Page 1 I N D U N D U S T R I A L T R U C K S 2001/2002 MAINTENANCE & SERVICE MANUAL M a n u a l N o . 1 0 2 1 9 0 0 1 3 E d i t i o n C o d e 1 0 0 1 A 0 0 0 0 0...
Page 3 Club Car. It is the policy of Club Car, Inc. to assist its distributors and dealers in continually updating their service knowl- edge and facilities so they can provide prompt and efﬁcient service for vehicle owners. Regional technical rep- resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and other service publications also represent Club Car’s continuing commitment to customer support.
Page 4 NOTE: This manual represents the most current information at the time of publication. Club Car, Inc. is continually working to further improve our vehicles and other products. These improvements may affect servicing procedures.
Page 5: Table Of Contents
CONTENTS SECTION 1 – SAFETY General Warning ..........................SECTION 2 – VEHICLE SPECIFICATIONS SECTION 3 – GENERAL INFORMATION Serial Number Identification ......................Storage .............................. Preparing the Vehicle for Extended Storage ................Returning the Stored Vehicle to Service ..................SECTION 4 – BODY AND TRIM Cleaning the Vehicle .........................
Page 6 Flat Bed Trim – Carryall 6 ........................ 4-10 Flat Bed Trim Removal ........................ 4-10 Flat Bed Trim Installation ......................4-13 Access Door – Carryall 6 ......................... 4-13 Access Door Removal ........................4-13 Access Door Installation ....................... 4-13 Side Door – Carryall 6 ........................4-13 Side Door Removal ........................
Page 7 SECTION 6 – PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES General Information .......................... Park Brake System Inspection ......................Park Brake System ..........................Park Brake Cable Removal ......................Park Brake Cable Installation ....................... Park Brake Handle Removal ......................Park Brake Handle Installation ..................... Park Brake Adjustment .........................
Page 8 SECTION 7 – STEERING AND FRONT SUSPENSION General Information ......................... Steering Wheel ..........................Steering Wheel Removal ......................Steering Wheel Installation ......................Steering Column ..........................Steering Column Removal ......................Steering Column Disassembly ..................... Steering Column Assembly ......................Steering Column Installation ......................Steering Adjustment .........................
Page 9 Tires ..............................Tire Removal ..........................Tire Repair ............................ Tire Installation ..........................SECTION 9 – REAR SUSPENSION General Information .......................... Shock Absorbers ..........................Shock Absorber Inspection and Removal ..................Shock Absorber Installation ......................Multi-Leaf Springs ..........................Multi-Leaf Spring Removal ......................Multi-Leaf Spring Installation ......................Jounce Bumpers ..........................
Page 10 SECTION 12 – ELECTRICAL COMPONENTS Electrical Component Cover ......................12-2 Main Power Fuse ..........................12-4 Control Wiring Fuse ......................... 12-4 Key Switch ............................12-5 Battery Condition Indicator ....................... 12-6 Plug Diode............................12-7 Emergency Stop Switch ........................12-8 Forward/Reverse Switch ........................12-8 Forward/Reverse Limit Switches ....................
Page 11 Battery Charging ..........................13-7 Charger Shuts Off After 16 Hours ....................13-8 Deep-Discharge ..........................13-8 Early Excessive Discharging ......................13-8 Incoming AC Service ........................13-8 Fleet Rotation ..........................13-8 Numbering Vehicles and Chargers ....................13-8 Battery Troubleshooting Chart ......................13-9 Battery Testing ..........................
Page 12 SECTION 15 – MOTOR General Information ......................... 15-2 External Motor Testing ........................15-2 Motor ..............................15-3 Motor Component Testing and Inspection ..................15-4 Armature ............................15-4 Field Windings Inspection ......................15-6 Motor Components ........................15-6 Bearing Inspection ........................15-7 Bearing Removal .......................... 15-7 Bearing Installation ........................
Page 13: Section 1 - Safety
SECTION 1 – 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 impor- tant to note that throughout this manual there are statements labeled DANGER, WARNING, or CAUTION.
Page 14 SAFETY General Warning ∆ WARNING • Do not leave children unattended on vehicle. • Only trained technicians should repair or service the vehicle or battery charger. Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair.
Page 15 SAFETY General Warning CARRYALL 1 POWERDRIVE BATTERY CONFIGURATION FRONT OF VEHICLE Remove negative cable first. DISCONNECT BATTERY CABLES HERE CARRYALL 2 AND CARRYALL 6 POWERDRIVE BATTERY CONFIGURATION FRONT OF VEHICLE Remove negative cable first. DISCONNECT BATTERY CABLES HERE Figure 1-1 Battery Conﬁguration 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual Page 1-3...
Page 17: Section 2 - Vehicle Specifications
SECTION 2 – VEHICLE SPECIFICATIONS SPECIFICATIONS Carryall 1 Carryall 2 Carryall 6 POWER SOURCE Drive motor : Direct drive, 48 volts DC, series wound, 3.1 hp • • • Transaxle: Double reduction helical gear with 12.28:1 direct drive axle • •...
Page 18 VEHICLE SPECIFICATIONS SPECIFICATIONS Carryall 1 Carryall 2 Carryall 6 30 cm 30 cm 30 cm Floorboard height (11.8 in.) (11.8 in.) (11.8 in.) 69 cm 70 cm 69 cm Load bed height (27 in.) (27.6 in.) (27 in.) 72 cm 73 cm 72 cm Seat height...
Page 19: Section 3 - General Information
• Warranties SERIAL NUMBER IDENTIFICATION The serial number of each Club Car vehicle is printed on a bar code decal mounted on the frame directly above the accelerator pedal (Example: F0101-123456) (Figure 3-1, Page 3-1). There is also a second serial number decal mounted on the front body frame behind the center dash panel.
Page 20: Storage
GENERAL INFORMATION Storage STORAGE Read DANGER and WARNING in Section 1 – Safety. PREPARING THE VEHICLE FOR EXTENDED STORAGE ∆ WARNING • Turn the key switch OFF, remove the key, and leave the Forward/Reverse handle in the NEUTRAL position during storage. This is to prevent unintentionally starting the vehicle or a ﬁre hazard.
Page 21: Section 4 - Body And Trim
SECTION 4 – BODY AND TRIM ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed space. Wear a full face shield and rubber gloves when working on or near batteries.
Page 22: Cleaning The Vehicle
BODY AND TRIM Cleaning the Vehicle • To avoid unintentionally starting the vehicle, press the emergency stop switch down and disconnect the batteries as shown. See Figure 1-1, Section 1, Page 1-3. • After disconnecting the batteries, discharge the controller capacitors as follows: - Turn the key switch to ON, place the Forward/Reverse handle in the REVERSE position, and wait until the reverse warning buzzer can no longer be heard.
Page 23: Seat
BODY AND TRIM Seat SEAT Read DANGER, WARNING, and CAUTION on page 4-1. SEAT REMOVAL 1. Tilt seat (2) forward (Figure 4-1, Page 4-3). 2. Underneath the drivers side seat, disconnect the two wires from the seat switch. 3. Lift seat to remove from seat support (1) (Figure 4-1, Page 4-3). TYPICAL 4 PLACES Figure 4-1 Seats and Seat Support...
Page 24: Seat Support
BODY AND TRIM Seat Support The vehicle will not operate if the seat switch wires are not connected. 3. Lower seat and press down to lock in place. See following WARNING. ∆ WARNING • Make sure seat hinges and latch are securely engaged before operating vehicle. SEAT SUPPORT Read DANGER, WARNING, and CAUTION on page 4-1.
Page 25: Armrest Removal
BODY AND TRIM Front Body Repair 2. Reinstall park brake equalizer cable. See Equalizer Cable Installation, Section 6, Page 6-5. 3. Reinstall the ring terminals onto the emergency stop switch. Tighten hardware to 8 ft-lb (10.8 N·m). NOTE: Either wire can be connected to either terminal. The vehicle will not operate if the emergency stop wires are not connected.
Page 26: Small Scratches That Cannot Be Buffed Out
Gouges, Punctures, Tears, Large Scratches, and Abrasions on page 4-6. 3. Using the brush provided with the touch-up paint (available from Club Car Service Parts – see following color chart), apply paint to the scratch. Multiple layers of paint may be required to ﬁll the scratch.
Page 27: Front Body
BODY AND TRIM Front Body FRONT BODY Read DANGER, WARNING, and CAUTION on page 4-1. FRONT BODY REMOVAL 1. Remove screws (8) and lock nuts (9) and lift front bumper (6) from vehicle frame (Figure 4-3, Page 4-7). 1.1. Carryall 1 vehicles: Remove blind rivets (10). 2.
Page 28: Front Body Installation
BODY AND TRIM Tilt Bed – Carryall 1 and Carryall 2 FRONT BODY INSTALLATION 1. Install front body (12) under trim (13), align holes and ﬁnger-tighten screws (14) securing front body to frame (Figure 4-3, Page 4-7). 2. Install carriage bolts (15), washers (16) and lock nuts (17) onto front body trim. Tighten bolts to 11 ft-lb (14.9 N·m).
Page 29: Tilt Bed Installation
BODY AND TRIM Tilt Bed – Carryall 1 and Carryall 2 TILT BED INSTALLATION 1. Hold bed at a slight angle (front of bed lower than rear of bed) to vehicle and place front edge of bed onto vehicle frame. Bed latches (5) should engage with latch plates (1) (Figure 4-4, Page 4-9). 2.
Page 30: Flat Bed - Carryall 6
BODY AND TRIM Flat Bed – Carryall 6 4. Use a small hammer to lightly tap bolts through hinge assembly. 5. Install a nylon lock nut (10) on each bolt (9) and tighten to 15 ft-lb (21 N·m). 6. Carryall 2 Only: Raise bed and place the prop rod (17) in bed mounting hole. Install a ﬂat washer (22) and cotter pin (23) on prop rod.
Page 31 BODY AND TRIM Flat Bed Trim – Carryall 6 6. Remove remaining hardware securing driver side trim strip and remove trim strip from bed. 7. Repeat steps 5 and 6 to remove passenger side trim strip and brackets. TYPICAL 2 PLACES SHIM AS REQUIRED TYPICAL 2...
Page 32 BODY AND TRIM Flat Bed Trim – Carryall 6 REF. TYPICAL 3 TYPICAL 2 PLACES PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES AT BODY TYPICAL 2 PLACES AT DOOR Figure 4-6 Flat Bed Trim, Access Door and Side Door – Carryall 6 Page 4-12 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual...
Page 33: Flat Bed Trim Installation
BODY AND TRIM Access Door – Carryall 6 FLAT BED TRIM INSTALLATION 1. Install trim in the reverse order of removal. 2. Tighten bolts (4 and 7) to 8 ft-lb. (10.8 N·m) (Figure 4-6, Page 4-12). 3. Install bolts, ﬂat washers and lock nuts that secure bed to vehicle frame. Tighten bolts to 75 in-lb (8 N·m). ACCESS DOOR –...
Page 34: Rear Fender
BODY AND TRIM Rear Fender TYPICAL 2 PLACES Figure 4-7 Rear Fender, Trailer Hitch and Tailskirt – Carryall 1 and Carryall 2 REAR FENDER Read DANGER, WARNING, and CAUTION on page 4-1. REAR FENDER REMOVAL Vehicles With Taillights: 1. Remove taillight assembly. 1.1.
