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Club Car Carryall 500, Maintenance And Service Manual

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12

Test Procedures

ELECTRICAL SYSTEM TROUBLESHOOTING:

IQ PLUS ELECTRIC VEHICLES

TEST PROCEDURES

Using the following procedures, the entire IQ Plus electrical system can be tested without major disassembly of the
vehicle.

See following WARNING.

WARNING

• If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured.

Failure to properly route and secure wiring could result in vehicle malfunction, property damage,
personal injury, or death.

TESTING BASICS

• To use the CDT, the Run/Tow switch must be in the RUN position. The Run/Tow switch provides power to the logic

board and power board inside the controller.

• Battery Pack Voltage (BPV) will be referenced throughout the test procedures. BPV is accessed in

Test Procedure

1 – Batteries / Voltage Check (BPV) on page 12-15

.

• The Run/Tow switch powers the key switch, controller, Forward/Reverse switch, 15-amp fuse, and reverse buzzer.

• The key switch powers the MCOR 2-pin circuit, pin 1 of the 24-pin connector, solenoid, and the 12-Volt power strip.

• The MCOR 3-pin circuit, motor speed sensor circuit, the communication point for the connected car device

(white/black wire in position 21 of the 24-pin connector), and charge indicator light is powered by the controller
(with Run/Tow switch in RUN).

• The 2-amp fuse is powered directly by the batteries via the solenoid and carries BPV to the connected car

device. No switch is involved.

• The term “back-probe” refers to probing the side of a connector that the wire enters. This is usually done when the

connector must remain connected to a device.

See following CAUTION.

CAUTION

• Be careful not to damage the wire or terminal when back-probing.

• When testing voltage, the batteries must remain connected.

• When testing voltage, unless specifically directed to do otherwise in a procedure, connect the black (–) probe of

the multimeter to the negative post of battery no. 8 (6 x 8-Volt battery set) or the B- terminal of the controller,
whichever is easier to access.

• When testing controller functions, the Run/Tow switch must be in the RUN position. The TOW position removes

power to the controller.

Index of Test Procedures

1 – Batteries / Voltage Check (BPV)
2 – 48-Volt Battery Pack Voltage Under Load
3 – Run/Tow Switch
4 – Fuses
5 – Circuit Breaker
6 – Wire Harness Diodes
7 – Key Switch and MCOR Limit Switch Circuit
8 – Forward/Reverse Rocker Switch
9 – Solenoid Activating Coil
10 – Solenoid Contacts

Page 12-14

2017 Carryall 500 and 700 Maintenance and Service Manual

Summary of Contents for Carryall 500

Page 1: ...2017 Carryall 500 and 700 Maintenance and Service Manual Gasoline Vehicle with Subaru EX40 Engine Electric Vehicle with QuiQ Charger Manual Number 105342204 Edition Code B ...

Page 2: ......

Page 3: ... Regional technical representatives vehicle service seminars periodic service bulletins maintenance and service manuals and other service publications also represent Club Car s continuing commitment to customer support Club Car offers a full line of training and continuing education classes for technicians who want to learn more about our products For more information contact your local dealer or ...

Page 4: ...C PN 1014305 Dry Moly Lube CC PN 1012151 Chassis Lube EP NLGI Grade 2 commercially available Engine Air Filter 404 cc CC PN 102558201 Deionizer Filter Replacement Cartridge SPWS CC PN 104005901 Spark Plug O H C 404 cc CC PN 105017801 Deionizer Filter Replacement Cartridge non SPWS CC PN AM10975 NOTE This manual represents the most current information at the time of publication Club Car is continua...

Page 5: ...g the Stored Electric Vehicle to Service 3 3 Storage Gasoline Vehicles 3 4 Preparing the Gasoline Vehicle for Extended Storage 3 4 Returning the Stored Gasoline Vehicle to Service 3 5 SECTION 4 Body and Trim 4 1 Cleaning the Vehicle 4 1 Seat Cleaning 4 1 Front Body Repair 4 2 Light Scratches 4 2 Abrasions and Haze 4 2 Large Scratches and Abrasions 4 2 Touch Up Paint Color Chart 4 2 Front Body 4 3 ...

Page 6: ...oup Adjustment Gasoline Vehicles 5 10 Pedal Group Adjustment Electric Vehicles 5 16 SECTION 6 Wheel Brake Assemblies 6 1 General Information 6 1 Brake Shoe Removal 6 1 Brake Assembly Cleaning 6 3 Brake Shoe Installation 6 5 Brake Adjustment 6 6 Brake Cluster Adjustment 6 7 Brake Cable Equalization 6 9 Final Brake Cluster Adjustment 6 10 Test Drive Vehicle 6 10 Brake Cluster Removal and Installatio...

Page 7: ...Play Inspection 7 21 Front Hub and Wheel Bearings Removal 7 21 Front Hub and Wheel Bearings Installation 7 22 SECTION 8 Wheels and Tires 8 1 General Information 8 1 Wheels 8 1 Wheel Removal 8 1 Wheel Installation 8 1 Tires 8 2 Tire Removal 8 2 Tire Repair 8 2 Tire Installation 8 3 SECTION 9 Rear Suspension 9 1 General Information 9 1 Shock Absorbers 9 1 Shock Absorber Inspection and Removal 9 1 Sh...

Page 8: ... Cont 11 12 Password Tries OEM Access Level Only 11 12 Cir BRKR Open 11 12 THRTL Fault 11 12 Undervoltage 11 12 Overvoltage 11 12 Temp Cutback 11 12 HPD 11 12 Main Welded 11 12 Relay Welded 11 13 SPD Sensor 11 13 Main DRV On 11 13 Main Coil OPN 11 13 Main Dropout 11 13 Motor Stall 11 13 Main DRVR Off 11 13 Relay DNC 11 13 Current Sense 11 13 M Shorted 11 13 Relay Coil 11 13 Precharge 11 13 FLD Mis...

Page 9: ...ailsafe 11 21 25 Incorrect Password 11 22 26 Circuit BRKR Open 11 22 27 Max Password Tries 11 22 29 Relay DRVR Off 11 22 30 Relay Coil Fault 11 22 Anti Tamper Fault 11 22 Lockout Fault 11 22 Low SOC 11 22 Main CONT DNC 11 23 Main Coil Fault 11 23 PROC Wiring 11 23 Open Armature 11 23 Incorrect Password OEM Access Level Only 11 23 Fault History 11 23 Clearing Fault History 11 23 Programming 11 24 C...

Page 10: ...peed Controller Cover 13 7 Solenoid 13 8 Solenoid Removal 13 8 Solenoid Installation 13 8 Speed Controller 13 9 Speed Controller Removal 13 9 Speed Controller Installation 13 9 Charge Indicator Light 13 11 Testing the Charge Indicator Light 13 11 Charge Indicator Light Removal 13 11 Charge Indicator Light Installation 13 11 SECTION 14 Batteries IQ Plus Electric Vehicles 14 1 General Information 14...

