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Carryall 550 2015
Club Car Carryall 550 2015 Manuals
Manuals and User Guides for Club Car Carryall 550 2015. We have
1
Club Car Carryall 550 2015 manual available for free PDF download: Maintenance And Service Manual
Club Car Carryall 550 2015 Maintenance And Service Manual (460 pages)
Gasoline Vehicle with Subaru EX40 Engine Electric Vehicle with QuiQ Charger
Brand:
Club Car
| Category:
Golf Cars
| Size: 65.43 MB
Table of Contents
Table of Contents
5
Section 1 - Safety
17
Safety Details
17
General Warnings
17
Disabling the Vehicle
20
Disconnecting the Batteries - Electric Vehicles
20
Connecting the Batteries - Electric Vehicles
20
Disconnecting the Battery - Gasoline Vehicles
20
Connecting the Battery - Gasoline Vehicles
20
Recycling Lead-Acid Batteries
21
International Safety Symbols on Batteries
22
Section 2 - Vehicle Specifications
23
Vehicle Specifications
23
Vehicle Specifications - Electric Vehicles
23
Quiq Battery Charger Specifications
25
Vehicle Specifications - Gasoline Vehicles
26
Section 3 - General Information
29
Carryall 550 Wheels
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
Touch-Up Paint Color Chart
37
Front Body
38
Heavy Duty Bumper Removal
38
Heavy Duty Bumper Installation
40
Cowl Removal
40
Cowl Installation
40
Grille Removal
41
Grille Installation
43
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
54
Electric Bed Lift Installation
54
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
Brake Pedal and Park Brake (Gas and Electric Vehicles)
57
Brake Pedal Removal (Gas and Electric Vehicles)
57
Brake Pedal Installation (Gas and Electric Vehicles)
57
Park Brake Removal (Gas and Electric Vehicles)
60
Park Brake Installation (Gas and Electric Vehicles)
60
Accelerator Pedal - Gasoline Vehicles
61
Accelerator Pedal Removal - Gasoline Vehicles
61
Accelerator Pedal Installation - Gasoline Vehicles
62
Accelerator Pedal - Electric Vehicles
63
Accelerator Pedal Removal - Electric Vehicles
63
Accelerator Pedal Installation - Electric Vehicles
66
Pedal Group Adjustment - Gasoline Vehicles
66
Pedal Group Adjustment - Electric Vehicles
71
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 Cluster Removal
87
Front Brake Cluster Installation
87
Rear Brake Cluster Removal
89
Rear Brake Cluster Installation
89
Front Brake Cables
90
Front Brake Cable Removal
90
Front Brake Cable Installation
90
Rear Brake Cables
92
Rear Brake Cable Removal
92
Rear Brake Cable Installation
92
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
Rack and Pinion Inspection
101
Rack and Pinion Removal - Maintenance-Free Ball Joints
101
Rack and Pinion Disassembly
102
Rack and Pinion Assembly
104
Rack and Pinion Installation - Maintenance-Free Ball Joints
106
Tie Rod and Drag Link
107
Tie Rod and Drag Link Removal - Maintenance-Free Ball Joints
107
Tie Rod and Drag Link Installation - Maintenance-Free Ball Joints
107
Front Suspension
108
Lubrication
108
Wheel Alignment
108
Front Suspension Components
110
Leaf Spring Removal
110
Leaf Spring Installation
110
Kingpin and Steering Spindle Removal - Maintenance-Free Ball Joints
110
Kingpin and Steering Spindle Installation - Maintenance-Free Ball Joints
113
Delta A-Plate Removal
113
Delta A-Plate Installation
113
Shock Absorber Removal
113
Shock Absorber Installation