Page 35 BODY AND TRIM Rear Fender Carryall 6 Only: 3.1. Remove pan head screws (16) connecting reverse buzzer (17) to rear fender (6) and disconnect the two wires from the reverse buzzer (Figure 4-8, Page 4-15). All Vehicles: 4. Remove fender (6) from vehicle (Figure 4-7, Page 4-14 or Figure 4-8, Page 4-15). REF.
Page 36: Rear Fender Installation
BODY AND TRIM Trailer Hitch – Optional on Some Models REAR FENDER INSTALLATION 1. Reverse removal procedure. Tighten bolts (2) to 35 in-lb (4.0 N·m). TRAILER HITCH – OPTIONAL ON SOME MODELS Read DANGER, WARNING, and CAUTION on page 4-1. TRAILER HITCH REMOVAL 1.
Page 37: Bumper Installation
BODY AND TRIM Floor Mat BUMPER INSTALLATION 1. Install the rear bumper in the reverse order of removal. Tighten nuts to 65 in-lb (7.3 N·m) (Figure 4-8, Page 4-15). FLOOR MAT Read DANGER, WARNING, and CAUTION on page 4-1. FRONT FLOOR MAT REMOVAL 1.
Page 39: Section 5 - Accelerator And Brake Pedal Group
SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed space. Wear a full face shield and rubber gloves when working on or near batteries.
Page 40: General Information
ACCELERATOR AND BRAKE PEDAL GROUP General Information • To avoid unintentionally starting the vehicle, press the emergency stop switch down and disconnect the batteries as shown. See Figure 1-1, Section 1, Page 1-3. • After disconnecting the batteries, discharge the controller capacitors as follows: - Turn the key switch to ON, place the Forward/Reverse handle in the REVERSE position, and wait until the reverse warning buzzer can no longer be heard.
Page 41: Accelerator Pedal Installation
ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal 12. Remove the accelerator pedal from the vehicle. 13. Inspect all parts for wear and damage. Replace as necessary. Figure 5-1 Accelerator Pedal Assembly ACCELERATOR PEDAL INSTALLATION 1. 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 5-1, Page 5-3).
Page 42: Brake Pedal - Carryall 1
ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal – Carryall 1 7. Install spacer (24) and nylon lock nut (23) on the pivot rod. Tighten nut to 18 ft-lb (24.5 N·m). 8. Install the MCOR (2) and drive bar (3). See MCOR Installation, Section 12, Page 12-19. 9.
Page 43: Brake Pedal Installation - Carryall 1
ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal – Carryall 1 Brake Pedal Removal – Carryall 1, Continued: 3.2. Remove nuts (34), washers (27), bolts (28) and mounting blocks (26) (Figure 5-2, Page 5-4). If the mounting blocks show signs of excessive wear or are damaged, they must be replaced with new ones before installing pedal assembly.
Page 44: Brake Pedal - Carryall 2 And Carryall 6
ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal – Carryall 2 and Carryall 6 BRAKE PEDAL – CARRYALL 2 AND CARRYALL 6 Read DANGER and WARNING on page 5-1. BRAKE PEDAL REMOVAL – CARRYALL 2 AND CARRYALL 6 1. Disconnect the batteries as instructed. See WARNING on page 5-2. 2.
Page 45: Brake Pedal Installation - Carryall 2 And Carryall 6
ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal Height Adjustment BRAKE PEDAL INSTALLATION – CARRYALL 2 AND CARRYALL 6 1. From the top side of the ﬂoorboard, insert the brake pedal assembly through the opening in the ﬂoor as shown (Figure 5-5, Page 5-7). Install the brake stop bumper (24) on the brake pedal assembly, but do not tighten jam nut at this time (Figure 5-4, Page 5-6).
Page 46 ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal Height Adjustment 3. For Carryall 2 and Carryall 6 vehicles only: To provide slack in the front brake cables, loosen the equal- izer retaining nuts (2) on the equalizer rod (1) (Figure 5-7, Page 5-8). 4.
Page 47: Brake Pedal Free Play Adjustment - Carryall 1 Only
ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal Free Play Adjustment – Carryall 1 Only BRAKE PEDAL FREE PLAY ADJUSTMENT – CARRYALL 1 ONLY Read DANGER and WARNING on page 5-1. NOTE: This procedure is applicable to Carryall 1 vehicles only. Vehicles with four-wheel manually adjusted brakes do not require this procedure.
Page 48: Accelerator Pedal Height Adjustment
ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal Height Adjustment ACCELERATOR PEDAL HEIGHT ADJUSTMENT Read DANGER and WARNING on page 5-1. 1. Loosen the nut and bolt (Figure 5-11, Page 5-10) securing the accelerator pedal to the pivot plate. 1/2 INCH WRENCH 1/2 INCH SOCKET Figure 5-11 Accelerator Pedal Height Adjustment 2.
Page 49 SECTION 6 – PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed space. Wear a full face shield and rubber gloves when working on or near batteries.
Page 50: General Information
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES General Information • For vehicles with cargo beds, 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 51: Park Brake System
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Park Brake System PARK BRAKE SYSTEM Read DANGER and WARNING on page 6-1. PARK BRAKE CABLE REMOVAL Equalizer Cable Removal NOTE: Pay particular attention to the routing of the equalizer cable before removal in order to ease the installation process.
Page 52 PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Park Brake System BRACKET PRESENT ON TYPICAL CARRYALL 1 ONLY EQUALIZER IS ROTATED 180° 2 PLACES ON CARRYALL 1 ONLY TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES TYPICAL EACH SIDE OF VEHICLE REAR BRAKE CABLE...
Page 53: Park Brake Cable Installation
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Park Brake System 6. Remove the cable from the cable support bracket (14 or 15). 7. Slide the cable through the hanger (16) and remove the cable from the vehicle. 8. If necessary, remove the other wheel brake cable in the same manner. PARK BRAKE CABLE INSTALLATION Equalizer Cable Installation 1.
Page 54 PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Park Brake System PARK BRAKE DRIVER SIDE HANDLE SEAT BUMPER WHEEL BRAKE CABLE EQUALIZER CABLE HANGERS PASSENGER SIDE EQUALIZER WHEEL BRAKE CABLE View from underside of vehicle. Figure 6-4 Park Brake Cable Routing – Carryall 2 DRIVER SIDE PARK BRAKE EQUALIZER...
Page 55: Park Brake Handle Removal
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Park Brake System Wheel Brake Cable Installation 1. Secure the brake cable (22 or 23) to the brake actuator arm with the clevis pin (17) and Rue pin (24) (Figure 6-2, Page 6-4). See following NOTE. NOTE: The park brake cable is secured to the brake actuator arm using the same hardware as the rear brake cables.
Page 56: Park Brake Adjustment
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Wheel Brake Assemblies – Carryall 1 4. Adjust the park brake. See Park Brake Adjustment on page 6-8. 5. Perform the park brake system inspection to ensure that the park brake system is adjusted and operating correctly before placing the vehicle into service.
Page 57 PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Brake Shoe Removal – Carryall 1 TYPICAL 4 PLACES TYPICAL 4 PLACES FRONT OF VEHICLE Figure 6-7 Self-Adjusting Brake Assembly 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual Page 6-9...
Page 58 PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Brake Shoe Removal – Carryall 1 Brake Shoe Removal – Carryall 1, Continued: 3. Remove the rear wheels and remove the brake drums. If the brake drums were easily removed, proceed to step 5. See following CAUTION and NOTE. ∆...
Page 59 PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Brake Shoe Removal – Carryall 1 BRAKE SHOE RETAINING PINS Figure 6-10 Shoe Retainer Pins Figure 6-11 Rotate Clip Retainer Figure 6-12 Remove Shoes Figure 6-13 Remove Adjuster Wheel Figure 6-14 Lubricate Slide 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual Page 6-11...
Page 60: Brake Assembly Cleaning - Carryall 1
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning – Carryall 1 BRAKE ASSEMBLY CLEANING – CARRYALL 1 Read DANGER and WARNING on page 6-1. 1. Carefully clean the brake backing plate and all of its mechanical components. 2. Remove the rubber boot from backing plate and wipe with a clean damp cloth. 3.
Page 61: Brake Shoe Installation - Carryall 1
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Brake Shoe Installation – Carryall 1 17T STAMPING Figure 6-17 Lubricate Adjuster Figure 6-18 Trailing Shoe BRONZE SPRING SPRING COILS ADJUSTMENT SILVER SPRING LEVER SPRING Figure 6-19 Retainer Clip Figure 6-20 Spring Orientation BRAKE SHOE INSTALLATION –...
Page 62 PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Brake Shoe Installation – Carryall 1 3. Attach the springs onto the trailing shoe already installed. Then hold the leading shoe next to the trailing shoe, correctly oriented, and attach the springs to it (Figure 6-20, Page 6-13). 4.
Page 63: Brake Adjustment - Carryall 1
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Brake Adjustment – Carryall 1 ADJUSTING ADJUSTING WHEEL Figure 6-22 Slide Shoes Figure 6-23 Turn Adjusting Wheel BRAKE ADJUSTMENT – CARRYALL 1 Read DANGER and WARNING on page 6-1. 1. When cleaning or repair on both wheels is complete, and with brake cable still loose, lower the vehicle to the ﬂoor.
Page 64: Brake Cluster Installation
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Brake Cables – Carryall 1 5. Remove the axle. 5.1. Using 90° snap ring pliers (CCI P/N 1012560), remove axle retaining ring (1) (Figure 6-9, Page 6-10). 5.2. Pull the axle shaft (2) from the axle tube. 6.
Page 65: Brake Cable Installation
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Wheel Brake Assemblies – Carryall 2 and Carryall 6 TYPICAL 2 PLACES BRAKE ACTUATOR ARM Figure 6-24 Loosen Equalizer Nuts Figure 6-25 Disconnect Cables at Brakes BRAKE CABLE INSTALLATION 1. Place the cables ends in the equalizer (4) (Figure 6-24, Page 6-17). Route cables through hangers in the same manner as the ones removed.
Page 66: Brake Shoe Removal - Carryall 2 And Carryall 6
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Brake Shoe Removal – Carryall 2 and Carryall 6 Figure 6-28 Remove Axle Retaining Ring Figure 6-29 Rotate Clip Retainer Pin BRAKE SHOE REMOVAL – CARRYALL 2 AND CARRYALL 6 Read DANGER and WARNING on page 6-1. 1.
Page 67: Brake Assembly Cleaning - Carryall 2 And Carryall 6
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning – Carryall 2 and Carryall 6 9. Using needle nose pliers, rotate the clip retainer pin (2) 90° to remove the shoe retainer clip (1) on each shoe (Figure 6-29, Page 6-18). See following CAUTION. ∆...
Page 68: Brake Shoe Installation - Carryall 2 And Carryall 6
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Brake Shoe Installation – Carryall 2 and Carryall 6 6. Use a small brush to carefully apply a light coat of white lithium NLGI #2 grease (Dow Corning BR2-Plus or equivalent) to the brake actuator assembly as shown (Figure 6-34, Page 6-20). See preceding WARNING.
Page 69 PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Brake Shoe Installation – Carryall 2 and Carryall 6 TYPICAL 4 PLACES TYPICAL 4 PLACES FRONT OF VEHICLE Figure 6-35 Rear Manually Adjusted Brake Assembly 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual Page 6-21...
Page 70 PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Brake Shoe Installation – Carryall 2 and Carryall 6 FRONT OF VEHICLE Figure 6-36 Front Manually Adjusted Brake Assembly Page 6-22 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual...