Page 11: ...omponent Testing and Inspection 16 7 Armature Inspection and Testing 16 7 Motor Frame and Field Windings Inspection 16 8 Motor Brush Spring and Terminal Insulator Inspection 16 8 Reconditioning the Motor 16 11 Motor Specifications 16 11 Motor Assembly 16 11 Motor Installation 16 13 SECTION 17 Transaxle Electric Vehicles 17 1 Lubrication 17 1 Axle Bearing and Shaft 17 1 Axle Shaft 17 1 Axle Bearing...

Page 12: ... for EFI Engines 20 13 Voltage Regulator 20 15 Voltage Regulator Removal 20 15 Voltage Regulator Installation 20 16 Engine Control Unit ECU 20 17 Engine Control Unit Removal 20 17 Engine Control Unit Installation 20 17 Key Switch 20 18 Key Switch Removal 20 18 Key Switch Installation 20 18 Maintenance Operate Switch 20 19 Maintenance Operate Switch Removal 20 19 Maintenance Operate Switch Installa...

Page 13: ... Vibration Damage 20 34 Battery Removal 20 35 Charging the Battery 20 35 Battery Installation 20 35 Battery Storage 20 36 Charging a Dead Battery 20 36 Ground Cables 20 36 SECTION 21 Electrical Components Key Start Gas Vehicle 21 1 General Information 21 1 Key Switch 21 1 Key Switch Removal 21 1 Key Switch Installation 21 2 Maintenance Operate Switch 21 3 Maintenance Operate Switch Removal 21 3 Ma...

Page 14: ... 11 Closed Throttle or Idle Adjustment Pedal Start Vehicles 23 12 Closed Throttle or Idle Adjustment Key Start Vehicles 23 12 How to Measure Ground Speed 23 13 Engine RPM Adjustment 23 13 Air Intake System 23 14 Air Filter 23 15 Air Cleaner Removal 23 15 Air Cleaner Installation 23 15 Fuel Line 23 16 Fuel Line Removal 23 16 Fuel Line Installation 23 17 Fuel Pump Module 23 18 General Information 23...

Page 15: ...ED65 Gasoline Vehicles 26 1 General Information 26 1 Shifter Lever 26 1 Neutral Lockout 26 1 Governor System 26 2 Transaxle Service 26 2 Lubrication 26 2 Tools Required For This Section 26 3 Rear Hubs 26 4 Rear Hub Removal 26 4 Rear Hub Installation 26 4 Axle Tubes Axle Shafts and Wheel Bearings 26 6 Axle Tube and Axle Shaft Removal 26 6 Axle Tube and Axle Shaft Installation 26 7 Rear Wheel Bearin...

Page 16: ......

Page 17: ...njury or death The color associated with Warning is ORANGE CAUTION A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury The color associated with Caution is YELLOW MACHINE SAFETY CAUTION A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could result in property damage A CAUTION without the s...

Page 18: ...ny modification or change to the vehicle that affects the electrical system stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications can result in severe personal injury or death Check the vehicle for proper location of all vehicle safety and operation decals and make sure they are in place and are easy to read For vehicles with cargo beds remove all ca...

Page 19: ...e when disconnecting battery cables or other electrical wiring Do not allow a positive wire to touch the vehicle frame engine or any other metal component All vehicles Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches cha...

Page 20: ...er capacitors to discharge CONNECTING THE BATTERIES ELECTRIC VEHICLES 1 Ensure the Run Tow switch is in the TOW position 2 Connect the battery cables positive cable first 3 Tighten battery terminals to 110 in lb 12 4 N m 4 Coat terminals with Battery Terminal Protector Spray to minimize corrosion Viewed from driver side of vehicle 1 Place Run Tow Switch in TOW before disconnecting or connecting ba...

Page 21: ...her metals acids and other compounds If improperly handled they can contaminate both water and soil causing environmental damage and personal injury Lead acid batteries are identified by the symbol shown below and should be properly recycled Figure 1 3 They cannot be disposed as municipal waste and must be collected separately Responsibility for environmental protection must be shared not only by ...

Page 22: ...5 Battery acid hazard 2 Read and follow operating instructions 4 Keep away from children 6 Explosive gas hazard Refer to General Warnings for more information 1642 Figure 1 4 International Safety Symbols on Batteries Page 1 6 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 23: ...am welded aluminum Side and rear body Aluminum Front body ArmorFlex Front body finish Automotive grade paint with clear coat finish Tires 20 x 10 10 tubeless 6 ply rated load range front and rear Tires Turf 23 x 10 5 12 tubeless 4 ply rated load range front and rear Tires All Terrain 22 x 11 10 tubeless 6 ply rated load range front and rear DIMENSIONS WEIGHT Overall length Standard boxbed configur...

Page 24: ... inside dimensions 44 2 x 47 5 x 10 5 in 112 2 x 120 6 x 26 6 cm 64 5 x 47 5 x 10 5 in 163 8 x 120 6 x 26 6 cm Load bed size Flat bed inside dimensions 46 2 x 48 8 in 117 3 x 123 9 cm 65 5 x 48 8 in 166 4 x 123 9 cm Vehicle rated capacity Level surface only 1200 lb 544 3 kg 1500 lb 680 3 kg Standard seating capacity 2 2 LIQUID CAPACITIES Transaxle 22 fl oz 0 67 L 22 fl oz 0 67 L TIRE PRESSURE Fron...

Page 25: ...ER CONSUMPTION AC current amps Max 12 Amps Nominal 9 5 Amps rms 120 VAC 5 Amps rms 230 VAC DC OUTPUT DC voltage VDC nominal 48 V DC voltage VDC maximum 68 V DC current maximum 18 Amps Interlock current maximum 1 Amp DIMENSIONS WEIGHT Case Overall length 11 in 28 cm Case Overall width 9 7 in 24 6 cm Case Overall height 4 3 in 11 cm Weight with standard output cord 11 lb 5 kg MOUNTING CONFIGURATION ...

Page 26: ...tem 23 amps at max RPM Torque converter Automatic variable speed dry type STEERING SUSPENSION BRAKES Steering Self adjusting rack and pinion Suspension Independent leaf spring with dual hydraulic shocks Brakes Mechanical brake cable system to manually adjusted drum brakes on all four wheels Park brake is automatically released Multi latch ratchet and pawl BODY CHASSIS Frame chassis Twin I Beam wel...

Page 27: ...9 cm 29 5 in 74 9 cm Load bed size Box bed inside dimensions 44 2 x 47 5 x 10 5 in 112 2 x 120 6 x 26 6 cm 64 5 x 47 5 x 10 5 in 163 8 x 120 6 x 26 6 cm Load bed size Flat bed inside dimensions 46 2 x 48 8 in 117 3 x 123 9 cm 65 5 x 48 8 in 166 4 x 123 9 cm Vehicle rated capacity Level surface only 1200 lb 544 3 kg 1500 lb 680 3 kg Standard seating capacity persons 2 2 LIQUID CAPACITIES Engine cra...

