUMPTION Max:...
Page 26: Vehicle Specifications - Gasoline Vehicles
Vehicle Specifications VEHICLE SPECIFICATIONS VEHICLE SPECIFICATIONS – GASOLINE VEHICLES NOTE: Engine horsepower and torque specifications are provided by the engine manufacturer. Actual horsepower and torque in use may differ and are dependent on environmental conditions as well as maintenance condition of the engine. SPECIFICATIONS CARRYALL 500 CARRYALL 700...
Page 27 VEHICLE SPECIFICATIONS Vehicle Specifications SPECIFICATIONS CARRYALL 500 CARRYALL 700 POWER SOURCE GASOLINE GASOLINE Ground clearance 5.2 in (13.2 cm) 5.2 in (13.2 cm) Front wheel tread 36.6 in (92.9 cm) 36.6 in (92.9 cm) Rear wheel tread 39.5 in (100.3 cm) 39.5 in (100.3 cm) Weight: Standard gasoline vehicle (curb weight) 907 lb (411 kg)
Page 28 Vehicle Specifications VEHICLE SPECIFICATIONS Pagination Page Page 2-6 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 29: Section 3 - General Information
• See General Warnings on page 1-1. Important features unique to the different models covered in this manual are highlighted. Club Car, LLC recommends the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s).
Page 30: Storage - Electric Vehicles
Storage – Electric Vehicles GENERAL INFORMATION 2843 Figure 3-1 Serial Number Decal STORAGE – ELECTRIC VEHICLES See General Warnings on page 1-1. WARNING • Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse handle or switch in the NEUTRAL position during storage.
Page 31: Returning The Stored Electric Vehicle To Service
GENERAL INFORMATION Storage – Electric Vehicles Immediately Prior to Storage, Perform the Following Steps Unload the vehicle so that tires are supporting only the weight of the vehicle. Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse switch in the NEUTRAL position during storage.
Page 32: Storage - Gasoline Vehicles
Storage – Gasoline Vehicles GENERAL INFORMATION STORAGE – GASOLINE VEHICLES See General Warnings on page 1-1. DANGER • Do not attempt to drain fuel when the engine is hot or while it is running. • Be sure to clean up any spilled gasoline before operating the vehicle. •...
Page 33: Returning The Stored Gasoline Vehicle To Service
GENERAL INFORMATION Storage – Gasoline Vehicles not allow this solution to enter the batteries. Let the terminals dry and then coat them with Battery Terminal Protector Spray. To protect the engine, remove spark plug and pour 0.5 fl-oz (14.2 mL) of SAE 10 weight oil into the engine through the spark plug hole.
Page 34 Storage – Gasoline Vehicles GENERAL INFORMATION Pagination Page Page 3-6 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 35: Section 4 - Body And Trim
SECTION 4 — BODY AND TRIM DANGER Body and Trim • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. CLEANING THE VEHICLE See General Warnings on page 1-1. CAUTION • Do not use detergents or cleaning solvents that contain ammonia, aromatic solvents, or alkali materials on body panels or seats.
Page 36: Front Body Repair
Front Body Repair BODY AND TRIM CAUTION • To prevent damage to the vehicle when removing difficult stains or heavy soiling, remove the seat from the vehicle first. FRONT BODY REPAIR See General Warnings on page 1-1. LIGHT SCRATCHES Clean entire area to be repaired with clean, clear water. Using 1200 grit sandpaper, water-sand entire area of scratch until original scratch is no longer visible, either with finishing sander or wet sanding block.
Page 37: Brushguard Installation
BODY AND TRIM Front Body Remove the bolts (1) (Figure 4-1, Page 4-3). Remove the screws (2) and washers (3). Remove the brushguard (4). BRUSHGUARD INSTALLATION Position the brushguard (4) onto the vehicle (Figure 4-1, Page 4-3). Install the washers (3), screws (2), and bolts (1). Tighten the bolts to 36 ft·lb (49 N·m). Tighten the screws to 25 ft·lb (34 N·m).
Page 38: Cowl Removal
Front Body BODY AND TRIM COWL REMOVAL Park vehicle and chock tires. Disconnect the batteries. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. See Disconnect the Battery- Gasoline Vehicles on page 1-4. The cowl is secured by tabs located behind the front fenders (2), and under the lip of the dash (1) (Figure 4-2, Page 4-5).
Page 39: Grille Removal
BODY AND TRIM Front Body 2846 Figure 4-2 Front Cowl GRILLE REMOVAL Park vehicle and chock the tires. Disconnect the batteries. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. See Disconnect the Battery- Gasoline Vehicles on page 1-4. Remove HD bumper (if equipped).
Page 40: Grille Installation
Front Body BODY AND TRIM 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 41 BODY AND TRIM Front Body 2844 Figure 4-3 Front Grille, Bumper, and Side Fenders 2019 Carryall 500 and 700 Maintenance and Service Manual Page 4-7...
Page 42: Front Bumper And Side Fender Removal
Front Body BODY AND TRIM FRONT BUMPER AND SIDE FENDER REMOVAL Park the vehicle, chock tires. Disconnect the batteries. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. See Disconnect the Battery- Gasoline Vehicles on page 1-4. Remove HD bumper, (if equipped). See Brushguard Removal on page 4-2. Remove cowl.
Page 43: Instrument Panel Removal
BODY AND TRIM Front Body INSTRUMENT PANEL REMOVAL Disconnect the batteries. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. See Disconnect the Battery- Gasoline Vehicles on page 1-4. Remove front cowl. See Cowl Removal, Section 4, Page 4-4. From the inside of the dash, press upper snap tabs (1) of the instrument panel inward to release from dash.
Page 44: Dash Removal
Front Body BODY AND TRIM DASH REMOVAL Disconnect the batteries. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. See Disconnect the Battery- Gasoline Vehicles on page 1-4. Remove cowl. See Cowl Removal on page 4-4. Remove steering wheel. See Steering Wheel Removal, Section 7, Page 7-1. Disconnect instrument panel wiring.
Page 45 BODY AND TRIM Front Body 2863 Figure 4-5 Dash Assembly 2019 Carryall 500 and 700 Maintenance and Service Manual Page 4-11...
Page 46: Tilt Bed
Tilt Bed BODY AND TRIM TILT BED See General Warnings on page 1-1. TILT BED REMOVAL NOTE: This procedure requires two people. WARNING • Remove all cargo before raising the bed or servicing the vehicle. If the vehicle is equipped with a prop rod, ensure that it is securely engaged while bed is raised.
Page 47 BODY AND TRIM Tilt Bed 2980 Figure 4-6 Tilt Bed Mounting 2019 Carryall 500 and 700 Maintenance and Service Manual Page 4-13...
Page 48: Bed Latch Assembly Removal
Tilt Bed BODY AND TRIM BED LATCH ASSEMBLY REMOVAL NOTE: This procedure requires the aid of an assistant. Park the vehicle and chock the tires. Disconnect the batteries. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. See Disconnect the Battery- Gasoline Vehicles on page 1-4. Raise bed and secure prop rod (9) in prop rod track (2) (Figure 4-6, Page 4-13).
Page 49 BODY AND TRIM Tilt Bed 2982 Figure 4-7 Bed Latch Assembly 2019 Carryall 500 and 700 Maintenance and Service Manual Page 4-15...
Page 50: Rear Fenders And Tailskirt
Rear Fenders and Tailskirt BODY AND TRIM 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 51: Rear Fender And Tailskirt Installation
BODY AND TRIM Rear Fenders and Tailskirt Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s). See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. See Disconnect the Battery- Gasoline Vehicles on page 1-4. Remove the tilt bed.
Page 52: Electric Bed Lift
Electric Bed Lift BODY AND TRIM ELECTRIC BED LIFT ELECTRIC BED LIFT REMOVAL NOTE: For vehicles equipped with an electric bed lift. This procedure requires the aid of an assistant. Disconnect the batteries. See Disconnect the Batteries – Electric Vehicles on page 1-5. See Disconnect the Battery- Gasoline Vehicles on page 1-4.
Page 53 BODY AND TRIM Electric Bed Lift 2983 Figure 4-9 Electric Bed Lift 2019 Carryall 500 and 700 Maintenance and Service Manual Page 4-19...
Page 54 Electric Bed Lift BODY AND TRIM 2985 Figure 4-10 Electric Bed Mounting Page 4-20 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 55: Floor Mat
BODY AND TRIM Floor Mat FLOOR MAT See General Warnings on page 1-1. FLOOR MAT REMOVAL Remove the brake and accelerator pedals. See Accelerator and Brake Pedal Group, Section 5, Page 5-1. Remove the top edge of the floor mat from the overlapping flange under the dash. Lift the mat from the vehicle.
Page 56 Trailer Hitch BODY AND TRIM Pagination Page Page 4-22 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 57: Section 5 - Accelerator And Brake Pedal Group
SECTION 5 — ACCELERATOR AND BRAKE PEDAL GROUP DANGER Accelerator and Brake Pedal Group • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. BRAKE PEDAL AND PARK BRAKE (GAS AND ELECTRIC VEHICLES) See General Warnings on page 1-1. BRAKE PEDAL REMOVAL (GAS AND ELECTRIC VEHICLES) Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s).
Page 58 Brake Pedal and Park Brake (Gas and Electric Vehicles) ACCELERATOR AND BRAKE PEDAL GROUP Carryall 500 and 700 Electric Vehicle shown, (Gasoline Vehicle similar) 3208 Figure 5-1 Brake and Park Brake Pedal Assembly and Mounting Page 5-2 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 59 ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake (Gas and Electric Vehicles) 2999 Figure 5-2 Brake Pedal Weldment Through Floor Position and attach brake pedal assembly, mounting blocks (3 and 8), and washers (10) to vehicle frame as shown.
Page 60: Park Brake Removal (Gas And Electric Vehicles)
Brake Pedal and Park Brake (Gas and Electric Vehicles) ACCELERATOR AND BRAKE PEDAL GROUP PARK BRAKE REMOVAL (GAS AND ELECTRIC VEHICLES) Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s). See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. See Disconnect the Battery- Gasoline Vehicles on page 1-4.
Page 61: Accelerator Pedal - Gasoline Vehicles
ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles Install the two bushings (30) in the park brake pedal and position the park brake pedal on the shaft on the brake pedal assembly weldment (10). Then attach the ends of the torsion spring to the park brake pedal and to the brake pedal weldment as shown (Figure 5-5, Page 5-4).
Page 62: Accelerator Pedal Installation - Gasoline Vehicles
Accelerator Pedal – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP 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 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).
Page 63: Accelerator Pedal - Electric Vehicles
ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles Install the plastic spacer (20) on the pivot rod (6). Insert the pivot rod through the pivot rod supports on the vehicle frame. Tighten the four bolts (22) attaching the pivot rod supports to the frame to 75 in·lb (8.5 N·m). Install the bolt (4), two washers (5), and a new lock nut (7) through the lower hole in the pedal and through the pivot rod.
Page 64 Accelerator Pedal – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP WARNING • Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic floor jack) with 1000 lb (454 kg) minimum lifting capacity. Do not use lifting device to hold vehicle in raised position.
Page 65 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles 2642 Figure 5-8 Accelerator Pedal – Electric Vehicle with MCOR 2019 Carryall 500 and 700 Maintenance and Service Manual Page 5-9...
Page 66: Accelerator Pedal Installation - Electric Vehicles
Pedal Group Adjustment – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP ACCELERATOR PEDAL INSTALLATION – ELECTRIC VEHICLES If the accelerator pivot rod supports were replaced, position the supports (21) on the vehicle frame and install the four bolts (22), flat washers (16), and lock nuts (15) (Figure 5-8, Page 5-9). Finger-tighten nuts at this time. Insert the lower end of the accelerator pedal (1) through the floorboard and install the accelerator pivot rod (6) through the uppermost hole in the pedal.
Page 67 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles Figure 5-9 Loosen Rear Brake Equalizer Rod Nuts 2.3. Loosen the brake stop jam nut (31), then relieve pedal pressure on the stop by pushing down slightly on the pedal. Next, adjust the brake stop bumper (22) up or down (Figure 5-10, Page 5-11). Adjusting the bumper upward decreases distance between pedal and floorboard.
Page 68 Pedal Group Adjustment – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP 3.2. Tighten the nut (2) on the equalizer rod (1) so that the brake pedal free play is 1/4 inch to 1/2 inch (6 mm to 13 mm) (Figure 5-3, Page 5-3). 3.3.
Page 69 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles 1. Locked Position 2. Ratchet (B) Tooth Length 3. Make sure pawl (A) engages at least 75% of ratchet tooth length (B). Figure 5-13 Accelerator Pedal Height Measurement Figure 5-14 Ratchet/Pawl Tooth Engagement 4.5.
Page 70 Pedal Group Adjustment – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP 1. Accelerator Pedal Adjustment Tool 2. Rubber Strap Figure 5-17 Accelerator Pedal Height Adjustment Adjust the accelerator rod. See following DANGER. DANGER • Before servicing, turn the key switch to the OFF position and place the Forward/Reverse handle in the NEUTRAL position.
Page 71 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles 0 to 5° Top View of the Electrical Component Box 3016 Figure 5-18 Accelerator Cable CAUTION • After accelerator rod adjustment, make sure that approximately the same number of threads are exposed at each end of the accelerator rod.
Page 72: Pedal Group Adjustment - Electric Vehicles
Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP PEDAL GROUP ADJUSTMENT – ELECTRIC VEHICLES See General Warnings on page 1-1. Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. Adjust brake pedal height.
Page 73 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles Correct pedal position is 6 inches (15.2 cm) from floormat to back of brake pedal. 1400-18000-10211 1400-18000-10212 Figure 5-20 Brake Pedal Height Adjustment Figure 5-21 Brake Pedal Height Measurement Adjust brake pedal free play.
Page 74 Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP 0.060 inch (1.5 mm) A. Bottom View B. Cutaway Side View 2643 Figure 5-22 Park Brake Ratchet/Pawl Gap Adjustment 4.3. With the park brake unlocked, measure and note the distance from the top of the accelerator pedal to the floorboard, then lock the park brake (Figure 5-23, Page 5-18).
Page 75 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles closest to the floorboard. Press the accelerator pedal until the end of the tool rests against the floorboard; pedal height should be 5-5/8 inches (14.3 cm). Use a rubber strap to hold pedal in position against the floorboard and then tighten nut to 26 ft·lb (35.3 N·m) (Figure 5-27, Page 5-19).
Page 76 Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP Pagination Page Page 5-20 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 77: Section 6 - Wheel Brake Assemblies
SECTION 6 — WHEEL BRAKE ASSEMBLIES DANGER Wheel Brake Assemblies • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. Asbestos Dust Warning • Some aftermarket brake shoes contain asbestos fiber, and asbestos dust is created when these brake mechanisms are handled.
Page 78 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES BRAKE DRUM TWO BRAKE SHOE RETAINER PIN HEADS AXLE TUBE 1/2 INCH X 5/8 INCH COLD CHISEL 2814 2834a Figure 6-1 Loosen Equalizer Nut Figure 6-2 Shoe Retainer Pins 4.2. Insert a 1/2 inch x 5/8 inch cold chisel (1) under the head (2) of each pin and shear them off as illustrated (Figure 6-2, Page 6-2).
Page 79: Brake Assembly Cleaning
WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning 2824 2825 Figure 6-3 Rotate Clip Retainer Figure 6-4 Remove Shoes BRAKE ASSEMBLY CLEANING See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. Carefully clean the brake backing plate and all mechanical components. Remove the rubber boot from backing plate and wipe with a clean damp cloth.
Page 80 Brake Assembly Cleaning WHEEL BRAKE ASSEMBLIES Use a small brush to carefully apply a light coat of white lithium NLGI #2 grease (Dow Corning ® BR2-Plus or equivalent) on each of the six raised bosses on brake backing plate (Figure 6-7, Page 6-4). See preceding WARNING.
Page 81: Brake Shoe Installation
WHEEL BRAKE ASSEMBLIES Brake Shoe Installation BRAKE SHOE INSTALLATION See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. NOTE: Components of the front wheel brake assembly are identical to the rear wheel manually-adjusted brake assembly. The front brake assembly is rotated 90° (when compared to the rear brake assembly) so the adjusting bolt on each assembly is oriented to the rear of the vehicle rather than at the top of the assembly (Figure 6-23, Page 6-14).
Page 82: Brake Adjustment
Brake Adjustment WHEEL BRAKE ASSEMBLIES 2808 2800 Figure 6-13 Insert Shoes Figure 6-14 Position Shoes CAUTION • Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to installing the axle shaft. For electric vehicles: Install the axle shaft.
Page 83: Brake Cluster Adjustment
Figure 6-18 Front Brake Adjustment Bolt Use a torque wrench and a 7 mm 8–point socket or Club Car brake adjustment tool to turn the brake adjustment bolt (5) on each brake clockwise until it is tightened to 15 ft·lb (20.3 N·m) then back off 5 clicks. See following...
Page 84 Brake Adjustment WHEEL BRAKE ASSEMBLIES 2806 Figure 6-19 Front Manually Adjusted Brake Assembly Page 6-8 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 85: Brake Cable Equalization
WHEEL BRAKE ASSEMBLIES Brake Adjustment TYPICAL 4 PLACES TYPICAL 4 PLACES 2903 Figure 6-20 Rear Manually-Adjusted Brake Assembly BRAKE CABLE EQUALIZATION Set park brake in the third tooth of the ratchet. Place a wedge between the park brake pedal and brake pedal to prevent the park brake from disengaging while equalizing the brake cables (Figure 6-21, Page 6-10).
Page 86: Final Brake Cluster Adjustment
Brake Adjustment WHEEL BRAKE ASSEMBLIES 2809 Figure 6-21 Set Park Brake and Insert Wedge Equalize the brake cables. 2.1. Tighten the nylon lock nut (6) on the front equalizer rod (2) to 35 in·lb (4 N·m) (Figure 6-16, Page 6-7). 2.2.
Page 87: Brake Cluster Removal And Installation
WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation Test drive vehicle. Be sure the brakes function properly. When brake pedal is fully pressed under moderate pressure, it should not go more than halfway to floor, and the vehicle should come to a smooth, straight stop. If the brake pedal goes more than halfway to the floor, or if the vehicle swerves or fails to stop, check pedal group adjustment, and readjust cable tension and brakes.
Page 88 Brake Cluster Removal and Installation WHEEL BRAKE ASSEMBLIES TYPICAL 4 PLACES 2810 Figure 6-22 Front Spindle Assembly Page 6-12 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 89: Rear Brake Cluster Removal
WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation REAR BRAKE CLUSTER REMOVAL Place chocks at the front wheels, loosen the lug nuts on the rear wheels and lift the rear of the vehicle with a chain hoist or floor jack. Place jack stands under the axle tubes to support the vehicle. Release park brake and loosen equalizer retaining nuts (1 and 5) on equalizer rod (2) to slightly loosen brake cable (Figure 6-15, Page 6-7).
Page 90: Front Brake Cables
Front Brake Cables WHEEL BRAKE ASSEMBLIES FRONT BRAKE CABLES See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. 3189 Figure 6-23 Front Brake Cables and Equalizer Page 6-14 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 91: Front Brake Cable Removal
WHEEL BRAKE ASSEMBLIES Front Brake Cables FRONT BRAKE CABLE REMOVAL Remove bow-tie pin (9) and clevis pin (6) from brake lever arm on front brake cluster (Figure 6-23, Page 6-14). Remove E-clip (7) from brake cable housing at the front spindle bracket and remove cable (8 or 18) from spindle. Remove bow-tie pin (9), clevis pin (6), and E-clip (7) from brake cable (8 or 18) at equalizer (2).
Page 92: Rear Brake Cables
Rear Brake Cables WHEEL BRAKE ASSEMBLIES REAR BRAKE CABLES 3191 Figure 6-25 Rear Brake Cables and Equalizer Page 6-16 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 93: Rear Brake Cable Removal
WHEEL BRAKE ASSEMBLIES Rear Brake Cables REAR BRAKE CABLE REMOVAL Chock wheels to keep vehicle from unintentionally moving. Release park brake if latched and loosen equalizer retaining nuts (13 and 14) on equalizer rod (2) to slightly loosen brake cables (7) (Figure 6-25, Page 6-16). Rotate brake cables (7) upward and pull ends through holes in top of equalizer (3).