Page 71 PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Brake Shoe Installation – Carryall 2 and Carryall 6 Brake Shoe Installation – Carryall 2 and Carryall 6, Continued: 2. Install shoe retainer clip (1), using pliers to compress clip while turning clip retainer pin (2) into position (Figure 6-38, Page 6-23).
Page 72: Rear Brake Cluster - Carryall 2 And Carryall 6
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Rear Brake Cluster – Carryall 2 and Carryall 6 6. For rear brake shoe removal only: Install axle shaft (2) into axle tube and install retaining ring (1) (Figure 6-28, Page 6-18). See following WARNING. ∆...
Page 73: Front Brake Cluster - Carryall 2 And Carryall 6
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Front Brake Cluster – Carryall 2 and Carryall 6 2. Be sure bolts (20) and new cone lock nuts (19) are used to mount the brake assembly (Figure 6-35, Page 6-21). 3. Tighten bolts to 30 ft-lb (40 N·m). See following WARNING. ∆...
Page 74: Front Brake Cluster Installation
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Front Brake Cables – Carryall 2 and Carryall 6 2. Release park brake if engaged. 3. Loosen the equalizer retaining nuts (1 and 6) on the front equalizer rod (2) to slightly loosen the brake cable (Figure 6-41, Page 6-25, Detail B).
Page 75 PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Front Brake Cables – Carryall 2 and Carryall 6 TYPICAL BOTH SIDES OF VEHICLE Figure 6-43 Front Brake Cables FLOORBOARD REMOVED FOR CLARITY TYPICAL 2 PLACES Figure 6-44 Front Brake Equalizer 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual Page 6-27...
Page 76: Front Brake Cable Installation
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Front Brake Cables – Carryall 2 and Carryall 6 Front Brake Cable Removal, Continued: 4. Remove cotter pin (9), clevis pin (10), and E-clip (8) from brake cable at equalizer (18) (Figure 6-44, Page 6-27).
Page 77: Rear Brake Cables - Carryall 2 And Carryall 6
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Rear Brake Cables – Carryall 2 and Carryall 6 Front Brake Cable Installation, Continued: 12. Install a wire tie (16) to secure the brake cables to the driver side I-beam as shown (Figure 6-41, Page 6-25).
Page 78: Rear Brake Cable Installation
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Brake Adjustment – Carryall 2 and Carryall 6 TYPICAL 2 PLACES BRAKE ACTUATOR ARM Figure 6-47 Loosen Equalizer Nut Figure 6-48 Disconnect Cables at Rear Brakes REAR BRAKE CABLE INSTALLATION 1. Place the new cable ends through the access holes in the frame and into the equalizer (4) and secure with new E-clips (5) (Figure 6-47, Page 6-30).
Page 79: Equalizing Brake Cables
Brake Adjustment – Carryall 2 and Carryall 6 4. Using a torque wrench and a 7 mm 8 point socket or Club Car brake adjustment tool (CCI P/N 1013582), turn the brake adjustment bolt (5) on each brake clockwise until it is tightened to 15 ft-lb (20.3 N·m) and continue clockwise rotation to the point at which torque is released.
Page 80: Final Brake Cluster Adjustment
PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Brake Adjustment – Carryall 2 and Carryall 6 Equalizing Brake Cables, Continued: 7. Hold the lock nut (6) on the front equalizer rod (2) in place with a wrench and tighten the jam nut (1) to 13 ft-lb (17.6 N·m) (Figure 6-52, Page 6-32).
Page 81 PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES Brake Adjustment – Carryall 2 and Carryall 6 4. Test drive vehicle. Be sure the brakes function properly. When brake pedal is fully depressed under mod- erate pressure, it should not go more than halfway to ﬂoor, and the vehicle should come to a smooth, straight stop.
Page 83: Section 7 - Steering And Front Suspension
SECTION 7 – STEERING AND FRONT SUSPENSION ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed space. Wear a full face shield and rubber gloves when working on or near batteries.
Page 84: General Information
STEERING AND FRONT SUSPENSION General Information • To avoid unintentionally starting the vehicle, press the emergency stop switch down and disconnect the batteries as shown. See Figure 1-1, Section 1, Page 1-3. • After disconnecting the batteries, discharge the controller capacitors as follows: - Turn the key switch to ON, place the Forward/Reverse handle in the REVERSE position, and wait until the reverse warning buzzer can no longer be heard.
Page 85 STEERING AND FRONT SUSPENSION Steering Wheel 4. Use the steering wheel puller (CCI P/N 102061201) to remove steering wheel. 4.1. Place the puller anvil (4) through the top opening of the steering wheel (Figure 7-1, Page 7-2). 4.2. Insert the anvil feet through the two slots in the base plate (marked “B”) (5) as shown (Figure 7-1, Page 7-2).
Page 86: Steering Wheel Installation
STEERING AND FRONT SUSPENSION Steering Column Steering Wheel Removal, Continued: 4.3. Rotate the anvil screw (6) clockwise until the base plate contacts the bottom of the steering wheel where it attaches to the steering column (Figure 7-2, Page 7-2). 4.4. Using a 1/2 inch drive air impact wrench, tighten the anvil screw (6) until the steering wheel breaks free from the steering shaft.
Page 87: Steering Column Disassembly
STEERING AND FRONT SUSPENSION Steering Column Figure 7-4 Dash Removal 5. Remove the driver side dash pocket. 5.1. Remove the ﬂange lock screw from the top of the dash pocket. 5.2. Drill out the two pop rivets holding the dash pocket in place. 5.3.
Page 88: Steering Column Assembly
STEERING AND FRONT SUSPENSION Steering Column STEERING COLUMN ASSEMBLY 1. Insert bearing seat (18) into both ends of steering tube (20). Place a block of wood on bearing seat and tap lightly on block until bearing seat (18) is fully seated in steering tube (20) (Figure 7-5, Page 7-6). 2.
Page 89: Steering Adjustment
STEERING AND FRONT SUSPENSION Steering Adjustment 3. Position the steering column assembly in the vehicle while inserting the steering column shaft into the upper universal joint (1). The ﬂat portion of the steering shaft spline (19) must be aligned with the bolt hole in the universal joint (1) before sliding the spline into the universal joint.
Page 90: Rack And Pinion
STEERING AND FRONT SUSPENSION Rack and Pinion Steering Adjustment, Continued: 4. Straighten wheels and then turn steering wheel from lock to lock. Wheels should turn smoothly and eas- ily. If steering wheel does not turn smoothly and easily, inspect steering assemblies; e.g., ball joints (23) (Figure 7-12, Page 7-11) and (6 and 13) (Figure 7-20, Page 7-17), spindle bushings (3 and 4) (Figure 7-21, Page 7-18), wave washers (20) (Figure 7-21, Page 7-18), and rack assembly (17) (Figure 7-12, Page 7-11).
Page 91 STEERING AND FRONT SUSPENSION Rack and Pinion 3. Remove both bellows clamps (2) (plastic wire ties) (Figure 7-12, Page 7-11). 4. Remove the hex nut (29) and slide off the dust seal bellows (1) (Figure 7-12, Page 7-11). 5. Remove the retaining ring (21), then slide off dust seal bellows (20) (Figure 7-12, Page 7-11). PRESS RAM PINION GEAR BEARING...
Page 92: Rack And Pinion Assembly
STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Disassembly, Continued: 11. If the ball bearing (9) has been damaged, remove the external snap ring (10) (Figure 7-12, Page 7-11) and press the bearing off (Figure 7-10, Page 7-9). 12.
Page 93 STEERING AND FRONT SUSPENSION Rack and Pinion TYPICAL 3 PLACES TYPICAL 3 PLACES Figure 7-12 Steering Gear 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual Page 7-11...
Page 94 STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Assembly, Continued: 11. Install the rack guide (13), pressure spring (14), and screw (16). The screw should be threaded in until a rotational torque of 10 in-lb (1.13 N·m) is achieved (Figure 7-12, Page 7-11). 11.1.
Page 95: Rack And Pinion Installation
STEERING AND FRONT SUSPENSION Tie Rod and Drag Link VISE 3/8 INCH 1/4 DRIVE DEEP WELL SOCKET Figure 7-15 Rack and Pinion Resistance RACK AND PINION INSTALLATION 1. Position the steering gear box assembly on the shock and gear support and install the bolts (30), wash- ers (31), and nuts (32).
Page 96: Tie Rod And Drag Link Installation
STEERING AND FRONT SUSPENSION Front Suspension TIE ROD AND DRAG LINK INSTALLATION 1. Thread ball joints (6 and 13) into tie rod (11) to a depth of 1/2 inch (12.5 mm) (Figure 7-20, Page 7-17). ∆ WARNING • The ball joints must be threaded into the rod at least 5/16 of an inch (8 mm). Failure to thread ball joints in deep enough may cause a ball joint to separate from the rod during adjustment or while being operated, possibly resulting in loss of vehicle control and severe personal injury.
Page 97 Page 7-15. 6. Tighten the hex nut (8) on the adjustment eccentric (7) to 10 ft-lb (13.5 N·m) (Figure 7-21, Page 7-18) See also Figure 7-17, Page 7-15. PROPER CAMBER Club Car ADJUSTMENT EQUAL SPACE BETWEEN TIRES AND FRAMING SQUARES...
Page 98: Front Suspension Components
There should be equal travel to the left and right. See following NOTE. NOTE: If the minimum turning radius is not the same for both left and right turns, adjust the steering. See Steering Adjustment on page 7-7. Club Car Figure 7-18 Check Toe-In Figure 7-19 Adjust Toe-In FRONT SUSPENSION COMPONENTS Read DANGER and WARNING on page 7-1.
Page 99 STEERING AND FRONT SUSPENSION Front Suspension Components TYPICAL 4 PLACES TYPICAL 3 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES Figure 7-20 Two-Wheel Brake Vehicle – Upper Portion 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual Page 7-17...
Page 100 STEERING AND FRONT SUSPENSION Front Suspension Components TYPICAL 4 PLACES DRIVER TYPICAL SIDE ONLY 4 PLACES PASSENGER SIDE ONLY TYPICAL 4 PLACES Figure 7-21 Two-Wheel Brake Vehicle – Lower Portion Page 7-18 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual...
Page 101: Leaf Spring Installation
STEERING AND FRONT SUSPENSION Front Suspension Components LEAF SPRING INSTALLATION 1. Install urethane bushings (27) and steel bushings (28) into leaf spring eyes (Figure 7-21, Page 7-18). 2. Install tapered leaf spring (6), bottom spring plate (29), four bolts (30), four lock washers (31), and four nuts (32).
Page 102: Kingpin And Steering Spindle Installation
STEERING AND FRONT SUSPENSION Front Suspension Components Kingpin and Steering Spindle Removal, Continued: 8. Remove the wave washer (20) and inspect it (Figure 7-21, Page 7-18). If the washer is broken or has a wave bottom to wave crest height dimension of less than .040 inch (0.10 cm), it must be replaced. 9.
Page 103: Shock Absorber Inspection And Removal
STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs SHOCK ABSORBER INSPECTION AND REMOVAL 1. Inspect the shock absorbers for ﬂuid leakage at the point where the shaft enters the shock absorber body. Leaking shock absorbers should be replaced. 2. Remove the nut (9) attaching the shock absorber to the A-Plate (Figure 7-20, Page 7-17). 3.
