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Carryall 300 2021
Club Car Carryall 300 2021 Manuals
Manuals and User Guides for Club Car Carryall 300 2021. We have
1
Club Car Carryall 300 2021 manual available for free PDF download: Maintenance And Service Manual
Club Car Carryall 300 2021 Maintenance And Service Manual (596 pages)
Gasoline Vehicle with Kohler ECH440 Engine Electric Vehicle with ERIC Charging System
Brand:
Club Car
| Category:
Golf Cars
| Size: 38.44 MB
Table of Contents
Table of Contents
5
SECTION 1 - Safety
17
Safety Details
17
Personal Safety
17
Machine Safety
17
Information
17
General Warnings
17
Disable the Vehicle
19
Disconnect the Battery- Gasoline Vehicles
20
Connect the Battery- Gasoline Vehicles
20
Disconnect the Batteries - Electric Vehicles
21
Connect the Batteries - Electric Vehicles
21
Recycling Lead-Acid Batteries
21
International Safety Symbols on Batteries
22
SECTION 2 - Vehicle Specifications
24
Vehicle Specifications
24
E.r.I.C. Battery Charger Specifications
25
Vehicle Specifications - Gasoline Vehicles
26
SECTION 3 - General Information
29
Model Identification
29
Storage - Electric Vehicles
30
Preparing the Electric Vehicle for Extended Storage
30
Returning the Stored Electric Vehicle to Service
31
Storage - Gasoline Vehicles
32
Preparing the Gasoline Vehicle for Extended Storage
32
Returning the Stored Gasoline Vehicle to Service
33
SECTION 4 - Body and Trim
35
Cleaning the Vehicle
35
Seat Cleaning
35
Front Body Repair
36
Light Scratches
36
Abrasions and Haze
36
Large Scratches and Abrasions
36
Front Body
37
Brushguard Removal
37
Brushguard Installation
37
Cowl Removal
38
Cowl Installation
38
Grille Removal
39
Grille Installation
39
Front Bumper and Side Fender Removal
42
Front Bumper and Side Fender Installation
42
Instrument Panel Removal
43
Instrument Panel Installation
43
Dash Removal
44
Dash Installation
44
Tilt Bed
46
Tilt Bed Removal
47
Tilt Bed Installation
47
Bed Latch Assembly Removal
48
Bed Latch Assembly Installation
48
Rear Fenders and Tailskirt
50
Rear Fender and Tailskirt Removal
50
Rear Fender and Tailskirt Installation
51
Rear Triangle Reflector
52
Rear Triangle Reflector Removal
52
Rear Triangle Reflector Installation
52
Floor Mat
53
Floor Mat Removal
53
Floor Mat Installation
53
SECTION 5 - Accelerator and Brake Pedal Group
55
Brake Pedal and Park Brake (Gas and Electric Vehicles)
55
Brake Pedal Removal (Gas and Electric Vehicles)
55
Brake Pedal Installation (Gas and Electric Vehicles)
55
Park Brake Removal (Gas and Electric Vehicles)
58
Park Brake Installation (Gas and Electric Vehicles)
58
Accelerator Pedal - Gasoline Vehicles
59
Accelerator Pedal Removal - Gasoline Vehicles
59
Accelerator Pedal Installation - Gasoline Vehicles
61
Accelerator Pedal - Electric Vehicles
62
Accelerator Pedal Removal - Electric Vehicles
62
Accelerator Pedal Installation - Electric Vehicles
64
Pedal Group Adjustment - Gasoline Vehicles
64
Pedal Group Adjustment - Electric Vehicles
69
SECTION 6 - Wheel Brake Assemblies
75
General Information
75
Brake Shoe Removal
77
Brake Assembly Cleaning
79
Brake Shoe Installation
81
Brake Adjustment
83
Brake Assembly Removal and Installation
84
Brake Assembly Removal
84
Brake Assembly Installation
84
Brake Cable Removal and Installation
85
Brake Cable Removal
85
Brake Cable Installation
85
SECTION 7 - Steering and Front Suspension
87
General Information
87
Steering Wheel
87
Steering Wheel Removal
87
Steering Wheel Installation
88
Steering Column
89
Steering Column Removal
89
Steering Column Disassembly
89
Steering Column Assembly
89
Steering Column Installation
91
Steering Adjustment
92
Rack and Pinion
93
Rack and Pinion Inspection
93