Page 28: ...Pagination Page 2 Vehicle Specifications VEHICLE SPECIFICATIONS Page 2 6 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 29: ...er of each vehicle is printed on a bar code decal mounted below the center dash panel Example CC5819 123456 Figure 3 1 The two letters 1 at the beginning of the serial number indicate the vehicle model The following four digits 2 indicate the model year and production week during which the vehicle was built The six digits 3 following the hyphen represent the unique sequential number assigned to ea...

Page 30: ...o avoid exposing electrical components to moisture and subsequent damage do not use any type or pressure washing or steam cleaning equipment to wash the vehicle PREPARING THE ELECTRIC VEHICLE FOR EXTENDED STORAGE Check Battery Water Levels Two Weeks Prior to Storage Check water levels at least two weeks prior to winter storage to ensure proper mixing of water and electrolyte Note that it takes app...

Page 31: ...It is recommended that the vehicles be plugged in and the electrolyte level maintained throughout the storage period If any of the following conditions exist however then disconnect the batteries for storage 1 The charger cannot remain plugged in 2 AC power will not be available during extended storage or 3 Electrolyte levels will not be maintained To disconnect batteries for storage go to step 13...

Page 32: ...ries with bulged cases Discard the battery Frozen batteries can explode CAUTION Batteries in a low state of charge will freeze at low temperatures PREPARING THE GASOLINE VEHICLE FOR EXTENDED STORAGE 1 Unload the vehicle so that tires are supporting only the weight of the vehicle 2 Store vehicle in a cool dry place This will minimize battery self discharge If the battery appears to be weak have it ...

Page 33: ...ETURNING THE STORED GASOLINE VEHICLE TO SERVICE 1 Restore fuel system to operation 1 1 Remove plug from the fuel tank vent Figure 23 16 Page 23 25 1 2 Connect vent tube to fuel tank vent 2 Connect battery and spark plug wire See Connecting the Battery Gasoline Vehicles on page 1 5 3 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position ...

Page 34: ...Pagination Page 3 Storage Gasoline Vehicles GENERAL INFORMATION Page 3 6 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 35: ...ve cleaning solutions with a sponge or soft cloth The painted finish is the same paint used in automotive applications Automotive cleaning polishing products are available at automotive specialty and hardware stores Use non abrasive wax products Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible stains SEAT CLEANING Clean seats reg...

Page 36: ...ch buffing compound as necessary to achieve this step If at any time original scratches can be seen repeat steps 2 and 3 as needed When all 1500 grit scratches have disappeared there will be a dull luster over entire area 5 Install a foam polishing pad 3M 5725 or equivalent on buffer and repeat step 4 using approx 1 2 tsp 2 mL buffing compound 3M 5933 or equivalent Buff compound off until scratche...

Page 37: ...Disconnect the batteries See Disconnecting the Batteries Electric Vehicles Section 1 Page 1 4 See Disconnecting the Battery Gasoline Vehicles on page 1 5 2 Loosen and remove screws 1 washers 3 and locknuts 2 that attach heavy duty HD bumper mounting bracket 4 to HD bumper weldment 5 Figure 4 1 Page 4 4 3 Remove plastic bumper 13 4 Remove HD bumper and weldment 2017 Carryall 500 and 700 Maintenance...

Page 38: ...4 Front Body BODY AND TRIM 3 5 3 1 6 7 5 12 2 1 3 4 8 1 3 2 7 4 11 6 10 9 2 8 13 2986 Figure 4 1 Heavy Duty Bumper Page 4 4 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 39: ...cured by tabs located behind the front fenders 2 and under the lip of the dash 1 Figure 4 2 Page 4 6 4 Push down and rearward on front fenders to unsnap cowl in two locations 5 Slide cowl forward until free then lift out cowl COWL INSTALLATION 1 Slide bottom edges of cowl into grooves in front fenders 2 Ensure the three tabs on cowl install under lip of dash 1 Figure 4 2 Page 4 6 3 Ensure sides of...

Page 40: ...ed See Heavy Duty Bumper Removal Section 4 Page 4 3 4 Remove cowl See Cowl Removal on page 4 5 5 Loosen and remove the two M6 self tapping fasteners 1 at the top of grille 7 Figure 4 3 Page 4 8 6 Loosen and remove the two lower left and right side bolts 1 and 7 that attach the grille and plastic bumper 6 7 Remove charger receptacle if equipped by removing the three screws that attach the receptacl...

Page 41: ...red with the front bumper ensure lower bumper screws are attached first then install grille 4 Line up upper and lower bolt holes 5 Install and tighten upper bolts then lower right and left side bolts Tighten to 44 in lb 5 N m 6 Connect the batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 See Connecting the Battery Gasoline Vehicles on page 1 5 2017 Carryall 500 and 700 M...

Page 42: ...4 Front Body BODY AND TRIM 6 7 2 3 4 5 6 9 8 1 1 2844 Figure 4 3 Front Grille Bumper and Side Fenders Page 4 8 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 43: ... to the frame repeat procedure on opposite side 9 Unsnap body clips and remove side fenders 5 FRONT BUMPER AND SIDE FENDER INSTALLATION 1 Install side fenders 5 by snapping in body clips 2 Install inner screws nuts and spacers 1 2 3 and 4 that attach the side fender to the frame 3 Install front bumper 6 4 Install the two upper and lower bolts 7 that attach the bumper to the vehicle frame Push down...

Page 44: ... out the lower body clips be careful not to pry the lower clips off 5 Pull instrument panel out from the dash panel 2 INSTRUMENT PANEL INSTALLATION 1 Place upper tab of instrument panel into slot 1 2 Snap panel into dash while pushing in on the driver and passenger side tabs and sliding the top portion of the panel into place 3 Snap lower body clips in at each lower corner 4 Connect the batteries ...

Page 45: ... sides and bottom of the dash 10 Figure 4 5 Page 4 12 6 Remove dash assembly DASH INSTALLATION 1 Install dash assembly 2 Install the bolts and washers 5 6 7 8 and 9 to the top sides and bottom of dash 10 Figure 4 5 Page 4 12 3 Connect instrument panel wiring 4 Install steering wheel See Steering Wheel Installation Section 7 Page 7 2 5 Install cowl See Cowl Installation Section 4 Page 4 5 6 Connect...

Page 46: ...4 Front Body BODY AND TRIM 10 6 7 8 9 4 5 2863 Figure 4 5 Dash Assembly Page 4 12 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 47: ... 4 14 2 Remove two lock nuts 8 from left and right hinge assemblies C 3 Apply slight upward pressure by hand on the rear of the bed to relieve pressure on the hinges and remove the hinge bolts 7 from the hinge assemblies 4 Raise rear edge of bed approximately 6 inches 15 2 cm and pull bed assembly toward rear of vehicle approximately 3 inches 7 6 cm to release bed latch assembly A from latch plate...

Page 48: ...4 Tilt Bed BODY AND TRIM 14 6 1 12 10 1 13 7 8 17 11 2 9 18 16 3 15 5 4 19 9 A B C 2980 Figure 4 6 Tilt Bed Mounting Page 4 14 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 49: ...ds clear of all crush areas Do not drop cargo bed lower gently and keep entire body clear Failure to heed this warning could result in severe personal injury or death 4 Remove the four bolts 12 and lock nuts 7 that secure the bed latch 6 to the underside of the bed Figure 4 7 Page 4 16 5 Remove the bed latch 6 and springs 5 BED LATCH ASSEMBLY INSTALLATION 1 Install bed latch 6 and springs 5 NOTE L...