Page 104 STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs REFERENCE STEERING GEAR TYPICAL 4 PLACES TYPICAL 3 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES Figure 7-23 Four-Wheel Brake Vehicle – Upper Portion Page 7-22 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual...
Page 105 STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs REFERENCE STEERING GEAR ASSEMBLY TYPICAL 4 PLACES DRIVER SIDE ONLY PASSENGER SIDE ONLY TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 7-24 Four-Wheel Brake – Lower Portion 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual Page 7-23...
Page 106: Front Wheel Bearings And Hub Installation
STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs Figure 7-25 Front Wheel Bearings and Hub FRONT WHEEL BEARINGS AND HUB INSTALLATION 1. Pack the wheel bearings (5) and hub cavities, and lubricate cups (7) with wheel bearing grease or chas- sis lube.
Page 107: Section 8 - Wheels And Tires
SECTION 8 – WHEELS AND TIRES ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed space. Wear a full face shield and rubber gloves when working on or near batteries.
Page 108: General Information
WHEELS AND TIRES General Information • After disconnecting the batteries, discharge the controller capacitors as follows: - Turn the key switch to ON, place the Forward/Reverse handle in the REVERSE position, and wait until the reverse warning buzzer can no longer be heard. When the buzzer stops sounding, the controller is discharged.
Page 109: Tire Repair
WHEELS AND TIRES Tires 1. Remove the tire and wheel assembly from the vehicle as instructed. See Wheel Removal on page 8-2. 2. Remove the valve cap and valve core and allow air to escape from the tire. 3. If possible, use a tire machine to remove the tire from the rim. 3.1.
Page 110: Tire Installation
WHEELS AND TIRES Tires TIRE INSTALLATION ∆ WARNING • While mounting or inﬂating tire, keep hands, ﬁngers, etc. from exposed areas between the tire bead and rim. 1. Clean both tire beads to remove dirt or other foreign matter. 2. Where the tire beads seat, clean the rim with a wire brush. Wipe away any debris with a clean cloth. NOTE: Because tubeless tires require a perfect seal in order to seat, keeping the tire and rim clean is very important.
Page 111: Section 9 - Rear Suspension
SECTION 9 – REAR SUSPENSION ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed space. Wear a full face shield and rubber gloves when working on or near batteries. •...
Page 112: General Information
REAR SUSPENSION General Information • After disconnecting the batteries, discharge the controller capacitors as follows: - Turn the key switch to ON, place the Forward/Reverse handle in the REVERSE position, and wait until the reverse warning buzzer can no longer be heard. When the buzzer stops sounding, the controller is discharged.
Page 113: Shock Absorber Installation
REAR SUSPENSION Multi-Leaf Springs SHOCK ABSORBER INSTALLATION NOTE: When installing shock absorbers, make sure front shocks have identical part numbers and rear shocks have identical part numbers. 1. To install, reverse the removal procedure. 2. On the upper shock absorber mount, tighten nut (5) until rubber bushing (10) expands to the same diam- eter as the cup washer.
Page 114 REAR SUSPENSION Multi-Leaf Springs REAR BRAKE CABLES TYPICAL 4 PLACES TYPICAL 4 PLACES TYPICAL EACH SIDE OF VEHICLE Figure 9-2 Rear Suspension – Carryall 1 Page 9-4 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual...
Page 115 REAR SUSPENSION Multi-Leaf Springs REAR BRAKE CABLES TYPICAL 4 PLACES TYPICAL 4 PLACES TYPICAL EACH SIDE OF VEHICLE Figure 9-3 Rear Suspension – Carryall 2 and Carryall 6 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual Page 9-5...
Page 116: Multi-Leaf Spring Installation
REAR SUSPENSION Multi-Leaf Springs Lifting position for Carryall 1 Lifting position for Carryall 2 Position floor jack under hitch bracket or frame. Lifting position for Carryall 6 Figure 9-4 Lift Vehicle MULTI-LEAF SPRING INSTALLATION NOTE: When installing rear leaf springs, make sure that both springs have identical part numbers. 1.
Page 117: Jounce Bumpers
REAR SUSPENSION Jounce Bumpers 7. For Carryall 2 and Carryall 6 vehicles: Install U-bolt (11) and lock nuts (26). Tighten lock nuts (26) to 25 ft-lb (34 N·m) (Figure 9-3, Page 9-5). 8. Install shock absorber. See Shock Absorber Installation on page 9-3. NOTE: When installing shock absorbers, make sure rear shocks have identical part numbers.
Page 119: Section 10 - Periodic Maintenance
SECTION 10 – PERIODIC MAINTENANCE ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed space. Wear a full face shield and rubber gloves when working on or near batteries. •...
Page 120: General Information
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 ser- vice.
Page 121: Performance Inspection
Use the following checklist as a guide to inspect the vehicle and check daily for proper operation. Any prob- lems should be corrected by a Club Car distributor/dealer or a trained technician. • Forward/Reverse switch: Check for proper operation. See Controls and Indicators in the vehicle owner’s manual.
Page 122 PERIODIC MAINTENANCE Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Daily service by owner Charge batteries (after each use only). Batteries Weekly service by owner Check electrolyte level. Add water as Batteries necessary. See Section 13 – Batteries. Monthly service by owner Wash battery tops and clean terminals Batteries or trained technician...
Page 123: Periodic Lubrication Schedule
PERIODIC MAINTENANCE Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE Read DANGER and WARNING on page 10-1. PERIODIC LUBRICATION SCHEDULE REGULAR INTERVAL SERVICE LUBRICATE* RECOMMENDED LUBRICANT Semiannually by owner Brake pedal shaft bearings Dry Moly Lube (CCI P/N 1012151) or trained technician (every 50 hours of operation) Brake linkage and pivots Dry Moly Lube (CCI P/N 1012151)
Page 125: Section 11 - Electrical System And Testing
SECTION 11 – ELECTRICAL SYSTEM AND TESTING ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed space. Wear a full face shield and rubber gloves when working on or near batteries.
Page 126: General Information
ELECTRICAL SYSTEM AND TESTING General Information • To avoid unintentionally starting the vehicle, press the emergency stop switch down and disconnect the batteries as shown. See Figure 1-1, Section 1, Page 1-3. • After disconnecting the batteries, discharge the controller capacitors as follows: - Turn the key switch to ON, place the Forward/Reverse handle in the REVERSE position, and wait until the reverse warning buzzer can no longer be heard.
Page 127 ELECTRICAL SYSTEM AND TESTING Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Vehicle will not operate – Test Procedure 6 – Forward/Reverse Anti- F&R anti-arcing limit switch – loose wires. no solenoid click, continued Arcing Limit Switch on page 11-14 F&R anti-arcing limit switch –...
Page 128 ELECTRICAL SYSTEM AND TESTING Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Vehicle runs slowly, continued Test Procedure 1 and Batteries – improperly wired. Section 13 – Batteries Test Procedure 1 and Batteries – batteries failed. Section 13 – Batteries Test Procedure 1 and Batteries –...
Page 129: Wiring Diagrams
ELECTRICAL SYSTEM AND TESTING Wiring Diagrams WIRING DIAGRAMS HORN SONIC TWO-PIN WELD PLUG SONIC WELD THREE-PIN PLUG ORANGE SONIC TWO-PIN FUSE WELD PLUG ONBOARD HORN COMPUTER SWITCH SIX PIN PLUG SONIC WELD SONIC FUSE WELD VMN2 BATT– SH– FUSE BATT+ VMN1 CONTROLLER PLUG...
Page 130 ELECTRICAL SYSTEM AND TESTING Wiring Diagrams PASSENGER SIDE HEADLIGHT HORN GROUND TERMINAL BLOCK DRIVER SIDE HEADLIGHT GREEN FUSE LIGHT FUSE AND SWITCH RECEPTACLE SEAT SWITCH TWO-PIN CONNECTOR HORN SWITCH BRAKE LIMIT SWITCH Figure 11-2 Wiring Diagram – Carryall 6 Electric Industrial Truck (Front) Page 11-6 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual...
Page 131 ELECTRICAL SYSTEM AND TESTING Wiring Diagrams TWO-PIN PLUG THREE-PIN PLUG TWO-PIN PLUG SONIC DC TO DC WELD CONVERTER FUSE THREE-PIN PLUG ONBOARD COMPUTER GREEN SONIC TERMINAL WELD BLOCK FUSE VMN2 BATT– SH– BATT+ VMN1 BATTERIES CONTROLLER PLUG DIODE SONIC PASSENGER SIDE WELD BRAKE LIGHT DRIVER SIDE...
Page 132 ELECTRICAL SYSTEM AND TESTING Wiring Diagrams HORN SONIC TWO-PIN WELD PLUG SONIC WELD THREE-PIN PLUG ORANGE SONIC TWO-PIN FUSE WELD PLUG ONBOARD HORN COMPUTER SWITCH SIX PIN TERMINAL PLUG BLOCK SONIC WELD SONIC FUSE WELD VMN2 BATT– SH– FUSE BATT+ VMN1 CONTROLLER PLUG...
Page 133: Electrical Circuits
5. Receptacle fuse link 6. Batteries The onboard fuse link provides additional protection to the vehicle charging circuit. The fuse is rated for use with a Club Car PowerDrive charger only. 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual Page 11-9...
Page 134: Battery Warning Light
ELECTRICAL SYSTEM AND TESTING Electrical Circuits BATTERY WARNING LIGHT Use this chart as a starting point for troubleshooting when the battery warning light is illuminated. More detailed system testing instructions follow. Battery Warning Light In Dash Is Illuminated DC plug DC plug is Charge interrupt is connected...
Page 135: Test Procedures
ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURES Using the following procedures, the entire PowerDrive electrical system can be tested without major disas- sembly of the vehicle. ∆ WARNING • If wires are removed or replaced make sure wiring and wire harness is properly routed and secured to vehicle frame.
Page 136 ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE 1 – BATTERIES / VOLTAGE CHECK Read DANGER and WARNING on page 11-1. 1. Slide the rubber boot away from the positive (+) terminal on battery no. 1, exposing the battery terminal. Slide the rubber boot away from the negative (–) terminal on battery no.
Page 137 ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE 3 – MAIN POWER FUSE Read DANGER and WARNING on page 11-1. 1. Disconnect the batteries as instructed. See WARNING on page 11-1. 2. Remove the electrical component cover to expose the main power fuse. 3.
Page 138 ELECTRICAL SYSTEM AND TESTING Test Procedures WAVETEK 1000 2000 200k Ω Ω 200nA 1000 --- FUSED 750V GREEN/WHITE 200 Ω SETTING WIRE FROM WIRE HARNESS Figure 11-8 MCOR Limit Switch Test TEST PROCEDURE 5 – MCOR LIMIT SWITCH Read DANGER and WARNING on page 11-1. NOTE: The key switch and connecting wires should be tested and repaired (if necessary) prior to perform- ing this test procedure.
Page 139 ELECTRICAL SYSTEM AND TESTING Test Procedures 4. With a multimeter set to 200 Ω (ohms), place the red (+) probe on the top terminal (COM) of the limit switch where the green wire is normally connected. Place the black (–) probe on the middle terminal (NO) of the anti-arcing limit switch where the gray wire is normally connected.
Page 140 ELECTRICAL SYSTEM AND TESTING Test Procedures Test Procedure 7 – Solenoid Activating Coil and Diode, Continued: 4.2. Reverse the positions of the probe and the alligator clip (Figure 11-10, Page 11-15). The tester should not illuminate. If any other reading is obtained, the diode must be replaced. If the diode is functioning correctly, proceed to step 6.