Rack and Pinion Removal - Maintenance-Free Ball Joints
93
Rack and Pinion Disassembly
94
Rack and Pinion Assembly
96
Rack and Pinion Installation - Maintenance-Free Ball Joints
99
Tie Rod and Drag Link
100
Tie Rod and Drag Link Removal - Maintenance-Free Ball Joints
100
Tie Rod and Drag Link Installation - Maintenance-Free Ball Joints
100
Front Suspension
101
Lubrication
101
Wheel Alignment
101
Front Suspension Components
103
Leaf Spring Removal
103
Leaf Spring Installation
103
Kingpin and Steering Spindle Removal - Maintenance-Free Ball Joints
103
Kingpin and Steering Spindle Installation - Maintenance-Free Ball Joints
106
Delta A-Plate Removal
106
Delta A-Plate Installation
106
Shock Absorber Removal
106
Shock Absorber Installation
106
Front Wheel Bearings and Hubs
107
Front Wheel Free Play Inspection
107
Front Hub Removal
107
Front Hub Installation
107
SECTION 8 - Wheels and Tires
109
General Information
109
Wheels
109
Wheel Removal
109
Wheel Installation
109
Tires
110
Tire Removal
110
Tire Repair
110
Tire Installation
111
SECTION 9 - Rear Suspension
113
General Information
113
Shock Absorbers
113
Shock Absorber Inspection and Removal
113
Shock Absorber Installation
114
Multi-Leaf Springs
114
Multi- Leaf Spring Removal
114
Multi-Leaf Spring Installation
117
Jounce Bumpers
117
Jounce Bumper Removal
117
Jounce Bumper Installation
117
SECTION 10 - Periodic Maintenance
119
General Information
119
Pre-Operation and Daily Safety Checklist
119
Performance Inspection
119
Maintenance
121
Periodic Service Schedules
121
Periodic Lubrication Schedules
125
Air Filter
127
Air Filter Removal
127
Air Filter Installation
127
Engine Oil
128
Engine Oil Viscosity
128
Engine Oil Level Inspection
128
Engine Oil Replacement
129
Add Engine Oil
132
Refuel
133
Lift the Vehicle
134
Lift the Front of the Vehicle
134
Lift the Rear of the Vehicle
135
Lower the Front of the Vehicle
136
Lower the Rear of the Vehicle
137
Spark Plug
138
Spark Plug Removal
138
Spark Plug Inspection
139
Spark Plug Gap
139
Spark Plug Installation
140
Valve Clearance Check and Adjustment
140
SECTION 11 - Controller Diagnostic Tool (CDT)
141
General Information
142
Features
142
Plugging the CDT into the Vehicle
143
Introductory Display
143
Quick Reference Guide - Excel with ERIC Charging System
144
System Info
145
Model Number
145
Serial Number
145
Hardware Version
145
Protocol Version
145
Param Block Version
145
MFG Date Code
145
OS Version
145
SM Version
145
VCL App Version
145
Settings
146
Amp Hours
148
Access Codes
148
Vehicle ID
149
Monitor Menu
149
Batt Voltage
150
Min I
150
Signed Battery Current
150
BDI Percent
150
Speed
150
Throttle
150
Temperature
150
Arm Current
150
Field Current
150
Armature PWM
150
Field PWM
151
Speed Pulses
151
Foot Input
151
Key Input
151
Forward Input
151
Reverse Input
151
Mode Switch Input
151
Charger Inhibit
151
Main Cont Driver
151
LED Driver
151
Odometer
152
BDI Info
152
Battery Monitor
152
Charging Totals
152
Amp Hours Display
153
Lin
153
Vehicle Speeds
153
Pedal Counters
153
Fault Counters
153
Fault Count Odometers
153
Diagnostics Menu
154
Present Errors Folder
154
Fault History Folder
154
Causes of Faults
155
Fault Recovery
157
Fault Descriptions
158
Incorrect Password (OEM Access Level Only)
158
Max Password Tries (OEM Access Level Only)
158
Throttle Fault
158
Low Battery Voltage (Undervoltage)
158
Overvoltage
158
Thermal Cutback
159
Anti-Tamper Fault
159
Hpd
159
Main Drvr Overcurrent
159
Lockout Fault
159
Low SOC
159
Main Welded
160
High Speed Walkaway
160
Speed Sensor
160
Main Driver on
160
Main Coil Open
160
Main Dropout (1 or 2)
161
Motor Stall
161
Main Driver off
161
Current Sense Fault
161
M- Shorted
161
FLD (Field) Missing
162
HW Failsafe
162
Fault History