Page 94 Rear Brake Cables WHEEL BRAKE ASSEMBLIES Pagination Page Page 6-18 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 95: Section 7 - Steering And Front Suspension
SECTION 7 — STEERING AND FRONT SUSPENSION DANGER Steering and Front Suspension • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION Steering is controlled through a rack and pinion steering assembly that is connected by a steering column to a steering wheel.
Page 96: Steering Wheel Installation
Steering Wheel STEERING AND FRONT SUSPENSION 2862 1500-18300-10253 Figure 7-1 Steering Wheel Figure 7-2 Steering Wheel Puller STEERING WHEEL INSTALLATION NOTE: To minimize corrosion and to make future removal of the steering wheel easier, apply a small amount of oil or anti-seize compound to steering shaft splines and taper before installing the steering wheel.
Page 97: Steering Column
STEERING AND FRONT SUSPENSION Steering Column STEERING COLUMN See General Warnings on page 1-1. 2609 Figure 7-3 Steering Column 2019 Carryall 500 and 700 Maintenance and Service Manual Page 7-3...
Page 98: Steering Column Removal
Steering Column STEERING AND FRONT SUSPENSION STEERING COLUMN REMOVAL Remove the steering wheel as previously instructed. Remove cowl. See Cowl Removal, Section 4, Page 4-4. Remove the upper bolt (2) and lock washer (3) from the universal joint (Figure 7-3, Page 7-3). Remove the nuts (9), bolts (8 and 10), and washers (7 and 11) from the steering column mount (4 and 5) (Figure 7-3, Page 7-3).
Page 99: Steering Column Installation
STEERING AND FRONT SUSPENSION Steering Column 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 – Bottom End Figure 7-5 Steering Shaft – Top End STEERING COLUMN INSTALLATION Install boot (12).
Page 100: Steering Adjustment
Steering Adjustment STEERING AND FRONT SUSPENSION STEERING ADJUSTMENT See General Warnings on page 1-1. Turn the steering wheel all the way to the right. Note the distance between the passenger side spindle stop (2) and passenger side A-plate (3) (Figure 7-6, Page 7-8). The internal stop on the rack must reach its limit of travel against rack and pinion housing at exactly the same time the spindle stops against the passenger side A-plate (with vehicle wheels turned to the right).
Page 101: Rack And Pinion
STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION See General Warnings on page 1-1. CAUTION • Front impacts that bend tie rods and/or drag links can possibly damage internal steering gear components. See Rack and Pinion Inspection on page 7-7. The manufacturer recommends inspecting the rack and pinion and replacing if damaged.
Page 102: Rack And Pinion Disassembly
Rack and Pinion STEERING AND FRONT SUSPENSION 1838 Figure 7-6 Adjust Steering Alignment RACK AND PINION DISASSEMBLY CAUTION • The ball joint (23) (Figure 7-10, Page 7-10) has left-hand threads. Remove ball joint from the spindle and inspect it for excessive wear. Remove the drag link (28) (Figure 7-10, Page 7-10).
Page 103 STEERING AND FRONT SUSPENSION Rack and Pinion 1. Press Ram 2. Pinion Gear 3. Bearing 1500-18400-10259 1500-18400-10260 Figure 7-7 Remove Pinion from Housing Figure 7-8 Remove Bearing from Pinion If necessary, remove the dust seal (12). See following NOTE. NOTE: If the dust seal (12) is removed, replace with a new one. Use snap ring pliers to remove the internal snap ring (11) (Figure 7-10, Page 7-10).
Page 104: Rack And Pinion Assembly
Rack and Pinion STEERING AND FRONT SUSPENSION 1839 Figure 7-10 Steering Gear – Maintenance-Free Ball Joints RACK AND PINION ASSEMBLY Install a new tab washer (4) and an inner ball joint (3) (Figure 7-9, Page 7-9). Install the ball joint onto the rack by securing the rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack from damage.
Page 105 STEERING AND FRONT SUSPENSION Rack and Pinion Apply a light coating of EP grease to the teeth of the rack (17), then slide the rack through the bushing (5) and housing (6). Install the stop washer (18) and retaining ring (19) to the end of the rack (Figure 7-10, Page 7-10). CAUTION •...
Page 106 Rack and Pinion STEERING AND FRONT SUSPENSION 1500-18400-10265 Figure 7-13 Rack and Pinion Resistance Install the internal snap ring (11) (Figure 7-10, Page 7-10). Using an appropriate size deep well socket (1) to apply pressure evenly, press in a new dust seal (2) (Figure 7-11, Page 7-11).
Page 107: Rack And Pinion Installation - Maintenance-Free Ball Joints
STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION INSTALLATION – MAINTENANCE-FREE BALL JOINTS Position the steering gear box assembly on the shock and gear support and install the bolts (30), washers (31), and nuts (32). Do not tighten the mounting bolts (Figure 7-10, Page 7-10). For ease of assembly and to prevent corrosion, apply a light coat of anti-seize and lubricating compound to the splined end of the steering column shaft.
Page 108: Tie Rod And Drag Link
Tie Rod and Drag Link STEERING AND FRONT SUSPENSION TIE ROD AND DRAG LINK See General Warnings on page 1-1. TIE ROD AND DRAG LINK REMOVAL – MAINTENANCE-FREE BALL JOINTS Using locking pliers to hold tie rod and drag link, loosen jam nuts (7 and 12) on tie rod ball joints (Figure 7-18, Page 7-18) and loosen jam nuts (27 and 29) on the drag link (Figure 7-10, Page 7-10).
Page 109: Front Suspension
STEERING AND FRONT SUSPENSION Front Suspension FRONT SUSPENSION See General Warnings on page 1-1. LUBRICATION Two grease fittings (one in each spindle housing) are provided. Lubricate these fittings at the recommended interval with the proper lubricant. See Periodic Lubrication Schedules, Section 10, Page 10-7. WHEEL ALIGNMENT Wheel alignment is limited to equalizing the camber angle of each front wheel and adjusting toe-in of the front wheels.
Page 110 Front Suspension STEERING AND FRONT SUSPENSION Tighten the hex nut (8) on the adjustment eccentric (7) to 23 ft·lb (31 N·m) (Figure 7-19, Page 7-19). See also Figure 7-15, Page 7-15. Toe-in Adjustment On a level surface, roll the vehicle forward, then stop. Make sure the front wheels are pointed straight ahead. Do not turn the steering wheel again during this procedure.
Page 111: Front Suspension Components
STEERING AND FRONT SUSPENSION Front Suspension Components FRONT SUSPENSION COMPONENTS See General Warnings on page 1-1. LEAF SPRING REMOVAL Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s). See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. See Disconnect the Battery- Gasoline Vehicles on page 1-4.
Page 112 Front Suspension Components STEERING AND FRONT SUSPENSION 2610 Figure 7-18 Front Suspension – Upper Portion Page 7-18 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 113 STEERING AND FRONT SUSPENSION Front Suspension Components 2611 Figure 7-19 Front Suspension – Lower Portion 2019 Carryall 500 and 700 Maintenance and Service Manual Page 7-19...
Page 114: Kingpin And Steering Spindle Installation - Maintenance-Free Ball Joints
Front Suspension Components STEERING AND FRONT SUSPENSION KINGPIN AND STEERING SPINDLE INSTALLATION – MAINTENANCE-FREE BALL JOINTS Inspect all parts and replace them as necessary. Install the kingpin (26) over the leaf spring eye. Insert the bolt (25) and install the nut (14) (Figure 7-19, Page 7-19).
Page 115: Front Wheel Bearings And Hubs
STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs FRONT WHEEL BEARINGS AND HUBS See General Warnings on page 1-1. FRONT WHEEL FREE PLAY INSPECTION Raise the front of the vehicle. Using your hands, attempt to rock the wheel and hub assembly back and forth on the spindle. If there is any observable movement of the wheel and hub on the spindle, remove dust cap (1) and cotter pin (2) and then tighten the spindle nut (3) until the bearing (5) fully seats in the bearing race (7) (Figure 7-20, Page 7-21).
Page 116: Front Hub And Wheel Bearings Installation
Front Wheel Bearings and Hubs STEERING AND FRONT SUSPENSION FRONT HUB AND WHEEL BEARINGS INSTALLATION Pack the wheel bearings (5) and hub cavities, and lubricate cups (7) with wheel bearing grease or chassis lube. Make sure the grease is forced between the rollers (Figure 7-20, Page 7-21). If bearing cups (7) were removed, press new ones in squarely against stops in the hub (Figure 7-20, Page 7-21).
Page 117: Section 8 - Wheels And Tires
• See General Warnings on page 1-1. GENERAL INFORMATION NOTE: Use only Club Car approved tires when replacing tires. Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care. • Keep tires properly inflated. See Vehicle Specifications on page 2-1.
Page 118: Tires
Tires WHEELS AND TIRES TIRES See General Warnings on page 1-1. TIRE REMOVAL NOTE: Tire must be removed or installed from the valve stem side of the rim. Remove the tire and wheel assembly from the vehicle as instructed above. See Wheel Removal on page 8-1. Remove the valve cap and valve core and allow air to escape from the tire.
Page 119: Tire Installation
WHEELS AND TIRES Tires NOTE: An air leak could be due to a punctured casing, faulty valve core, improperly seated valve stem, or improperly seated tire bead. Small holes in the casing can be plugged using a standard automotive tubeless tire repair kit available at auto supply stores.
Page 120 Tires WHEELS AND TIRES Figure 8-2 Inflate Tire Page 8-4 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 121: Section 9 - Rear Suspension
SECTION 9 — REAR SUSPENSION DANGER Rear Suspension • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION The rear suspension and powertrain of the vehicle move independently from the vehicle frame. It consists of two leaf springs controlled by two shock absorbers mounted between the springs and the vehicle frame.
Page 122: Multi-Leaf Springs
Multi-Leaf Springs REAR SUSPENSION NOTE: Tighten 3/8 hex nut at shock absorber until shock absorber cushions are approximately the same diameter as the retainers. Do not over tighten. On the upper and lower shock absorber mounting stems, tighten the nut (1) until the rubber bushing (3) expands to the size of the cup washer (4).
Page 123: Multi-Leaf Spring Installation
REAR SUSPENSION Multi-Leaf Springs 2600-30000-10369 1400-18100-10243 Figure 9-2 Support Vehicle on Jack Stands Figure 9-3 Disconnect Brake Cable MULTI-LEAF SPRING INSTALLATION NOTE: Tighten bolt (11) after clamp from brake cable has been positioned between nut and frame component. Install the bushings and spacers in the spring eyes. See following CAUTION. CAUTION •...
Page 124 Multi-Leaf Springs REAR SUSPENSION 2987 Figure 9-4 Rear Suspension Assembly and Mounting Page 9-4 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 125: Section 10 - Periodic Maintenance
Contact your local authorized distributor/dealer to perform all repairs and semiannual and annual periodic service. PRE-OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new vehicle(s), you should become familiar with its controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery.
Page 126 Club Car vehicles operate at reduced speed in reverse. When the pedal is released, it should return to the original position and the motor should rotate freely or go into motor braking mode. See Pedal Up Motor Braking below.
Page 127: Maintenance
Any vehicle not functioning correctly should be removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service. WARNING •...
Page 128: Periodic Service Schedules
Periodic Service Schedules PERIODIC MAINTENANCE PERIODIC SERVICE SCHEDULES See General Warnings on page 1-1. WARNING • Service, repairs, and adjustments must be made per instructions in the maintenance and service manual. NOTE: If the vehicle is constantly hauling heavy loads or hauling a trailer, these preventive maintenance procedures should be performed more often than recommended in the Periodic Service Schedule.
Page 129 PERIODIC MAINTENANCE Periodic Service Schedules PERIODIC SERVICE SCHEDULE – ELECTRIC VEHICLES REGULAR INTERVAL SERVICE Check brake shoes; replace if necessary or adjust as required. Check brake cables for damage; replace if Brake system necessary. Check brake cable equalizer adjustment; adjust if Semiannual service by trained technician necessary.
Page 130 Periodic Service Schedules PERIODIC MAINTENANCE PERIODIC SERVICE SCHEDULE – GASOLINE VEHICLES REGULAR INTERVAL SERVICE Battery Clean terminals and wash dirt from casing. Check and adjust if necessary. Front wheel alignment and camber See Steering and Front Suspension section in the maintenance and service manual. Electrical wiring and connections Check for tightness and damage.
Page 131: Periodic Lubrication Schedules
PERIODIC MAINTENANCE Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE – ELECTRIC VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Brake pedal shaft bearings Dry Moly Lube Brake linkage and pivots Dry Moly Lube Semiannually by owner or trained technician (or every 50 Accelerator pivot rod supports Dry Moly Lube hours of operation, whichever...
Page 132 Periodic Lubrication Schedules PERIODIC MAINTENANCE PERIODIC LUBRICATION SCHEDULE – GASOLINE VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Brake pedal shaft bearings Dry Moly Lube Brake linkage and pivots Dry Moly Lube Semiannually by owner or trained technician (or every 50 Accelerator pivot rod supports and Dry Moly Lube hours of operation, whichever...
Page 133: 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 134: Engine Oil
Engine Oil PERIODIC MAINTENANCE Install the air cleaner cover (2). Engage the latches (1). ENGINE OIL ENGINE OIL VISCOSITY Select the engine oil viscosity for your environmental conditions. Figure 10-4 Engine Oil Viscosity ENGINE OIL LEVEL INSPECTION Before the engine oil is examined: •...
Page 135: Engine Oil Replacement
PERIODIC MAINTENANCE Engine Oil Figure 10-5 Dipstick Location Make sure that the oil level is between the maximum (1) and minimum (2) indicators (Figure 10-6, Page 10-11). Figure 10-6 Dipstick Indicators If the oil level is below the minimum indicator, add engine oil. Install the dipstick.
Page 136 Engine Oil PERIODIC MAINTENANCE Before the engine oil is replaced: • Disable the vehicle. • Disconnect the battery. To replace the engine oil: Remove the dipstick (1) (Figure 10-7, Page 10-12). Figure 10-7 Dipstick Location Clean the area around the oil drain plug (2) (Figure 10-8, Page 10-13). Page 10-12 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 137 PERIODIC MAINTENANCE Engine Oil Figure 10-8 Oil Drain Plug Put a drain pan below the oil drain plug. Remove the oil drain plug. Drain the oil fully. Clean the oil drain plug. Examine the gasket on the oil drain plug for damage. Replace if necessary. Install the oil drain plug and tighten to 13 lb·ft (18 N·m).
Page 138: Add Engine Oil
Engine Oil PERIODIC MAINTENANCE Figure 10-9 Oil Fill Location Install the dipstick. Connect the battery. Correctly discard the used engine oil. ADD ENGINE OIL CAUTION • Hot engine oil will cause skin burns. Do not change the engine oil when the engine is hot. Let the engine temperature decrease before the oil is changed.
Page 139: Refuel
PERIODIC MAINTENANCE Refuel Figure 10-10 Dipstick Location Add engine oil until the oil level is between the maximum (1) and minimum (2) indicators (Figure 10-11, Page 10-15). Figure 10-11 Dipstick Indicators Install the dipstick. REFUEL DANGER • Fuel is flammable and explosive. Do not add fuel with the key switch set to ON. Before fuel is added, turn the key switch to OFF.
Page 140: Lift The Vehicle
Lift The Vehicle PERIODIC MAINTENANCE DANGER • Fuel is flammable and explosive. Do not fill the fuel tank when the engine is on or hot. Wait for the engine temperature to decrease before fuel is added. • Fuel is flammable and explosive. Do not operate the vehicle when fuel is spilled. Correctly clean the spilled fuel.
Page 141: Lift The Rear Of The Vehicle
PERIODIC MAINTENANCE Lift The Vehicle • Use a jack and jack stands rated for the vehicle. To lift the front of the vehicle: Figure 10-12 Lift The Front Place the jack in the center of the lift point. Lift the front of the vehicle. Put jack stands under the frame rails.
Page 142: Lower The Front Of The Vehicle
Lift The Vehicle PERIODIC MAINTENANCE Figure 10-13 Lift The Rear Place the jack in the center of the lift point. Lift the rear of the vehicle. Put jack stands under the frame rails. Lower the vehicle onto the jack stands. LOWER THE FRONT OF THE VEHICLE Before the vehicle is lowered: •...
Page 143: Lower The Rear Of The Vehicle
PERIODIC MAINTENANCE Lift The Vehicle Figure 10-14 Lower The Front Place the jack in the center of the lift point. Lift the vehicle off of the jack stands. Remove the jack stands. Lower the vehicle. LOWER THE REAR OF THE VEHICLE Before the vehicle is lowered: •...
Page 144: Spark Plug
Spark Plug PERIODIC MAINTENANCE Figure 10-15 Lower The Rear Place the jack in the center of the lift point. Lift the vehicle off of the jack stands. Remove the jack stands. Lower the vehicle. SPARK PLUG SPARK PLUG REMOVAL Before the spark plug is removed: •...
Page 145: Spark Plug Inspection
PERIODIC MAINTENANCE Spark Plug Figure 10-16 Spark Plug Wire Disconnect Use a spark plug socket to remove the spark plug. SPARK PLUG INSPECTION Use a wire brush to clean the electrodes (1). Figure 10-17 Spark Plug Inspection Examine the spark plug electrodes for corrosion and damage. Examine the spark plug insulator (2) for cracks.
Page 146: Spark Plug Installation
Valve Clearance Check and Adjustment PERIODIC MAINTENANCE Figure 10-18 Spark Plug Gap SPARK PLUG INSTALLATION Apply a thin layer of high temperature anti-seize lubricant to the spark plug threads. Use a spark plug socket to install and tighten the spark plug to 20 lb·ft (27 N·m). Connect the spark plug wire (1) (Figure 10-19, Page 10-22).
Page 147: 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 148: 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 149: Introductory Display
CONTROLLER DIAGNOSTIC TOOL (CDT) Plugging the CDT into the Vehicle Connect one end of the cable to the port located on the bottom of the CDT. Connect the cable adaptor to the CDT cable. Find the communication port on the vehicle (Figure 11-2, Page 11-2). Remove the dust cap from the communication port.
Page 150: Quick Reference Guide - Iq Plus With Quiq Charger
Quick Reference Guide – IQ Plus with Quiq Charger CONTROLLER DIAGNOSTIC TOOL (CDT) QUICK REFERENCE GUIDE – IQ PLUS WITH QUIQ CHARGER OPERATION: Change screen contrast for better viewing by selecting the following: HPP Settings, Backlight Preset Favorites: Select a frequently viewed screen, press “Add to” softkey, highlight “Favorites”, press “Select” softkey. CONTROLLER FAULTS: Anti Tamper: If car not equipped with Visage, make sure Control Mode Main Weld: Replace solenoid, if it doesn’t correct fault of car running at...
Page 151: 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 152: Settings
A vehicle programmed for speed setting 4 does not conform to ANSI Z130.1 – American National Standard for Golf Cars – Safety and Performance Specifications because it is capable of speeds in excess of 15 mph (24.1 km/h). For more information on this feature, contact your local Club Car distributor or dealer. M1/M2 Fast Accel M1/M2 fast accel (fast acceleration) is an option that can be enabled or disabled.
Page 153 CONTROLLER DIAGNOSTIC TOOL (CDT) Parameters M1/M2 PEDAL UP SETTING MODE OPERATION DESCRIPTION Pedal up motor braking is disabled Mild pedal up Mild pedal up motor braking Aggressive pedal up Aggressive pedal up motor braking M1/M2 Speed Cal The M1/M2 speed cal (speed calibration) menu item allows the user to fine tune the vehicle speed. This feature cannot be used to increase the vehicle speed.
Page 154 Parameters CONTROLLER DIAGNOSTIC TOOL (CDT) 5.7 mph (9.2 km/h) 9.7 mph (15.6 km/h) 12.7 mph (20.4 km/h) 14.7 mph (23.7 km/h) 5.6 mph (9.0 km/h) 9.6 mph (15.4 km/h) 12.6 mph (20.3 km/h) 14.6 mph (23.5 km/h) 5.5 mph (8.9 km/h) 9.5 mph (15.3 km/h) 12.5 mph (20.1 km/h) 14.5 mph (23.3 km/h)
Page 155: Amp Hours
Once activated, Mode 2 settings can be programmed using the same procedures as Mode 1 settings. This allows the vehicle to be customized to perform according to which mode it is operated in. For more information on this feature, contact your local Club Car distributor or dealer. To activate Mode 2: Enter Code A, Code B, and Code C.
