Club Car Carryall 500 Manuals

Club Car Carryall 500 Manuals

Manuals and User Guides for Club Car Carryall 500. We have 2 Club Car Carryall 500 manuals available for free PDF download: Maintenance And Service Manual, Owner's Manual

Club Car Carryall 500 Maintenance And Service Manual

Club Car Carryall 500 Maintenance And Service Manual (456 pages)

Brand: Club Car | Category: Golf Cars | Size: 28 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
SECTION 2 - Vehicle Specifications
24
- Vehicle Specifications
  24
  - Quiq Battery Charger Specifications
    25
  - Vehicle Specifications - Gasoline Vehicles
    26
SECTION 3 - General Information
29
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
  - Touch-Up Paint Color Chart
    36
- Front Body
  37
  - Heavy Duty Bumper Removal
    37
  - Heavy Duty Bumper Installation
    39
  - Cowl Removal
    39
  - Cowl Installation
    39
  - Grille Removal
    40
  - Grille Installation
    41
  - Front Bumper and Side Fender Removal
    43
  - Front Bumper and Side Fender Installation
    43
  - Instrument Panel Removal
    44
  - Instrument Panel Installation
    44
  - Dash Removal
    45
  - Dash Installation
    45
- Tilt Bed
  47
  - Tilt Bed Removal
    47
  - Tilt Bed Installation
    47
  - Bed Latch Assembly Removal
    49
  - Bed Latch Assembly Installation
    49
- Rear Fenders and Tailskirt
  51
  - Rear Fender and Tailskirt Removal
    51
  - Rear Fender and Tailskirt Installation
    52
- Electric Bed Lift
  53
  - Electric Bed Lift Removal
    53
  - Electric Bed Lift Installation
    53
- Floor Mat
  56
  - Floor Mat Removal
    56
  - Floor Mat Installation
    56
- Trailer Hitch
  56
  - Trailer Hitch Removal
    56
  - Trailer Hitch Installation
    56
SECTION 5 - Accelerator and Brake Pedal Group
57
SECTION 6 - Wheel Brake Assemblies
77
- General Information
  77
- Brake Shoe Removal
  77
- Brake Assembly Cleaning
  79
- Brake Shoe Installation
  81
- Brake Adjustment
  82
  - Brake Cluster Adjustment
    83
  - Brake Cable Equalization
    85
  - Final Brake Cluster Adjustment
    86
  - Test Drive Vehicle
    86
- Brake Cluster Removal and Installation
  87
- Front Brake Cables
  90
  - Front Brake Cable Removal
    91
  - Front Brake Cable Installation
    91
- Rear Brake Cables
  92
  - Rear Brake Cable Removal
    93
  - Rear Brake Cable Installation
    93
SECTION 7 - Steering and Front Suspension
95
- General Information
  95
- Steering Wheel
  95
  - Steering Wheel Removal
    95
  - Steering Wheel Installation
    96
- Steering Column
  97
  - Steering Column Removal
    98
  - Steering Column Disassembly
    98
  - Steering Column Assembly
    98
  - Steering Column Installation
    99
- Steering Adjustment
  100
- Rack and Pinion
  101
- Tie Rod and Drag Link
  108
  - Tie Rod and Drag Link Removal - Maintenance-Free Ball Joints
    108
  - Tie Rod and Drag Link Installation - Maintenance-Free Ball Joints
    108
- Front Suspension
  109
  - Lubrication
    109
  - Wheel Alignment
    109
- Front Suspension Components
  111
- Front Wheel Bearings and Hubs
  115
SECTION 8 - Wheels and Tires
117
- General Information
  117
- Wheels
  117
  - Wheel Removal
    117
  - Wheel Installation
    117
- Tires
  118
  - Tire Removal
    118
  - Tire Repair
    118
  - Tire Installation
    119
SECTION 9 - Rear Suspension
121
- General Information
  121
- Shock Absorbers
  121
  - Shock Absorber Inspection and Removal