113
Front Wheel Bearings and Hubs
114
Front Wheel Free Play Inspection
114
Front Hub and Wheel Bearings Removal
114
Front Hub and Wheel Bearings Installation
115
Section 8 - Wheels and Tires
117
General Information
117
Wheels
117
Wheel Removal
117
Wheel Installation
117
Tires
119
Tire Removal
119
Tire Repair
119
Tire Installation
120
Section 9 - Rear Suspension
123
General Information
123
Shock Absorbers
123
Shock Absorber Inspection and Removal
123
Shock Absorber Installation
124
Multi-Leaf Springs
126
Multi-Leaf Spring Removal
126
Multi-Leaf Spring Installation
127
Section 10 - Periodic Maintenance
129
General Information
129
Pre-Operation and Daily Safety Checklist
129
Performance Inspection
130
Maintenance
131
Periodic Service Schedules
132
Periodic Lubrication Schedules
135
Section 11 - Controller Diagnostic Tool (Cdt)
137
General Information
138
Features
138
Plugging the CDT into the Vehicle
138
Introductory Display
139
Quick Reference Guide - IQ Plus with Quiq Charger
140
System Info
141
Model Number
141
Serial Number
141
Hardware Version
141
Protocol Version
141
Param Block Version
141
MFG Date Code
141
OS Version
141
SM Version
142
VCL App Version
142
Parameters
142
Settings
142
Amp Hours
145
Access Codes
145
Vehicle ID
146
Monitor Menu
146
Speed in
146
Throttle
146
Batt Voltage
146
Heatsink Temp
147
Mode
147
Arm Current
147
Field Current
147
Arm PWM
147
Field PWM
147
Foot Input
147
Key Input
147
Forward Input
148
Reverse Input
148
Mode Switch
148
WK Away Relay
148
Main Cont
148
Password Tries (OEM Access Level Only)
148
Cir BRKR Open
148
THRTL Fault
149
Undervoltage
149
Overvoltage
149
Temp Cutback
149
Hpd
149
Main Welded
149
Relay Welded
149
SPD Sensor
149
Main DRV on
149
Main Coil OPN
150
Main Dropout
150
Motor Stall
150
Main DRVR off
150
Relay DNC
150
Current Sense
150
M-Shorted
150
Relay Coil
150
Precharge
150
FLD Missing
151
HW Failsafe
151
DRVR Overcur
151
RLY DRVR on
151
RLY DRVR off
151
Min I
151
Signed Battery Current
151
BDI Percent
151
Charger Inhibit
151
LED Driver
152
Odometer
152
BDI Info
152
Battery Monitor
152
Charging Totals
152
Amp Hours Display
153
Lin
153
Diagnostics Menu
154
Present Errors Folder
154
Fault History Folder
154
System Faults
154
Fault Recovery
156
Fault Descriptions
157
Throttle Fault 1
157
02 Low Battery Voltage
157
03 Overvoltage
157
04 Thermal Cutback
157
06 Hpd
157
07 Main Welded
157
08 Relay Welded
157
09 Speed Sensor
158
10 Main Driver on
158
11 Main Coil Open
158
12 Main Dropout
158
13 Motor Stall
158
14 Main Driver off
158
15 Relay Dnc
158
16 Keyswitch Sro
158
17 Current Sense
159
18 M- Shorted
159
20 Driver Overcurrent
159
21 Precharge Fault
159
22 Field Missing
159
23 Relay Driver on
159
24 Hw Failsafe
159
25 Incorrect Password
159
26 Circuit Brkr Open
160
27 Max Password Tries
160
29 Relay Drvr off
160
30 Relay Coil Fault
160
Anti-Tamper Fault
160
Lockout Fault
160
Low SOC
160
Main CONT DNC
161
Main Coil Fault
161
Proc/Wiring
161
Open Armature
161
Incorrect Password (OEM Access Level Only)
161
Fault History
161
Clearing Fault History
162
Programming
163
Cloning
163
Favorites
163
HHP Settings
164
Plot & Log
165
Plot
165
Log
165
CDT Troubleshooting
166
Connection Tests
167
Section 12 - Electrical System Troubleshooting: Iq Plus Electric Vehicles
171
General Information
171
Accessories
171
Charge Indicator Light