Page 156: Monitor Menu
Monitor Menu CONTROLLER DIAGNOSTIC TOOL (CDT) ASCII NUMBER ASCII CHARACTER ASCII NUMBER ASCII CHARACTER Vehicle Date of Manufacture Four digit number programmed by vehicle manufacturer. Example: 1401 represents Model Year 2014, week 1. Vehicle S/N Six digit number programmed by vehicle manufacturer. Vehicle Decal Decal number ranging from 0 to 999 and programmed by vehicle manufacturer.
Page 157: Throttle
CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu THROTTLE % Indicates the position of the accelerator pedal from 0% (pedal not pressed) to 95% and 100% (pedal fully pressed). This item can be monitored when the key switch is in the ON or OFF position. BATT VOLTAGE Displays the current battery voltage at the speed controller.
Page 158: Reverse Input
Mode 2. If repeated attempts are unsuccessful, the speed controller will permanently lock out access to Mode 2. In the event that Mode 2 is locked out, the controller must be removed and shipped to Club Car before Mode 2 can be activated.
Page 159: Relay Welded
CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu RELAY WELDED # Displays the number of times the RELAY WELDED fault has been detected. See Fault Descriptions on page 11-20. SPD SENSOR # Displays the number of times the SPD SENSOR fault has been detected. See Fault Descriptions on page 11-20. MAIN DRV ON # Displays the number of times the MAIN DRV ON fault has been detected.
Page 160 Monitor Menu CONTROLLER DIAGNOSTIC TOOL (CDT) DRVR OVERCUR # Displays the number of times the DRVR OVERCUR fault has been detected. See Fault Descriptions on page 11-20. RLY DRVR ON # Displays the number of times the RLY DRVR ON fault has been detected. See Fault Descriptions on page 11-20. RLY DRVR OFF # Displays the number of times the RLY DRVR OFF fault has been detected.
Page 161 CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu Open Circuit SOC Start Open Circuit SOC Start is the estimated state of charge following a cycle of the Run/Tow switch or coming out of sleep mode. BATTERY MONITOR These menu items reset every time the vehicle is charged. Lowest Battery Voltage Displays the lowest battery pack voltage reached since the last charge.
Page 162 Monitor Menu CONTROLLER DIAGNOSTIC TOOL (CDT) Charger Additional Page 11-16 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 163 CONTROLLER DIAGNOSTIC TOOL (CDT) Diagnostics Menu DIAGNOSTICS MENU CAUTION • A failed motor will damage the controller. Always inspect the motor before replacing the controller. See External Motor Testing, Section 16, Page 16-1. NOTE: The software is subject to frequent updates, and this manual may span many versions. Be aware that some faults listed in this manual may not display in the CDT, indicating older software.
Page 164 Diagnostics Menu CONTROLLER DIAGNOSTIC TOOL (CDT) Causes of Faults Some common causes of faults are • Loose, broken, or disconnected wires or connectors • Failed components • Improper adjustment or installation of electrical or mechanical components (examples: brake adjustment, improper MCOR installation) •...
Page 165 CONTROLLER DIAGNOSTIC TOOL (CDT) Diagnostics Menu FAULT RECOVERY When a fault is detected by the speed controller, the speed controller will attempt to recover from the fault and resume normal operation. In the case of an intermittent problem such as a loose wiring connection, the controller may be able to recover and operate normally for a while, but the problem should be repaired before placing the vehicle in service.
Page 166 Fault Descriptions CONTROLLER DIAGNOSTIC TOOL (CDT) FAULT DESCRIPTIONS The following faults can be detected by the IQ Plus controller and seen under both the Monitor Menu and Diagnostics Menu: 01 THROTTLE FAULT 1 If the MCOR (Motor Controller Output Regulator) voltage is less than 0.20 volts or greater than 4.80 volts, the controller detects a throttle fault.
Page 167 CONTROLLER DIAGNOSTIC TOOL (CDT) Fault Descriptions 12 MAIN DROPOUT If the controller detects that the solenoid contacts have opened while the vehicle is in operation, a main dropout fault is detected. 13 MOTOR STALL If the motor current is high and there is no movement of the vehicle wheels for a short period of time, a motor stall is detected by the speed controller.
Page 168 The max password tries fault is declared when the incorrect password fault has been declared several times. In the event that the max password tries fault is indicated, the speed controller must be removed and shipped to Club Car before it can ever be placed in Mode 2. See also Password Tries (OEM Access Level Only) on page 11-12.
Page 169 CONTROLLER DIAGNOSTIC TOOL (CDT) Fault Descriptions What to do: Charge batteries. If fault occurs more frequently than normal, test battery pack. Section 14 — Batteries: IQ Plus Electric Vehicles MAIN CONT DNC The main cont dnc (main contactor (solenoid) did not close) fault is detected when the speed controller has sent voltage to the solenoid activating coil but the solenoid contacts are not closed.
Page 170: Programming
Programming CONTROLLER DIAGNOSTIC TOOL (CDT) PROGRAMMING The Programming menu is accessed by using the arrow keys to highlight Programming and pressing the Select softkey to activate the menu. The Programming menu selection allows the user to save and restore parameter settings files (.cpf files). These files contain controller information and are saved to the internal memory or SD card.
Page 171: Hhp Settings
CONTROLLER DIAGNOSTIC TOOL (CDT) HHP Settings HHP SETTINGS The HHP Settings menu is accessed by using the arrow keys to highlight HHP Settings and pressing the Select softkey to activate the menu. The HHP Settings menu selection allows the user to adjust the appearance of the screen displays, adjust several aspects of the handheld programmer’s functionality, and displays information pertaining to the handset.
Page 172: Plot & Log
Plot & Log CONTROLLER DIAGNOSTIC TOOL (CDT) MENU ITEM DESCRIPTIONS Remember Last View When set to On, when you select a menu from the Main Menu screen, you will be returned to the screen you were on before you last exited that menu. When set to Off, each time you select a menu from the Main Menu screen, you will go to the selected root menu.
Page 173: Cdt Troubleshooting
CONTROLLER DIAGNOSTIC TOOL (CDT) CDT Troubleshooting CDT TROUBLESHOOTING In the event that the handset does not function as described in this manual, the following troubleshooting guide should be studied and the referenced test procedures should be performed to troubleshoot the handset. TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES...
Page 174: Connection Tests
Connection Tests CONTROLLER DIAGNOSTIC TOOL (CDT) TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Section 12 — Electrical System Speed controller malfunction Troubleshooting: IQ Plus Electric Vehicles Disconnect the CDT cord from the vehicle. Handset malfunction Wait a few seconds and reconnect the handset to the vehicle Display screen shows jumbled or Loose connection at CDT port...
Page 175 CONTROLLER DIAGNOSTIC TOOL (CDT) Connection Tests Using a multimeter set for 200 ohms, place the red (+) probe into one of the terminals on the end of the cord with the square plug. Place the black (–) probe on each of the pins, one at a time, on the plug on the other end of the cord. The multimeter should indicate continuity on only one pin.
Page 176 Connection Tests CONTROLLER DIAGNOSTIC TOOL (CDT) 1.3. Connect the handset cord to the handset. 1.4. Connect the other end of the handset cord (without the adapter) to the four-pin connector of the speed controller. 1.5. Connect the vehicle batteries, positive (+) cable first. If the handset does not function during Test Procedure 3A, but does function when connected directly to the speed controller, the handset cord adapter and vehicle wire harness should be thoroughly tested.
Page 177: Section 12 - Electrical System Troubleshooting: Iq Plus Electric Vehicles
SECTION 12 — ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES DANGER Electrical System Troubleshooting: IQ Plus Electric Vehicles • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION The IQ Plus vehicle uses a 48-volt electrical system with a shunt-wound, 3.7 hp motor that is powered by eight 6-Volt, lead-acid batteries and charged by a high-frequency charger.
Page 178: Features
Contact your Club Car dealer/distributor to inquire about this programmable feature. • Regenerative Braking: When motor braking is activated, the vehicle motor acts as a generator, slowing the vehicle as it creates energy that is used to charge the batteries.
Page 179 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES General Information If either situation arises, an HPD fault is recorded by the speed controller and will be displayed on an CDT handset in the Diagnostic History menu. See CDT Troubleshooting, Section 11, Page 11-27. 2019 Carryall 500 and 700 Maintenance and Service Manual Page 12-3...
Page 180: Sonic Weld, Diode, And 10K Ohm Resistor Locations
ELECTRICAL SYSTEM TROUBLESHOOTING: Sonic Weld, Diode, and 10k Ohm Resistor Locations IQ PLUS ELECTRIC VEHICLES SONIC WELD, DIODE, AND 10K OHM RESISTOR LOCATIONS 3119 Figure 12-1 Sonic Weld, Diode and 10k Ohm Resistor Locations (Approximate) – CA300 with ERIC Charging Page 12-4 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 181: Troubleshooting
TROUBLESHOOTING THE VEHICLE WITH THE CDT Club Car recommends the use of the CDT handset for troubleshooting vehicles equipped with the IQ Plus electrical system. Troubleshooting Guide 1 is to be used in conjunction with the CDT handset. Refer to the CDT Owner’s Manual for operating instructions.
Page 182: Troubleshooting Guide 1
ELECTRICAL SYSTEM TROUBLESHOOTING: Troubleshooting IQ PLUS ELECTRIC VEHICLES TROUBLESHOOTING GUIDE 1 The following troubleshooting guide is intended for use with an CDT handset. For CDT operating instructions, refer to the CDT Owner’s Manual. See following NOTE. NOTE: Before troubleshooting the vehicle, check the diagnostic history from the Special Diagnostics Menu. Note any fault codes.
Page 183 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Speed controller logic malfunction Disconnect the batteries and allow the speed controller capacitors to discharge. See WARNING “To avoid unintentionally starting...” in See General Warnings Failed controller FET (that powers up Monitor Menu –...
Page 184 ELECTRICAL SYSTEM TROUBLESHOOTING: Troubleshooting IQ PLUS ELECTRIC VEHICLES TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected motor field coil wires at motor or speed controller or Repair and/or connect the field coil wires broken wire Diagnostic Menu – FIELD MISSING fault code Failure of the motor field windings Section 16 —...
Page 185: Troubleshooting Guide 2
ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Troubleshooting TROUBLESHOOTING GUIDE 2 TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Batteries discharged Charge batteries Check vehicle wiring. See Wiring Diagrams Improper or poor battery connections beginning on page Battery charger is connected to the vehicle – Disconnect the battery charger from the vehicle Solenoid lockout feature has disabled the vehicle Check for loose or disconnected wires at key...
Page 186 ELECTRICAL SYSTEM TROUBLESHOOTING: Troubleshooting IQ PLUS ELECTRIC VEHICLES TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Procedure 13 – Motor Speed Sensor on page Speed sensor disconnected or failed 12-26 To change the programmed top speed of the Incorrect speed setting vehicle, an CDT handset must be used Check vehicle wiring.
Page 187: Test Procedures
ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures TEST PROCEDURES Using the following procedures, the entire IQ Plus electrical system can be tested without major disassembly of the vehicle. See following WARNING. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
Page 188 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES 11 – Charger Interlock 12 – MCOR Voltage 13 – Motor Speed Sensor 14 – A1 and A2 Motor Voltage 15 – 24-Pin Connector 16 – Reverse Buzzer 17 – Walk Away Braking Relay 18 –...
Page 189 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures (Viewed from driver side of vehicle) 1. RED probe to battery no. 1 (+). 2. BLACK probe to battery no. 8 (-). 3072 Figure 12-2 Battery Voltage Test – 500/700 2019 Carryall 500 and 700 Maintenance and Service Manual Page 12-13...
Page 190 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES 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 12-11. Be sure the batteries are fully charged and that the electrolyte level is correct in all cells. Connect the tester leads to the positive (+) post of battery no.1 and negative (–) post of battery no.
Page 191 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures A fully charged set of batteries in good condition should read between 47 and 49 volts while under load. A reading of 32 to 42 volts indicates discharged or failed batteries. Each battery should be checked with a multimeter while under load.
Page 192 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES TEST PROCEDURE 4 – Fuses See General Warnings on page 1-1. WARNING • Failure to use properly rated fuse can result in a fire hazard. NOTE: These vehicles predominately use a combination of ATC-style and ATM-style blade fuses. A single AGC-style glass fuse is used for the charger interlock circuit.
Page 193 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures – For one of the 15-amp ATC fuses, check Run/Tow switch to make sure it is in RUN position. – Check if 12 gauge red wire is coming off large post on solenoid. 1-amp AGC Glass Fuse Only: With the Run/Tow switch in the RUN position: 4.1.
Page 194 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES If there is 48 volts, do the following: Make sure that the green and tan wires are securely connected to the circuit breaker. Make sure that the 24 pin connector has no corrosion. Make sure that the 24 pin connector is securely connected to the controller.
Page 195 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures TEST PROCEDURE 6 – Wire Harness Diodes See General Warnings on page 1-1. A diode is designed to conduct current in one direction only. Depending on the application, diodes are used in the vehicle to control electrical system logic, or to help protect relay and switch contacts from excessive arcing.
Page 196 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES TEST PROCEDURE 7 – Key Switch and MCOR Limit Switch Circuit See General Warnings on page 1-1. NOTE: This is a voltage test. The MCOR provides FOOT INPUT to the controller. The key switch provides KEY INPUT to the controller.
Page 197 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures 4.1. Locate and connect an insulation-piercing probe to the pin 1 tan wire in the 24-pin connector. 4.2. With the key switch in the OFF position and the accelerator pedal at rest, the tan wire should show zero (0) volts.
Page 198 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES 4.1. Access the Monitor menu and select REVERSE INPUT by using the SCROLL DISPLAY buttons. The CDT should indicate OFF when the Forward/Reverse switch is in the NEUTRAL or FORWARD position. 4.2.
Page 199 See General Warnings on page 1-1. NOTE: Unlike other controllers used by Club Car, the pre-charge resistor is internal to the IQ Plus controller. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame crossmember between the spring mount and side stringer, just forward of each rear wheel.
Page 200 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES Insert the onboard charger AC plug into an AC outlet. In a few seconds, the CDT should indicate ON and the vehicle can no longer be driven. If not, check the KEY, FORWARD, REVERSE and FOOT INPUTS to the controller.
Page 201 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures MCOR Voltage Test with the CDT Handset Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame crossmember between the spring mount and side stringer, just forward of each rear wheel. See WARNING “Lift only one end...”...
Page 202 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES at the MCOR. The reading should be zero (0) volts with the pedal up. Slowly press the accelerator pedal and note the readings on the multimeter. As the pedal is pressed, the reading should increase until it reaches approximately 4.65 volts when the pedal is fully pressed.
Page 203 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures Turn the key switch to the OFF position and place the Forward/Reverse switch in the NEUTRAL position. With batteries connected, disconnect the three-pin connector at the motor speed sensor. Check voltage at black/white wire: 3.1.
Page 204 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES Figure 12-9 Test 13: Speed Sensor Red Wire Check voltage at the light green wire: 5.1. Set a multimeter to 20 volts DC. Place the black (–) probe on the battery no. 8 negative post and place the red (+) probe on the light green wire female terminal in the three-pin connector at the motor speed sensor.
Page 205 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures Figure 12-11 Test 13: Speed Sensor Green Wire 6.1. Raise one rear wheel off ground. Slowly turn the rear wheel to rotate the motor armature. As the armature rotates, the voltage reading should alternate from zero to approximately 4.85 volts. The voltage reading will fluctuate from zero to 4.85 volts and back to zero four times for each revolution of the motor armature.
Page 206 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES NOTE: Voltage can vary depending on controller speed setting as well as which zone a Guardian equipped vehicle is located. Example: Speed setting 1 may only read 30 volts. 4.1. If there is no voltage reading or if there is no increase in voltage as the pedal is pressed, check the MCOR. See MCOR Voltage on page 12-24.
Page 207 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures If the results of any of the referenced procedures are different from those described in the procedure, check the continuity of the wires in the wire harness and test the connected components with the appropriate test procedures. (See Index of Test Procedures on page 12-11).
Page 208 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame crossmember between the spring mount and side stringer, just forward of each rear wheel.
Page 209 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures Pin 8 See General Warnings on page 1-1. Pin 8 in the 24-pin connector provides a connection point for the MCOR limit switch to the speed controller. Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5.
Page 210 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES – Run/Tow switch for proper operation. See Run/Tow Switch on page 12-15. – Key switch and MCOR limit switch for proper operation. See Key Switch and MCOR Limit Switch Circuit on page 12-20. –...
Page 211 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures Detail A: Front of 24-Pin Connector Figure 12-15 Test: Pin 19 (Orange/White Wire) Pins 10 and 11 See General Warnings on page 1-1. Pins 10 and 11 in the 24-pin connector provide a connection point for the Forward/Reverse rocker switch to the speed controller.
Page 212 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES Place the Forward/Reverse switch in the FORWARD position. The multimeter should indicate full battery voltage (approximately 48 volts). Insert the red (+) probe of the multimeter into pin 11 (blue wire) of the 24-pin connector. Leave the black (–) probe (alligator clip) connected to the B–...
Page 213 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures With a multimeter set for 200 volts DC, insert the red (+) probe of the multimeter into pin 1 (tan wire) of the 24-pin connector. See following CAUTION. With an alligator clip, connect the black (–) probe to the B– terminal of the speed controller (Figure 12-17, Page 12-37).
Page 214 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES Set a multimeter to 200 volts DC. Use an alligator clip to connect the red (+) probe to the positive terminal on battery no. 1. With an insulation-piercing probe, connect the black (–) probe to the blue/white wire attached to pin 17 of the 24-pin connector.
Page 215 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures TEST PROCEDURE 16 – Reverse Buzzer See General Warnings on page 1-1. Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. Remove the instrument panel. See Instrument Panel Removal, Section 4, Page 4-9. Place the Run/Tow switch in the TOW position and connect the battery cables, positive (+) cable first.
Page 216 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES With batteries connected, Run/Tow switch in the RUN position and the key switch in the OFF position, connect charger DC cord to vehicle. In a few seconds, the light will flash three times and the reverse buzzer simultaneously will sound three times to indicate charging has begun.
Page 217 ELECTRICAL SYSTEM TROUBLESHOOTING: IQ PLUS ELECTRIC VEHICLES Test Procedures Check for continuity between pin 1 (yellow/black wire) (Figure 12-18, Page 12-40) and pin 3 (purple/white wire) of the 16-pin connector. It should indicate continuity. If not, check sonic welds no. 1 and no. 2. Probe pin 2 (red/white wire).
Page 218 ELECTRICAL SYSTEM TROUBLESHOOTING: Test Procedures IQ PLUS ELECTRIC VEHICLES Pagination Page Page 12-42 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 219: Section 13 - Electrical Components: Iq Plus Electric Vehicles
SECTION 13 — ELECTRICAL COMPONENTS: IQ PLUS ELECTRIC VEHICLES DANGER Electrical Components: IQ Plus Electric Vehicles • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. KEY SWITCH See General Warnings on page 1-1. TESTING THE KEY SWITCH See Test Procedure 7 –...
Page 220 ELECTRICAL COMPONENTS: IQ PLUS Key Switch ELECTRIC VEHICLES Figure 13-1 Key Switch Page 13-2 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 221: Forward/Reverse Rocker Switch
ELECTRICAL COMPONENTS: IQ PLUS ELECTRIC VEHICLES Forward/Reverse Rocker Switch FORWARD/REVERSE ROCKER SWITCH See General Warnings on page 1-1. TESTING THE FORWARD/REVERSE ROCKER SWITCH See Test Procedure 8 – Forward/Reverse Rocker Switch on page 12-21. FORWARD/REVERSE ROCKER SWITCH REMOVAL Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5.
Page 222: Run/Tow Switch Removal
ELECTRICAL COMPONENTS: IQ PLUS Circuit Breaker ELECTRIC VEHICLES See Test Procedure 3 – Run/Tow Switch on page 12-15. RUN/TOW SWITCH REMOVAL Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. Using a 5/8 in (16 mm) socket, remove Run/Tow switch boot/hex nut (6). Remove Run/Tow switch (10) and nut (9) from bracket (5).