162
Clear Fault History
162
Programming
162
Cloning
163
Favorites
163
HHP Settings
163
Plot & Log
165
Plot
165
Log
165
CDT Troubleshooting
166
Connection Tests
167
SECTION 12 - Electric Vehicle - Electrical System Troubleshooting
171
General Information
171
Accessories
171
Charge Indicator Light
171
Attributes of the Excel System
171
Key Differences: Excel with ERIC Charging System Vs. Powerdrive Chargers
172
Features
172
Sonic Weld, Diode, and 10K Ohm Resistor Locations
174
Troubleshooting
175
Troubleshooting the Vehicle with the CDT
175
Troubleshooting Guide 1
175
Troubleshooting Guide 2
178
Test Procedures
182
Testing Basics
182
SECTION 13 - Electric Vehicle - Electrical Components
205
Key Switch
205
Testing the Key Switch
205
Key Switch Removal
205
Key Switch Installation
205
Forward/Neutral/Reverse Control (FNR)
206
Testing the Forward/Neutral/Reverse Control (FNR)
206
Forward/Neutral/Reverse Control (FNR) Removal
206
Forward/Neutral/Reverse Control (FNR) Installation
206
Run/Tow Switch
207
Testing the Run/Tow Switch
207
Run/Tow Switch Removal
207
Run/Tow Switch Installation
207
Motor Controller Output Regulator (MCOR)
208
Testing the MCOR
208
MCOR Removal
208
MCOR Installation
208
Reverse Buzzer
209
Reverse Buzzer Removal
209
Reverse Buzzer Installation
209
Solenoid
210
Testing the Solenoid
210
Solenoid Removal
210
Solenoid Installation
210
Speed Controller
211
Testing the Solid State Speed Controller
211
Speed Controller Removal
211
Speed Controller Installation
212
Charger Receptacle
213
Testing the Charger Receptacle
213
Charger Receptacle Inspection
213
Charger Receptacle Removal
213
Charger Receptacle Installation
213
Charge Indicator Light
214
Testing the Charge Indicator Light
214
Charge Indicator Light Removal
214
Charge Indicator Light Installation
214
DC/DC Converter
214
DC/DC Converter Removal
214
DC/DC Converter Installation
215
Fuse Block
215
Fuse Block Removal
215
Fuse Block Installation
215
Headlight Switch
216
Headlight Switch Removal
216
Headlight Switch Installation
216
Headlights
216
Headlight Bezel Removal
216
Headlight Bezel Installation
216
Headlight Bulb Removal (Halogen)
217
Headlight Bulb Installation (Halogen)
217
Headlight Bulb Removal (LED)
217
Headlight Bulb Installation (LED)
217
USB Receptacle
219
USB Receptacle Removal
219
USB Receptacle Installation
219
SECTION 14 - Electric Vehicle - Batteries
221
General Information
221
Battery Testing Basics - 8 Volt
222
Observation
222
Measuring Voltage of Battery Set
222
Battery Cell Numbering
222
Battery Testing - 8 Volt
223
Battery Regrouping
223
Battery Replacement
225
Battery Care
226
Water Quality
226
Deionizer
227
Battery Care - Vehicles Equipped with the Single-Point Watering System (SPWS)
228
Battery Care - Vehicles Without the Single-Point Watering System (SPWS)
229
Self-Discharge
230
Electrolyte Level
230
Vibration Damage
231
Single Point Watering System (SPWS)
231
Initial Maintenance of the SPWS
232
Watering Batteries with the SPWS
232
Battery Storage
234
Fleet Rotation
234
Deep-Discharge
234
Early Excessive Discharging
234
SECTION 15 - Electric Vehicle - Battery Charger
235
General Information
236
USB Service Port
237
UL and CSA Listing
237
CE Compliance
237
Plug and Receptacle
237
Charger Power Connection Fuse
237
Charger Interlock
237
AC Input Voltage Detection
238
Thermal Cutback
238
Charge Indicator Light
238
External Charger Status Indicators
238
Onboard Charger Status Indicators
239
Long-Term Storage
240
External Charger Mounting
241
AC Power Connection
242
The Charge Circuit
243
Battery Charging
244
Charging with External Charger
245
Charging with Onboard Charger
246
Algorithm
248
External Battery Charger
248
Onboard Battery Charger
253