Page 141 ELECTRICAL SYSTEM AND TESTING Test Procedures 5. Use a multimeter set to 200 Ω (ohms) to test the F&R switch in both directions. With Forward/Reverse handle in FORWARD, place red (+) probe of multimeter on SH– terminal of speed controller and place black (–) probe on D1 motor terminal.
Page 142 ELECTRICAL SYSTEM AND TESTING Test Procedures 8. With Forward/Reverse handle in REVERSE, place red (+) probe on the A2 motor terminal and the black (–) probe on the D1 motor terminal. Meter should indicate continuity (Figure 11-17, Page 11-17). If con- tinuity is not obtained, and all wires and connections are correct, replace F&R switch.
Page 143 ELECTRICAL SYSTEM AND TESTING Test Procedures 9. With the accelerator pedal fully up (not depressed), the multimeter should indicate between 5.67k Ω (ohms) and 7.43k Ω (ohms). 10. Slowly depress the accelerator pedal while monitoring the multimeter. The resistance should drop as the pedal is depressed.
Page 144 ELECTRICAL SYSTEM AND TESTING Test Procedures Test Procedure 11 – Solid State Speed Controller, Continued: 2.3. Remove the 6 gauge wire from the A2 motor terminal and secure wire so it will not make contact with any metal component or connection. 2.4.
Page 145 ELECTRICAL SYSTEM AND TESTING Test Procedures CONTROLLER YELLOW PURPLE/WHITE WAVETEK 1000 WHITE ORANGE 2000 200k PINK Ω BLUE Ω 200nA 1000 --- FUSED 750V GRAY BLUE / WHITE 200 DCV SETTING (READING WITH KEY SWITCH ON) Figure 11-23 Seat Switch Input Voltage Test 3.
Page 146 ELECTRICAL SYSTEM AND TESTING Test Procedures Test Procedure 11 – Solid State Speed Controller, Continued: CONTROLLER YELLOW PURPLE/WHITE WAVETEK 1000 WHITE ORANGE 2000 200k PINK Ω BLUE Ω 200nA 1000 --- FUSED 750V GRAY BLUE / WHITE 200 DCV SETTING (READING WITH KEY SWITCH ON) Figure 11-24 Forward/Reverse and MCOR Limit Switch Input Voltage Test...
Page 147 6 gauge wire to the A2 motor terminal. See Wiring Diagrams on page 11-5. Connect the battery cables, positive (+) cable ﬁrst. ONBOARD COMPUTER HALF-SPEED REVERSE LIMIT SWITCH (F&R No. 3) USE ONLY WITH CLUB CAR POWER DRIVE BATTERY CHARGERS ON 48 VDC(24 CELL) BATTERY SYSTEMS LE0001000094 Ver. 1.35S PATENT PENDING Figure 11-27 Onboard Computer Version Figure 11-28 F&R Limit Switch...
Page 148 ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE 12 – ONBOARD COMPUTER (OBC) LOCKOUT CIRCUIT Read DANGER and WARNING on page 11-1. 1. Inspect the charger receptacle for water in the contacts. If water is found, proceed as follows: NOTE: If battery pack is wet, make sure 18 gauge gray wire from OBC is not touching batteries. Wire tie the 18 gauge gray lead and 18 gauge gray wire to wire harness if necessary.
Page 149 ELECTRICAL SYSTEM AND TESTING Test Procedures 3. Check the half-speed reverse limit switch for proper wiring and tight connections. 4. Using a multimeter set to 200 Ω (ohms), check continuity across common (COM) and normally open (NO); and across common (COM) and normally closed (NC) (Figures 11-28 and 11-29, Pages 11-23 and 11-25).
Page 150 ELECTRICAL SYSTEM AND TESTING Test Procedures REVERSE BUZZER WILL NOT FUNCTION REVERSE BUZZER REVERSE BUZZER WILL NOT FUNCTION AND WILL NOT FUNCTION AND VEHICLE WILL NOT RUN VEHICLE RUNS CHECK REVERSE BUZZER CHECK BATTERIES LIMIT SWITCH (TEST PROCEDURE 1) (TEST PROCEDURE 14) USE MULTIMETER TO TEST LIMIT SWITCH CORRECT...
Page 151 ELECTRICAL SYSTEM AND TESTING Test Procedures Testing the Front Mounted Reverse Buzzer Circuit NOTE: Batteries should remain connected for this test. 1. Remove the electrical component cover to expose the Forward/Reverse switch. 2. Disconnect the black/white wire from F&R limit switch no. 2 and place the black probe of a multimeter set to 200 volts DC on the wire.
Page 152 ELECTRICAL SYSTEM AND TESTING Test Procedures 4. Remove the center dash. See step 2 of Key Switch Removal, Section 12, Page 12-5. 5. Disconnect the18 gauge brown wire from the battery warning light. 6. Set the multimeter to 200 Ω (ohms) and connect the black (–) probe to the male side of the brown wire spade connector.
Page 153 ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE 20 – EMERGENCY STOP SWITCH Read DANGER and WARNING on page 11-1. 1. Disconnect the batteries as instructed. See WARNING on page 11-1. 2. Remove the electrical component cover to expose the main power fuse and the solenoid terminals. 3.
Page 154 ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE 22 – GROUND TERMINAL BLOCK (CARRYALL 6 VEHICLES) Read DANGER and WARNING on page 11-1. NOTE: Before performing the following test, the rear of the vehicle must be raised and secured on jack stands with the drive wheels off the ground.
Page 155 ELECTRICAL SYSTEM AND TESTING Test Procedures 12. With the key switch OFF, there should be no voltage reading. If voltage is present with the key switch in the OFF position, check the DC/DC converter for proper operation. See Test Procedure 24 – DC/DC Converter (Vehicles with Headlights) on page 11-32.
Page 156 ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE 24 – DC/DC CONVERTER (VEHICLES WITH HEADLIGHTS) Read DANGER and WARNING on page 11-1. NOTE: Before performing the following test, the rear of the vehicle must be raised and secured on jack stands with the drive wheels off the ground.
Page 157 ELECTRICAL SYSTEM AND TESTING Test Procedures Test Procedure 24 – DC/DC Converter (Vehicles with Headlights), Continued: 6. Check DC/DC converter input. 6.1. Disconnect the three-pin connector from the DC/DC converter. 6.2. Using a multimeter set for 200 DC volts, place the red (+) probe into the three-pin terminal with the blue wire attached (wire harness side).
Page 158 ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE 25 – VOLTAGE AT TAILLIGHT SOCKET (VEHICLES WITH TAIL- LIGHTS) Read DANGER and WARNING on page 11-1. NOTE: Before performing the following test, the rear of the vehicle must be raised and secured on jack stands with the drive wheels off the ground.
Page 159 ELECTRICAL SYSTEM AND TESTING Test Procedures Test Procedure 26 – Taillight Bulb Socket, Continued: 4. Inspect the light bulb and make sure there is no corrosion on the bulb contacts. TEST PROCEDURE 27 – VOLTAGE AT HEADLIGHT SOCKET Read DANGER and WARNING on page 11-1. NOTE: Before performing the following test, the rear of the vehicle must be raised and secured on jack stands with the drive wheels off the ground.
Page 160 ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE 28 – BRAKE PEDAL LIMIT SWITCH Read DANGER and WARNING on page 11-1. NOTE: Before performing the following test, the rear of the vehicle must be raised and secured on jack stands with the drive wheels off the ground. 1.
Page 161 ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE 29 – VOLTAGE AT HORN Read DANGER and WARNING on page 11-1. NOTE: Before performing the following test, the rear of the vehicle must be raised and secured on jack stands with the drive wheels off the ground. 1.
Page 162 ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE 30 – HORN SWITCH Read DANGER and WARNING on page 11-1. NOTE: Before performing the following test, the rear of the vehicle must be raised and secured on jack stands with the drive wheels off the ground. 1.
Page 163: Communication Display Module (Cdm)
Func4 - 1 = Incomplete, 2 = DVDT, 4 = Normal, 8 = Max. timer). POWER Club Car PART #17075 Figure 11-44 CDM COMMUNICATION DISPLAY MODULE (CDM) The CDM can be used to retrieve from the onboard computer four important items of information that can be useful in troubleshooting the PowerDrive System 48 vehicle.
Page 164: Using The Cdm To Retrieve Data From The Onboard Computer
ELECTRICAL SYSTEM AND TESTING Communication Display Module (CDM) • F3 – Total accumulated energy units removed since initial vehicle start-up: This information is most useful in making sure that all vehicles in a ﬂeet receive equal usage over long periods of time. •...
Page 165: Cdm Troubleshooting Guide
CDM Troubleshooting Guide CDM TROUBLESHOOTING GUIDE Use the following chart as a starting point for troubleshooting problems with communication between the CDM and onboard computer. Contact your Club Car representative for more comprehensive information. OBC Will Not Communicate With The CDM...
Page 167: Section 12 - Electrical Components
SECTION 12 – ELECTRICAL COMPONENTS ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed space. Wear a full face shield and rubber gloves when working on or near batteries. •...
Page 168: Electrical Component Cover
ELECTRICAL COMPONENTS Electrical Component Cover • After disconnecting the batteries, discharge the controller capacitors as follows: - Turn the key switch to ON, place the Forward/Reverse handle in the REVERSE position, and wait until the reverse warning buzzer can no longer be heard. When the buzzer stops sounding, the controller is discharged.
Page 169 ELECTRICAL COMPONENTS Electrical Component Cover Passenger Side Electrical Component Cover Removal (Carryall 2 and Carryall 6) 1. Disconnect the batteries as instructed. See WARNING on page 12-1. ® 2. Loosen, but do not remove the two Tuﬂok screws (3) securing the passenger side electrical component cover to the vehicle frame (Figure 12-1, Page 12-2).
Page 170: Main Power Fuse
ELECTRICAL COMPONENTS Main Power Fuse MAIN POWER FUSE Read DANGER and WARNING on page 12-1. The main power fuse is located on the component mounting plate under the passenger seat on carryall 2 and Carryall 6 vehicles, and under the bed on Carryall 1 vehicles. Testing the Main Power Fuse See Test Procedure 3, Section 11, Page 11-13.
Page 171: Key Switch
ELECTRICAL COMPONENTS Key Switch KEY SWITCH Read DANGER and WARNING on page 12-1. Testing the Key Switch See Test Procedure 4, Section 11, Page 11-13. Figure 12-3 Dash removal Key Switch Removal 1. Disconnect the batteries as instructed. See WARNING on page 12-1. 2.
Page 172: Battery Condition Indicator
ELECTRICAL COMPONENTS Battery Condition Indicator Figure 12-4 Key Switch Key Switch Installation 1. Position the key switch and ﬂat washer (9) in the center dash, then install and tighten the switch retaining nut (6) to 40 in-lb (4.5 N·m). Install key switch cap (8) in center dash (Figure 12-4, Page 12-6). 2.
Page 173: Plug Diode
ELECTRICAL COMPONENTS Plug Diode PLUG DIODE Read DANGER and WARNING on page 12-1. Testing the Plug Diode See Test Procedure 21, Section 11, Page 11-29. Plug Diode Removal 1. Disconnect the batteries as instructed. See WARNING on page 12-1. 2. Remove the electrical component cover to expose the plug diode. 3.
