Club Car CARRYALL 6 2002 Manuals

Manuals and User Guides for Club Car CARRYALL 6 2002. We have 1 Club Car CARRYALL 6 2002 manual available for free PDF download: Maintenance Service Manual

Club Car CARRYALL 6 2002 Maintenance Service Manual (284 pages)

Brand: Club Car | Category: Utility Vehicle | Size: 10 MB

Table of Contents
5
Section 1 - Safety
13
General Warning
13
Section 2 - Vehicle Specifications
17
Section 3 - General Information
19
Serial Number Identification
19
Storage
20
Preparing the Vehicle for Extended Storage
20
Returning the Stored Vehicle to Service
20
Section 4 - Body and Trim
21
Cleaning the Vehicle
22
Seat
23
Seat Removal
23
Seat Installation
23
Seat Support
24
Seat Support Removal
24
Seat Support Installation
24
Armrest Removal
25
Armrest Installation
25
Front Body Repair
25
Stress Lines or Streaks
25
Minor Impact Damage/Deformations
25
Minor Scratches and Surface Blemishes
25
Small Scratches that Cannot be Buffed out
26
Touch-Up Paint Color Chart
26
Gouges, Punctures, Tears, Large Scratches, and Abrasions
26
Front Body
27
Front Body Removal
27
Front Body Installation
28
Tilt Bed - Carryall 1 and Carryall 2
28
Tilt Bed Removal
28
Tilt Bed Installation
29
Flat Bed - Carryall 6
30
Flat Bed Removal
30
Flat Bed Installation
30
Flat Bed Trim - Carryall 6
30
Flat Bed Trim Removal
30
Flat Bed Trim Installation
33
Access Door - Carryall 6
33
Access Door Removal
33
Access Door Installation
33
Side Door - Carryall 6
33
Side Door Removal
33
Side Door Installation
33
Rear Fender
34
Rear Fender Removal
34
Rear Fender Installation
36
Trailer Hitch - Optional on some Models
36
Trailer Hitch Removal
36
Trailer Hitch Installation
36
Tailskirt
36
Tailskirt Removal
36
Tailskirt Installation
36
Bumper
36
Bumper Removal
36
Bumper Installation
37
Floor Mat
37
Front Floor Mat Removal
37
Front Floor Mat Installation
37
Rear Floor Mat Removal - Carryall 6 Only
37
Rear Floor Mat Installation - Carryall 6 Only
37
Section 5 - Accelerator and Brake Pedal Group
39
General Information
40
Accelerator Pedal
40
Accelerator Pedal Removal
40
Accelerator Pedal Installation
41
Brake Pedal - Carryall 1
42
Brake Pedal Removal - Carryall 1
42
Brake Pedal Installation - Carryall 1
43
Brake Pedal - Carryall 2 and Carryall 6
44
Brake Pedal Removal - Carryall 2 and Carryall 6
44
Brake Pedal Installation - Carryall 2 and Carryall 6
45
Brake Pedal Height Adjustment
45
Brake Pedal Free Play Adjustment - Carryall 1 Only
47
Accelerator Pedal Height Adjustment
48
General Information
50
Park Brake System Inspection
50
Park Brake System
51
Park Brake Cable Removal
51
Park Brake Cable Installation
53
Park Brake Handle Removal
55
Park Brake Handle Installation
55
Park Brake Adjustment
56
Wheel Brake Assemblies - Carryall 1
56
Brake Shoe Removal - Carryall 1
56
Brake Assembly Cleaning - Carryall 1
60
Brake Shoe Installation - Carryall 1
61
Brake Adjustment - Carryall 1
63
Brake Cluster - Carryall 1
63
Brake Cluster Removal
63
Brake Cluster Installation
64
Brake Cables - Carryall 1
64
Brake Cable Removal
64
Brake Cable Installation
65
Wheel Brake Assemblies - Carryall 2 and Carryall 6
65
Brake Shoe Removal - Carryall 2 and Carryall 6
66
Brake Assembly Cleaning - Carryall 2 and Carryall 6
67
Brake Shoe Installation - Carryall 2 and Carryall 6
68
Rear Brake Cluster - Carryall 2 and Carryall 6
72
Rear Brake Cluster Removal
72
Rear Brake Cluster Installation
72
Front Brake Cluster - Carryall 2 and Carryall 6
73
Front Brake Cluster Removal
73
Front Brake Cluster Installation
74
Front Brake Cables - Carryall 2 and Carryall 6
74
Front Brake Cable Removal
74
Front Brake Cable Installation
76
Rear Brake Cables - Carryall 2 and Carryall 6
77
Rear Brake Cable Removal
77
Rear Brake Cable Installation
78
Brake Adjustment - Carryall 2 and Carryall 6
78
Brake Cluster Adjustment
78
Equalizing Brake Cables
79
Final Brake Cluster Adjustment
80
Test Drive Vehicle
80
Section 7 - Steering and Front Suspension
83
General Information
84
Steering Wheel
84
Steering Wheel Removal
84
Steering Wheel Installation
86
Steering Column
86
Steering Column Removal
86
Steering Column Disassembly
87
Steering Column Assembly
88
Steering Column Installation
88
Steering Adjustment
89
Rack and Pinion
90
Rack and Pinion Removal
90
Rack and Pinion Disassembly
90
Rack and Pinion Assembly
92
Rack and Pinion Installation
95
Tie Rod and Drag Link
95
Tie Rod and Drag Link Removal
95