Update Battery Charger with USB
255
Charger Maintenance
256
USB Service Port Cleaning and Care
256
Charger Troubleshooting
257
Numbering Vehicles and Chargers
257
USB Service Port
257
Incoming AC Service
257
Terminal Block Cover
258
Resetting Power - External Charger
258
Resetting Power - Onboard Charger
258
External Charger Troubleshooting Indicators
259
Onboard Charger Fault Codes
261
Test Procedures
263
External Charger Repairs
266
Terminal Block Cover Removal
266
Terminal Block Cover Installation
267
DC Cord and Strain Relief Removal
267
DC Cord and Strain Relief Installation
267
Handle Removal
267
Handle Installation
268
Foot Removal
268
Foot Installation
268
SECTION 16 - Electric Vehicle - Motor
269
General Information
269
External Motor Testing
269
Motor Removal
272
Motor Disassembly
274
Motor Component Testing and Inspection
276
Armature Inspection and Testing
276
Motor Frame and Field Windings Inspection
278
Motor Brush, Spring, and Terminal Insulator Inspection
278
Reconditioning the Motor
281
Motor Specifications
281
Motor Assembly
281
Motor Installation
283
SECTION 17 - Electric Vehicle - Transaxle
287
Lubrication
287
Axle Shaft
287
Axle Bearing
290
Transaxle
291
Transaxle Removal
291
Transaxle Disassembly, Inspection, and Assembly
294
Transaxle Disassembly and Inspection
294
Transaxle Assembly
296
Transaxle Installation
298
SECTION 18 - Gasoline Vehicle - Troubleshooting and Electrical System
299
General Information
299
Accessories
299
Low Oil Warning Light
299
Malfunction Indicator Light
300
Ground Locations
301
Features of the Electronic Fuel Injection (EFI) System
301
Troubleshooting Guide
301
Gasoline Powertrain
302
Electrical System
304
Test Procedures
305
Testing Basics
305
SECTION 19 - Gasoline Vehicle - Electrical Components
347
General Information
347
Starter/Generator
347
Starter/Generator Removal
347
Disassembly of the Starter/Generator to Service the Brushes
348
Brush Inspection and Replacement
349
Brush Spring Inspection and Replacement
349
Starter/Generator Assembly
350
Disassembly of the Starter/Generator to Service the Armature/Commutator
351
Bearing Cleaning and Inspection
352
Bearing Removal
353
Field Coil Assembly
353
Visual Inspection of Armature
353
Commutator Cleaning and Inspection
354
Armature Ground Test
355
Visual Inspection of Field Coils
356
Starter/Generator Rework
356
Starter/Generator Assembly
356
Starter/Generator Installation
359
Belt Tension Inspection for EFI Engines
360
Belt Tension Adjustment for EFI Engines
361
Belt Tension Tool Modification
364
Voltage Regulator
365
Voltage Regulator Removal
365
Voltage Regulator Installation
365
Key Switch
366
Key Switch Removal
366
Key Switch Installation
367
Maintenance/Operate Switch
368
Maintenance/Operate Switch Removal
368
Maintenance/Operate Switch Installation
368
Neutral Lockout Limit Switch
369
Neutral Lockout Limit Switch Removal
369
Neutral Lockout Limit Switch Installation
371
Solenoid
372
Solenoid Removal
372
Solenoid Installation
373
Fuse
374
Fuse Removal
375
Fuse Installation
375
Accelerator Pedal Limit Switch
376
Accelerator Pedal Limit Switch Removal
376
Accelerator Pedal Limit Switch Installation
376
Kill Limit Switch
377
Kill Limit Switch Removal
377
Kill Limit Switch Installation
377
Reverse Warning Buzzer
378
Reverse Warning Buzzer Removal
378
Reverse Warning Buzzer Installation
378
Reverse Buzzer Limit Switch
379
Reverse Buzzer Limit Switch Removal
379
Reverse Buzzer Limit Switch Installation
379
Low Oil Warning Light
380
Low Oil Warning Light Removal
380
Low Oil Warning Light Installation
380
Malfunction Indicator Light
381
Malfunction Indicator Light Removal
381
Malfunction Indicator Light Installation
381
Fuel Gauge/Hour Meter