Page 223 ELECTRICAL COMPONENTS: IQ PLUS ELECTRIC VEHICLES Circuit Breaker Figure 13-2 Circuit Breaker 2019 Carryall 500 and 700 Maintenance and Service Manual Page 13-5...
Page 224: Motor Controller Output Regulator (Mcor)
ELECTRICAL COMPONENTS: IQ PLUS Motor Controller Output Regulator (MCOR) ELECTRIC VEHICLES MOTOR CONTROLLER OUTPUT REGULATOR (MCOR) See General Warnings on page 1-1. TESTING THE MCOR See Test Procedure 12 – MCOR Voltage on page 12-24 and Test Procedure 7 – Key Switch and MCOR Limit Switch Circuit on page 12-20.
Page 225: Reverse Buzzer
ELECTRICAL COMPONENTS: IQ PLUS ELECTRIC VEHICLES Reverse Buzzer NOTE: Rotate the drive bar (5) back and forth if necessary to align the D-shaped end with the MCOR. Secure the MCOR (2) to the plastic housing (4) with two torx screws (3). Tighten screws to 12 in·lb (1.4 N·m). Connect the two-pin and three-pin connectors (1) from the wire harness to the MCOR (2).
Page 226: Solenoid
ELECTRICAL COMPONENTS: IQ PLUS Solenoid ELECTRIC VEHICLES SOLENOID See General Warnings on page 1-1. The solenoid is located on the passenger side of the electrical component mounting plate. TESTING THE SOLENOID See Test Procedure 9 – Solenoid Activating Coil on page 12-22 and Test Procedure 10 – Solenoid Contacts on page 12-23.
Page 227: Speed Controller
ELECTRICAL COMPONENTS: IQ PLUS ELECTRIC VEHICLES Speed Controller SPEED CONTROLLER See General Warnings on page 1-1. TESTING THE SPEED CONTROLLER See Test Procedure 14 – A1 and A2 Motor Voltage on page 12-29. SPEED CONTROLLER REMOVAL Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5.
Page 228 ELECTRICAL COMPONENTS: IQ PLUS Speed Controller ELECTRIC VEHICLES 2998 Figure 13-5 Speed Controller Page 13-10 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 229: Charge Indicator Light
ELECTRICAL COMPONENTS: IQ PLUS ELECTRIC VEHICLES Charge Indicator Light CHARGE INDICATOR LIGHT See General Warnings on page 1-1. TESTING THE CHARGE INDICATOR LIGHT See Test Procedure 18 – Charge Indicator Light on page 12-39. CHARGE INDICATOR LIGHT REMOVAL Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5.
Page 230 ELECTRICAL COMPONENTS: IQ PLUS Charge Indicator Light ELECTRIC VEHICLES Pagination Page Page 13-12 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 231: Section 14 - Batteries: Iq Plus Electric Vehicles
SECTION 14 — BATTERIES: IQ PLUS ELECTRIC VEHICLES DANGER Batteries: IQ Plus Electric Vehicles • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area.
Page 232: Battery Testing Basics - 6 Volt
Battery Testing Basics – 6 Volt BATTERIES: IQ PLUS ELECTRIC VEHICLES BATTERY TESTING BASICS – 6 VOLT See General Warnings on page 1-1. OBSERVATION Inspect the battery compartment for the following items: • Rusted, corroded, or broken battery posts • Rusted, corroded, loose or broken wires •...
Page 233: Battery Testing - 6 Volt
Regrouping is now Club Car’s standard battery replacement method. Regrouping is the practice of placing batteries of similar condition together in one vehicle. For example, if there was an issue with the batteries in two cars and the battery test indicated three failed batteries in each car, after removing the failed batteries, there will be six good batteries remaining.
Page 234 Battery Regrouping BATTERIES: IQ PLUS ELECTRIC VEHICLES 3104 Figure 14-2 Battery Regrouping Process Flow Page 14-4 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 235: Battery Replacement
BATTERIES: IQ PLUS ELECTRIC VEHICLES Battery Replacement BATTERY REPLACEMENT See General Warnings on page 1-1. WARNING • Wear steel-toe shoes when replacing batteries. • To prevent electrolyte leakage from the battery vents, batteries must be kept in an upright position. Tipping a battery beyond a 45°...
Page 236: 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 237: Deionizer
Replace filter immediately if the red light comes ON indicating service is required. Replacement filters are available from Club Car Service Parts. • Inspect the condition of all tubing, connections, and couplers. Make sure that all parts are in good working condition, secure, leak free, and properly connected.
Page 238: Battery Care - Vehicles Equipped With The Single-Point Watering System (Spws)
Battery Care BATTERIES: IQ PLUS ELECTRIC VEHICLES Single point watering systems will require seasonal maintenance if vehicles are taken out of service or put into storage for a period of 6 weeks or longer. To prepare the SPWS, ensure the feed tube and coupler are on top of battery. Then, use the following steps to bring vehicle back into service: After the batteries have been fully charged/equalized, connect the system to its water supply for 3 to 5 seconds, then disconnect regardless of whether or not the batteries are completely full.
Page 239: Battery Care - Vehicles Without The Single-Point Watering System (Spws)
• Do not overfill the batteries. NOTE: A battery watering gun or bottle 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 240: Self-Discharge
Battery Care BATTERIES: IQ PLUS ELECTRIC VEHICLES 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 14-3 Electric Battery Electrolyte Level SELF-DISCHARGE Contaminants on dirty batteries can provide a path for a small current draw that can slowly discharge batteries, thus wasting valuable energy.
Page 241: Vibration Damage
A deionizer for vehicles with SPWS, Club Car Part Number 105166801 is available from Service Parts (DC powered water quality indicator light). Replacement cartridge: 104005901. Bottled distilled water, with hand pump, Club Car Part Number 104006101, is recommended for private consumer applications.
Page 242 Single Point Watering System (SPWS) BATTERIES: IQ PLUS ELECTRIC VEHICLES • Do not use a longer garden hose than provided with the System (20 feet or 6 meters), as a decrease in water pressure can overfill the batteries and damage the refill system. Before screwing the hose-end assembly (3) onto the opposite end of the water hose, check the screen filter (4) inside the end of the assembly to make sure it is clean (Figure 14-4).
Page 243: Battery Storage
BATTERIES: IQ PLUS ELECTRIC VEHICLES Battery Storage 2829 2830 Figure 14-6 Dust Cap Figure 14-7 Connecting Hose-end Assembly to Battery Fill Connector The red flow indicator balls should swirl, indicating that the batteries are being filled. See following CAUTION. CAUTION •...
Page 244: Deep-Discharge
Deep-Discharge BATTERIES: IQ PLUS ELECTRIC VEHICLES DEEP-DISCHARGE Never discharge batteries to the point the vehicle will no longer operate. This will considerably shorten the cycle life of the batteries, and may permanently damage the batteries. It is possible the batteries will not accept a charge if they are completely discharged.
Page 245: Section 15 - Quiq High Frequency Charger
If a charger cannot be properly identified, contact your local authorized Club Car dealer or distributor. The High Frequency Battery Charger functions as an integral part of the vehicles' electrical system and will not work with other electric vehicles.
Page 246: How To Identify Charge Algorithm Number
General Information QUIQ HIGH FREQUENCY CHARGER HOW TO IDENTIFY CHARGE ALGORITHM NUMBER The algorithm numbers offered can be found in See Battery Charger Algorithms on page 15-2. The charger can display its algorithm number by initiating Algorithm Display Mode. To enter Algorithm Display Mode, do the following: Disconnect the AC cord from the power outlet.
Page 247: How To Change The Algorithm
QUIQ HIGH FREQUENCY CHARGER General Information HOW TO CHANGE THE ALGORITHM Set the Run/Tow switch to TOW. If equipped, disconnect the DC/DC converter connector. Disconnect the AC cord. Disconnect the main positive (+) battery wire. Wait for 1 to 1.5 minutes. Connect the AC cord.
Page 248: Onboard Charger Operation
– 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 249 QUIQ HIGH FREQUENCY CHARGER Onboard Charger Operation WARNING – Do not use an adapter to plug the charger with a three-prong plug into a two-prong outlet. Improper connection of the equipment-grounding conductor can result in a fire or an electrical shock. –...
Page 250: Charger Displays
Onboard Charger Operation QUIQ HIGH FREQUENCY CHARGER CHARGER DISPLAYS 10-LED display on charger: 2379 Figure 15-4 10–LED Display on Charger Icon Indication (following LED Color STATUS EXPLANATION “Power-On Self Test”) Solid: Displays approximate scale of current output during bulk phase. Flashing: High internal charger temperature.
Page 251 QUIQ HIGH FREQUENCY CHARGER Onboard Charger Operation Solid: Charging is complete. Charger in Maintenance Mode. 100% Charge (Green) Flashing: Absorption phase complete. In Finish phase Solid: AC Power good AC on (Amber) Low AC Voltage. Check Voltage and power cord length (refer to guidelines) Flashing: See AC Power Connection on page 15-8.
Page 252: Ac Power Connection
Vehicles should be restricted to 40 to 50 amp hours of discharge between charges until the batteries have been properly seasoned (20 to 50 charge cycles). For maximum battery life, Club Car recommends that electric vehicles always be recharged after 40 to 50 amp hours of discharge or each night in order to avoid deep discharging the batteries.
Page 253: Maintenance
Any charger not functioning correctly should be removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service WARNING •...
Page 254: Troubleshooting
Troubleshooting QUIQ HIGH FREQUENCY 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 255: Test Procedures
QUIQ HIGH FREQUENCY CHARGER Test Procedures TEST PROCEDURES See General Warnings, Section 1, Page 1-1. Index of Test Procedures 1 – Battery Voltage Using Multimeter 2 – Battery Condition Using Charger – All Batteries 3 – On-Charge Battery Voltage Using Charger And Multimeter 4 –...
Page 256: Charger Repairs
Charger Repairs QUIQ HIGH FREQUENCY CHARGER TEST PROCEDURE 4 – AC Power and Continuity Test of AC Circuit Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle. Check the AC line fuse or circuit breaker in the storage facility. With a multimeter set to 500 volts AC, check incoming AC voltage.
Page 257: Onboard Charger Installation
QUIQ HIGH FREQUENCY CHARGER Onboard Charger Removal And Installation Remove charger from vehicle. ONBOARD CHARGER INSTALLATION Install charger onto vehicle. Install the four lock nuts (5) securing charger to charger mounting plate. Tighten to 40 in·lb (5.4 N·m). Connect the AC and DC connector. Connect 8-pin grey connector.
Page 258 Onboard Charger Removal And Installation QUIQ HIGH FREQUENCY CHARGER Pagination Page Page 15-14 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 259: Section 16 - Motor (Model Da5-4006): Electric Vehicles
The IQ Plus vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. This 3.7 horsepower motor is designed for use on IQ Plus vehicles only. Club Car recommends that motors requiring major repair be sent to a qualified motor repair shop; however, there are many relatively simple tasks that can be performed by a technician with general knowledge and experience in electric motor repair.
Page 260: Motor Removal
MOTOR (MODEL DA5-4006): ELECTRIC Motor Removal VEHICLES Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. 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 261 MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor Removal 1. Position floor jack under hitch bracket or frame. 2. Carryall 700 (shown) 2867 Figure 16-2 Vehicle Supported on Jack Stands Figure 16-1 Lift Vehicle with Floor Jack Remove both rear wheels. Remove the nut, cup washer, and bushing from the bottom side of the shock absorber. Compress the shock absorber (pushing upwards) to move it out of the way (Figure 16-3, Page 16-3).
Page 262: Motor Disassembly
MOTOR (MODEL DA5-4006): ELECTRIC Motor Disassembly VEHICLES Figure 16-4 Speed Sensor Magnet Figure 16-5 End Cap Removal MOTOR DISASSEMBLY Release the clasp and remove the headband assembly (21) from the motor. Visually inspect brushes and springs. (Figure 16-13, Page 16-10). Before continuing disassembly, place match marks on the motor end cap (20) and motor frame (14).
Page 263 MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor Disassembly Remove the four end cap bolts. The weight of the motor housing will cause it to drop when the bolts are removed. See following CAUTION. CAUTION • The motor housing will drop when the bolts are removed. Do not put fingers under the motor housing when removing bolts.
Page 264 MOTOR (MODEL DA5-4006): ELECTRIC Motor Disassembly VEHICLES Figure 16-8 Brush Rigging Removal Figure 16-9 Retaining Ring Removal Page 16-6 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 265: Motor Component Testing And Inspection
MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor Component Testing and Inspection MOTOR COMPONENT TESTING AND INSPECTION See General Warnings on page 1-1. ARMATURE INSPECTION AND TESTING Remove the motor from the vehicle. See Motor Removal, Section 16, Page 16-2. Remove the end cap and armature by performing steps 1 through 6 of Motor Disassembly on page 16-4. Visual Inspection •...
Page 266: Motor Frame And Field Windings Inspection
MOTOR (MODEL DA5-4006): ELECTRIC Motor Component Testing and Inspection VEHICLES Figure 16-10 Armature Test MOTOR FRAME AND FIELD WINDINGS INSPECTION Remove the motor from the vehicle. See Motor Removal, Section 16, Page 16-2. Remove the end cap and armature by performing steps 1 through 6 of Motor Disassembly on page 16-4. Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings.
Page 267 MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor Component Testing and Inspection Install the brushes in the same rigging 180° apart from each other. Brush Inspection Remove the motor from the vehicle. See Motor Removal, Section 16, Page 16-2. Release the clasp and remove the headband from the motor. Inspect the brushes (16) for damage or excessive wear (Figure 16-13, Page 16-10).
Page 268 MOTOR (MODEL DA5-4006): ELECTRIC Motor Component Testing and Inspection VEHICLES Figure 16-13 Motor Page 16-10 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 269: Reconditioning The Motor
MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Reconditioning the Motor RECONDITIONING THE MOTOR See General Warnings on page 1-1. Motor reconditioning must be performed by a qualified motor repair technician. The use of proper tools and procedures is absolutely essential for successful motor reconditioning. MOTOR SPECIFICATIONS Any rework must be performed by a qualified technician.
Page 270 MOTOR (MODEL DA5-4006): ELECTRIC Motor Assembly VEHICLES Figure 16-14 Retracted Brushes Figure 16-15 Armature Installation With the brushes retracted, use an arbor press to press the armature shaft into the end cap bearing (Figure 16-15, Page 16-12). See following CAUTION. CAUTION •...
Page 271: Motor Installation
MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor Installation A. End View B. Side View 3066 Figure 16-16 Speed Sensor Clamp MOTOR INSTALLATION See General Warnings on page 1-1. Clean the transaxle input shaft. 1.1. Spray the input shaft thoroughly with CRC ®...
Page 272 MOTOR (MODEL DA5-4006): ELECTRIC Motor Installation VEHICLES inch inch 1/8 INCH 3/8 INCH (9.5 MM) (3.1 MM) Figure 16-17 Grease on Putty Knife Figure 16-18 Application of grease to Input Shaft Grooves 2.6. Check the chamfer (1) and end (2) of the input shaft to ensure these areas are completely clean of grease as shown (Figure 16-19, Page 16-15).
Page 273 MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor Installation 1/16 INCH (1.6 MM) Figure 16-19 Clean Chamfer and Input Shaft End Figure 16-20 Gap at Motor and Transaxle If using a chain hoist, lower the vehicle and guide the leaf springs into the shackles. If using a floor jack, raise the transaxle until the leaf springs can be guided into the shackles.
Page 274 MOTOR (MODEL DA5-4006): ELECTRIC Motor Installation VEHICLES Viewed From Driver Side Figure 16-21 Motor Tightening Sequence Page 16-16 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 275: Section 17 - Transaxle: Electric Vehicles
SECTION 17 — TRANSAXLE: ELECTRIC VEHICLES DANGER Transaxle: Electric Vehicles • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. LUBRICATION See General Warnings on page 1-1. There are two plugs located on the lower half of the transaxle housing. The upper plug (21) (as viewed when the vehicle is on a level surface) is used as a lubricant level indicator (Figure 17-5, Page 17-3).
Page 276 Axle Bearing and Shaft TRANSAXLE: ELECTRIC VEHICLES Inspect the axle shaft assembly to be sure the bearing and collar have not slipped and are still seated against the shoulder on the axle shaft. Inspect bearing (5) (Figure 17-5, Page 17-3). If the bearing in a Type G transaxle is worn or damaged, the entire axle shaft assembly (1 or 2) must be replaced.
Page 277 TRANSAXLE: ELECTRIC VEHICLES Axle Bearing and Shaft Figure 17-5 Transaxle – Type G 2019 Carryall 500 and 700 Maintenance and Service Manual Page 17-3...
Page 278: Axle Bearing
Axle Bearing and Shaft TRANSAXLE: ELECTRIC VEHICLES Axle Shaft and Oil Seal Installation If previously removed, install a new oil seal. 1.1. Clean seal seat in the adapter ring (39) (Figure 17-3, Page 17-2). 1.2. Place a new seal (15) in the adapter ring with the seal lip facing toward the adapter ring lip (Figure 17-3, Page 17-2).
Page 279: Transaxle
TRANSAXLE: ELECTRIC VEHICLES Transaxle TRANSAXLE See General Warnings on page 1-1. TRANSAXLE REMOVAL Disconnect the batteries and discharge the controller. See Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5. 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 280 Transaxle TRANSAXLE: ELECTRIC VEHICLES 2629 2631 Figure 17-8 Disconnect Shocks Figure 17-9 Detach Spring From Shackles Disconnect the shock absorbers from their lower mounts (Figure 17-8, Page 17-6). Disconnect the four motor wires. Use two wrenches to prevent the post from turning. With a floor jack supporting the transaxle, remove lower spring shackle nuts and bolts.
Page 281 TRANSAXLE: ELECTRIC VEHICLES Transaxle CAUTION 1. Motor Mounting Bolts 2. Input Pinion Gear 3. Intermediate Gear Assembly 4. Differential Gear Case 2639 Figure 17-11 Motor Mounting Bolts and Gear Assembly Figure 17-10 Detach Axle From Leaf Springs Carefully remove the motor from the transaxle. Slide the motor away from the transaxle until the motor spline becomes disengaged from the input shaft, then lift motor out.
Page 282: Transaxle Disassembly, Inspection, And Assembly
Transaxle Disassembly, Inspection, and Assembly TRANSAXLE: ELECTRIC VEHICLES TRANSAXLE DISASSEMBLY, INSPECTION, AND ASSEMBLY See General Warnings on page 1-1. TRANSAXLE DISASSEMBLY AND INSPECTION To detach axle tubes (14 and 35) from the transaxle housing, remove the bolts (8) (Figure 17-5, Page 17-3). Remove 11 bolts (24) that hold housing together.
Page 283 TRANSAXLE: ELECTRIC VEHICLES Transaxle Disassembly, Inspection, and Assembly Disassemble the differential gear case: 8.1. Remove the hex bolts (33) and the ring gear (32) from the differential case (Figure 17-5, Page 17-3). 8.2. Remove the ring gear. 8.3. Separate the differential gear case housing. If necessary, install two of the hex bolts (removed previously in step 8.1) into the differential gear unit and, while holding the unit slightly above the work area, lightly tap the bolt heads (Figure 17-14, Page 17-9).
Page 284: Transaxle Assembly
Transaxle Disassembly, Inspection, and Assembly TRANSAXLE: ELECTRIC VEHICLES NOTE: Damaged or worn gears should be replaced as sets. TRANSAXLE ASSEMBLY CAUTION • Do not press against the bearing outer race. • The housing and all parts must be wiped clean and dry before reassembly. If bearings (13) were removed during disassembly, install new bearings using an arbor press (Figure 17-5, Page 17-3).
Page 285 TRANSAXLE: ELECTRIC VEHICLES Transaxle Disassembly, Inspection, and Assembly WARNING • Be sure retaining ring is properly seated in its groove. If ring is not properly installed, the axle assembly will separate from the transaxle and damage the axle assembly and other components. Loss of vehicle control could result in severe personal injury or death.