Page 50: ...4 Tilt Bed BODY AND TRIM 2 13 9 8 11 11 7 7 12 8 4 3 10 6 5 1 2982 Figure 4 7 Bed Latch Assembly Page 4 16 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 51: ...on page 1 1 4 3 2 1 5 2984 Figure 4 8 Rear Fender and Tailskirt REAR FENDER AND TAILSKIRT REMOVAL 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL and set the park brake Chock the wheels 2017 Carryall 500 and 700 Maintenance and Service Manual Page 4 17 ...

Page 52: ...le frame 7 Remove fenders and tailskirt REAR FENDER AND TAILSKIRT INSTALLATION 1 Using a 10 mm socket install the two screws 2 that attach the tailskirt 3 to the vehicle frame Figure 4 8 Page 4 17 Tighten to 44 in lb 5 N m 2 Using a 10 mm socket install the three fasteners 5 that attach the rear fender 4 to the vehicle frame Tighten to 5 in lb 0 56 N m Do not over torque 3 Connect the taillight wi...

Page 53: ...hat secures lift 7 Figure 4 9 Page 4 20 5 Lower the bed 6 Remove the hex head bolts lock nuts spacers and bushings 1 2 5 6 7 and 8 Figure 4 10 Page 4 21 ELECTRIC BED LIFT INSTALLATION 1 Install hex head bolts lock nuts spacers and bushings 1 2 5 6 7 and 8 Figure 4 10 Page 4 21 2 Lift bed 3 Install actuator hardware that secures lift 7 Figure 4 9 Page 4 20 4 Connect actuator wires 5 Lower bed 6 Con...

Page 54: ...4 Electric Bed Lift BODY AND TRIM 7 14 2 5 9 3 13 12 11 4 5 14 2 1 4 7 7 2983 Figure 4 9 Electric Bed Lift Page 4 20 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 55: ...BODY AND TRIM Electric Bed Lift 4 3 4 8 2 1 6 5 1 7 2985 Figure 4 10 Electric Bed Mounting 2017 Carryall 500 and 700 Maintenance and Service Manual Page 4 21 ...

Page 56: ...ction 5 Page 5 1 TRAILER HITCH See General Warnings Section 1 Page 1 1 TRAILER HITCH REMOVAL 1 Remove the tailskirt See Rear Fender and Tailskirt Removal on page 4 17 2 Where the hitch is mounted to frame remove two nuts lockwashers flat washers and bolts 3 Where the hitch is mounted to hitch brace remove the nut lockwasher flat washer and bolt 4 Remove hitch from vehicle TRAILER HITCH INSTALLATIO...

Page 57: ...oved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 3 Remove the brake pedal assembly 3 1 Disconnect the equalizer rod 5 from the pedal shaft by removing the clevis pin 7 and bow tie pin 4 Figure 5 1 Page 5 2 3 2 Remove the nuts 2 flat was...

Page 58: ...ic Vehicles ACCELERATOR AND BRAKE PEDAL GROUP Carryall 500 and 700 Electric Vehicle shown Gasoline Vehicle similar 3208 Figure 5 1 Brake and Park Brake Pedal Assembly and Mounting Page 5 2 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 59: ...ng NOTE NOTE Brake pedal free play is the distance the brake pedal can be pressed before the brake actuator arm moves 5 Tighten the jam nut 3 while holding the adjustment nut 2 in the correct position 6 Adjust the pedal group Refer to the appropriate adjustment procedure For gasoline vehicles see Pedal Group Adjustment Gasoline Vehicles on page 5 10 For electric vehicles see Pedal Group Adjustment...

Page 60: ... brake rod and pawl assembly 17 through 20 remove the push nut 19 and disconnect the ball joint sleeve 21 from the park brake pedal 1 Figure 5 4 Page 5 4 See following NOTE NOTE New push nuts 19 and 32 must be used when reassembling the park brake 3 2 To remove the park brake pedal 1 remove the push retainer nut 32 disconnect the torsion spring 22 and slide the pedal off of the shaft See preceding...

Page 61: ...tion Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 3 Disconnect the accelerator rod assembly 17 24 and 25 Figure 5 6 Page 5 6 at the front and rear ball studs and remove it from the vehicle 4 Use a 9 16 inch 14 mm socket and ...

Page 62: ... Gasoline Vehicles ACCELERATOR PEDAL INSTALLATION GASOLINE VEHICLES 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 19 and lock nuts 18 Finger tighten nuts at this time Figure 5 6 Page 5 6 2 Insert the lower end of the accelerator pedal 1 through the floorboard and install the accelerator pivot rod 6 thr...

Page 63: ...tate freely on the rod Figure 5 7 Ratchet Installation 9 Rotate the ratchet clockwise until it touches the park brake pawl then slide the ratchet onto the splines of the pivot rod it may be necessary to push the pivot rod toward the driver side of the vehicle to make the splines accessible The ratchet may have to be rotated counterclockwise slightly to align the splines 10 Install the nylon lock n...

Page 64: ...vot rod 7 Inspect the pivot support bearing 9 for wear and replace if necessary 8 Use a marker to mark the position of the park brake ratchet 24 on the accelerator pivot rod 6 See following NOTE NOTE Failure to mark position of the ratchet could cause it to be installed improperly resulting in improper adjustment and possible failure of the park brake 9 Remove the lock nut 23 from the accelerator ...

Page 65: ...AL GROUP Accelerator Pedal Electric Vehicles 5 GO 3 2 11 10 7 5 4 5 1 8 9 6 15 16 21 20 21 22 24 23 2642 Figure 5 8 Accelerator Pedal Electric Vehicle with MCOR 2017 Carryall 500 and 700 Maintenance and Service Manual Page 5 9 ...

Page 66: ...lide the ratchet onto the pivot rod do not slide the ratchet onto the pivot rod splines Release the brake pedal and allow the ratchet to rotate until its tip is pointed downward Figure 5 7 Page 5 7 The ratchet should now rotate freely on the rod 9 Rotate the ratchet clockwise until it touches the park brake pawl then slide the ratchet onto the splines of the pivot rod it may be necessary to push t...

Page 67: ...hten the jam nut 31 to 8 ft lb 9 5 N m Figure 5 10 Page 5 11 22 31 PARK STO P 1 2 3 4 5 6 7 8 9 10 11 12 Correct pedal position is 6 inches 15 2 cm from floormat to back of brake pedal Figure 5 10 Brake Pedal Height Adjustment Figure 5 11 Brake Pedal Height Measurement 3 Adjust brake pedal free play See following NOTE NOTE Brake pedal free play is the distance the brake pedal can be pressed before...

Page 68: ...lerator pivot rod supports and adjust the supports If the gap becomes smaller as the park brake pedal is pressed move the pivot rod supports slightly rearward until the gap is consistent If the gap becomes larger as the park brake pedal is pressed move the pivot rod supports slightly forward until gap is consistent See following NOTE NOTE The accelerator rod must also be checked if the ratchet paw...