Page 174: Emergency Stop Switch
ELECTRICAL COMPONENTS Emergency Stop Switch EMERGENCY STOP SWITCH Read DANGER and WARNING on page 12-1. Testing the Emergency Stop Switch See Test Procedure 20, Section 11, Page 11-29. Emergency Stop Switch Removal 1. Disconnect the batteries as instructed. See WARNING on page 12-1. 2.
Page 175: Forward/Reverse Limit Switches
ELECTRICAL COMPONENTS Forward/Reverse Switch Forward/Reverse Switch Removal 1. Disconnect the batteries as instructed. See WARNING on page 12-1. 2. Remove the Forward/Reverse handle mounting screw (7) and handle (6) (Figure 12-7, Page 12-10). 3. Note all wire connection points for proper reinstallation of the Forward/Reverse switch. 4.
Page 176 ELECTRICAL COMPONENTS Forward/Reverse Switch 2. Note all wire connection points for proper reinstallation of the limit switches. 3. Remove all three limit switches from Forward/Reverse switch by removing two screws (5), lock washers (4) and nuts (3). Label each wire prior to disconnecting wire terminals from each switch (Figure 12-7, Page 12-10).
Page 177: Reverse Buzzer
ELECTRICAL COMPONENTS Reverse Buzzer REVERSE BUZZER Read DANGER and WARNING on page 12-1. The reverse buzzer is mounted on the back of the center dash panel, under the front body. An additional buzzer is mounted on the rear fender of the Carryall 6 vehicle. Testing the Reverse Buzzer See Test Procedure 15, Section 11, Page 11-26.
Page 178: Diode - Solenoid
ELECTRICAL COMPONENTS Solenoid Solenoid Installation 1. Install the solenoid onto the mounting plate and tighten screws to 50 in-lb (5.7 N·m). 2. Connect wires and the resistor to the solenoid as shown in the appropriate wiring diagram. See Wiring Diagrams, Section 11, Page 11-5. Tighten hex nuts (5) to 60 in-lb (6.7 N·m) (Figure 12-8, Page 12-12). TYPICAL 2 PLACES TYPICAL...
Page 179: Resistor - Solenoid
ELECTRICAL COMPONENTS Solenoid CLIP DIODE LEADS Figure 12-9 Diode Removal Figure 12-10 Install New Diode Diode Installation 1. Install a new diode assembly (CCI P/N 1014948), making sure that the red ring terminal of the replace- ment diode is connected to the positive (+) solenoid terminal (Figure 12-10, Page 12-13). Tighten the hex nuts to 19 in-lb (2.1 N·m).
Page 180: Onboard Computer (Obc)
ELECTRICAL COMPONENTS Onboard Computer (OBC) ONBOARD COMPUTER (OBC) Read DANGER and WARNING on page 12-1. Testing the Onboard Computer See Test Procedure 12, Section 11, Page 11-24. Figure 12-11 Charger Receptacle Wiring Onboard Computer Removal 1. Disconnect the batteries as instructed. See WARNING on page 12-1. 2.
Page 181 ELECTRICAL COMPONENTS Onboard Computer (OBC) Figure 12-12 Controller and Onboard Computer – Carryall 1 Vehicles Figure 12-13 Controller and Onboard Computer – Carryall 2 and Carryall 6 Vehicles 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual Page 12-15...
Page 182: Solid State Speed Controller
ELECTRICAL COMPONENTS Solid State Speed Controller SOLID STATE SPEED CONTROLLER Read DANGER and WARNING on page 12-1. Testing the Speed Controller See Test Procedure 11, Section 11, Page 11-19. Speed Controller Removal 1. Disconnect the batteries as instructed. See WARNING on page 12-1. 2.
Page 183: Receptacle Fuse Link
ELECTRICAL COMPONENTS Charger Receptacle 2. Remove the 10 gauge red wire. • Carryall 1 Vehicles: Remove the 10 gauge red wire (4) from the positive post of battery no. 1 (Figure 12-14, Page 12-18). • Carryall 2 and Carryall 6 Vehicles: Remove the 10 gauge red wire (4) from the fuse located on the component mounting plate (Figure 12-14, Page 12-18).
Page 184: Motor Controller Output Regulator (Mcor)
ELECTRICAL COMPONENTS Motor Controller Output Regulator (MCOR) TYPICAL 2 PLACES Figure 12-14 Charger Receptacle Receptacle Fuse Link Installation 1. Insert the two fuse link mounting studs into the mounting holes in the charger receptacle. 2. Place the two 10 gauge black wires in their original positions on the fuse link mounting posts. Tighten to 23 in-lb (2.6 N·m).
Page 185 ELECTRICAL COMPONENTS Motor Controller Output Regulator (MCOR) TYPICAL 2 PLACES Figure 12-15 Motor Controller Output Regulator (MCOR) Mounting MCOR Installation 1. Insert the splined end of the drive bar (4) through the hole in the passenger side frame I-beam as shown (Figure 12-15, Page 12-19).
Page 186: Headlight Switch
ELECTRICAL COMPONENTS Headlight Switch SET SCREW Figure 12-16 Headlight Switch HEADLIGHT SWITCH Read DANGER and WARNING on page 12-1. Testing the Headlight Switch See Test Procedure 23, Section 11, Page 11-31. Headlight Switch Removal 1. Disconnect the batteries as instructed. See WARNING on page 12-1. 2.
Page 187: Horn
ELECTRICAL COMPONENTS Horn HORN Read DANGER and WARNING on page 12-1. Testing the Horn See Test Procedure 29, Section 11, Page 11-37. Horn Removal 1. Disconnect the batteries as instructed. See WARNING on page 12-1. 2. Remove the two wire terminals (6) from the horn (Figure 12-17, Page 12-21). 3.
Page 188: Horn Switch
ELECTRICAL COMPONENTS Horn Switch HORN SWITCH Read DANGER and WARNING on page 12-1. Testing the Horn Switch See Test Procedure 30, Section 11, Page 11-38. Horn Switch Removal 1. Disconnect the batteries as instructed. See WARNING on page 12-1. 2. Remove the tie wrap securing the horn switch wire harness to the vehicle frame. 3.
Page 189: Battery Warning Light
ELECTRICAL COMPONENTS Battery Warning Light WELDED STOP ON BRAKE PEDAL Figure 12-18 Brake Pedal Limit Switch BATTERY WARNING LIGHT Read DANGER and WARNING on page 12-1. Testing the Battery Warning Light See Test Procedure 17, Section 11, Page 11-27. Battery Warning Light Removal 1.
Page 190: Seat Switch
ELECTRICAL COMPONENTS Seat Switch Figure 12-19 Battery Warning Light SEAT SWITCH Read DANGER and WARNING on page 12-1. Testing the Seat Switch See Test Procedure 10, Section 11, Page 11-18. SEAT TYPICAL 2 PLACES Figure 12-20 Seat Switch Page 12-24 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual...
Page 191: Dc/Dc Converter
ELECTRICAL COMPONENTS DC/DC Converter Seat Switch Removal 1. Disconnect the batteries as instructed. See WARNING on page 12-1. 2. Remove the two wire terminals (11) from the seat switch (12), and remove the seat from the vehicle (Figure 12-20, Page 12-24). 3.
Page 193: Section 13 - Batteries
SECTION 13 – BATTERIES ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed space. Wear a full face shield and rubber gloves when working on or near batteries. •...
Page 194: General Information
The outward appearance of these two batteries is similar, but the operating characteristics are very different. The Club Car electric vehicle battery is a deep-cycle battery, and the automotive battery is a “starting, lighting and ignition” (SLI) battery. They should never be substituted for one another.
Page 195 BATTERIES General Information CHARGER PbSO 4 PbSO DISCHARGED BATTERY BATTERY CHARGING Figure 13-3 Discharged Battery Figure 13-4 Charging Battery The rechargeable lead-acid battery turns chemical energy into electrical energy and vice versa. The main active elements within a battery are the positive plates, the negative plates and the electrolyte (sulfuric acid). Another very important element (but, inactive) is the separator.
Page 196: Common Misconceptions About Batteries
BATTERIES Common Misconceptions About Batteries COMMON MISCONCEPTIONS ABOUT BATTERIES The chart below describes some of the more common misconceptions that are associated with the deep cycle vehicle batteries and battery care. PROBLEM MISCONCEPTION REALITY Avoid deep discharge of batteries whenever “This vehicle is running slowly, but we can run Deep-discharge possible.
Page 197: Battery Care
BATTERIES Battery Care 3. If old battery cables are to be reused, inspect them for broken or frayed wires, damaged terminals, or worn insulation. Remove any corrosion on the connectors. A solution of baking soda and water (1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water) does an excellent job of neutralizing and removing the corrosion.
Page 198: Self-Discharge
BATTERIES Battery Care Preventive Maintenance, Continued: 2. Batteries should be clean and free of corrosion. Wash tops and terminals of batteries with a solution of baking soda and water (1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water). Rinse solution off bat- teries.
Page 199: Mineral Content
BATTERY CHARGING Read DANGER and WARNING on page 13-1. The charger supplied with the Club Car electric vehicle resolves the most common problems associated with battery charging. Undercharging and overcharging are prevented provided the charger is allowed to shut off by itself.
Page 200: Charger Shuts Off After 16 Hours
The deeper the discharge, the harder it is on the batter- ies. For this reason, it is recommended that Club Car electric vehicle batteries be charged after each use (pro- vided the charge cycle will not be interrupted and the charger will be allowed to shut off automatically). Placing the batteries on charge after each use reduces the depth of discharge and prolongs battery life.
Page 201: Battery Troubleshooting Chart
BATTERIES Battery Troubleshooting Chart BATTERY TROUBLESHOOTING CHART Vehicle not operating to expectation. Fully Charge Batteries. Battery Charger Test Reading of 6 amps or more. Reading below 6 amps and on-charge voltage above 56 volts. Check electrical system and charger for problems. SeeTroubleshooting Guide On-Charge Voltage Test If problem is not found, go to...
Page 202: Battery Testing
BATTERIES Battery Testing BATTERY TESTING Read DANGER and WARNING on page 13-1. Four tests have been developed to help diagnose problems with batteries that have not performed as expected. Because each test becomes progressively more detailed and time-consuming, begin with the ﬁrst test and follow through with the other tests until the problem has been identiﬁed as outlined in the Battery Troubleshooting Chart (Figure 13-7, Page 13-9).
Page 203 BATTERIES Battery Testing 5. Hold the hydrometer vertically, ensuring that the ﬂoat is not touching the sides of the barrel. Hold the hydrometer at eye level and read the scale at the level of electrolyte (Figure 13-8, Page 13-11). 6. Record the reading and return the electrolyte to the cell from which it was taken. Replace vent cap. 7.
Page 204 BATTERIES Battery Testing CORRECTED SPECIFIC GRAVITY VEHICLE BATTERY ELECTROLYTE CORRECTION REQUIRED TEMPERATURE FACTOR ACTION CELL 1 CELL 2 CELL 3 CELL 4 1.275 – .024 = 1.280 – .024 = 1.280 – .024 = 1.280 – .024 = Sound Battery – 20 °F (-6.6 °C) -.024 1.251...
Page 205 BATTERIES Battery Testing 3. Check and record the electrolyte temperature of the battery packs. Check cell no. 2 (second cell from positive post) in each battery. 4. Reset discharge machine and turn the tester ON. 5. When the batteries have been discharging for approximately 60 minutes, set the discharge machine to function 3 and check battery set voltage.