Page 286: Transaxle Installation
Transaxle Installation TRANSAXLE: ELECTRIC VEHICLES TRANSAXLE INSTALLATION See General Warnings on page 1-1. If using a chain hoist, raise the vehicle and place transaxle in position on the jack stands. If using a floor jack, lower the jack stands to their lowest settings and place the transaxle in position on the jack stands. Align the center hole in the saddle of the transaxle with the pilot bolt in the leaf spring assembly.
Page 287: Section 18 - Troubleshooting And Electrical System: Gasoline Vehicles
SECTION 18 — TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES DANGER Troubleshooting and Electrical System: Gasoline Vehicles • 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 288: Malfunction Indicator Light
TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: GASOLINE VEHICLES Low oil warning light STATUS CONDITION Normal Operation When possible: Stop the vehicle. Turn the key to OFF. Examine the engine oil level. Add engine oil as necessary. If the low oil level warning light stays on, have a trained technician examine the vehicle.
Page 289: Gasoline Powertrain
TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Troubleshooting Guide GASOLINE POWERTRAIN TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Maintenance/Operate switch is in the Set the Maintenance/Operate switch to MAINTENANCE position OPERATE Fuse is blown See the Fuses Test Procedure Battery is dead See the Battery Test Procedure Pedal-Start: See the Key Switch (Start Circuit) Test Procedure...
Page 290 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: GASOLINE VEHICLES TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Engine mounting nuts or bolts are loose See the Engine (Kohler ECH440) Section Snubber on frame is worn or damaged See the Engine (Kohler ECH440) Section See the Exhaust System: Gasoline Vehicles Loose muffler mounting hardware Section...
Page 291: Electrical System
TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES 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 292: Test Procedures
TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES 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 293 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures 2 – Fuses 3 – Ground Cables 4 – Key Switch (Start Circuit) - Pedal-Start Vehicles Only 5 – Key Switch (Engine Kill Circuit) - Pedal-Start Vehicles Only 6 – Accelerator Pedal Limit Switch – Pedal-Start Vehicles Only 7 –...
Page 294 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES 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 295 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES 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 296 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES 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 297 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES 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 18-2, Page 18-10). 4.2. Each contact should show battery voltage. 4.3.
Page 298 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURE 3 – Ground Cables See General Warnings on page 1-1. NOTE: This is a continuity test for the main ground wire of the vehicle. An additional ground wire is located on top of the fuel tank.
Page 299 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures TEST PROCEDURE 4 – Key Switch (Start Circuit) - Pedal-Start Vehicles Only 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.
Page 300 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURE 5 – Key Switch (Engine Kill Circuit) - Pedal-Start Vehicles Only See General Warnings on page 1-1. NOTE: This is a continuity test. If necessary, see Testing Basics. Disconnect battery and spark plug wire. Remove the instrument panel.
Page 301 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures TEST PROCEDURE 6 – Accelerator Pedal Limit Switch – Pedal-Start Vehicles Only See General Warnings on page 1-1. NOTE: This is a continuity test. The accelerator pedal limit switch (1) is the top switch located in the electrical component box (Figure 18-5). There is a green wire and a pink wire connected to this limit switch.
Page 302 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURE 7 – Solenoid - Pedal-Start Vehicles Only See General Warnings on page 1-1. NOTE: This is a resistance and voltage test. If necessary, see Testing Basics. Remove the electrical component box cover (1) (Figure 18-6). 3025B Figure 18-6 Solenoid Wires Make sure that the wires are connected correctly and are tight.
Page 303 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures Check the voltage between the empty large post (1) and ground (Figure 18-7, Page 18-17). WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 3027B Figure 18-7 Solenoid Voltage Test With accelerator pedal in the UP position: The meter should read no voltage. 10.1.
Page 304 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURE 8 – 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.
Page 305 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures TEST PROCEDURE 9 – Neutral Lockout Limit Switch – Pedal-Start Vehicles Only See General Warnings on page 1-1. NOTE: This is a continuity test. This switch is located on the transaxle. A black/white wire, a gray wire, and a red wire are connected to this limit switch with a 3-pin connector.
Page 306 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURE 10 – Kill Limit Switch – Pedal-Start Vehicles Only See General Warnings on page 1-1. NOTE: This is a continuity test. The kill limit switch (1) is the lower of the two limit switches located in the electrical component box (Figure 18-10). There is a white/black wire and a blue wire connected to this limit switch.
Page 307 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 476B Figure 18-11 Kill Limit Switch Test 8.1. If there is continuity, replace the kill limit switch. 8.2. If there is no continuity, go to the next step. Press the lever and check for continuity.
Page 308 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES 3029B Figure 18-12 Jumper Wire Ground – DF to A1 Cover terminal on yellow wire to make sure it will not short to ground. Use a jumper wire (3) to ground DF terminal to A1 terminal (4). Set the multimeter 20 VDC.
Page 309 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures 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 310 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES – A grounded armature/commutator. – A grounded A1 or A2 terminal. Put the red (+) probe on the F1 terminal and the black (–) probe on the F2 terminal. The reading should be between approximately 0.1 and 0.3 ohms.
Page 311 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES 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. Disable the vehicle.
Page 312 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES 15.4.1. If the starter/generator is good, replace the voltage regulator. TEST PROCEDURE 14 – Ignition Spark See General Warnings on page 1-1. NOTE: Keep the battery connected while performing this test procedure. ®...
Page 313 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures TEST PROCEDURE 15 – Reverse Buzzer and Reverse Buzzer Limit Switch See General Warnings on page 1-1. NOTE: Reverse Buzzer: This is a voltage test. A reverse buzzer is mounted on the back side of the instrument panel. On some models, another reverse buzzer is also mounted on a bracket at the left rear of the vehicle.
Page 314 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURE 16 – Malfunction Indicator Light (MIL) See General Warnings on page 1-1. NOTE: This is a voltage test. If necessary, see Testing Basics. Remove the instrument panel. Make sure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Turn the key switch to ON.
Page 315 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures 3030C Figure 18-16 Battery Test (Under Load) Put the black (–) probe on the negative (–) battery post. Turn the key switch to ON. Make sure that the FNR is in N, and push the accelerator pedal. NOTE: With the accelerator pedal pushed, the battery is under load.
Page 316 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURE 19 – 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 317 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures 6.2.2. If there is voltage, check the fuel pump resistance. Fuel Pump Resistance Procedure If necessary, see Testing Basics. Disconnect the battery. Disconnect the fuel pump connector from the top of the fuel pump module. Set the multimeter to 200 Ohms.
Page 318 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES Wire Color Description Switched 12V Power Constant 12V Power Open Malfunction Indicator Light (MIL) White Ground Kill Wire Green Low Oil Light Black / White Fuel Pump Open Figure 18-19 ECU Connector Page 18-32 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 319 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures TEST PROCEDURE 20 – Fuel Level Sending Unit 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 320 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES FLOAT POSITION RESISTANCE READING FUEL GAUGE READINGS Lower position (tank empty) 250 ohms (±10) Empty Center position (tank half full) 141 ohms (±8) Half full Upper position (tank full) 33.3 ohms (±6) Full 5.1.
Page 321 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures TEST PROCEDURE 21 – Fuel Gauge See General Warnings on page 1-1. NOTE: This is a voltage test. 1. Black 2. Red/White 4. Purple 6. Black 7. White Figure 18-21 Fuel Gauge/Hour Meter If necessary, see Testing Basics.
Page 322 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES Put the black (–) probe on terminal 1 of the fuel gauge/hour meter with the black wire (3) connected. Turn the key switch ON. The voltage reading should be the same as the battery voltage reading recorded earlier. 11.1.
Page 323 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures TEST PROCEDURE 23 – Headlight 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 18-10. This is a voltage test.
Page 324 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURE 24 – Voltage at Headlight Socket See General Warnings on page 1-1. NOTE: This is a voltage test. If necessary, see Test Basics. Inspect the wires at the light bulb socket. Make sure the wires are securely fastened to the contacts inside the socket and that wires are installed correctly.
Page 325 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures TEST PROCEDURE 25 – 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 326 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURE 26 – 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 327 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures 9.2. If the voltage is incorrect, check the wiring and then the ECU. See following NOTE. NOTE: If pin 4 has no voltage, the ECU LIN (Local Interconnect bus) may have failed. If the vehicle does not use Guardian or Visage, the vehicle can be driven and will not show any symptoms.
Page 328 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURE 29 – Solenoid - Key-Start Vehicles Only See General Warnings on page 1-1. NOTE: This is a resistance and voltage test. If necessary, see Testing Basics. Remove the electrical component box cover (1) (Figure 18-27). 3025B Figure 18-27 Solenoid Wires Make sure that the wires are connected correctly and are tight.
Page 329 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 3027B Figure 18-28 Solenoid Voltage Test 6.4. With key switch in the OFF and ON positions: The multimeter should read no voltage. 6.4.1. If there is voltage, replace the solenoid.
Page 330 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURE 30 – 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.
Page 331 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures TEST PROCEDURE 31 – Charging Diode (Generator Circuit) – Key-Start Vehicles Only See General Warnings on page 1-1. WARNING • Incorrect wiring could result in severe injury or death. • Diode and solenoid connections must have correct polarity. •...
Page 332 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES Connect the black (–) multimeter probe to the red lead of the charging diode. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1700-30100-10384 Figure 18-31 Diode Test – Probes Reversed Connect the red (+) multimeter probe to the white lead of the charging diode. 9.1.
Page 333: Section 19 - Electrical Components: Gasoline Vehicles
SECTION 19 — ELECTRICAL COMPONENTS: GASOLINE VEHICLES DANGER Electrical Components: Gasoline Vehicles • 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 334: Disassembly Of The Starter/Generator To Service The Brushes
ELECTRICAL COMPONENTS: GASOLINE Starter/Generator VEHICLES 3033C Figure 19-1 Starter/Generator Wiring Loosen the pivot nuts (1) and pivot bolts (2) (Figure 19-2, Page 19-2). 2997B Figure 19-2 Starter/Generator Removal Remove the adjustment nut (3), washer (4) and adjustment bolt (5). Lower the starter/generator and remove the belt (6) from the pulley. Support the starter/generator so that when the pivot bolts are removed the starter/generator will not fall.
Page 335: Brush Inspection And Replacement
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Starter/Generator NOTE: If the brushes are not removed, contact between the brushes and commutator as the commutator end cover is being removed or installed could damage the brushes. Lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover.
Page 336: Starter/Generator Assembly
ELECTRICAL COMPONENTS: GASOLINE Starter/Generator VEHICLES Install the four brushes (27) into their holders and insert the four brush springs (28) (Figure 19-4, Page 19-3). Using a spring scale, test brush spring tension. If any spring has a tension less than 24 ozf (0.68 kgf), replace all four springs (Figure 19-6, Page 19-4).
Page 337: Disassembly Of The Starter/Generator To Service The Armature/Commutator
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Starter/Generator Figure 19-7 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 338: Bearing Cleaning And Inspection
ELECTRICAL COMPONENTS: GASOLINE Starter/Generator VEHICLES 1342 Figure 19-8 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 19-9, Page 19-6). Replace the bearing if it is noisy, does not spin smoothly, or has excessive play.
Page 339: Bearing Removal
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Starter/Generator BEARING REMOVAL Place the wedge attachment tool 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 to the wedge attachment tool and pull the bearing off of the end of the armature shaft.
Page 340: Commutator Cleaning And Inspection
ELECTRICAL COMPONENTS: GASOLINE Starter/Generator VEHICLES Figure 19-11 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 341: Armature Ground Test
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Starter/Generator 1. Measure each position in two places, 90 degrees apart Figure 19-12 Inspect Commutator ARMATURE GROUND TEST CAUTION • Do not submerge armature in solvent. NOTE: Before testing, wipe the armature with a clean cloth and remove carbon dust and metal particles from between commutator bars.
Page 342: Visual Inspection Of Field Coils
ELECTRICAL COMPONENTS: GASOLINE Starter/Generator VEHICLES WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 200 Ohms Setting 2. Commutator 3. Armature Shaft Figure 19-13 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 343 ELECTRICAL COMPONENTS: GASOLINE VEHICLES Starter/Generator Press a new ball bearing (35) onto the output end of the armature (Figure 19-8, Page 19-6). Press a new ball bearing onto the commutator end of the armature shaft. See following CAUTION. CAUTION • To prevent damage to the retainer, use care while pressing new bearing onto the output end of the shaft.
Page 344 ELECTRICAL COMPONENTS: GASOLINE Starter/Generator VEHICLES 90° 1. Jumper Wire 2. 1 inch (25.4 mm) Minimum Radius 3. Jumper Wire Not Allowed in this Area. 2687 Figure 19-14 A1 to F1 Terminal Jumper Wire Routing Page 19-12 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 345: Starter/Generator Installation
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Starter/Generator STARTER/GENERATOR INSTALLATION Disable the vehicle. Disconnect the battery and spark plug wire. Install the green wire (1) from the F1 terminal to the A2 terminal on the starter/generator (Figure 19-15). 3033B Figure 19-15 Starter/Generator Green Wire Install a flat washer, lock washer, and nut onto each terminal and tighten to 48 in·lb (5.4 N·m).
Page 346: Belt Tension Inspection For Efi Engines
ELECTRICAL COMPONENTS: GASOLINE Starter/Generator VEHICLES Adjust the belt tension. See Belt Tension Adjustment For EFI Engines. Connect the yellow wire (7) from the voltage regulator to the DF terminal on the starter/generator (Figure 19-17). 3033D Figure 19-17 Starter/Generator Yellow Wire Install a flat washer, lock washer, and nut onto the terminal.
Page 347: Belt Tension Adjustment For Efi Engines
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Starter/Generator Existing Belts Only Disconnect the battery and spark plug wire. Mark a location on belt to repeat tension measurement each time. Use paint pen or permanent marker of light color. Install a Universal Belt Tension Gauge (OTC 6673 recommended) midway between the pulleys.
Page 348 ELECTRICAL COMPONENTS: GASOLINE Starter/Generator VEHICLES 2724 Figure 19-20 Belt Tension Gauge Tighten the adjustment nut (1) and pivot nut (2) with your hand (Figure 19-21, Page 19-16) . 2997C Figure 19-21 Starter/Generator Mounting Hardware Install the belt tension tool. Page 19-16 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 349 ELECTRICAL COMPONENTS: GASOLINE VEHICLES Starter/Generator 2725 Figure 19-22 Belt Tensioning Tool Installation 5.1. Carefully insert pry bar between starter/generator and bracket. NOTE: In some cases, the threaded J-bolt of the belt tension tool does not have enough length to consistently fit under the starter/generator mounting ear.
Page 350: Belt Tension Tool Modification
ELECTRICAL COMPONENTS: GASOLINE Starter/Generator VEHICLES Maintain tension and tighten the adjustment nut (1) to 15 to 18 ft·lb (20 to 24.5 N·m). Tighten the pivot nuts (2) to 20 to 25 ft·lb (27 to 34 N·m) (Figure 19-23, Page 19-18). 2997C Figure 19-23 Starter/Generator Mounting Hardware Installation...
Page 351: Voltage Regulator
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Voltage Regulator VOLTAGE REGULATOR VOLTAGE REGULATOR REMOVAL Disconnect the battery and spark plug wire. Remove the electrical component box cover. Disconnect the voltage regulator red wire (1) at the large post on the solenoid (Figure 19-25). 2973B Figure 19-25 Voltage Regulator Disconnect the yellow wire (2) at the bullet connector.
Page 352: Key Switch
ELECTRICAL COMPONENTS: GASOLINE Key Switch VEHICLES KEY SWITCH KEY SWITCH REMOVAL Disconnect the battery and spark plug. Remove the instrument panel. NOTE: Take care to prevent key switch terminals and wires from touching the metal frame around the dash. Disconnect the wires from the key switch. Do not allow wires to touch. From the back of the instrument panel, push down on the retaining tabs (1) and remove the key switch cap (2) (Figure 19-26, Page 19-20).
Page 353: Key Switch Installation
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Key Switch KEY SWITCH INSTALLATION Install the key switch (1) and washer (2) into the instrument panel (Figure 19-27, Page 19-21). 2931C Figure 19-27 Key Switch Installation Install the key switch nut (3). Tighten the nut to 35 to 45 in·lb (4 to 5 N·m). Install key switch cap (4) into instrument panel.
Page 354: Maintenance/Operate Switch
ELECTRICAL COMPONENTS: GASOLINE Maintenance/Operate Switch VEHICLES MAINTENANCE/OPERATE SWITCH MAINTENANCE/OPERATE SWITCH REMOVAL Disconnect the battery and spark plug wire. Remove the boot/hex nut (1) (Figure 19-28). 000755-004 Figure 19-28 Maintenance/Operate Switch Remove the Maintenance/Operate switch (2) from bracket (3). Disconnect the wires and remove Maintenance/Operate switch. MAINTENANCE/OPERATE SWITCH INSTALLATION Connect the wires to the Maintenance/Operate switch.
Page 355: Neutral Lockout Limit Switch
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Neutral Lockout Limit Switch 000755-004 Figure 19-29 Maintenance/Operate Switch Install the boot/hex nut (1). Tighten the boot/hex nut to 16 in·lb (1.8 N·m). Connect the battery. NEUTRAL LOCKOUT LIMIT SWITCH NEUTRAL LOCKOUT LIMIT SWITCH REMOVAL On Transaxle Disable the vehicle.
Page 356 ELECTRICAL COMPONENTS: GASOLINE Neutral Lockout Limit Switch VEHICLES 000999-003 Figure 19-30 Transaxle - Neutral Lockout Limit Switch Remove the nuts (2),washers (3), and bolts (4). Remove the neutral lockout limit switch. On FNR Disable the vehicle. Disconnect the battery and spark plug wire. Remove the instrument panel.
Page 357: Neutral Lockout Limit Switch Installation
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Neutral Lockout Limit Switch NEUTRAL LOCKOUT LIMIT SWITCH INSTALLATION CAUTION • Do not overtighten the retaining nuts. If the nuts are overtightened, limit switches could be damaged. On Transaxle Install the limit switch (1) with the screws (4), washers (3), and nuts (2). Tighten the hardware to 5 in·lb (0.6 N·m) (Figure 19-32).
Page 358: Solenoid
ELECTRICAL COMPONENTS: GASOLINE Solenoid VEHICLES 000999-004 Figure 19-33 FNR - Neutral Lockout Limit Switch Move the Forward/Neutral/Reverse control (FNR) to make sure the switch actuates Connect the 3-wire connector to the neutral lockout limit switch lead. Connect the battery and spark plug wire. Test drive the vehicle in both forward and reverse for proper operation.
Page 359 ELECTRICAL COMPONENTS: GASOLINE VEHICLES Solenoid 3025C Figure 19-34 Solenoid Wires Disconnect the wires from the solenoid (2). Remove the screws (3) from the solenoid (Figure 19-35). 001014-003 Figure 19-35 Solenoid Screws Remove the solenoid. 2019 Carryall 500 and 700 Maintenance and Service Manual Page 19-27...
Page 360: Solenoid Installation
ELECTRICAL COMPONENTS: GASOLINE Solenoid VEHICLES SOLENOID INSTALLATION Install the solenoid in the electrical component box. Install the screws (1) (Figure 19-36). Tighten the screws to 14 in·lb (1.6 N·m) . 001014-004 Figure 19-36 Solenoid Screws Pedal-Start Vehicle: 3.1. Connect the 4 gauge white wire, 18 gauge white wire, and the 18 gauge red wire to the large post. 3.2.
Page 361: Fuse
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Fuse FUSE ATC-style fuses are located inside the electrical component box near the battery. ATM-style fuses are located on the main wire harness in front of the engine. FUSE REMOVAL Disconnect the battery. ATC Fuse Only: Remove electrical component box cover cover. ATM Fuse Only: Remove fuse holder cover.
Page 362: Accelerator Pedal Limit Switch
ELECTRICAL COMPONENTS: GASOLINE Accelerator Pedal Limit Switch VEHICLES ACCELERATOR PEDAL LIMIT SWITCH ACCELERATOR PEDAL LIMIT SWITCH REMOVAL Disconnect the battery and spark plug wire. Remove the screw (1) (Figure 19-37). 2948D Figure 19-37 Accelerator Pedal Limit Switch Remove the electrical component box cover (2). Remove the two nuts (3) and washers (4).