Tie Rod and Drag Link Installation
96
Front Suspension
96
Lubrication
96
Wheel Alignment
96
Front Suspension Components
98
Leaf Spring Removal
98
Leaf Spring Installation
101
Kingpin and Steering Spindle Removal
101
Kingpin and Steering Spindle Installation
102
Delta A-Plate Removal
102
Delta A-Plate Installation
102
Shock Absorber Inspection and Removal
103
Shock Absorber Installation
103
Front Wheel Bearings and Hubs
103
Check Front Wheel Free Play
103
Front Wheel Bearings and Hub Removal
103
Front Wheel Bearings and Hub Installation
106
Section 8 - Wheels and Tires
107
General Information
108
Wheels
108
Wheel Removal
108
Wheel Installation
108
Tires
108
Tire Removal
108
Tire Repair
109
Tire Installation
110
Section 9 - Rear Suspension
111
General Information
112
Shock Absorbers
112
Shock Absorber Inspection and Removal
112
Shock Absorber Installation
113
Multi-Leaf Springs
113
Multi-Leaf Spring Removal
113
Multi-Leaf Spring Installation
116
Jounce Bumpers
117
Removal
117
Installation
117
Section 10 - Periodic Maintenance
119
General Information
120
Pre-Operation and Daily Safety Checklist
120
Performance Inspection
121
Periodic Service Schedule
121
Periodic Lubrication Schedule
123
Section 11 - Electrical System and Testing
125
General Information
126
Troubleshooting Guide
126
Wiring Diagrams
129
Electrical Circuits
133
Control Circuit
133
Power Circuit
133
Speed Control Circuit
133
Charge Circuit
133
Battery Warning Light
134
Test Procedures
135
Index of Test Procedures
135
Communication Display Module (CDM)
163
Using the CDM to Retrieve Data from the Onboard Computer
164
CDM Troubleshooting Guide
165
Section 12 - Electrical Components
167
Electrical Component Cover
168
Main Power Fuse
170
Control Wiring Fuse
170
Key Switch
171
Battery Condition Indicator
172
Plug Diode
173
Emergency Stop Switch
174
Forward/Reverse Switch
174
Forward/Reverse Limit Switches
175
Reverse Buzzer
177
Solenoid
177
Diode - Solenoid
178
Resistor - Solenoid
179
Onboard Computer (OBC)
180
Solid State Speed Controller
182
Charger Receptacle
182
Receptacle Fuse Link
183
Motor Controller Output Regulator (MCOR)
184
Headlight Switch
186
Horn
187
Horn Switch
188
Brake Pedal Limit Switch
188
Battery Warning Light
189
Seat Switch
190
DC/DC Converter
191
Section 13 - Batteries
193
General Information
194
Common Misconceptions about Batteries
196
Battery Replacement
196
Battery Care
197
Preventive Maintenance
197
Self-Discharge
198
Electrolyte Level
198
Mineral Content
199
Vibration Damage
199
Battery Charging
199
Charger Shuts off after 16 Hours
200
Deep-Discharge
200
Early Excessive Discharging
200
Incoming AC Service
200
Fleet Rotation
200
Numbering Vehicles and Chargers
200
Battery Troubleshooting Chart
201
Battery Testing
202
Battery Charger Test
202
On-Charge Voltage Test
202
Hydrometer Test
202
Battery Troubleshooting Examples
206
Battery Storage
207
Battery Tray
208
Charging a Battery Pack that Has Low Voltage
209
Section 14 - European Powerdrive Battery Charger
211
General Information
212
Powerdrive Charger Features
213
Battery Warning Light
213
The Charge Circuit
214
Charger Installation and Operation
215
DC Cord and Plug Inspection
219
Checking Battery Condition
219
Troubleshooting
221
Test Procedures
223
Index of Test Procedures
223
Charger Repairs
236
DC Cord
236
Heatsink
238
Transformer
238
Ammeter
239
Fuse Link
240
Voltage Suppressor
241
Charger Relay
242
Charger AC Circuit Breakers
242
AC Charger Receptacle
242
Charging a Battery Pack that Has Low Voltage
243
Battery Charger Specifications
245
Section 15 - Motor
247
General Information
248
External Motor Testing
248
Motor
249
Motor Component Testing and Inspection
250
Armature
250
Field Windings Inspection
252
Motor Components
252
Bearing Inspection
253
Bearing Removal
253
Bearing Installation
253
Reconditioning the Motor
253
Motor Assembly
254
Motor Installation
256
Section 16 - Transaxle (Type G)
261
Lubrication
262
Axle Bearing and Shaft
262
Axle Shaft
262
Axle Bearing
264
Axle Bearing
265
Transaxle
265
Transaxle Removal
265
Transaxle Disassembly, Inspection, and Assembly
268
Transaxle Disassembly and Inspection
268
Transaxle Assembly
270
Transaxle Installation
271

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Club Car CARRYALL 6 2002 Manuals

Club Car CARRYALL 6 2002 Maintenance Service Manual (284 pages)

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