Page 206: Battery Troubleshooting Examples
BATTERIES Battery Testing BATTERY TROUBLESHOOTING EXAMPLES The following information represents a few examples of troubleshooting battery problems. Example 1 Vehicle no. 68 was suspected of having a bad battery due to its performance. As a result, the battery charger test was performed. After a full charge, the battery charger ammeter read 8.0 amps. Next, the on-charge volt- age test was performed and the following results were recorded: BATTERY NO.
Page 207: Battery Storage
BATTERIES Battery Storage BATTERY STORAGE Read DANGER and WARNING on page 13-1. When storing batteries during the off-season or when maintaining a replacement stock, follow these guide- lines: 1. Keep the batteries clean and free of corrosion. See Battery Care on page 13-5. 2.
Page 208: Battery Tray
BATTERIES Battery Tray TYPICAL 5 PLACES Figure 13-11 Battery Tray – Carryall 2 and Carryall 6 BATTERY TRAY Battery Tray Removal Read DANGER and WARNING on page 13-1. 1. Park the vehicle on a level surface. 1. Disconnect the batteries as instructed. See WARNING on page 13-1. 2.
Page 209: Charging A Battery Pack That Has Low Voltage
BATTERIES Charging a Battery Pack that has Low Voltage ∆ 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. Follow with milk of magnesia or vegetable oil.
Page 211: Section 14 - European Powerdrive Battery Charger
SECTION 14 – EUROPEAN POWERDRIVE BATTERY CHARGER ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed space. Wear a full face shield and rubber gloves when working on or near batteries.
Page 212: General Information
20310-11 and 20310-18). Depending on the geographic region, the charger provided with your vehi- cle may be a different model. Do not attempt to service a battery charger that has not been properly identiﬁed. If a charger cannot be properly identiﬁed, contact your local Club Car dealer or distributor. 220 V...
Page 213: Powerdrive Charger Features
BATTERY WARNING LIGHT The 48-volt Club Car electric vehicle features a dash-mounted battery warning light (above the steering col- umn) which, when the vehicle is in operation, indicates low battery voltage, or, when the vehicle is being charged, indicates a charging problem.
Page 214: The Charge Circuit
EUROPEAN POWERDRIVE BATTERY CHARGER The Charge Circuit THE CHARGE CIRCUIT The vehicle charge circuit consists of the charger receptacle, receptacle fuse link, onboard computer, and the batteries. The negative terminal of the receptacle is connected to the onboard computer. The 10 gauge black wire from the onboard computer connects to the –BATT terminal on the speed controller, and the 6 gauge black wire (also on the controller –BATT terminal) goes through the onboard computer and connects to the negative (–) post of battery no.
Page 215: Charger Installation And Operation
EUROPEAN POWERDRIVE BATTERY CHARGER Charger Installation and Operation SOLID STATE ONBOARD SPEED CONTROLLER COMPUTER FUSE LINK CHARGER No.6 BLACK RECEPTACLE No.10 BLACK No.10 BLACK No.18 GRAY No.18 GRAY No.10 BLACK SENSE LEAD FUSE No.10 RED BATT – FUSE BLACK TO RED TO NEGATIVE MAIN FUSE...
Page 216 • Make sure that the AC cord provided with your charger has the proper AC plug for your location. If it does not, contact your Club Car representative to obtain the proper cord or plug. With charger DC cord disconnected, connect the power supply cord to an AC supply. See Read DANGER and WARNING on page 14-1.
Page 217 EUROPEAN POWERDRIVE BATTERY CHARGER Charger Installation and Operation connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electric Code and all local codes and ordinances. The use of an extension cord with the charger should be avoided. If an extension cord must be used, use a three-conductor no.
Page 218 Vehicles should be restricted to 40 to 50 energy units of discharge between charges until the bat- teries 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 energy units of discharge or each night in order to avoid deep discharging the batteries.
Page 219: Dc Cord And Plug Inspection
EUROPEAN POWERDRIVE BATTERY CHARGER Checking Battery Condition 2. Disconnect the AC cord from the wall outlet and connect the DC plug to the receptacle. The charger relay should close with an audible click after a 2 to 15 second delay. See following NOTE. NOTE: Monitor the charge cycle to make sure the charger turns off properly.
Page 220 EUROPEAN POWERDRIVE BATTERY CHARGER Checking Battery Condition Figure 14-8 European PowerDrive Battery Charger Page 14-10 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual...
Page 221: Troubleshooting
EUROPEAN POWERDRIVE BATTERY CHARGER Troubleshooting TROUBLESHOOTING Read DANGER and WARNING on page 14-1. ∆ 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. ∆...
Page 222 EUROPEAN POWERDRIVE BATTERY CHARGER Troubleshooting EUROPEAN POWERDRIVE BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Relay closes and transformer hums but Test Procedure 5 – Charger DC Circuit Blown charger fuse ammeter does not move Continuity Test on page 14-18. Test Procedure 4B –...
Page 223: Test Procedures
EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures EUROPEAN POWERDRIVE BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Battery trouble light illuminates for ten Test Procedure 3 – AC Power and seconds, at four second intervals (with AC power interrupted Continuity Test of AC Circuit on DC charger cord plugged in) page 14-15.
Page 224 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures Test Procedure 1 – Battery Voltage and DC Plug and Receptacle, Continued: 3.2. Check the connections of the 18 gauge gray wire from the receptacle to the sense lead fuse, and from the sense lead fuse to the onboard computer gray wire. ∆...
Page 225 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures TEST PROCEDURE 2 – ONBOARD COMPUTER Read DANGER and WARNING on page 14-1. 1. Select a second charger that is normally connected to another vehicle and is known to operate properly. Leave the AC cord of the second charger connected to the AC outlet that it normally is connected to. This will ensure that AC power is present.
Page 226 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures 5.3. With relay bypassed, there should be continuity across the AC cord blades (Figure 14-11, Page 14-16). AC plug may have different appearance depending on geographic region. Figure 14-11 AC Cord Test 6. If the circuit is not complete, check the wiring of the AC cord (16 or 17), AC charger receptacle (14), trans- former primary coil wires (21), internal AC circuit breakers (13), voltage selector switch (9), and jumper wires (Figure 14-8, Page 14-10).
Page 227 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures 5. Reverse test probes and check each diode again and note the reading (Figure 14-13, Page 14-17). A diode is designed to conduct current in one direction only. If a diode conducts current (shows continuity) in both directions, the entire heatsink with diodes must be replaced.
Page 228 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures Test Procedure 4B – Both Diodes Failed, Continued: 3. On rare occasions, both diodes may fail as a result of a lightning strike at the charging location. 4. Excessive heat due to a loose connection may also cause both fuse links to blow. Be sure fuse connec- tions are tightened to 22 in-lb (2.5 N·m).
Page 229 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures DC CORD DIODES WITH HEATSINK BLUE LIMITER BLACK BLACK BLACK SECONDARY COIL BLACK DIODE FUSE AMMETER PRIMARY COIL RELAY AC CORD SOCKET BLACK CAP. BLACK GRN/YEL RELAY BYPASS RELAY BYPASS JUMPER WIRE JUMPER WIRE CASE GROUND BLACK...
Page 230 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures Test Procedure 6 – Transformer, Continued: 4.3. Use a jumper wire with alligator clips to connect the black wire from relay terminal 2 to the black wire from relay terminal 4 (Figure 14-16, Page 14-19). 4.4.
Page 231 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures TEST PROCEDURE 8 – CONTINUITY Read DANGER and WARNING on page 14-1. AC Cord and Battery Charger AC Receptacle 1. Disconnect the AC cord from the wall outlet and the DC plug from the vehicle receptacle, then remove the charger cover.
Page 232 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures Test Procedure 8 – Continuity, Continued: 4. Using a multimeter, set for 200 Ω (ohms), place the red (+) probe on the terminal at the end of the black wire removed from relay terminal 4 (4) (Figure 14-17, Page 14-21). Test for continuity on each of the ﬂat blades and then on the round pin of the AC plug.
Page 233 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures AC Charger Receptacle 1. Disconnect the AC cord from the AC receptacle (on front of battery charger) and the incoming AC outlet. Disconnect the battery charger from the vehicle. 2. Disconnect black wire from charger relay terminal 4 (4) (Figure 14-19, Page 14-23 and Figure 14-7, Page 14-8).
Page 234 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures DC Cord 1. Disconnect the AC cord from the wall outlet and the DC plug from the vehicle receptacle, then remove the charger cover. 2. To check the continuity of the DC cord, disconnect the black wire (17) of the DC cord from the ammeter (Figure 14-20, Page 14-27).
Page 235 EUROPEAN POWERDRIVE BATTERY CHARGER Test Procedures 5. If the continuity readings agree with the chart, replace the voltage selector switch. If the continuity read- ings differ from the chart, replace the transformer. Secondary Coil 1. Disconnect both AC and DC cords and remove charger cover. 2.
Page 236: Charger Repairs
EUROPEAN POWERDRIVE BATTERY CHARGER Charger Repairs 3. Remove the black wire from terminal 2 of the relay and black wire from terminal 4 of the relay (Figure 14-7, Page 14-8). Place continuity tester leads on terminals 2 and 4 of the relay. Tester should register no continuity.
Page 237 EUROPEAN POWERDRIVE BATTERY CHARGER Charger Repairs Figure 14-20 DC Cord, Relay, and Limiter DC Cord Installation 1. Insert the leads of the new DC cord through the hole in the charger base. 2. Attach the red wire of the new DC cord to the center terminal of the heatsink and tighten the nut to 18 in-lb (2.0 N·m).
Page 238: Heatsink
EUROPEAN POWERDRIVE BATTERY CHARGER Charger Repairs HEATSINK Heatsink Removal 1. Disconnect the AC and DC cords and remove the charger cover. See WARNING on page 14-26. 2. Remove both secondary coil transformer wires (tan) from the heatsink (Figure 14-7, Page 14-8 and Figure 14-8, Page 14-10).
Page 239: Ammeter
EUROPEAN POWERDRIVE BATTERY CHARGER Charger Repairs 7. Connect the black primary coil transformer wire marked 1 to the bottom terminal of the bottom AC circuit breaker. 8. Connect each of the remaining black primary coil transformer wires marked 2, 3, 4, and 5 to the corre- sponding terminals marked on the voltage selector switch.
Page 240: Fuse Link
EUROPEAN POWERDRIVE BATTERY CHARGER Charger Repairs Figure 14-21 Ammeter Removal FUSE LINK Read DANGER and WARNING on page 14-1. Fuse Link Removal 1. Disconnect the AC and DC cords and remove the charger cover. See WARNING on page 14-26. 2. Remove the charger cover. 3.
Page 241: Voltage Suppressor
EUROPEAN POWERDRIVE BATTERY CHARGER Charger Repairs VOLTAGE SUPPRESSOR Read DANGER and WARNING on page 14-1. Voltage Suppressor Removal The voltage suppressor, which is incorporated into a wire assembly in the charger, protects the onboard com- puter by capturing very high, but very brief voltage spikes which occur due to the collapse of the electrical ﬁeld in the charger relay when the charger is disconnected from the vehicle.
Page 242: Charger Relay
EUROPEAN POWERDRIVE BATTERY CHARGER Charger Repairs CHARGER RELAY Read DANGER and WARNING on page 14-1. Charger Relay Removal 1. Disconnect the AC and DC cords and remove the charger cover. See WARNING on page 14-26. 2. Disconnect all wires from the relay (8) (Figure 14-8, Page 14-10). 3.