Page 69: ...nect ball joint Figure 5 15 Page 5 13 4 7 If the accelerator push rod was disconnected from the accelerator pedal reconnect it 4 8 Check for proper brake operation prior to driving the vehicle 1 2 1 1 2 Inch Socket 2 1 2 Inch Wrench Figure 5 15 Brake Rod Adjustment Figure 5 16 Accelerator Pedal Height Adjustment 5 Adjust accelerator pedal height 5 1 Loosen the nut and bolt Figure 5 16 Page 5 13 se...

Page 70: ...o prevent accidentally starting the vehicle disconnect the battery cables as instructed See Disconnecting the Battery Gasoline Vehicles on page 1 5 This will prevent the possibility of the vehicle running over you when you are adjusting the accelerator rod 6 1 Remove the electrical box screw and cover See preceding DANGER 6 2 Loosen the jam nuts 25 and disconnect the accelerator rod 17 at the acce...

Page 71: ... rod set park brake to first ratchet and pawl position Press accelerator pedal and make sure the following events occur in the exact order shown _ EVENT APPROXIMATE PEDAL TRAVEL Park brake release 2 to 4 Solenoid activation 4 to 8 Throttle body actuation 8 to 12 6 5 If the events above occur as they should hold the ball joint at each end of the accelerator rod with pliers and tighten the accelerat...

Page 72: ...qualizer retaining nuts 1 on the equalizer rod 2 Figure 5 19 Page 5 16 1 3 2 4 1400 18100 10209 Figure 5 19 Loosen Rear Brake Equalizer Rod Nuts 2 3 Loosen the brake stop jam nut 31 then relieve pedal pressure on the stop by pushing down slightly on the pedal Next adjust the brake stop bumper 22 up or down Figure 5 20 Page 5 17 Adjusting the bumper upward decreases distance between pedal and floor...

Page 73: ...mm Figure 5 3 Page 5 3 3 3 Tighten the jam nut 3 while holding the adjustment nut 2 in the correct position 4 Adjust park brake ratchet pawl gap and pawl engagement 4 1 Inspect the park brake pawl 1 and ratchet 2 for excessive wear grooves cracks or chips Figure 5 22 Page 5 18 If either the pawl or ratchet is damaged both must be replaced 4 2 Adjust retaining nut 3 on spring support rod until ther...

Page 74: ...ure 5 23 Accelerator Pedal Height Measurement Figure 5 24 Ratchet Pawl Tooth Engagement 4 5 With park brake still locked measure the distance from the top of accelerator pedal to floorboard If the measurement has changed ratchet tooth engagement is too deep and must be adjusted 4 6 If ratchet pawl engagement must be adjusted disconnect the ball joint at the top of the brake rod and rotate the ball...

Page 75: ... 35 3 N m Figure 5 27 Page 5 19 1 2 1 1 2 Inch Socket 2 1 2 Inch Wrench Figure 5 25 Brake Rod Adjustment Figure 5 26 Accelerator Pedal Height Adjustment STOP PARK GO GO STOP PARK MICRO BREAK POINT MICRO BREAK POINT 1 2 1 Accelerator Pedal Adjustment Tool CC P N 101871001 2 Rubber Strap Figure 5 27 Accelerator Pedal Height Adjustment 6 Adjust the brakes See Brake Adjustment Section 6 Page 6 6 7 Con...

Page 76: ...Pagination Page 5 Pedal Group Adjustment Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP Page 5 20 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 77: ...ations BRAKE SHOE REMOVAL See General Warnings on page 1 1 See also Asbestos Dust Warning on page 6 1 1 To remove rear brake shoes place chocks at the front wheels loosen the rear wheel lug nuts and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to support the vehicle 2 Release park brake if latched and loosen equalizer retaining nuts 1 on equa...

Page 78: ...tep 7 See following NOTE NOTE Although step 6 allows easier access to the brake shoes it is not imperative to do so in order to remove the brake shoes 5 For electric vehicles Remove the axle shaft See Axle Shaft and Oil Seal Removal Section 17 Page 17 1 For gasoline vehicles Remove the wheel hub assembly See Rear Hub Removal Section 26 Page 26 4 6 Using needle nose pliers turn the clip retainer pi...

Page 79: ...d slide plate 2 with dry moly lubricant P N 1012151 on both sides of the backing plate After lubricating work slide back and forth against backing plate to ensure that it slides smoothly and easily Figure 6 5 Page 6 3 Install rubber boot onto backing plate Reinstall rubber boot onto backing plate See following WARNiNG WARNING Apply grease carefully when performing the following steps Do not allow ...

Page 80: ... or equivalent to each end of both brake shoes and into the slots in the brake shoe mounting block as shown Figure 6 10 Page 6 4 See preceding WARNING 640 Figure 6 7 Lubricate Bosses 641 Figure 6 8 Lubricate Brake Shoes and Slots 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 9 P...

Page 81: ...g the retainer pin 2 into position Figure 6 12 Page 6 5 3 Attach the springs with hooks pointing outwards 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 13 Page 6 6 NOTE With brake shoe tips marked J10 oriented to the mounting block the stamping will be visible on one shoe only The other J10 sta...

Page 82: ...to be adjusted vertically in the mounting slots 8 After the drum is installed make sure the axle and drum turn freely BRAKE ADJUSTMENT See General Warnings on page 1 1 See also Asbestos Dust Warning on page 6 1 CAUTION Pedal group adjustment must be within specifications prior to beginning brake adjustment Perform the appropriate pedal group adjustment For gasoline vehicles refer to Pedal Group Ad...

Page 83: ...ake cluster assemblies Figure 6 17 Page 6 7 4 5 4 5 2804 Figure 6 17 Rear Brake Adjustment Bolt 2803 Figure 6 18 Front Brake Adjustment Bolt 5 Use a torque wrench and a 7 mm 8 point socket or Club Car brake adjustment tool CC P N 1013582 to turn the brake adjustment bolt 5 on each brake clockwise until it is tightened to 15 ft lb 20 3 N m then back off 5 clicks See following NOTE NOTE If a wheel c...

Page 84: ... 9 22 11 10 11 16 17 14 2 TYPICAL 2 PLACES TYPICAL 2 PLACES 13 1 3 TYPICAL 4 PLACES 4 5 6 7 TYPICAL 2 PLACES TYPICAL 2 PLACES 8 18 15 12 2806 Figure 6 19 Front Manually Adjusted Brake Assembly Page 6 8 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 85: ...6 8 7 18 12 14 2 2903 Figure 6 20 Rear Manually Adjusted Brake Assembly BRAKE CABLE EQUALIZATION 1 Set park brake in the third tooth of the ratchet Place a wedge between the park brake pedal and brake pedal to prevent the park brake from disengaging while equalizing the brake cables Figure 6 21 Page 6 10 2017 Carryall 500 and 700 Maintenance and Service Manual Page 6 9 ...