    121
  - Shock Absorber Installation
    121
- Multi-Leaf Springs
  122
  - Multi-Leaf Spring Removal
    122
  - Multi-Leaf Spring Installation
    123
SECTION 10 - Periodic Maintenance
125
- General Information
  125
- Pre-Operation and Daily Safety Checklist
  125
  - Performance Inspection
    125
- Maintenance
  127
- Periodic Service Schedules
  128
- Periodic Lubrication Schedules
  131
SECTION 11 - Controller Diagnostic Tool (CDT)
133
- General Information
  134
  - Features
    134
- Plugging the CDT into the Vehicle
  134
  - Introductory Display
    135
- Quick Reference Guide - IQ Plus with Quiq Charger
  136
- System Info
  137
  - Model Number
    137
  - Amp Hours Display
    147
  - Lin
    147
  - Diagnostics Menu
    149
  - Present Errors Folder
    149
  - Fault History Folder
    149
  - System Faults
    149
  - Fault Recovery
    151
  - Fault Descriptions
    152
  - Throttle Fault 1
    152
  - 02 Low Battery Voltage
    152
  - 03 Overvoltage
    152
  - 04 Thermal Cutback
    152
  - 06 Hpd
    152
  - 07 Main Welded
    152
  - 08 Relay Welded
    152
  - 09 Speed Sensor
    152
  - 10 Main Driver on
    152
  - 12 Main Dropout
    153
  - 13 Motor Stall
    153
  - 14 Main Driver off
    153
  - 15 Relay Dnc
    153
  - 16 Keyswitch Sro
    153
  - 17 Current Sense
    153
  - 18 M- Shorted
    153
  - 20 Driver Overcurrent
    153
  - 21 Precharge Fault
    153
  - 22 Field Missing
    153
  - 25 Incorrect Password
    154
  - 26 Circuit Brkr Open
    154
  - 27 Max Password Tries
    154
  - 29 Relay Drvr off
    154
  - 30 Relay Coil Fault
    154
  - Anti-Tamper Fault
    154
  - Lockout Fault
    154
  - Low SOC
    154
  - Main CONT DNC
    155
  - Main Coil Fault
    155
  - Proc/Wiring
    155
  - Open Armature
    155
  - Incorrect Password (OEM Access Level Only)
    155
  - Fault History
    155
  - Clearing Fault History
    155
  - Programming
    156
  - Cloning
    156
  - Favorites
    156
  - HHP Settings
    157
  - Plot & Log
    158
  - Plot
    158
  - Log
    158
  - CDT Troubleshooting
    159
  - Connection Tests
    160
  - SECTION 12 - Electrical System Troubleshooting: IQ Plus Electric Vehicles
    163
  - General Information
    163
  - Accessories
    163
  - Charge Indicator Light
    163
  - Key Differences: IQ Plus with Quiq Charger Vs. IQ Plus Charger
    163
  - Features
    164
  - Wiring Diagrams
    166
  - Troubleshooting
    170
  - Troubleshooting the Vehicle with the CDT
    170
  - Troubleshooting Guide 1
    171
  - Troubleshooting Guide 2
    174
  - Test Procedures
    176
  - Testing Basics
    176
  - SECTION 13 - Electrical Components: IQ Plus Electric Vehicles
    207
  - Key Switch
    207
  - Testing the Key Switch
    207
  - Key Switch Removal
    207
  - Key Switch Installation
    207
  - Forward/Reverse Rocker Switch
    209
  - Forward/Reverse Rocker Switch Removal
    209
  - Forward/Reverse Rocker Switch Installation
    209
  - Run/Tow Switch
    209
  - Run/Tow Switch Removal
    210
  - Run/Tow Switch Installation
    210
  - Circuit Breaker
    210
  - Circuit Breaker Removal
    210
  - Circuit Breaker Installation
    210
  - Motor Controller Output Regulator (MCOR)
    212
  - Testing the MCOR
    212
  - MCOR Removal
    212
  - MCOR Installation
    212
  - Reverse Buzzer
    213
  - Reverse Buzzer Removal
    213
  - Reverse Buzzer Installation
    213
  - Speed Controller Cover