171
Key Differences: IQ Plus with Quiq Charger Vs. IQ Plus Charger
171
Features
172
Wiring Diagrams
174
Troubleshooting
178
Troubleshooting the Vehicle with the CDT
178
Troubleshooting Guide 1
179
Troubleshooting Guide 2
182
Test Procedures
184
Testing Basics
184
Section 13 - Electrical Components: Iq Plus Electric Vehicles
215
Key Switch
215
Testing the Key Switch
215
Key Switch Removal
215
Key Switch Installation
215
Forward/Reverse Rocker Switch
217
Forward/Reverse Rocker Switch Removal
217
Forward/Reverse Rocker Switch Installation
217
Tow/Run Switch
217
Tow/Run Switch Removal
218
Tow/Run Switch Installation
218
Circuit Breaker
218
Circuit Breaker Removal
218
Circuit Breaker Installation
218
Motor Controller Output Regulator (MCOR)
220
Testing the MCOR
220
MCOR Removal
220
MCOR Installation
221
Reverse Buzzer
221
Reverse Buzzer Removal
221
Reverse Buzzer Installation
221
Speed Controller Cover
221
Removing the Speed Controller Cover
221
Installing the Speed Controller Cover
222
Solenoid
222
Solenoid Removal
222
Solenoid Installation
222
Speed Controller
223
Speed Controller Removal
223
Speed Controller Installation
223
Charge Indicator Light
225
Testing the Charge Indicator Light
225
Charge Indicator Light Removal
225
Charge Indicator Light Installation
225
Section 14 - Batteries: Iq Plus Electric Vehicles
227
General Information
227
Battery Testing Basics - 6 Volt
228
Observation
228
Measuring Voltage of Battery Set
228
Battery Cell Numbering
228
Battery Testing - 6 Volt
229
Battery Regrouping
229
Battery Replacement
231
Battery Care
232
Water Quality
232
Deionizer
233
Battery Care - Vehicles Equipped with the Single-Point Watering System (SPWS)
234
Battery Care - Vehicles Without the Single-Point Watering System (SPWS)
235
Self-Discharge
236
Electrolyte Level
236
Vibration Damage
237
Single Point Watering System (SPWS)
237
Initial Maintenance of the SPWS
237
Watering Batteries with the SPWS
237
Battery Storage
239
Fleet Rotation
239
Deep-Discharge
240
Early Excessive Discharging
240
Section 15 - Quiq High Frequency Charger
241
General Information
241
Features
241
UL and CSA Listing
241
CE Compliance
242
IP (Ingress Protection) Rating
242
How to Identify Charge Algorithm Number
242
The Charge Circuit
243
Onboard Charger Operation
243
Charger Displays
245
AC Power Connection
247
Charging Batteries
247
Maintenance
248
Troubleshooting
249
Test Procedures
250
Charger Repairs
251
Onboard Charger Removal and Installation
251
Onboard Charger Removal
251
Onboard Charger Installation
252
Section 16 - Motor (Model Da5-4006): Electric Vehicles
253
General Information
253
External Motor Testing
253
Motor Removal
254
Motor Disassembly
256
Motor Component Testing and Inspection
259
Armature Inspection and Testing
259
Motor Frame and Field Windings Inspection
260
Motor Brush, Spring, and Terminal Insulator Inspection
260
Reconditioning the Motor
263
Motor Specifications
263
Motor Assembly
263
Motor Installation
265
Section 17 - Transaxle: Electric Vehicles
269
Lubrication
269
Axle Bearing and Shaft
269
Axle Shaft
269
Axle Bearing
272
Transaxle
273
Transaxle Removal
273
Transaxle Disassembly, Inspection, and Assembly
275
Transaxle Disassembly and Inspection
275
Transaxle Assembly
277
Transaxle Installation
279
Section 18 - Troubleshooting and Electrical System: Pedal-Start Gas Vehicle