Page 86: ...KE CLUSTER ADJUSTMENT 1 To adjust the brake shoes turn the adjustment bolt counterclockwise five clicks 2 Repeat step 1 at other brake cluster s 3 Install the rubber dust covers 4 over the brake adjustment bolts 5 Figure 6 17 Page 6 7 and Figure 6 18 Page 6 7 4 Carefully support the vehicle with the lifting device remove jack stands and lower the vehicle to the ground TEST DRIVE VEHICLE 1 With the...

Page 87: ...ck stands under the round tube crossmember of the frame to support vehicle 2 Release park brake 3 Loosen the equalizer retaining nuts 1 and 6 on the front equalizer rod 2 to slightly loosen the brake cable Figure 6 16 Page 6 7 4 Remove the front wheels and then the brake drums 5 Remove bow tie pin 17 and clevis pin 16 from brake cable Figure 6 23 Page 6 14 Figure 6 22 Page 6 12 6 Remove dust cap 6...

Page 88: ...ke Cluster Removal and Installation WHEEL BRAKE ASSEMBLIES 6 11 10 1 2 3 TYPICAL 4 PLACES 4 5 9 8 7 2810 Figure 6 22 Front Spindle Assembly Page 6 12 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 89: ...r to the transaxle Figure 6 20 Page 6 9 7 Remove rear brake cluster assembly from transaxle REAR BRAKE CLUSTER INSTALLATION 1 Install in reverse order of disassembly Use new bow tie locking pins when installing brake cables See following CAUTION for Electric Vehicles CAUTION Clean any residual oil from the exposed end of the axle tube and from the oil seal area prior to installing the axle shaft 2...

Page 90: ... See General Warnings on page 1 1 See also Asbestos Dust Warning on page 6 1 18 8 B C 18 A 5 17 15 18 7 9 14 4 16 18 2 13 12 3 11 1 5 8 9 6 7 6 10 3189 Figure 6 23 Front Brake Cables and Equalizer Page 6 14 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 91: ...vis pin 6 and new bow tie pin 9 3 Route inner cable 8 through slot opening in passenger side of I beam A 4 Route outer cable 18 over rear brake equalizer rod B and through slot opening in driver side of I beam C 5 Route cables 8 and 18 along inside of frame rails towards front of vehicle Figure 6 23 Page 6 14 through gap between floorboard and tubular crossmember under cowl frame supports and cris...

Page 92: ...Brake Cables WHEEL BRAKE ASSEMBLIES REAR BRAKE CABLES 2 1 6 3 14 12 13 8 8 10 9 4 5 7 6 7 11 3191 Figure 6 25 Rear Brake Cables and Equalizer Page 6 16 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 93: ... clevis pins 5 and E clips 6 Figure 6 25 Page 6 16 4 2 Remove cable 7 from plate under leaf spring 4 3 Note location of hangers 11 and pull cables out of vehicle REAR BRAKE CABLE INSTALLATION 1 Place the cable ends in the equalizer 3 Figure 6 25 Page 6 16 Route cables through hangers 11 in the same manner as the ones removed 2 At the rear wheel brakes connect the cables 7 to the brake actuator arm...

Page 94: ...Pagination Page 6 Rear Brake Cables WHEEL BRAKE ASSEMBLIES Page 6 18 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 95: ...3 Match mark the steering wheel 3 and steering column shaft 4 so when the steering wheel is removed it can be placed back in exactly the same position on steering column shaft 4 Loosen the steering wheel nut 5 and back it off approximately 1 4 inch 6 mm Do not remove the nut 5 Use the steering wheel puller CC P N 102061201 to remove steering wheel 5 1 Place the puller anvil 6 through the top openi...

Page 96: ...ing wheel 1 Install the steering wheel 3 on the splines of the steering shaft 4 Be sure to align the match marks placed on the wheel and steering column shaft in step 3 above Figure 7 1 Page 7 2 2 Install the steering wheel nut 5 and tighten to 156 in lb 17 6 N m 3 Install the plate 2 and screws 1 Figure 7 1 Page 7 2 Tighten screws to 16 in lb 1 8 N m 4 Connect the battery cables See Connecting th...

Page 97: ...eering Column 7 STEERING COLUMN See General Warnings on page 1 1 22 17 16 18 20 18 16 14 12 21 19 17 15 13 11 10 7 8 6 4 1 9 7 5 2 3 35 2609 Figure 7 3 Steering Column 2017 Carryall 500 and 700 Maintenance and Service Manual Page 7 3 ...

Page 98: ...LUMN 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 4 Page 7 5 2 Press the bearing 17 all the way into the bearing seat 18 using a steering column bearing press tool CC P N 1014264 or a metal tube approximately six inches 15 2 cm long with a maximu...

Page 99: ...n 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 While holding the steering column in place attach it to the frame using bolts 8 washers 7 and nuts 9 Figure 7 3 Page 7 3 Thread the nuts onto the bolts but do not tighten them 4 Install wide washer 35 washer 11 and screw 10 Tighten to 20 ft lb 27 N m Figu...

Page 100: ...ht See following CAUTION CAUTION The drag link has both left and right hand threads The end of the drag link toward the spindle has left hand threads and the end toward the rack has right hand threads To prevent damage to threaded parts care should be taken when servicing the drag link 3 When all adjustments have been completed tighten the nuts 27 and 29 on the drag link assembly with an open end ...

Page 101: ... any binding clunking or tight loose spots Listen for unusual noises Replace the rack and pinion as an assembly if any is found 4 In the event of an known impact and obvious visible damage is not found in the method described above disconnect the tie rods and or drag links from the spindles Turn the steering wheel from stop to stop While turning feel for any binding or tight loose spots Listen for...

Page 102: ...ge 7 10 3 Remove both bellows clamps 2 plastic wire ties 4 Remove the hex nut 29 and slide off the dust seal bellows 1 5 Remove the retaining ring 21 then slide off dust seal bellows 20 6 Remove the rack screw lock nut 15 rack guide screw 16 rack guide pressure spring 14 and the rack guide 13 Figure 7 10 Page 7 10 7 Remove the universal joint assembly from the pinion 8 by fully removing the bolt a...

Page 103: ...ng 9 has been damaged remove the external snap ring 10 Figure 7 10 Page 7 10 and press the bearing off Figure 7 8 Page 7 9 12 Remove retaining ring 19 and stop washer 18 then remove rack 17 from housing 6 Figure 7 10 Page 7 10 13 If the inner ball joint 3 is excessively worn remove the ball joint and tab washer 4 from the rack Figure 7 9 Page 7 9 13 1 Secure the rack in a vise using wood blocks 5 ...

Page 104: ...tall a new tab washer 4 and an inner ball joint 3 Figure 7 9 Page 7 9 Install the ball joint onto the rack by securing the rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack from damage Tighten the ball joint to 60 ft lb 81 N m 2 Bend the edges of the tab washer 4 up against the ball joint 3 Figure 7 9 Page 7 9 Page 7 10 2017 Carryall 500 and 700 Mainten...