Page 363: Kill Limit Switch
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Kill Limit Switch KILL LIMIT SWITCH KILL LIMIT SWITCH REMOVAL Disconnect the battery and spark plug wire. Remove the screw (1) (Figure 19-38). 2948E Figure 19-38 Kill Limit Switch Remove the electrical component box cover (2). Remove the two nuts (3) and washers (4).
Page 364: Reverse Warning Buzzer
ELECTRICAL COMPONENTS: GASOLINE Reverse Warning Buzzer VEHICLES Install the electrical component box cover (2). Be sure to press down firmly all corners. Install the screw (1). Tighten the screw to 18 in·lb (2 N·m). Connect the battery and spark plug wire. REVERSE WARNING BUZZER REVERSE WARNING BUZZER REMOVAL Disconnect the battery and spark plug wire.
Page 365: Reverse Buzzer Limit Switch
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Reverse Buzzer Limit Switch REVERSE BUZZER LIMIT SWITCH REVERSE BUZZER LIMIT SWITCH REMOVAL Disconnect the battery and spark plug wire. Remove the instrument panel. Cut the wire tie that retains the limit switch leads to the instrument panel harness. Remove the nuts (1) and washers (2) (Figure 19-40, Page 19-33).
Page 366: Low Oil Warning Light
ELECTRICAL COMPONENTS: GASOLINE Low Oil Warning Light VEHICLES Connect the battery and spark plug wire. Turn the key switch to the ON position. Set the FNR to R. Make sure that the buzzer sounds. LOW OIL WARNING LIGHT LOW OIL WARNING LIGHT REMOVAL Disconnect the battery and spark plug wire.
Page 367: Malfunction Indicator Light
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Malfunction Indicator Light MALFUNCTION INDICATOR LIGHT MALFUNCTION INDICATOR LIGHT REMOVAL Disconnect the battery and spark plug wire. Remove the instrument panel. Disconnect the malfunction indicator light (1) wires (Figure 19-42, Page 19-35). Do not allow wires to touch. 3003C Figure 19-42 Malfunction Indicator Light Push the retaining tabs and remove the malfunction indicator light from the instrument panel.
Page 368: Fuel Gauge/Hour Meter Removal
ELECTRICAL COMPONENTS: GASOLINE Fuel Level Sending Unit VEHICLES FUEL GAUGE/HOUR METER REMOVAL Disconnect the battery and spark plug wire. Remove the instrument panel. Disconnect the fuel gauge/hour meter (1) wires (Figure 19-43, Page 19-36). Do not allow wires to touch. 3003D Figure 19-43 Fuel Gauge/Hour Meter Alternate pulling the lower and upper tabs away from the gauge housing to remove clip.
Page 369: Voltage Limiter
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Voltage Limiter VOLTAGE LIMITER VOLTAGE LIMITER REMOVAL NOTE: Battery will charge reducing the voltage going to accessories. The voltage limiter is located on the driver side cowl frame. Disable the vehicle. Disconnect the battery and spark plug wire. Remove the cowl.
Page 370: Headlight Switch
ELECTRICAL COMPONENTS: GASOLINE Headlight Switch VEHICLES HEADLIGHT SWITCH HEADLIGHT SWITCH REMOVAL Disconnect the battery and spark plug wire. Remove the instrument panel. Disconnect the wires from the headlight switch (1) (Figure 19-45). 3003E Figure 19-45 Headlight Switch Push the tabs and remove the headlight switch from the instrument panel. HEADLIGHT SWITCH INSTALLATION Connect the wires to the headlight switch (1) (Figure 19-45).
Page 371: Headlights
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Headlights HEADLIGHTS HEADLIGHT BEZEL REMOVAL Disconnect the battery Remove the cowl. Remove the front fender. Disconnect the headlight and turn signal electrical connectors. Remove the bolts (1) (Figure 19-46, Page 19-39). Figure 19-46 Headlight Bezel Remove the headlight bezel (2). HEADLIGHT BEZEL INSTALLATION Install the headlight bezel (2) to vehicle frame (Figure 19-46, Page 19-39).
Page 372: Halogen Headlight Bulb Removal
ELECTRICAL COMPONENTS: GASOLINE Headlights VEHICLES HALOGEN HEADLIGHT BULB REMOVAL CAUTION • Do not touch the glass part of the headlight bulb. Oil from fingertips can decrease the life of the headlight bulb. Disconnect the battery Remove the cowl. Lift the tabs on the connector harness to release the electrical connector from the headlight bulb (1) (Figure 19-47, Page 19-40).
Page 373: Halogen Headlight Lens Removal
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Headlights HALOGEN HEADLIGHT LENS REMOVAL CAUTION • Do not touch the glass part of the headlight bulb. Oil from fingertips can decrease the life of the headlight bulb. Disconnect the battery Remove the cowl. Lift the tabs on the connector harness to release the electrical connector from the headlight bulb (1) (Figure 19-48, Page 19-41).
Page 374: Led Headlight Removal
ELECTRICAL COMPONENTS: GASOLINE Battery VEHICLES LED HEADLIGHT REMOVAL Disconnect the battery. Remove the cowl. Lift the tabs on the connector harness to release the electrical connector from the LED headlight (1) (Figure 19-49, Page 19-42). 2993E Figure 19-49 LED Headlight Remove the screws (2) and washers (3).
Page 375: General Information
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Battery DANGER • Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or clothing. Antidotes: – External: Flush with water. Call a physician immediately. – Internal: Drink large quantities of milk or water followed with milk of magnesia or vegetable oil.
Page 376: Vibration Damage
ELECTRICAL COMPONENTS: GASOLINE Battery VEHICLES VIBRATION DAMAGE The battery hold-down clamp should always be tight enough to keep the battery from bouncing. Battery life may be severely shortened if the clamp is too loose. Excessive vibration shortens the life of the battery. It may also cause acid to leak out of the vent caps and corrosion to build up on surrounding metal parts.
Page 377: Battery Storage
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Battery Connect the battery and spark plug wire. 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. 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 378: Oxygen Sensor
ELECTRICAL COMPONENTS: GASOLINE Oxygen Sensor VEHICLES OXYGEN SENSOR OXYGEN SENSOR REMOVAL Disconnect the battery. Disconnect the oxygen sensor connector from the engine wire harness (1) (Figure 19-50, Page 19-46). Figure 19-50 Oxygen Sensor Remove the oxygen sensor (2). OXYGEN SENSOR INSTALLATION Install the oxygen sensor (2) into the muffler tube (Figure 19-50, Page 19-46).
Page 379: Charging Dioded (Key-Start Only)
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Charging Dioded (Key-Start Only) CHARGING DIODED (KEY-START ONLY) See General Warnings on page 1-1. CHARGING DIODE REMOVAL Disable the vehicle. Disconnect the battery and spark plug wire. Remove the screw (1) (Figure 19-51, Page 19-47) 2978Beps Figure 19-51 Charging Diode Remove the electrical component box cover (2).
Page 380: Charging Diode Installation
ELECTRICAL COMPONENTS: GASOLINE Charging Dioded (Key-Start Only) VEHICLES CHARGING DIODE INSTALLATION CAUTION • Be sure to remove and discard the protective film from both sides of the thermal pad before installing it. If not removed, the film will reduce the thermal heat transfer and therefore reduce the power handling capability of the diode, causing it to overheat and damage the electrical system.
Page 381: Section 20 - Engine (Kohler Ech440)
SECTION 20 — ENGINE (KOHLER ECH440) DANGER Engine (Kohler ECH440) • 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 Kohler, high-compression, chain driven, overhead valve engine (OHV). See following NOTE.
Page 382: Engine Removal
Engine Removal ENGINE (KOHLER ECH440) ENGINE REMOVAL See General Warnings on page 1-1. CAUTION • Before removal and disassembly, clean the engine. Disconnect the battery. Disconnect the spark plug wire. For some vehicles, the engine can be removed by lifting it up and out of the chassis. For other vehicles, it is easier to remove the entire powertrain assembly first.
Page 383 ENGINE (KOHLER ECH440) Engine Removal Remove the bolts (5 and 6) (Figure 20-2, Page 20-3). Figure 20-2 Clutch Plate Removal Remove the clutch plate (7). Remove the bolts (8) (Figure 20-3, Page 20-3). Figure 20-3 Exhaust Weldment Removal Remove the exhaust weldment (9). 2019 Carryall 500 and 700 Maintenance and Service Manual Page 20-3...
Page 384 Engine Removal ENGINE (KOHLER ECH440) Remove the bolts (10), washers (11), and nuts (12) (Figure 20-4, Page 20-4). Figure 20-4 Engine Pan Removal Lift the engine from engine pan (13). See following NOTE. NOTE: The engine weighs approximately 54 lb (24.5 kg). Remove the oil drain plug and drain all oil from crankcase.
Page 385: Engine Installation
ENGINE (KOHLER ECH440) Engine Installation ENGINE INSTALLATION See General Warnings on page 1-1. If replacing engine, install starter/generator mounting weldment on engine with the screws. Tighten the screws to 17 ft·lb (23 N·m). Install oil drain plug and tighten to 13 ft·lb (18 N·m). Place the engine onto the engine pan (13) and secure with mounting hardware (10, 11, and 12) (Figure 20-5, Page 20-5).
Page 386 Engine Installation ENGINE (KOHLER ECH440) Install the clutch plate (7) with bolts (5 and 6) (Figure 20-7, Page 20-6). Tighten the bolts (5) to 27 ft·lb (36 N·m). Tighten the bolts (6) to 50 ft·lb (68 N·m). Figure 20-7 Clutch Plate Installation Install the drive clutch.
Page 387 ENGINE (KOHLER ECH440) Engine Installation Connect the ground cable to the engine (4) (Figure 20-8, Page 20-7). Figure 20-8 Throttle Cover and Ground Cable Installation Route the vent line (3) through the throttle body cover (2). Connect the vent line. Install the throttle body cover with the screw (1).
Page 388: Snubber
Snubber ENGINE (KOHLER ECH440) 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 20-9, Page 20-8).
Page 389: Section 21 - Fuel System: Gasoline Vehicles
SECTION 21 — 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: General Information
Engine Control Linkages FUEL SYSTEM: GASOLINE VEHICLES 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 391 FUEL SYSTEM: GASOLINE VEHICLES Engine Control Linkages 1345 Figure 21-1 Accelerator Rod Figure 21-2 Accelerator Rod – Pull Spring Release to Attach (Bottom View) Accelerator Rod Installation and Adjustment Before installing the accelerator rod, adjust accelerator pedal position. See Pedal Group Adjustment – Gasoline Vehicles in the Accelerator and Brake Pedal Group Section.
Page 392 Engine Control Linkages FUEL SYSTEM: GASOLINE VEHICLES 3113 Figure 21-3 Accelerator Cable Cam Position – 7° (Top 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. While pressing the accelerator pedal, the following events should occur in exactly the order shown: NOTE: Always perform a visual check to ensure the starter motor begins rotating the engine prior to the throttle body lever moving.
Page 393: 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/Neutral/Reverse control (FNR) in the NEUTRAL position, and chock the wheels. Disconnect battery and spark plug wire. At engine: 3.1.
Page 394 Engine Control Linkages FUEL SYSTEM: GASOLINE VEHICLES Governor Cable Installation and Adjustment At engine: 1.1. Snap governor cable into throttle body bracket (4) (Figure 21-6, Page 21-6). Figure 21-6 Governor Cable Installation - Throttle Body 1.2. Connect the governor cable fitting (1) to throttle lever (2). 1.3.
Page 395: Accelerator Cable
FUEL SYSTEM: GASOLINE VEHICLES Engine Control Linkages Loosen adjustment screw jam nut (4) and back off throttle stop screw (5) several turns (Figure 21-8, Page 21-7). A = 0.055 in. ± 0.039 (1.4 mm ± 1) 3111B Figure 21-8 Throttle Stop Screw Gap Rotate governor arm counterclockwise until it stops and hold in this position.
Page 396 Engine Control Linkages FUEL SYSTEM: GASOLINE VEHICLES At transaxle: 3.1. Unhook spring fitting of accelerator cable (1) from governor arm (2) (Figure 21-9, Page 21-8). 3110D Figure 21-9 Accelerator Cable Removal - Governor Arm 3.2. Unsnap accelerator cable from FNR/accelerator cable bracket (3). At electrical component box: 4.1.
Page 397 FUEL SYSTEM: GASOLINE VEHICLES Engine Control Linkages 3110C Figure 21-11 Accelerator Cable Installation - Governor 1.2. Snap accelerator cable into FNR/accelerator cable bracket (3). 1.3. Push dust shield (4) onto end of cable housing. At electrical component box: 2.1. Insert barrel fitting (5) of accelerator cable (6) into cam (7) in electrical component box (Figure 21-12, Page 21-9).
Page 398: Closed Throttle Or Idle Adjustment - Pedal-Start Vehicles
Engine Control Linkages FUEL SYSTEM: GASOLINE VEHICLES CLOSED THROTTLE OR IDLE ADJUSTMENT – PEDAL-START VEHICLES To adjust the idle, see ECU Reset Procedure and TPS Learn Procedure for Pedal Start Applications in the Kohler Service Manual. CLOSED THROTTLE OR IDLE ADJUSTMENT – KEY-START VEHICLES To adjust the idle, see ECU Reset Procedure and TPS Learn Procedure for Key Start Applications in the Kohler Service Manual.
Page 399 FUEL SYSTEM: GASOLINE VEHICLES Engine Control Linkages 5.3. Be sure both jam nuts are locked against the electrical component box and check ground speed again. If ground speed needs to be adjusted, repeat previous step. See following NOTE. NOTE: If more adjustment is required than the cable housing will allow, make sure the spring fitting on the other end of the accelerator cable is properly installed.
Page 400: Air Intake System
Air Intake System FUEL SYSTEM: GASOLINE VEHICLES AIR INTAKE SYSTEM See General Warnings on page 1-1. 3049 Figure 21-13 Air Intake System Page 21-12 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 401: Air Cleaner Removal
FUEL SYSTEM: GASOLINE VEHICLES Air Intake System AIR CLEANER REMOVAL Turn key switch to the OFF position and remove key, place Forward/Neutral/Reverse control (FNR) in the NEUTRAL position, and chock the wheels. Disconnect battery and spark plug wire. Remove clamp (5) and disconnect air intake hose (6) from air cleaner (3) (Figure 21-13, Page 21-12). Remove hardware (7, 8, and 9) securing air cleaner (3) to vehicle.
Page 402: Relieving Fuel Pressure
CAUTION • This EFI gasoline vehicle is equipped with 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 403: Fuel Line Removal
FUEL SYSTEM: GASOLINE VEHICLES Fuel Line FUEL LINE REMOVAL WARNING • Fuel may be under pressure. Use extreme caution when disconnecting fuel line to prevent the spray of fuel onto hot engine. See Relieving Fuel Pressure. • Carefully drain any fuel into an approved container. Add drained fuel back into fuel tank or dispose of properly.
Page 404: Fuel Line Installation
Fuel Line FUEL SYSTEM: GASOLINE VEHICLES Figure 21-15 Fuel Line Connector – Disconnect 5.3. Push in and hold the release tab (5). 5.4. Remove the fuel line from the throttle body. 5.5. Drain the fuel line into an appropriate container. At fuel tank: 6.1.
Page 405 FUEL SYSTEM: GASOLINE VEHICLES Fuel Line Figure 21-16 Fuel Line Support Bracket - Connect 1.3. Clean the nipple on top of fuel pump module. 1.4. Push the fuel line (5) onto the nipple until it locks into place (Figure 21-17, Page 21-17). Figure 21-17 Fuel Line Connector –...
Page 406: Fuel Pump Module
Fuel Pump Module FUEL SYSTEM: GASOLINE VEHICLES DANGER • Repair all fuel leaks before returning the vehicle to service. If no leaks are found, set the Maintenance/Operate switch in the OPERATE. 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.
Page 407: Fuel Pump Module Removal
FUEL SYSTEM: GASOLINE VEHICLES Fuel Pump Module FUEL PUMP MODULE REMOVAL 3052B Figure 21-18 Fuel Pump Module Removal 2019 Carryall 500 and 700 Maintenance and Service Manual Page 21-19...
Page 408: Fuel Pump Module Installation
Fuel Pump Module FUEL SYSTEM: GASOLINE VEHICLES Disable the vehicle. Disconnect the battery. Clean the top of the fuel tank (1) and fuel pump module (2) (Figure 21-18, Page 21-19). With a marker pen, make a mark across the top of the fuel pump module and onto the tank to note orientation before removal.
Page 409: Fuel Tank
SAEJ30R9 1/4 in (6.3 mm) fuel vent hose and 3/16 in (4.78 mm) fuel vent hose. To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car fuel vent hoses or equivalent. 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 410: Fuel Tank Removal
Fuel Tank FUEL SYSTEM: GASOLINE VEHICLES FUEL TANK REMOVAL 3052D Figure 21-19 Fuel Tank Removal Page 21-22 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 411: Fuel Tank Disposal
FUEL SYSTEM: GASOLINE VEHICLES Fuel Tank Disable the vehicle. Set the Maintenance/Operate switch to MAINTENANCE. Disconnect the battery. Clean the top of the fuel tank (1) and fuel pump module (2) (Figure 21-19, Page 21-22). Remove gas cap and siphon all fuel from tank into an approved container. See following DANGER and WARNING.
Page 412: Fuel Tank Installation
SAEJ30R9 1/4 in (6.3 mm) fuel vent hose and 3/16 in (4.78 mm) fuel vent hose. To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car fuel vent hoses or equivalent. Place fuel tank (1) in vehicle (Figure 21-19, Page 21-22).
Page 413: Fuel Filter
FUEL SYSTEM: GASOLINE VEHICLES Fuel Filter FUEL FILTER See General Warnings on page 1-1. GENERAL INFORMATION The fuel filter is located in the fuel tank. It is part of the fuel pump module assembly and should last the life of the vehicle;...
Page 414 Fuel Filter FUEL SYSTEM: GASOLINE VEHICLES 3052E Figure 21-21 Fuel Filter Installation Connect flex hoses (2 and 3) to the fuel filter. 2.1. Orient flex hoses with matching port in filter and push each hose end straight into filter until fully seated. 2.2.
Page 415: Section 22 - Exhaust System: Gasoline Vehicles
SECTION 22 — 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 the battery and spark plug wire. If necessary, remove the oxygen sensor (1) from the muffler (2) (Figure 22-1, Page 22-1). See Oxygen Sensor Removal.
Page 416: Muffler Installation
Muffler EXHAUST SYSTEM: GASOLINE VEHICLES MUFFLER INSTALLATION Install the new exhaust gasket (7) on the exhaust port studs (Figure 22-2, Page 22-2). Figure 22-2 Muffler Installation Put the muffler (2) into position on the engine. Install the nuts (3), bolt (4), washer (5), and bolts (6). Tighten the hardware by hand. Tighten the hardware in the following order: 4.1.
Page 417: Section 23 - Clutches: Gasoline Vehicles
SECTION 23 — 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 418 Troubleshooting CLUTCHES: GASOLINE VEHICLES Maintaining proper adjustment of the engine and governor, as well as the torque converter, is essential to the troubleshooting process. If these adjustments are within specifications and, when climbing a steep hill, the engine begins to lose RPM before the drive belt reaches the top of the driven clutch, there is a torque converter problem. If the torque converter is not operating properly, perform the following steps: Check the governor and throttle settings.
Page 419: 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 420: 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 421: Drive Clutch Removal
CLUTCHES: GASOLINE VEHICLES Drive Clutch 8. Drive Clutch Weight 17. Spacer, Idler, Drive 9. Thrust Washer 18. Sheave, Fixed, Drive 2960 Figure 23-2 Drive Clutch – Exploded View CAUTION • Be very careful when handling the clutches. A clutch that has been dropped will not be properly balanced.
Page 422: Drive Clutch Cleaning And Inspection
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 423: Drive Clutch Disassembly
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 23-5, Page 23-7).
Page 424 Drive Clutch CLUTCHES: GASOLINE VEHICLES 3053 Figure 23-7 Drive Button Mounting Figure 23-8 Weight Position Remove the clutch weights: 5.1. Remove the screws (1) and flat washers (2) attaching the weights (3) as shown (Figure 23-8, Page 23-8). 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 23-9, Page 23-9).