281
General Information
281
Accessories
281
Low Oil Warning Light
281
Ground Locations
282
Features of the Electronic Fuel Injection (EFI) System
282
Troubleshooting Guide
282
ECU Error Codes (Displayed by the Low Oil Warning Light)
282
Gasoline Powertrain
283
Wiring Diagrams
288
Electrical System
293
Test Procedures
294
Testing Basics
294
Section 19 - Troubleshooting and Electrical System: Key-Start Gas Vehicle
325
General Information
325
Wiring Diagrams
326
Test Procedures
330
Section 20 - Electrical Components: Pedal-Start Gas Vehicle
335
Starter/Generator
335
Starter/Generator Removal
335
Disassembly of the Starter/Generator to Service the Brushes
335
Brush Inspection and Replacement
336
Brush Spring Inspection and Replacement
336
Starter/Generator Assembly
337
Disassembly of the Starter/Generator to Service the Armature/Commutator
338
Bearing Cleaning and Inspection
338
Bearing Removal
339
Field Coil Removal
339
Visual Inspection of Armature
340
Commutator Cleaning and Inspection
340
Armature Ground Test
341
Visual Inspection of Field Coils
342
Starter/Generator Rework
342
Starter/Generator Assembly
342
Starter/Generator Installation
343
Belt Tension Adjustment
345
Voltage Regulator
346
Voltage Regulator Removal
346
Voltage Regulator Installation
346
Engine Control Unit (ECU)
347
Engine Control Unit Removal
347
Engine Control Unit Installation
347
Key Switch
347
Key Switch Removal
348
Key Switch Installation
348
Maintenance/Operate Switch
349
Maintenance/Operate Switch Removal
349
Maintenance/Operate Switch Installation
349
Neutral Lockout Limit Switch
349
Neutral Lockout Limit Switch Removal
349
Neutral Lockout Limit Switch Installation
350
Solenoid
350
Solenoid Removal
350
Solenoid Installation
350
Fuse
351
Fuse Removal
351
Fuse Installation
351
Kill Limit Switch
352
Kill Limit Switch Removal
352
Kill Limit Switch Installation
352
Reverse Warning Buzzer
353
Reverse Warning Buzzer Removal
353
Reverse Warning Buzzer Installation
353
Reverse Buzzer Limit Switch
355
Reverse Buzzer Limit Switch Removal
355
Reverse Buzzer Limit Switch Installation
355
Low Oil Warning Light
357
Low Oil Warning Light Removal
357
Low Oil Warning Light Installation
357
Fuel Gauge/Hour Meter
357
General Information
357
Fuel Gauge/Hour Meter Removal
358
Fuel Gauge/Hour Meter Installation
358
Fuel Level Sending Unit
358
Oil Level Sensor
358
Oil Level Sensor Removal
358
Oil Level Sensor Installation
359
Voltage Limiter
359
Voltage Limiter Removal
359
Voltage Limiter Installation
359
Headlight Switch
360
Headlight Switch Removal
360
Headlight Switch Installation
360
Headlights
361
Headlight Bezel Removal
361
Headlight Bezel Installation
361
Headlight Bulb Removal (Halogen)
361
Headlight Bulb Installation (Halogen)
361
Headlight Bulb Removal (LED)
362
Headlight Bulb Installation (LED)
362
Battery
364
General Information
364
Testing the Battery
364
Preventive Maintenance
365
Water Level
365
Self-Discharge
365
Vibration Damage
366
Mineral Content
366
Battery Removal
368
Charging the Battery
368
Battery Installation
368
Battery Storage
369
Charging a Dead Battery
369
Ground Cables
369
Section 21 - Electrical Components: Key-Start Gas Vehicle
371
General Information
371
Key Switch
371
Key Switch Removal
372
Key Switch Installation
372
Maintenance/Operate Switch