    213
  - Removing the Speed Controller Cover
    213
  - Installing the Speed Controller Cover
    213
  - Solenoid
    214
  - Solenoid Removal
    214
  - Solenoid Installation
    214
  - Speed Controller
    215
  - Speed Controller Removal
    215
  - Speed Controller Installation
    215
  - Charge Indicator Light
    217
  - Testing the Charge Indicator Light
    217
  - Charge Indicator Light Removal
    217
  - Charge Indicator Light Installation
    217
  - SECTION 14 - Batteries: IQ Plus Electric Vehicles
    219
  - General Information
    219
  - Battery Testing Basics - 6 Volt
    220
  - Observation
    220
  - Measuring Voltage of Battery Set
    220
  - Battery Cell Numbering
    220
  - Battery Testing - 6 Volt
    221
  - Battery Regrouping
    221
  - Battery Replacement
    223
  - Battery Care
    224
  - Water Quality
    224
  - Deionizer
    225
  - Battery Care - Vehicles Equipped with the Single-Point Watering System (SPWS)
    226
  - Battery Care - Vehicles Without the Single-Point Watering System (SPWS)
    227
  - Self-Discharge
    228
  - Electrolyte Level
    228
  - Vibration Damage
    229
  - Single Point Watering System (SPWS)
    229
  - Initial Maintenance of the SPWS
    229
  - Watering Batteries with the SPWS
    229
  - Battery Storage
    231
  - Fleet Rotation
    231
  - Deep-Discharge
    232
  - Early Excessive Discharging
    232
  - SECTION 15 - Quiq High Frequency Charger
    233
  - General Information
    233
  - Features
    233
  - UL and CSA Listing
    233
  - CE Compliance
    233
  - IP (Ingress Protection) Rating
    233
  - How to Identify Charge Algorithm Number
    234
  - How to Change the Algorithm
    235
  - The Charge Circuit
    235
  - Onboard Charger Operation
    236
  - Charger Displays
    238
  - AC Power Connection
    240
  - Charging Batteries
    240
  - Maintenance
    241
  - Troubleshooting
    242
  - Test Procedures
    243
  - Charger Repairs
    244
  - Onboard Charger Removal and Installation
    244
  - Onboard Charger Removal
    244
  - Onboard Charger Installation
    245
  - SECTION 16 - Motor (Model DA5-4006): Electric Vehicles
    247
  - General Information
    247
  - External Motor Testing
    247
  - Motor Removal
    248
  - Motor Disassembly
    250
  - Motor Component Testing and Inspection
    253
  - Armature Inspection and Testing
    253
  - Motor Frame and Field Windings Inspection
    254
  - Motor Brush, Spring, and Terminal Insulator Inspection
    254
  - Reconditioning the Motor
    257
  - Motor Specifications
    257
  - Motor Assembly
    257
  - Motor Installation
    259
  - SECTION 17 - Transaxle: Electric Vehicles
    263
  - Lubrication
    263
  - Axle Bearing and Shaft
    263
  - Axle Shaft
    263
  - Axle Bearing
    266
  - Transaxle
    267
  - Transaxle Removal
    267
  - Transaxle Disassembly, Inspection, and Assembly
    270
  - Transaxle Disassembly and Inspection
    270
  - Transaxle Assembly
    272
  - Transaxle Installation
    274
  - SECTION 18 - Troubleshooting and Electrical System: Pedal-Start Gas Vehicle
    275
  - General Information
    275
  - Accessories
    275
  - Low Oil Warning Light
    275
  - Ground Locations
    275
  - Features of the Electronic Fuel Injection (EFI) System
    276
  - Troubleshooting Guide
    276
  - ECU Error Codes (Displayed by the Low Oil Warning Light)
    276
  - Gasoline Powertrain
    278