Page 425: Inspection Of Drive Clutch Parts
CLUTCHES: GASOLINE VEHICLES Drive Clutch Figure 23-9 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 23-2, Page 23-4). 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 23-2, Page 23-4).
Page 426: 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 427: 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 23-12, Page 23-11).
Page 428: 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 429: Driven Clutch Removal
CLUTCHES: GASOLINE VEHICLES Driven Clutch 5. Cam, Driven Clutch 11. Sheave, Fixed, Driven 6. Spring, Driven Clutch, CCW, Red 12. Key, 3/16 in. (4.7 mm) Square X 1.50 in. (38 mm) Long 2961 Figure 23-13 Driven Clutch – Exploded View DRIVEN CLUTCH REMOVAL Remove the drive belt as instructed.
Page 430 Driven Clutch CLUTCHES: GASOLINE VEHICLES Install the cam press plate (5), thrust washer (6), thrust bearing (7), thrust washer (8), and nut (9) onto the threaded bolt. Thread the nut down onto the cam hub, centering the press hub onto the cam hub. Use two wrenches and hold the threaded bolt head while tightening the cam press plate to press the cam onto the keyed shaft.
Page 431 CLUTCHES: GASOLINE VEHICLES Driven Clutch 609B Figure 23-16 Cam Removal Use a driven clutch cam puller (12) to remove the cam (13) from the fixed sheave. Remove the spring (14) (Figure 23-17, Page 23-15). 2961B Figure 23-17 Driven Clutch Disassembly Retain the key (15).
Page 432: Driven Clutch Inspection
Driven Clutch CLUTCHES: GASOLINE VEHICLES Slide the moveable sheave (16) off the fixed sheave (17). DRIVEN CLUTCH INSPECTION Inspect the cam for excessive wear. Replace it if necessary. Inspect the drive buttons (2) for excessive wear (Figure 23-18, Page 23-16). Replace if necessary. To remove the drive buttons, remove the socket-head cap screws (1) and then the buttons.
Page 433 CLUTCHES: GASOLINE VEHICLES Driven Clutch 2961C Figure 23-19 Drive Button Installation Slide the acetal washer (3) and moveable sheave (4) onto the fixed sheave (5) (Figure 23-20, Page 23-17). 2961D Figure 23-20 Driven Clutch Assembly Place the end of the spring (6) into the hole in the moveable sheave (9). Install the key (7) into the keyway of the fixed sheave shaft.
Page 434 Driven Clutch CLUTCHES: GASOLINE VEHICLES Figure 23-21 Driven Clutch Tool - Assembly Assemble the threaded bolt (10) through the washer (11) and thrust collar (12). NOTE: It is very important that the bolt, washers, and thrust bearing assembly be assembled in the order described and shown.
Page 435: Driven Clutch Installation
CLUTCHES: GASOLINE VEHICLES Driven Clutch 608C Figure 23-22 Install Retaining Ring Remove the driven clutch tool. DRIVEN CLUTCH INSTALLATION To install the driven clutch, reverse the removal procedure. Make sure that the washer (2) is mounted with the flat portion of the washer against the driven clutch (Figure 23-13, Page 23-12).
Page 436 Driven Clutch CLUTCHES: GASOLINE VEHICLES Pagination Page Page 23-20 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 437: Section 24 - Transaxle (Ed65): Gasoline Vehicles
SECTION 24 — 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 438: 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/Neutral/Reverse control (FNR) 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. NOTE: Be sure to return the switch to the OPERATE position after servicing the vehicle, or it will not run with the Forward/Reverse handle in either the F or REVERSE position.
Page 439: 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 440: 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/Neutral/Reverse control (FNR) in the NEUTRAL position. Disconnect battery and spark plug wire. See Disconnect the Battery- Gasoline Vehicles on page 1-4. Place chocks at the front wheels and loosen lug nuts on both rear wheels.
Page 441 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 24-3, Page 24-4). 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 442: 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 24-9.
Page 443: 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 444: Axle Shaft Oil Seal Installation
Axle Tubes, Axle Shafts and Wheel Bearings TRANSAXLE (ED65): GASOLINE VEHICLES Remove axle tube (2) from gearcase (4) (Figure 24-5, Page 24-6). See Axle Tube and Axle Shaft Removal on page 24-6. 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 24-5, Page 24-6).
Page 445: 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/Neutral/Reverse control (FNR) in the NEUTRAL position. Disconnect battery and spark plug wire. See Disconnect the Battery- Gasoline Vehicles on page 1-4. Place chocks at the front wheels and loosen lug nuts on both rear wheels.
Page 446 Transaxle Removal TRANSAXLE (ED65): GASOLINE VEHICLES Figure 24-8 Disconnect Rear Shackles Figure 24-9 Disconnect Front of Leaf Spring Position floor jack under rear crossmember of chassis or trailer hitch mount (if equipped) (Figure 24-10, Page 24-10). 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 24-8, Page 24-10).
Page 447 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 24-11, Page 24-11). 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 448 Transaxle Removal TRANSAXLE (ED65): GASOLINE VEHICLES 3063 Figure 24-12 Transaxle Mounting Bolts Page 24-12 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 449: 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 24-12, Page 24-12). Then, tighten fasteners in the following order: 1.1.
Page 450: Shifter Cable Installation
Shifter Cable TRANSAXLE (ED65): GASOLINE VEHICLES Loosen jam nuts (1) securing shifter cable (2) to FNR/accelerator cable bracket (3) (Figure 24-14, Page 24-14). Then, remove bowtie clip (3) to disconnect shifter cable end (4) from transaxle shift lever (5). Cut wire ties securing shifter cable to chassis. Make note of cable routing, then remove shifter cable from vehicle.
Page 451 SECTION 25 — KOHLER ENGINE SERVICE MANUAL Kohler Engine Service Manual 2019 Carryall 500 and 700 Maintenance and Service Manual Page 25-1...
Page 452 Shifter Cable KOHLER ENGINE SERVICE MANUAL Pagination Page Page 25-2 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 453 ECH440 for CLUB CAR Service Manual IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating instruction of equipment that this engine powers. Ensure engine is stopped and level before performing any maintenance or service. Safety Maintenance Speciﬁ...
Page 454 Safety SAFETY PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property damage. NOTE: is used to notify people of important installation, operation, or maintenance information. CAUTION WARNING WARNING...
Page 455 Maintenance MAINTENANCE INSTRUCTIONS WARNING Before working on engine or equipment, disable engine as Accidental Starts can cause severe injury or follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing.
Page 456 Maintenance OIL RECOMMENDATIONS STORAGE If engine will be out of service for 2 months or more We recommend use of Kohler oils for best performance. follow procedure below. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ 1.
Page 457 Speciﬁ cations Engine Dimensions-Flywheel Side 214.1 mm (8.43 in.) 164.3 mm (6.47 in.) 138.6 mm (5.46 in.) 2 X 112.1 mm Throttle Body Throttle Cable Throttle Cable (4.42 in.) Evap Fitting Mount Face Center Line 239.0 mm (9.41 in.) 116.4 mm (4.58 in.) Oil Fill Plug Oil Drain Plug Throttle Body...
Page 458 Speciﬁ cations Engine Dimensions-Top Side 164.5 mm (6.48 in.) 288.2 mm (11.35 in.) 472.4 mm (18.60 in.) 155.1 mm (6.11 in.) Oxygen Sensor Fuel Injector Cap Bracket 155.8 mm (6.13 in.) M8 X 1.25-6H Tap Oxygen Sensor 64.1 mm (2.53 in.) 19.0 mm (0.75 78.6 mm (3.09) in.) Harness Clip...
Page 459 Speciﬁ cations Engine Dimensions-PTO Side 6 X M8 X 1.25-6H 202.7 mm (7.98 in.) Dipstick and 188.2 mm (7.41 in.) 18.00 mm Exhaust Port Oil Fill Tube (0.71 in.) Deep 300.9 mm (11.85 in.) 218.6 mm (8.61 in.) Oxygen Sensor 35.0 mm (1.38 in.) 32.4 mm (1.28 in.) Exhaust Port...
Page 460 Speciﬁ cations Engine Dimensions-Opposite Cylinder Head Side 229.8 mm (9.05 in.) 2 X M8 X 1.25-6H Throttle Cable 105.0 mm (4.13 in.) 56.6 mm (2.23 in.) Tap 22.0 mm Mount Face (0.87 in.) Deep M6 X 1.0-6H 14.5 mm Min. Primary Mounting 29.1 mm (1.14 in.) Full Thread...
Page 461 Speciﬁ cations Engine Dimensions-Bottom Side 195.5 mm ± 0.50 mm 2 X Ø 11.25 mm ± 2 X 94.5 mm ± 0.75 (7.70 in. ± 0.02 90.5 mm (3.56 in.) 0.25 mm (0.44 mm (3.72 in. ± in.) Machined in. ± 0.01 in.) 0.03 in.) Holes Distance 195.5 mm ±...
Page 462 Year Manufactured Code Factory Code Code Year 2018 2019 2020 GENERAL SPECIFICATIONS ECH440 for Club Car Bore 89 mm (3.5 in.) Stroke 69 mm (2.7 in.) Displacement 429 cc (26.2 cu. in.) Oil Capacity (reﬁ ll) 1.1 L (1.16 U.S. qt.) Maximum Angle of Operation (@ full oil level) 25°...
Page 463 Speciﬁ cations TORQUE SPECIFICATIONS ECH440 for Club Car Air Cleaner (OEM Supplied) Air Inlet Elbow Mounting Nuts 8.0 N·m (71 in. lb.) Blower Housing and Sheet Metal M6 Screw 10 N·m (89 in. lb.) Cylinder Shield to Cylinder Head Ground Stud and Screw 8.0 N·m (71 in.
Page 464 Speciﬁ cations TORQUE SPECIFICATIONS ECH440 for Club Car Throttle Body Studs 10 N·m (89 in. lb.) Primary Mounting Nuts 8.0 N·m (71 in. lb.) Temperature/Manifold Absolute Pressure (TMAP) Sensor Fastener 7.3 N·m (65 in. lb.) Throttle Position Sensor (TPS) Fastener 1.3 N·m (11.5 in.
Page 465 Speciﬁ cations CLEARANCE SPECIFICATIONS ECH440 for Club Car Crankshaft End Play (free) 0.0508/0.254 mm (0.002/0.010 in.) Ball Bearing Internal Clearance 0.006/0.020 mm (0.0002/0.0008 in.) Crankshaft O.D. (new) PTO end 34.975/34.989 mm (1.3770/1.3775 in.) 35.009/35.027 mm (1.3783/1.3790 in.) Flywheel end Connecting Rod Journal O.D.
Page 466 Speciﬁ cations CLEARANCE SPECIFICATIONS ECH440 for Club Car Piston, Piston Rings, and Piston Pin Piston-to-Piston Pin Running Clearance 0.002/0.016 mm (0.0001/0.0006 in.) Piston Pin Bore I.D. 20.000/20.008 mm (0.7874/0.7877 in.) Max. Wear Limit 20.05 mm (0.7894 in.) Piston Pin O.D.
Page 467 Speciﬁ cations GENERAL TORQUE VALUES English Fastener Torque Recommendations for Standard Applications Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners Into Aluminum Size Grade 2 Grade 5 Grade 8 Tightening Torque: N·m (in. lb.) ± 20% 8-32 2.3 (20) 2.8 (25)
Page 468 Tools and Aids Certain quality tools are designed to help you perform speciﬁ c disassembly, repair, and reassembly procedures. By using these tools, you can properly service engines easier, faster, and safer! In addition, you’ll increase your service capabilities and customer satisfaction by decreasing engine downtime. Here is a list of tools and their source.
Page 469 Tools and Aids TOOLS Description Source/Part No. Flywheel Puller SE Tools KLR-82408 For properly removing ﬂ ywheel from engine. Hose Removal Tool, Dual Size/End (also available in EFI Service Kit) Kohler 25 455 20-S Used to properly remove fuel hose from engine components. Hydraulic Valve Lifter Tool Kohler 25 761 38-S For removing and installing hydraulic lifters.
Page 470 Tools and Aids FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A ﬂ ywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft ﬂ ywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.
Page 471 Troubleshooting TROUBLESHOOTING GUIDE When troubles occur, be sure to check simple causes which, at ﬁ rst, may seem too obvious to be considered. For example, a starting problem could be caused by an empty fuel tank. NOTE: An EFI engine will not operate without a battery connected to system. Some general common causes of EFI engine troubles are listed below and vary by engine speciﬁ...
Page 472 Troubleshooting ● Check air cleaner element (OEM supplied). Look for Engine Loses Power holes, tears, cracked or damaged sealing surfaces, or ● Dirty air cleaner element (OEM supplied). other damage that could allow unﬁ ltered air into ● Engine overheated. engine.
Page 473 Troubleshooting CRANKCASE VACUUM TEST WARNING WARNING Carbon Monoxide can cause severe nausea, Rotating Parts can cause severe injury. fainting or death. Stay away while engine is in operation. Avoid inhaling exhaust fumes. Engine exhaust gases contain poisonous carbon Keep hands, feet, hair, and clothing away from all monoxide.
Page 474 Troubleshooting COMPRESSION TEST This engine is equipped with an automatic compression release (ACR) mechanism. It is diﬃ cult to obtain an accurate compression reading because of ACR mechanism. As an alternative, use cylinder leakdown test described below. CYLINDER LEAKDOWN TEST A cylinder leakdown test can be a valuable alternative to a compression test.
Page 475 Air Cleaner/Intake BREATHER TUBE AIR CLEANER (OEM Supplied) Ensure both ends of breather tube are properly These systems are CARB/EPA certiﬁ ed and components connected. should not be altered or modiﬁ ed in any way. AIR COOLING Refer to operating instructions of equipment this engine powers for speciﬁ...
Page 476 EFI SYSTEM An in-tank fuel pump is used to move fuel from tank WARNING through a fuel ﬁ lter and fuel line. Fuel pump regulates fuel pressure to a system operating pressure of 50 psi. Explosive Fuel can cause ﬁ res and severe Fuel is delivered through high pressure fuel line into burns.
Page 477 EFI SYSTEM ECU continually performs a diagnostic check of itself, Crankshaft position sensor is essential to engine each sensor, and system performance. If a fault is operation; constantly monitoring rotation and speed detected, ECU can turn on a Malfunction Indicator Light (RPM) of crankshaft.
Page 478 EFI SYSTEM Purpose of sensing air temperature is to help ECU Injector has sequential fueling that opens and closes calculate air density. Higher air temperature less dense once every other crankshaft revolution. Amount of fuel air becomes. As air becomes less dense ECU knows injected is controlled by ECU and determined by length that it needs to lessen fuel ﬂ...
Page 479 EFI SYSTEM EFI engines have no carburetor, so throttle function IMPORTANT NOTES! (regulate incoming combustion airﬂ ow) is achieved with ● Cleanliness is essential and must be maintained at all a throttle valve in a separate throttle body attached to times when servicing or working on EFI system.
Page 480 EFI SYSTEM ELECTRICAL COMPONENTS Grey Connector Side Electronic Control Unit (ECU) Pin # Description Pinout of ECU Not Used Black Connector Side Not Used Pin # Function Malfunction Indicator Light (MIL) Ground Ignition Coil Ground Not Used Battery Ground Not Used Diagnostic Communication Line Not Used Speed Sensor input...
Page 481 EFI SYSTEM Never attempt to disassemble ECU. It is sealed to TPS Learn Procedure for Pedal Start Applications prevent damage to internal components. Warranty is NOTE: Refer to equipment manufacturer's manual for void if case is opened or tampered with in any way. details on throttle body cover and throttle cable removal/reinstallation.
Page 482 EFI SYSTEM KohlerEngines.com 17 690 15 Rev. --...
Page 483 EFI SYSTEM Since there is no longer any wear elements inside Crankshaft Position Sensor sensor, most likely faults will be in electrical connections A sealed, non-serviceable assembly. If fault code P0337 between sensor and wire harness and wire harness to is present and engine does not start/run, proceed to step ECU.
Page 484 EFI SYSTEM 4. With throttle blade in full open position (WOT), press Temperature/Manifold Absolute Pressure (TMAP) magnet assembly fully on to throttle shaft. Full Sensor insertion can be checked by measuring height from A sealed non-serviceable integrated sensor that checks throttle body sensor mounting face to end of magnet both intake air temperature and manifold absolute assembly.
Page 485 EFI SYSTEM It is advisable to use an electronic meter such as a Oxygen Sensor (O2) digital voltmeter. Simple mechanical meters may place Detail a heavy electrical load on sensor and cause inaccurate readings. Since resistance of sensor is highest at low temperatures, such meters will cause largest inaccuracies when sensor is in a cool exhaust.
Page 486 EFI SYSTEM Sensor Signal Observation Removal Inspection NOTE: Apply anti-seize compound only to threads. Engine Harness O2 Sensor Connector Plug Detail Anti-seize compound will aﬀ ect sensor performance if it gets into lower shield of sensor. 1. If sensor has heavy deposits on lower shield, engine, oil, or fuel may be source.
Page 487 EFI SYSTEM Troubleshooting-Oxygen (O2) Sensor Condition Possible Cause Conclusion Continuous low voltage output (less Shorted sensor or sensor circuit. Replace sensor or replace and than 400mV) observed with throttle properly route wiring. Shorted lead wire. openings of 38-50% or more. Wiring shorted to ground.
Page 488 EFI SYSTEM Injector clogging is usually caused by a buildup of Fuel Injector deposits on director plate, restricting ﬂ ow of fuel, resulting in a poor spray pattern. Some contributing WARNING factors to injector clogging include higher than normal operating temperatures, short operating intervals, and Explosive Fuel can cause ﬁ...
Page 489 EFI SYSTEM 6. Pull retaining clip to separate fuel injector cap/ FUEL COMPONENTS bracket assembly from injector. Remove screw holding fuel injector cap/bracket assembly to throttle WARNING body. Lift injector from throttle body. Explosive Fuel can cause ﬁ res and severe 7.
Page 490 EFI SYSTEM 4. Check that hook is in upper 1/3 to 1/2 of window in Throttle Body Assembly throttle lever. If hook is further down in window, wire NOTE: ECU Reset is required if throttle body is is bound and steps 2 and 3 should be repeated. replaced.
Page 491 EFI SYSTEM TROUBLESHOOTING Troubleshooting Guide Condition Possible Cause Fuel pump not running. Empty fuel tank. Faulty spark plug. Old/stale fuel. Incorrect fuel pressure. Crankshaft position sensor loose or faulty. Engine Starts Hard TPS set incorrect (ECU Reset and TPS Learn). or Fails to Start TPS faulty.
Page 492 EFI SYSTEM Troubleshooting Guide Condition Possible Cause Faulty/malfunctioning ignition system. Dirty air ﬁ lter. Insuﬃ cient fuel delivery. Improper governor adjustment. Low Power Plugged/restricted exhaust. Basic engine problem exists. TPS faulty or mounting exists. Throttle plate in throttle body not fully opening to WOT stop (if equipped). Function Test Fault Codes Example of Diagnostic Display...
Page 493 EFI SYSTEM Diagnostic Fault Code Summary Fault Code Connection or Failure Description 0031 Oxygen Sensor Heater Circuit Low Voltage 0032 Oxygen Sensor Heater Circuit High Voltage 0107 Manifold Absolute Pressure (TMAP) Circuit Low Voltage or Open 0108 Manifold Absolute Pressure (TMAP) Circuit High Voltage 0112 Intake Air Temperature (TMAP) Circuit Low Voltage 0113...
Page 494 EFI SYSTEM Diagnostic Code Summary Code 0107 Code 0031 Component: Manifold Absolute Pressure (TMAP) NOTE: Codes 0031 and 0032 may have been Fault: MAP Circuit Low Voltage or Open mistakenly activated by turning key ON with Condition: Throttle body leak, open connection or oxygen sensor disconnected.
Page 495 EFI SYSTEM Code 0112 Code 0117 Component: Intake Air Temperature (TMAP) Component: Engine Temperature Sensor Fault: Intake Air Temperature Sensor Circuit Fault: Engine Temperature Sensor Circuit Low Low Voltage Voltage Condition: Shorted connection, faulty sensor or Condition: Shorted connection, faulty sensor or shorted wire.