Page 105: ... preceding CAUTION 5 If the needle bearing 7 is damaged the steering box assembly CC P N 101878302 must be replaced Figure 7 10 Page 7 10 6 Install pinion 8 and bearing 9 assembly into the housing 6 Figure 7 10 Page 7 10 Make sure the rack gear teeth will mesh with the gear teeth on the pinion The rack may need to be rotated slightly while lightly tapping on the pinion bearing assembly with a rubb...

Page 106: ...nal resistance should measure 7 to 15 in lb 0 8 to 1 7 N m 11 4 If measured resistance does not equal 7 to 15 in lb loosen the lock nut 15 and tighten the screw 16 until it bottoms out then back the screw off one quarter turn Tighten the lock nut to 28 ft lb 38 N m Figure 7 12 Page 7 11 See following NOTE NOTE When tightening the lock nut 15 make sure the screw 16 does not change adjustment Figure...

Page 107: ... steering column shaft 3 Align the flat portion of the steering shaft spline with the bolt hole in the universal joint and then slide the shaft into the upper universal joint Install the bolt and lock washer on the upper universal joint and tighten it to 15 ft lb 20 N m 4 Tighten the steering rack mounting bolts 30 to 22 ft lb 29 8 N m Figure 7 10 Page 7 10 5 Install the drag link ball joint 23 on...

Page 108: ...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 CAUTION The tie rod and drag link have right hand threads on one end and left hand threads on the other end Right hand threads are identified by a groove in the tie rod or drag link ...

Page 109: ...raming square At the floor or ground there should be an equal amount of space between each tire and the framing square Figure 7 14 Page 7 15 2 Loosen but do not remove the four nuts 32 that secure the leaf spring 6 to the bottom spring plate 29 Figure 7 19 Page 7 19 See also Figure 7 15 Page 7 15 A A B A 1 2 1 Proper Camber Adjustment 2 Improper Camber Adjustment 32 8 7 2868 Figure 7 14 Check Camb...

Page 110: ...tween the marks on the forward facing surfaces of the tires See following NOTE NOTE The front measurement must be less than the rear measurement 5 Subtract the measurement on the front of the tires from the measurement on the rear of the tires The difference is the toe in Proper toe in is 1 8 to 3 8 of an inch 3 2 to 9 5 mm 6 If adjustment is necessary loosen the jam nut on each tie rod ball joint...

Page 111: ...llation Section 8 Page 8 1 5 Adjust camber and toe in See Camber Adjustment on page 7 15 and Toe in Adjustment on page 7 16 KINGPIN AND STEERING SPINDLE REMOVAL MAINTENANCE FREE BALL JOINTS 1 Remove the front hub See Front Hub and Wheel Bearings Removal on page 7 21 2 Remove nuts 20 and remove ball joints from spindles Figure 7 18 Page 7 18 Remove drag link ball joint See also Tie Rod and Drag Lin...

Page 112: ...mponents STEERING AND FRONT SUSPENSION 1 5 2 2 2 2 2 4 4 24 5 15 3 2 14 10 6 7 10 8 9 18 12 13 11 38 5 14 20 2610 Figure 7 18 Front Suspension Upper Portion Page 7 18 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 113: ...ront Suspension Components 7 15 17 3 16 1 2 33 19 34 5 7 4 35 14 8 26 27 28 27 25 6 31 32 29 9 13 23 14 30 5 17 37 36 2611 Figure 7 19 Front Suspension Lower Portion 2017 Carryall 500 and 700 Maintenance and Service Manual Page 7 19 ...

Page 114: ...ounting nut 38 then slide the shock absorber 15 free of the Delta A Plate 1 4 Remove the Delta A Plate 1 5 Inspect the bushings 2 and sleeves 3 and 4 in the Delta A Plate and replace them if necessary DELTA A PLATE INSTALLATION 1 Install the A Plate 1 in reverse order of removal Tighten the A Plate suspension bolts 10 and 24 to 20 ft lb 27 N m Figure 7 18 Page 7 18 2 Tighten shock absorber mountin...

Page 115: ...EL BEARINGS REMOVAL 1 Remove the front wheels See Wheel Removal on page 8 1 2 Remove the front wheel hubs 2 1 Remove dust cover 1 cotter pin 2 spindle nut 3 and flat washer 8 Figure 7 20 Page 7 21 2 2 Remove the hub assembly 4 from the spindle shaft Figure 7 20 Page 7 21 3 Remove the seal 6 and the bearings 5 from the hub Figure 7 20 Page 7 21 4 Inspect the bearing cups 7 If they are worn or pitte...

Page 116: ... spindle nut 3 Figure 7 20 Page 7 21 5 Tighten the spindle nut 3 until the hub is hard to turn then back the nut off until the hub turns freely Install a new cotter pin 2 Figure 7 20 Page 7 21 See following WARNING and NOTE WARNING Make sure to install and bend the cotter pin Failure to bend the cotter pin could result in the separation of the wheel hub from the spindle Loss of vehicle control cou...

Page 117: ...y aligned and adjusted WHEELS See General Warnings on page 1 1 WHEEL REMOVAL 1 Slightly loosen the lug nuts on the wheel to be removed 2 Raise the end of the vehicle from which the wheel is to be removed Make sure the wheels are off the ground See WARNING Lift only one end of the vehicle in General Warnings on page 1 1 3 Remove the lug nuts and remove the wheel WHEEL INSTALLATION 1 Install wheel s...

Page 118: ... damage to the tire do not use excessive force when starting the bead over the edge of the rim 3 3 When top bead is free of the rim pull the bead from the bottom side of the rim up into the upper part of the rim well Insert the tire tool under the lower bead as shown Figure 8 1 Page 8 2 Detail C and carefully pry the lower bead over the rim flange 3 4 Once the lower bead is started over the rim fl...

Page 119: ... from the valve stem side If there is no tire machine available use a rubber mallet and tire iron 5 Remove the valve core and position the tire so that both beads are on the rim flange narrow bead seats 6 Place the tire and wheel assembly against a wall in an upright position and push it against the wall while inflating the tire to the recommended pressure See Vehicle Specifications on page 2 1 Th...

Page 120: ...8 Tires WHEELS AND TIRES Figure 8 2 Inflate Tire Page 8 4 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 121: ...ge or fluid leakage at the point where the shaft enters the shock absorber body Replace damaged or leaking shock absorbers Figure 9 1 Page 9 1 and Figure 9 4 Page 9 4 2 To remove a shock absorber remove the nut 1 cup washers 4 and rubber bushings 3 from the stem at the top of the shock absorber 3 Remove lower mounting hardware 1 3 and 4 on shock absorber lower mount 4 Compress the shock absorber t...

Page 122: ... lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 3 Place a floor jack under the transaxle differential casing to support but not lift the drivetrain Raise it just enough to reli...

Page 123: ...the nut 11 and bolt 17 attaching the rear spring to the lower end of the shackle brackets 13 4 Install the nuts 7 and the U bolt 9 securing the spring to the shock mounting bracket 16 Install the shock mount bracket 6 angle bracket 13 and the U bolt 5 Tighten the nuts 7 on the U bolt 9 to 22 to 27 ft lb 30 to 37 N m 6 Install the nut 1 cup washers 4 and rubber bushings 3 to the lower mounting stem...