381
General Information
381
Fuel Gauge/Hour Meter Removal
382
Fuel Gauge/Hour Meter Installation
382
Fuel Level Sending Unit
382
Voltage Limiter
383
Voltage Limiter Removal
383
Voltage Limiter Installation
383
Headlight Switch
384
Headlight Switch Removal
384
Headlight Switch Installation
384
Headlights
385
Headlight Bezel Removal
385
Headlight Bezel Installation
385
Halogen Headlight Bulb Removal
386
Halogen Headlight Bulb Installation
386
Halogen Headlight Lens Removal
387
Halogen Headlight Lens Installation
387
LED Headlight Removal
388
LED Headlight Installation
388
Battery
388
General Information
389
Preventive Maintenance
389
Self-Discharge
389
Vibration Damage
390
Battery Removal
390
Charging the Battery
390
Battery Installation
390
Battery Storage
391
Charging a Dead Battery
391
Oxygen Sensor
392
Oxygen Sensor Removal
392
Oxygen Sensor Installation
392
Ground Cables
392
Charging Dioded (Key-Start Only)
393
Charging Diode Removal
393
Charging Diode Installation
394
USB Receptacle
395
USB Receptacle Removal
395
USB Receptacle Installation
395
SECTION 20 - Gasoline Vehicle - Engine
397
General Information
397
Before Servicing
397
Louver Arm
398
Engine Removal
399
Engine Installation
402
Snubber
405
Snubber Removal
405
Snubber Installation
405
SECTION 21 - Gasoline Vehicle - Fuel System
407
General Information
407
EFI System Features/Specifications
407
Engine Control Linkages
407
General Information
408
Ground Speed
408
Accelerator Rod
408
Governor Cable
411
Accelerator Cable
413
Closed Throttle or Idle Adjustment - Pedal-Start Vehicles
416
Closed Throttle or Idle Adjustment - Key-Start Vehicles
416
How to Measure Ground Speed
416
Engine RPM Adjustment
416
Air Intake System
418
Air Cleaner Removal
419
Air Cleaner Installation
419
Relieving Fuel Pressure
420
To Relieve Fuel Pressure
420
Fuel Line
420
Fuel Line Removal
421
Fuel Line Installation
422
Fuel Pump Module
424
General Information
424
Fuel Pump Module Removal
425
Fuel Pump Module Installation
426
Fuel Tank
427
General Information
427
Fuel Tank Removal
428
Fuel Tank Disposal
429
Fuel Tank Storage
429
Fuel Tank Installation
430
Fuel Filter
431
General Information
431
Fuel Filter Removal
431
Fuel Filter Installation
431
SECTION 22 - Gasoline Vehicle - Exhaust System
433
Muffler
433
Muffler Removal
433
Muffler Installation
434
SECTION 23 - Gasoline Vehicle - Clutches
435
General Information
435
Troubleshooting
435
Drive Belt
437
Drive Belt Removal
437
Drive Belt Installation
437
Drive Clutch
438
Drive Clutch Removal
439
Drive Clutch Cleaning and Inspection
440
Drive Clutch Disassembly
441
Inspection of Drive Clutch Parts
443
Drive Clutch Assembly
444
Drive Clutch Installation
445
Driven Clutch
446
Driven Clutch Removal
447
Driven Clutch Disassembly
447
Driven Clutch Inspection
450
Driven Clutch Assembly
450
Driven Clutch Installation
453
SECTION 24 - Gasoline Vehicle - Transaxle
455
General Information
455
Forward/Neutral/Reverse Control (FNR)
455
Maintenance/Operate Switch
455
Governor System
456
Transaxle Service
456
Lubrication
456
Tools Required for this Section
457
Rear Hubs
458
Rear Hub Removal
458
Rear Hub Installation
458
Axle Tubes, Axle Shafts, Differential Guard, and Wheel Bearings
460
Differential Guard Removal
460
Differential Guard Installation
460
Axle Tube and Axle Shaft Removal
461
Axle Tube and Axle Shaft Installation
462
Rear Wheel Bearing Removal
462
Rear Wheel Bearing Installation
463
Axle Shaft Oil Seal Removal
463
Axle Shaft Oil Seal Installation
463
Transaxle Removal
464
Transaxle Installation
468
Shifter Cable
468
Shifter Cable Removal
468
Shifter Cable Installation
469
Shifter Cable Adjustment
469
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