Page 496 EFI SYSTEM Code 0122 Code 0131 Component: Throttle Position Sensor (TPS) Component: Oxygen Sensor Fault: TPS Circuit Low Voltage or Open Fault: O2S 1 Circuit Low Voltage Condition: Open connection, broken wire or faulty Condition: Open connection, broken wire or faulty sensor.
Page 497 EFI SYSTEM Code 0171 Code 0172 Component: Fuel System Component: Fuel System Fault: Maximum adaptation limit exceeded Fault: Minimum adaptation limit exceeded Condition: Fuel inlet screen/ﬁ lter plugged, low Condition: Too high pressure at high pressure fuel pressure at high pressure fuel line, TPS line, TPS malfunction, shorted malfunction, shorted connection, faulty connection, faulty sensor or fuel pump...
Page 498 EFI SYSTEM Code 0174 Code 0230 Component: Fuel System Component: Fuel Pump Relay Fault: Lean fuel condition Fault: Circuit Low Voltage or Open Condition: Fuel inlet screen/ﬁ lter plugged, low Condition: Shorted or open connection. pressure at high pressure fuel line, TPS Conclusion: Fuel Pump Relay Related malfunction, shorted connection or faulty ●...
Page 499 EFI SYSTEM Code 0336 Code 0337 NOTE: If fault code P0337 is present and engine does Component: Crankshaft Position Sensor not start/run, proceed to step 1 of Crankshaft Fault: Crankshaft Position Sensor Noisy Signal Position Sensor earlier in this section. If P0337 is present and engine operates, clear codes and Condition: Loose sensor, faulty/bad battery, shorted...
Page 500 EFI SYSTEM Code 0351 Code 0650 Component: Ignition Coil Component: MIL Circuit Fault: Ignition Coil Malfunction Fault: MIL Circuit Malfunction Condition: Broken wire in harness (may not be Condition: Failure in MIL circuit detected. visible), shorted connection or faulty Conclusion: Bad Connection. sensor.
Page 501 EFI SYSTEM EFI Diagnostic Flow Diagram START OF TEST PROCEED TO START OF TEST FOR RETEST KEY ON MALFUNCTION REFER TO DIAGNOSTIC AID #1 INDICATOR LIGHT SYSTEM POWER REFER TO ARE FAULT CODES DIAGNOSTIC FAULT CODE SUMMARY PRESENT? CLEAR CODES REFER TO DIAGNOSTIC AID #3 DOES ENGINE START? MIL GOES OFF?
Page 502 EFI SYSTEM Flow Chart Diagnostic Aids Diagnostic Aid #5 FUEL PUMP (fuel pump not turning on) Diagnostic Aid #1 SYSTEM POWER Condition (MIL does not illuminate for 3 seconds when key is ﬁ rst ● Inspect fuse(s) turned ON) ● Fuel pump relay circuit problem, pin circuits Black 9 NOTE: MIL is installed by vehicle OEM.
Page 503 Governor System GOVERNOR (OEM Supplied) Refer to operating instructions of equipment this engine powers for speciﬁ c governor instructions. 17 690 15 Rev. -- KohlerEngines.com...
Page 504 Lubrication System These engines use a splash lubrication system, supplying necessary lubrication to crankshaft, camshaft, connecting rod and valve train components. Lubrication Components Dipstick Tube Oil Drain Plug Oil Fill Plug Filler Neck OIL RECOMMENDATIONS WINTER LUBRICATION Refer to Maintenance. If engine is frequently used for short periods of time in ambient temperatures below 4°C (40°F), reduce oil CHECK OIL LEVEL...
Page 505 Lubrication System 4. Fill crankcase with new oil, up to point of overﬂ owing ﬁ ller neck. 5. Reinstall oil ﬁ ll plug/dipstick and tighten securely. 6. Dispose of used oil in accordance with local ordinances. OIL SENTRY (if equipped) ™...
Page 506 Electrical System BATTERY CHARGING SYSTEM (OEM Supplied) 5. Insert fuse into fuse holder until it is seated properly. Install fuse cover. 6. If replacement fuse fails, there is a problem within CAUTION circuit. Diagnostics are required. Identify which Electrical Shock can cause injury. circuit is aﬀ...
Page 507 Electrical System Carbon Fouled Inspection Inspect spark plug as it is removed from cylinder head. Deposits on tip are an indication of general condition of piston rings, valves, and fuel mixture. Normal and fouled plugs are shown in following photos: Normal Soft, sooty, black deposits indicate incomplete combustion caused by a restricted air cleaner, over rich...
Page 508 Electrical System Troubleshooting Guide Test Ignition System Isolate and verify trouble is within engine. 1. If Kohler diagnostic software is available, review "Safety System Active" status in Data Display screen. If yes is displayed, equipment safety circuit is active (Refer to equipment manufacturer's manual for safety system information).
Page 509 Starter System Starter (OEM Supplied) Refer to operating instructions of equipment this engine powers for speciﬁ c starter system instructions. 17 690 15 Rev. -- KohlerEngines.com...
Page 510 Disassembly/Inspection and Service WARNING Before working on engine or equipment, disable engine as Accidental Starts can cause severe injury or follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing.
Page 511 Disassembly/Inspection and Service Remove Throttle Body Assembly Remove Fuel Injector NOTE: Unless fuel injector is damaged or malfunctioning, disassembly from throttle body is unnecessary. NOTE: Make note of fuel injector position before removing. NOTE: Unless fuel injector cap is damaged, removing retainer securing cap to injector is unnecessary.
Page 512 Disassembly/Inspection and Service Fuses and ECU Components Blower Housing Components Fuses/Fuse Holders Screw Cable Clip Ignition Coil Blower Housing Screw Remove Fuses Screen Remove fuses from holders located on lower shield. Screw Blower Housing Clamp Remove Electronic Control Unit (ECU) 1.
Page 513 Disassembly/Inspection and Service Remove Crankshaft Position Sensor Remove Valve Cover NOTE: Do not remove sensor from bracket unless sensor is being replaced. 1. Unplug crankshaft position sensor electrical connector. 2. Remove upper screw securing crankshaft position sensor bracket to crankcase post. 3.
Page 514 Disassembly/Inspection and Service Cylinder Head Components Rocker Arm Pivot Hex Jam Nut Rocker Arm Rocker Arm Stud Adjuster Valve Spring Push Rod Guide Push Rod Valve Spring Retainer Valve Stem Seal Cylinder Head Screw Spark Plug Cylinder Head Cylinder Head Valve Dowel Pin Gasket...
Page 515 Disassembly/Inspection and Service Valve Guides If a valve guide is worn beyond speciﬁ cations, it will not guide valve in a straight line. This may result in burnt valve faces or seats, loss of compression, and excessive oil consumption. To check valve guide-to-valve stem clearance, thoroughly clean valve guide and, using a split-ball gauge, measure inside diameter of guide.
Page 516 Disassembly/Inspection and Service Crankcase/Crankshaft/Camshaft/Closure Plate Components Closure Plate Oil Seal Closure Plate Screw Closure Plate Bearing Closure Plate Balance Closure Plate Gasket Wave Spring Balance Shaft Shaft Bearing Crankcase Balance Connector Rod Crankshaft Connector Rod Shaft Bearing End Cap Piston Piston Pin Retainer Piston Pin Piston Ring Set...
Page 517 Disassembly/Inspection and Service Automatic Compression Release (ACR) Remove Oil Fill Tube ACR Operation Details Details Oil Fill Tube Oil Fill Tube Bracket Bracket Screw NOTE: Unless oil ﬁ ll tube is damaged, disassembly from closure plate is unnecessary. Camshaft Exhaust Cam Lobe 1.
Page 518 Disassembly/Inspection and Service Inspection and Service Dimension C Dimension A Camshaft Journal Speciﬁ cations Cam Lobe Dimension C Limit 32.286 mm 32.032 mm 15.900 mm INTAKE 15.975 mm (0.6289 in.) (1.271 in.) (1.261 in.) (0.6260 in.) 32.506 mm 32.252 mm EXHAUST (1.280 in.) (1.270 in.)
Page 519 Disassembly/Inspection and Service Some important points to remember when servicing Piston and Rings Inspection piston rings: Scuﬃ ng and scoring of piston and cylinder wall occurs 1. Cylinder bore must be deglazed before service ring when internal engine temperatures approach welding sets are used.
Page 520 Disassembly/Inspection and Service NOTE: Rings must be installed correctly. Use a piston 3. Remove oil seal from closure plate. ring expander to install rings. Install bottom (oil 4. Using a suitable press, push crankshaft bearing from control) ring ﬁ rst and top compression ring last. closure plate.
Page 521 Disassembly/Inspection and Service Honing Clean Cylinder Bore After Honing Proper cleaning of cylinder walls following boring and/ Crosshatch Detail or honing is very critical to a successful overhaul. Machining grit left in cylinder bore can destroy an engine in less than one hour of operation after a rebuild. Final cleaning operation should always be a thorough scrubbing with a brush and hot, soapy water.
Page 522 Reassembly Crankcase/Crankshaft/Camshaft/Closure Plate Components Closure Plate Oil Seal Closure Plate Screw Closure Plate Bearing Closure Plate Balance Closure Plate Gasket Wave Spring Balance Shaft Shaft Bearing Crankcase Balance Connector Rod Crankshaft Connector Rod Shaft Bearing End Cap Piston Piston Pin Retainer Piston Pin Piston Ring Set Oil Sentry...
Page 523 Reassembly Install Crankcase Bearings and Oil Seals Install Crankshaft Carefully slide ﬂ ywheel end of crankshaft through main Details ball bearing and seal. Install Connecting Rod with Piston and Rings Connecting Rod Details Outer Surface Seal Depth NOTE: Oil bearings liberally with engine oil when installing.
Page 524 Reassembly Install Balance Shaft Install Valve Tappets and Camshaft Timing Mark Detail Timing Mark Detail Camshaft Drive Balance Shaft Drive Camshaft Gear Balance Shaft Gear on Crankshaft Gear on Crankshaft Timing Mark Timing Mark Timing Mark Timing Mark 1. Lubricate face and stem of each tappet with engine 1.
Page 525 Reassembly Install Oil Fill Tube Install Closure Plate Details Torque Sequence Oil Fill Tube Oil Fill Tube Bracket 1. Check to make sure sealing surfaces of crankcase Bracket Screw and closure plate are clean and free of nicks/burrs. 1. If oil ﬁ ll tube was removed from closure plate, apply 2.
Page 526 Reassembly Cylinder Head Components Rocker Arm Pivot Hex Jam Nut Rocker Arm Rocker Arm Stud Adjuster Valve Spring Push Rod Guide Push Rod Valve Spring Retainer Valve Stem Seal Cylinder Head Screw Spark Plug Cylinder Head Cylinder Head Valve Dowel Pin Torque Sequence Gasket Assemble Cylinder Head...
Page 527 Reassembly Install Push Rods and Rocker Arms Flywheel Components NOTE: Push rods should always be installed in original location. 1. Identify proper position of each push rod. Dip ends of push rods in engine oil and install them in their respective locations, seating each into tappet socket.
Page 528 Reassembly Install Crankshaft Position Sensor Install Cylinder Shield NOTE: Ensure all parts are clean, undamaged and free of debris and make sure electrical connectors have seal in place. NOTE: When mounting ground wire on bottom screw of bracket, ensure ground wire is routed outside and away from ﬂ...
Page 529 Reassembly Install Upper Heat Shield and Engine Temperature Install Fuel Injector and TMAP Sensor Engine Temperature Upper Heat Shield Sensor Dipstick Tube Screw Bracket Oxygen Sensor Fuel Injector Cap Screw Clip Connector Metal Retaining Clip Fuel Injector 1. Position upper heat shield on crankcase and start 2 screws securing to crankcase.
Page 530 Reassembly Install Throttle Body Assembly Install Air Inlet Elbow Throttle Body Fuel Injector Throttle Position TMAP Air Inlet Elbow Sensor (TPS) Breather Hose with Insulator to Throttle Clamp Insulator Sleeve Body Gasket Throttle Body Gasket Governor Bracket Insulator to Cylinder Intake Studs Head Gasket Throttle Body...
Page 531 Reassembly External Engine Components Oil Fill Plug Dipstick Spark Plug Lead Oil Drain Plug Connect Spark Plug Lead Connect lead to spark plug. Secure lead to dipstick tube with a new wire tie. Prepare Engine for Operation NOTE: If ECU, throttle body, TPS, or fuel pump were replaced, an ECU Reset and TPS Learn is required.
Page 533 SECTION 26 — WIRING DIAGRAMS GENERAL INFORMATION Wiring Diagrams Wire Description EXAMPLE: 18_GRN_RED • 18 = 18 gauge wire • GRN_RED = Green wire with red stripe Wire Colors NOTE: The following colors will represented as a black wire in the wiring diagrams: •...
Page 534 Pedal-Start Connector Pinouts WIRING DIAGRAMS GRN_WHT Green with White Stripe ORG_BLK Orange with Black Stripe ORG_WHT Orange with White Stripe PUR_WHT Purple with White Stripe RED_GRN Red with Green Stripe RED_WHT Red with White Stripe RED_YEL Red with Yellow Stripe WHT_BLK White with Black Stripe PEDAL-START CONNECTOR PINOUTS...
Page 535 WIRING DIAGRAMS Pedal-Start Connector Pinouts To Engine Harness Wire Color Description Switched 12V Power Constant 12V Power OPEN OPEN Malfunction Indicator Light (MIL) White Ground Kill Wire Green Low Oil Light Black / White Fuel Pump OPEN OPEN To Instrument Panel (IP) Harness Wire Color Description Green / White...
Page 536 Pedal-Start Connector Pinouts WIRING DIAGRAMS Orange / Black Fuel Sending Unit Input White Hour Meter Input Green Low Oil Light To FNR Harness Wire Color Black / Yellow Orange Purple / White Black / Light Blue Blue / White Yellow To Accessories Wire Color Description...
Page 537 WIRING DIAGRAMS Pedal-Start Connector Pinouts To Brake Light Relay Wire Color Description Black Ground White / Black Power Gray / Black To Accessories Pin 3 To Fuel Pump Wire Color Description Open Open Orange/Black Sending Unit Positive (+) Black Sending Unit Negative (-) Black/White Fuel Pump Negative (-) Red/White...
Page 538 Pedal-Start Connector Pinouts WIRING DIAGRAMS Black/White Red/White Open Fuse Holder Wire Color Red/Black Orange/White Orange Fuse Connector Wire Color Pink Page 26-6 2019 Carryall 500 and 700 Maintenance and Service Manual...
Page 539 WIRING DIAGRAMS Key-Start Connector Pinouts KEY-START CONNECTOR PINOUTS KEY-START MAIN HARNESS CONNECTOR PINOUTS To Connected Car Wire Color Description Power Black Ground OPEN OPEN OPEN OPEN To Engine Harness Wire Color Description Switched 12V Power Constant 12V Power OPEN OPEN Malfunction Indicator Light (MIL) White...
Page 540 Key-Start Connector Pinouts WIRING DIAGRAMS To Instrument Panel (IP) Harness Wire Color Description Green / White Headlights / Taillights Green / Red Headlight Switch Power Red / Yellow To Key Switch (M+) OPEN OPEN Orange / White Reverse Buzzer Power Blue / White Power Black / White...
Page 541 WIRING DIAGRAMS Key-Start Connector Pinouts To Accessories Wire Color Description Blue Horn Power Gray To Rear Lights Gray / Black Brake Light Relay White To Rear Lights OPEN OPEN Black Ground Brown Power Right Turn Signal Power Green Left Turn Signal Power To Brake Light Relay Wire Color Description...
Page 542 Key-Start Connector Pinouts WIRING DIAGRAMS To Fuel Pump Wire Color Description Open Open Orange/Black Sending Unit Positive (+) Black Sending Unit Negative (-) Black/White Fuel Pump Negative (-) Red/White Fuel Pump Positive (+) Fuel Pump Relay Wire Color Green Black/White Red/White Open Page 26-10...
Page 543 WIRING DIAGRAMS Key-Start Connector Pinouts Fuse Holder Wire Color Red/Black Orange/White Orange Fuse Connector Wire Color Pink 2019 Carryall 500 and 700 Maintenance and Service Manual Page 26-11...
Page 544 Engine Harness Wiring Diagram Table WIRING DIAGRAMS ENGINE HARNESS WIRING DIAGRAM TABLE Callout Description Red/Black Red/White Yellow Light Green Dark Green Dark Blue Purple Pink White Grey Black To Main Harness Oil Level Switch 10-amp Fuse (Ignition Switch) 10-amp Fuse (Battery Power) Black Connector Grey Connector Fuel Injector...
Page 545 Wiring Diagrams Gasoline: Engine Harness GASOLINE: ENGINE HARNESS...
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Page 547 Wiring Diagrams Gasoline: CA 500 Key-Start Main Harness GASOLINE: CA 500 KEY-START MAIN HARNESS...
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Page 549 Wiring Diagrams Gasoline: CA 500 Pedal-Start Main Harness GASOLINE: CA 500 PEDAL-START MAIN HARNESS...
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Page 551 Wiring Diagrams Gasoline: CA 700 Key-Start Main Harness GASOLINE: CA 700 KEY-START MAIN HARNESS...
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Page 553 Wiring Diagrams Gasoline: CA 700 Pedal-Start Main Harness GASOLINE: CA 700 PEDAL-START MAIN HARNESS...
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Page 555 Wiring Diagrams Gasoline: Instrument Panel Harness GASOLINE: INSTRUMENT PANEL HARNESS...
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Page 557 Wiring Diagrams Gasoline: FNR Harness GASOLINE: FNR HARNESS...
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Page 559 Wiring Diagrams Electric: Main Harness ELECTRIC: MAIN HARNESS...
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Page 561 Wiring Diagrams Electric: Accessories Harness ELECTRIC: ACCESSORIES HARNESS...
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Page 563 Wiring Diagrams Electric: Instrument Panel Harness ELECTRIC: INSTRUMENT PANEL HARNESS...
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Page 565 Index Index voltage test........... 12-12 Index voltage test (under load) ........ 12-14 AC power and circuit vibration damage..........14-11 testing (QuiQ charger) ........15-12 battery accelerator installation ............19-44 cable storage ............19-45 installation ............21-8 testing ............... 18-8 removal ............21-7 testing under load........
Page 566 INDEX audible charging indicator ........11-9 see driven clutch ..........23-12 battery type............11-8 column, steering code A............... 11-9 see steering column ..........7-3 code B............... 11-9 commutator code C............... 11-9 see starter/generator .......... 19-1 connection tests ..........11-28 connector, 24-pin control mode ............
Page 567 INDEX installation ............4-18 installation ............21-24 removal ............. 4-18 removal ............21-22 electric motor storage ............21-23 see motor ............16-1 fuse electrical system ............ 12-1 installation ............19-29 gasoline vehicle ..........18-5 removal ............19-29 testing circuits ...........12-11 fuses engine ..............
Page 568 INDEX speed sensor magnet........16-9 inspection............16-7 shock absorber ............ 9-1 assembly ............16-11 starter/generator bearing armature ............19-7 inspection............16-9 bearing...........19-6–19-7 braking brush spring ........... 19-3 pedal down motor braking ....... 12-2 brushes ............19-3 pedal up motor braking........12-2 commutator ............
Page 569 INDEX removal ............19-46 removal ........... 13-8, 19-26 testing ............. 12-23 solenoid (key-start) testing ............. 18-42 solenoid (pedal-start) park brake testing ............. 18-16 adjustment (electric) ........... 5-17 solenoid activating coil adjustment (gas) ..........5-12 testing ............. 12-22 installation ............5-4 sonic weld removal ...............
Page 570 INDEX installation ............7-5 4-pin connector ..........18-40 removal ............... 7-4 accelerator pedal limit switch (pedal-start)... 18-15 steering wheel battery ............... 18-8 installation ............7-2 battery load test ..........18-28 removal ............... 7-1 charging diode (key-start) ......... 18-45 suspension, front fuel gauge............
Page 571 INDEX installation ............24-13 pedal-start gasoline vehicle......... 26-2 lubrication ............24-2 removal ............. 24-9 service............... 24-2 transaxle, type g assembly ............17-10 axle bearing ............17-4 axle shaft installation ............17-4 removal ............17-1 disassembly............17-8 inspection ............17-8 installation ............17-12 lubrication ............

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Carryall 700 2019

Club Car Carryall 500 2019 Maintenance And Service Manual

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