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Club Car Carryall 500 Owner's Manual

Club Car Carryall 500 Owner's Manual (89 pages)

Brand: Club Car | Category: Golf Cars | Size: 8 MB

Table of Contents

Maintenance Items
4
Table of Contents
5
Technical Publication Customer Satisfaction Survey
6
Electric Carryall 500
7
Safety Decal Identification
7
Electric Carryall 550
8
Practice Safety
17
Proposition 65 - State of California
17
Safety Details
18
General Warnings
18
General Information
23
- Carryall 550 Wheels
  24
- Serial Number Decal
  24
Model Identification
24
Controls and Indicators
24
- Key Switch
  25
- Forward/Reverse Control
  25
- Electric Vehicles
  25
- Gasoline Vehicles
  25
- Charging Confirmation
  26
- Battery Low State-Of-Charge Warning
  26
- Charge Indicator Light
  26
- Headlight Control
  26
- Low Oil Warning Light
  27
- Fuel Gauge/Hour Meter
  27
- Electric Bed Lift
  27
- 12-Volt Power Point
  27
- Accelerator Pedal
  28
- Brake Pedal
  29
- Park Brake Pedal
  29
- Accelerator and Brake Pedals
  29
- Tow/Run Switch
  30
- Park Brake
  30
- Circuit Breaker
  31
- Neutral Lockout Switch
  31
- Prop Rod
  32
- Bed Latch
  32
Pre-Operation and Daily Safety Checklist
33
Performance Inspection
34
Driving Instructions
35
- Starting the Vehicle
  36
- Stopping the Vehicle
  37
- Parking and Leaving the Vehicle
  37
- Occupant Capacity
  38
- Cargo Capacity
  38
Loading and Unloading
38
Vehicle Load Capacities
38
- Gross Trailer Weight
  39
- Vehicle Rated Capacity
  39
- Vehicle Combination Rated Capacity
  39
- Maximum Gross Vehicle Weight
  39
- Vehicle Load Capacity
  40
Towing with the Vehicle
40
Storage – Electric Vehicles
41
Transporting on a Trailer
41
Maintenance
45
Periodic Service Schedule – Electric Vehicles
46
Periodic Service Schedules
46
Periodic Lubrication Schedule – Electric Vehicles
49
Periodic Lubrication Schedules
49
- Water Quality
  51
- Batteries – Electric Vehicles
  51
- Preferred Methods
  52
- Deionizer Systems
  52
- Alternate Methods
  52
- Battery Care
  53
- Establishing the Watering Interval for New Vehicles
  54
- Single-Point Watering System (SPWS) Maintenance
  54
- Electric Battery Electrolyte Level
  55
Battery Charger, Quiq™ - Electric Vehicle
55
Single Point Watering System (Spws)
61
- Connecting Hose with Filter to Water Source
  62
- Refilling the Batteries
  62
- Battery – Gasoline Vehicle
  63
- Dust Cap
  63
- Side-Post Gasoline Vehicle Battery
  64
- Electrolyte Level for Side-Post Battery
  64
- Engine Oil Level Check
  65
- Top-Post Gasoline Vehicle Battery
  65
- Engine Oil – Gasoline Vehicle
  65
- Engine Oil Change
  66
- Engine Oil Drain Plug and Pan
  67
- Fueling Instructions – Gasoline Vehicle
  68
- Oil Viscosity Chart
  68
- Fuel Tank
  69
Cleaning the Vehicle
69
Accessories
70
Subsequent Owner Registration
70
Vehicle Specifications – Electric Vehicles
71
Vehicle Specifications
71
- Quiq Battery Charger Specifications
  72
- Vehicle Specifications – Gasoline Vehicles
  74
Warranties
76
EC Declaration of Conformity
84

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