Page 243: Charging A Battery Pack That Has Low Voltage
EUROPEAN POWERDRIVE BATTERY CHARGER Charging a Battery Pack that has Low Voltage CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE Read DANGER and WARNING on page 14-1. If battery pack voltage is below 34 volts, the charger will not activate. The charger relay will have to be bypassed to activate the charger.
Page 244 EUROPEAN POWERDRIVE BATTERY CHARGER Charging a Battery Pack that has Low Voltage Test Procedure 8 – Continuity, Continued: 7. After one or two hours, disconnect the charger AC cord from the electrical outlet ﬁrst. Then disconnect the DC cord from the charger receptacle in the vehicle. 8.
Page 245: Battery Charger Specifications
EUROPEAN POWERDRIVE BATTERY CHARGER Battery Charger Specifications BATTERY CHARGER SPECIFICATIONS EUROPEAN POWERDRIVE EXTERNAL CHARGER European PowerDrive Battery Charger SPECIFICATIONS Model number 20310-11 20310-18 (CCI P/N) (101956201) (101956202) AC input AC voltage: 100, 200, 220, or 240 VAC (selectable) • • AC voltage (acceptable range): 95-105 95-105...
Page 247: Section 15 - Motor
SECTION 15 – MOTOR ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed space. Wear a full face shield and rubber gloves when working on or near batteries. •...
Page 248: General Information
All PowerDrive electric vehicles are equipped with PowerDrive System 48 electrical systems that utilize 48 volt DC, series wound, reversible traction motors. 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 249: Motor
MOTOR Motor 4.1. An incorrect reading from the A1 or A2 terminal indicates three possible problems: a grounded A1 or A2 terminal, a grounded wire in the brush area, or a grounded armature/commutator. An incor- rect reading for the D1 or D2 terminal indicates a possible grounded D1 or D2 terminal or ﬁeld coil. TEST PROCEDURE 2 –...
Page 250: Motor Component Testing And Inspection
MOTOR Motor Component Testing and Inspection Motor Disassembly 1. Before beginning disassembly, place match marks on the motor end shield and stator shell, then place the motor in a vice with wooden blocks as shown (Figure 15-2, Page 15-4). 2. Remove the four bolts (8) securing the end shield (10) to the stator shell (2). 3.
Page 251 MOTOR Motor Component Testing and Inspection Visual Inspection, Continued: • Burned, charred or cracked insulation • Improperly cured varnish • Thrown solder • Flared armature windings • Damaged armature core laminations • Worn, burned or glazed commutators • Dirty or oily commutators •...
Page 252: Field Windings Inspection
MOTOR Motor Component Testing and Inspection FIELD WINDINGS INSPECTION Burned or scorched insulation on the ﬁeld windings indicates the motor has overheated due to overloads or grounded or shorted coil windings. If the insulation on the ﬁeld windings is scorched, replace the motor or the stator shell assembly.
Page 253: Bearing Inspection
MOTOR Reconditioning the Motor BEARING INSPECTION 1. Using a clean cloth, wipe the carbon dust off of the bearing. Inspect the bearing by spinning it by hand and checking for both axial (A) and radial (B) play (Figure 15-7, Page 15-7). 2.
Page 254: Motor Assembly
MOTOR Motor Assembly Motor Speciﬁcations Any rework must be performed by a qualiﬁed technician. Motor service speciﬁcations are listed in the table below. ITEM SERVICE LIMIT Commutator diameter (minimum) 2.625 in. (66.675 mm) Commutator concentric with 0.001 in. (0.0254 mm) armature shaft within Limit depth of cut when 0.005 in.
Page 255 MOTOR Motor Assembly TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES Figure 15-8 Motor 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual Page 15-9...
Page 256: Motor Installation
MOTOR Motor Installation RIGGING BRUSH HOLDER SCREWS BEARING TERMINAL END SHIELD RETAINER POST MOUNTING SCREW STATOR SHELL MOUNTING BRACKET Figure 15-9 Brush Installation Figure 15-10 End Shield Installation 3. Install end shield onto the stator shell. 3.1. Attach the end shield (10) to bearing retainer (16) by aligning the two holes in the bearing retainer with the two mating holes in the end shield and installing the screws (9) (Figure 15-8, Page 15-9).
Page 257 MOTOR Motor Installation GREASE inch inch 1/8 INCH 3/8 INCH (9.5 MM) (3.1 MM) Figure 15-11 Grease on Putty Knife Figure 15-12 Application of grease to Input Shaft Grooves 1/16 Inch (1.6 mm) CHAMFER SHAFT END Figure 15-13 Clean Chamfer and Input Shaft End Figure 15-14 Gap at Motor and Transaxle 1.3.
Page 258 MOTOR Motor Installation Motor Installation, Continued: 3. Install the molded bumper. 3.1. With the ﬂat side toward the bottom of the coupling, install the molded bumper (30) into the motor coupling (Figure 15-8, Page 15-9). See following NOTE. NOTE: The motor coupling must be new and free of grease and debris. 3.2.
Page 259 MOTOR Motor Installation VIEWED FROM DRIVER SIDE Figure 15-15 Motor Installation Figure 15-16 Motor Mount 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual Page 15-13...
Page 261: Section 16 - Transaxle (Type G)
SECTION 16 – TRANSAXLE (TYPE G) ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and ﬂames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed space. Wear a full face shield and rubber gloves when working on or near batteries.
Page 262: Lubrication
TRANSAXLE (TYPE G) Lubrication • After disconnecting the batteries, discharge the controller capacitors as follows: - Turn the key switch to ON, place the Forward/Reverse handle in the REVERSE position, and wait until the reverse warning buzzer can no longer be heard. When the buzzer stops sounding, the controller is discharged.
Page 263 TRANSAXLE (TYPE G) Axle Bearing and Shaft REFERENCE MOTOR – SECTION 15 Figure 16-3 Transaxle – Type G 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual Page 16-3...
Page 264: Axle Bearing
TRANSAXLE (TYPE G) Axle Bearing and Shaft Axle Shaft and Oil Seal Removal, Continued: 2. Remove the rear wheel and brake drum. See Section 6 – Park Brake System and Wheel Brake Assemblies and Section 8 – Wheels and Tires. 3.
Page 265: Axle Bearing
TRANSAXLE (TYPE G) Transaxle ∆ 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. 3. Clean the shaft splines and then insert the shaft, splined end ﬁrst, through the seal and into the axle tube. Be careful not to damage the seal.
Page 266 TRANSAXLE (TYPE G) Transaxle Transaxle Removal, Continued: Figure 16-6 Vehicle Supported on Jack Stands 7. Disconnect the four motor wires. Use two wrenches to prevent the post from turning. 8. With a ﬂoor jack supporting the transaxle, remove lower spring shackle nuts and bolts. Position shackles so they are clear of springs (Figure 16-11, Page 16-7).
Page 267 TRANSAXLE (TYPE G) Transaxle 11. Carefully remove the motor from the transaxle. Slide the motor away from the transaxle until the motor spline becomes disengaged from the input shaft, then lift motor out. See preceding WARNING. 12. If a ﬂoor jack was used, pull ﬂoor jack from beneath the transaxle and allow the springs to rest on the ﬂoor. 13.
Page 268: Transaxle Disassembly, Inspection, And Assembly
TRANSAXLE (TYPE G) Transaxle Disassembly, Inspection, and Assembly TRANSAXLE DISASSEMBLY, INSPECTION, AND ASSEMBLY Read DANGER and WARNING on page 16-1. TRANSAXLE DISASSEMBLY AND INSPECTION 1. To detach axle tubes (14 and 35) from the transaxle housing, remove the bolts and lock washers (8 and 9) (Figure 16-3, Page 16-3).
Page 269 TRANSAXLE (TYPE G) Transaxle Disassembly, Inspection, and Assembly Transaxle Disassembly and Inspection, Continued: Figure 16-13 Separate Housing 8.2. Remove the ring gear. Retain dowel pin from between the ring gear and differential case for reas- sembly. 8.3. Separate the differential gear case housing. If necessary, reinstall 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 16-13, Page 16-9).
Page 270: Transaxle Assembly
TRANSAXLE (TYPE G) Transaxle Disassembly, Inspection, and Assembly TRANSAXLE ASSEMBLY ∆ CAUTION • Do not press against the bearing outer race. • The housing and all parts must be wiped clean and dry before reassembly. 1. If bearings (13) were removed during disassembly, install new bearings using an arbor press (Figure 16-3, Page 16-3).
Page 271: Transaxle Installation
TRANSAXLE (TYPE G) Transaxle Installation ∆ WARNING • Be sure the retaining ring is properly seated in its groove. If the ring is not properly installed, the axle assembly will separate from the transaxle and damage the axle assembly and other components.
Page 272 TRANSAXLE (TYPE G) Transaxle Installation Transaxle Installation, Continued: 7. Connect the four motor wires. Tighten the retaining nuts to 65 in-lb (7.3 N·m). Use two wrenches to pre- vent the posts from turning. See following NOTE. NOTE: If the motor wires were not tagged when disconnected, refer to the appropriate wiring diagram. See Wiring Diagrams, Section 11, Page 11-5.
Page 273 INDEX ammeter installation ..........14-29 accelerator pedal removal ............. 14-29 height adjustment ..........5-10 battery charger features ........14-3 installation ............5-3 charge circuit .......... 11-9, 14-4 removal ............. 5-2 charge interlock ..........14-3 access door charger operation ..........14-7 installation ............
Page 274 INDEX bearing, motor button, horn see motor, bearing see horn switch bed, tilt see tilt bed body, front CAUTION installation ............4-8 definition of ............1-1 removal .............. 4-7 repair ..............4-5 see communication display module brake adjustment, Carryall 1 ......6-15 charger receptacle brake adjustment, Carryall 2 and Carryall 6 ..
Page 275 INDEX drive motor testing ............11-13 see motor headlight switch electric motor installation ............. 12-20 see motor removal ............12-20 electrical component cover testing ............11-31 see component cover, electrical headlight, testing ..........11-35 electrical system ..........11-2 hitch, trailer charge circuit ...........
Page 276 INDEX periodic lubrication schedule ......10-5 wheel brake cable installation .............6-7 transaxle, type g ..........16-2 removal ............6-3 periodic service schedule .........10-3 plug diode maintenance see diode, plug batteries ............13-5 lubrication, type g transaxle ......16-2 periodic lubrication schedule ......10-5 rack and pinion periodic service schedule ........
Page 277 INDEX solenoid ............12-11 shock absorber inspection ............. 9-2 see also diode, solenoid installation ............. 9-3 see also resistor, solenoid removal ............9-2 installation ............. 12-12 switch, headlight removal ............12-11 see headlight switch specifications battery charger ..........14-35 specifications, vehicle ......... 2-1 speed controller taillight installation .............
Page 278 INDEX 4 – diodes ............14-16 water level 5 – DC circuit continuity test ......14-18 see batteries, electrolyte level wheel 6 – transformer ..........14-19 installation ............8-2 7 – battery state of charge ......14-20 removal ..............8-2 8 – continuity ..........14-21 test procedures, motor see also tire 1 –...
Page 279 2001/2002 Carryall Electric Industrial Truck Maintenance and Service Manual...
Page 284 Club Car, Inc. www.clubcar.com P . Box 204658 Phone 1.706.863.3000 Augusta, GA 30917-4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...

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Club Car CARRYALL 1 2001 Maintenance Service Manual

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