373
Maintenance/ Operate Switch Removal
373
Maintenance/Operate Switch Installation
373
Solenoid
373
Solenoid Removal
373
Solenoid Installation
373
Charging Diode
374
Charging Diode Removal
374
Charging Diode Installation
375
Section 22 - Engine (Subaru Ex40)
377
General Information
377
Before Servicing
377
Engine Rotation
377
Torque Specifications
378
Adjustments and Settings
378
Engine Oil - Gasoline Vehicle
378
Spark Plug
381
Breather
382
Valve Clearance Check and Adjustment
383
Engine Removal
384
Engine Installation
385
Flywheel
386
Flywheel Removal
386
Flywheel Installation
387
Oil Level Sensor
388
Testing the Oil Level Sensor
388
Oil Level Sensor Removal
388
Oil Level Sensor Installation
388
Ignition Coil
389
Testing the Ignition Coil
389
Ignition Coil Removal
389
Ignition Coil Installation
389
Snubber
390
Snubber Removal
390
Snubber Installation
390
Section 23 - Fuel System: Gasoline Vehicles
391
General Information
391
EFI System Features/Specifications
391
Relieving Fuel Pressure
392
To Relieve Fuel Pressure
392
Throttle Body
393
Throttle Body Removal
393
Throttle Body Installation
394
Engine Control Linkages
396
General Information
396
Ground Speed
397
Accelerator Rod
397
Governor Cable
399
Accelerator Cable
401
Closed Throttle or Idle Adjustment - Pedal-Start Vehicles
402
Closed Throttle or Idle Adjustment - Key-Start Vehicles
402
How to Measure Ground Speed
403
Engine RPM Adjustment
403
Air Intake System
404
Air Filter
404
Air Cleaner Removal
405
Air Cleaner Installation
405
Fuel Line
406
Fuel Line Removal
406
Fuel Line Installation
407
Fuel Pump Module
408
General Information
408
Fuel Pump Module Removal
408
Fuel Pump Module Installation
408
Fuel Tank
411
General Information
411
Fuel Tank Removal
411
Fuel Tank Disposal
412
Fuel Tank Storage
412
Fuel Tank Installation
412
Fuel Filter
413
General Information
413
Fuel Filter Removal
413
Fuel Filter Installation
414
Fueling Instructions - Gasoline Vehicle
414
Section 24 - Exhaust System: Gasoline Vehicles
417
Muffler
417
Muffler Removal
417
Muffler Installation
417
Section 25 - Clutches: Gasoline Vehicles
419
General Information
419
Troubleshooting
420
Drive Belt
421
Drive Belt Removal
421
Drive Belt Installation
421
Drive Clutch
422
Drive Clutch Removal
423
Drive Clutch Cleaning and Inspection
424
Drive Clutch Disassembly
424
Inspection of Drive Clutch Parts
427
Drive Clutch Assembly
427
Drive Clutch Installation
429
Driven Clutch
430
Driven Clutch Removal
431
Driven Clutch Disassembly
431
Driven Clutch Inspection
432
Driven Clutch Assembly
432
Driven Clutch Installation
434
Section 26 - Transaxle (Ed65): Gasoline Vehicles
435
General Information
435
Shifter Lever
435
Neutral Lockout
435
Governor System
436
Transaxle Service
436
Lubrication
436
Tools Required for this Section
437
Rear Hubs
438
Rear Hub Removal
438
Rear Hub Installation
438
Axle Tubes, Axle Shafts and Wheel Bearings
440
Axle Tube and Axle Shaft Removal
440
Axle Tube and Axle Shaft Installation
441
Rear Wheel Bearing Removal
441
Rear Wheel Bearing Installation
441
Axle Shaft Oil Seal Removal
442
Axle Shaft Oil Seal Installation
442
Transaxle Removal
443
Transaxle Installation
446
Shifter Cable
446
Shifter Cable Removal
446
Shifter Cable Installation
447
Shifter Cable Adjustment
447
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