Page 124: ...Leaf Springs REAR SUSPENSION 17 17 9 14 19 11 15 6 1 1 7 11 13 5 2 3 4 10 12 8 17 10 11 16 2987 Figure 9 4 Rear Suspension Assembly and Mounting Page 9 4 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 125: ... installed Be sure that all nuts bolts and screws are tight On gasoline vehicles check all hose clamps for tight fit as well as the starter belt for tightness Safety and information decals Check to ensure that all safety and information decals are in place Tires Visually inspect for wear damage and proper inflation on a daily basis See Vehicle Specifications on page 2 1 Battery ies Check electroly...

Page 126: ... mode See Pedal Up Motor Braking below Walk Away Braking With the vehicle parked on level ground and the park brake disengaged place the Run Tow switch in the RUN position and attempt to push the vehicle Motor braking should engage and limit rolling to no more than 1 to 3 mph 1 6 to 4 8 km h with the Forward Reverse switch in any position When walk away motor braking is engaged the reverse buzzer ...

Page 127: ...d when performing maintenance service or accessory installation Do not work on vehicle powertrain or under the cargo bed when it is loaded Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle Turn the key switch to OFF remove the key place the Forward Reverse handle or switch in the NEUTRAL position and chock tires prior to servicing Do not close bed un...

Page 128: ...icles NOT equipped with the Single Point Watering System Check electrolyte level Add water if necessary See page 14 10 Batteries For vehicles equipped with the Single Point Watering System Water monthly or according to the established watering interval Water the batteries Observe that water flow occurs and no water overflows from any cell See Battery Care Vehicles Equipped with the Single Point Wa...

Page 129: ... expected see the Batteries section in the maintenance and service manual Annual service by trained technician only or every 100 hours of operation whichever comes first Safety decals Check safety decals Replace if damaged or illegible _ PERIODIC SERVICE SCHEDULE GASOLINE VEHICLES REGULAR INTERVAL SERVICE Pre Operation and Daily Safety Checklist See Pre Operation and Daily Safety Checklist on page...

Page 130: ...ecessary Check for leaks around gaskets fill plugs etc Engine Inspect clean and gap spark plug replace if necessary Check air filter element clean or replace if necessary Engine air intake system Check clamps for tightness check hose for cracks General vehicle Check for loose hardware and tighten if necessary Annual service by trained technician only or every 100 hours of operation whichever comes...

Page 131: ...151 Brake slides Dry Moly Lube CC PN 1012151 Semiannually by owner or trained technician or every 50 hours of operation whichever comes first Front suspension Chassis Lube EP NLGI Grade 2 Transaxle Check fill to plug level 22 fl oz 0 67 L SAE 30 WT API Class SE SF SG Oil or higher Annually by trained technician only or every 100 hours of operation whichever comes first Inspect front wheel bearings...

Page 132: ... every 50 hours of operation whichever comes first Brake slides Dry Moly Lube CC PN 1012151 Transaxle Check fill to plug level 67 6 fl oz 2 L SAE 80W 90 API Class GL 5 Annually by trained technician only or every 100 hours of operation whichever comes first Inspect front wheel bearings Repack as necessary Chassis Lube EP NLGI Grade 2 First change 100 hours additional change every 200 hours of oper...

Page 133: ...DT handheld programmer which replaced the IQDM series 2 handset How to use the CDT to troubleshoot the vehicle and to adjust controller parameters that affect vehicle behavior 1 7 8 3 4 5 6 12 2 11 10 9 1 Display Screen 5 Help Button 9 Favorites Button 2 Softkeys 6 Main Menu Button 10 Power Button 3 Key 7 System Port 11 Arrow Keys 4 Key 8 USB Port 12 SD card Slot 3115 Figure 11 1 CDT Overview 2017...

Page 134: ...ns give descriptions of adjustable parameters monitored variables and faults PC interface Files can be downloaded from a PC onto an Secure Digital SD card or into the programmer directly through its USB connector for installation into the controller Plot and Log The plot and log programs allow you to look at variables over time either in graphical format or as data files you can upload in a spread...

Page 135: ... vehicle it begins loading controller information During this time the loading status is shown as a percentage the CDT s software version is given and status information icons appear in the upper right corner Once loading is complete the screen displays the Main Menu NOTE If the Power button is used to turn ON the handset and the handset is not connected to a vehicle the message No System Detected...

Page 136: ...e Relay DNC Check wiring replace relay M Shorted Replace controller Relay Driver Off Replace controller M Main Coil Open Broken or disconnected coil wire B or B a defective solenoid coil Replace solenoid Relay Driver On Replace controller Main Driver Off Replace controller Relay Welded Replace relay Main Driver On Replace controller Speed Sensor Check connection replace speed sensor Main Driver Ov...

Page 137: ...er settings at time of manufacture MFG DATE CODE Displays the date the controller was manufactured OS VERSION Displays the controller operating system software version See following NOTE SM VERSION Displays the version number of the Start Manager software in the controller VCL APP VERSION Displays the version number of the Vehicle Control Language application software in the controller PARAMETERS ...

Page 138: ... 4 km h A vehicle programmed for speed setting 4 does not conform to ANSI Z130 1 American National Standard for Golf Cars Safety and Performance Specifications because it is capable of speeds in excess of 15 mph 24 1 km h For more information on this feature contact your local Club Car distributor or dealer M1 M2 Fast Accel M1 M2 fast accel fast acceleration is an option that can be enabled or dis...

Page 139: ... 23 5 km h 16 6 mph 26 7 km h 5 7 5 mph 12 1 km h 11 5 mph 18 5 km h 14 5 mph 23 3 km h 16 5 mph 26 6 km h 6 7 4 mph 11 9 km h 11 4 mph 18 3 km h 14 4 mph 23 2 km h 16 4 mph 26 4 km h 7 7 3 mph 11 7 km h 11 3 mph 18 2 km h 14 3 mph 23 0 km h 16 3 mph 26 2 km h 8 7 2 mph 11 6 km h 11 2 mph 18 0 km h 14 2 mph 22 9 km h 16 2 mph 26 1 km h 9 7 1 mph 11 4 km h 11 1 mph 17 9 km h 14 1 mph 22 7 km h 16 1...

Page 140: ... after changing the control mode to 2 cycle power to the controller by placing the Run Tow Switch in the TOW position for 30 seconds Then return it to RUN 3 Deterrent Demo Mode Uses maximum speeds defined by the deterrent demo setting to demonstrate the automatic speed control features of Guardian and UpLink See Deterrent Demo on page 11 8 Anti Tamper The anti tamper setting defines maximum speed ...

Page 141: ... functions in the Parameters Menu Each vehicle has a unique code for placing the vehicle in this mode Once activated Mode 2 settings can be programmed using the same procedures as Mode 1 settings This allows the vehicle to be customized to perform according to which mode it is operated in For more information on this feature contact your local Club Car distributor or dealer To activate Mode 2 1 En...

Page 142: ...s cycled Forward Reverse switch is activated etc See following NOTE NOTE Values appearing in these menus represent approximate measurements made by the controller and may differ from measurements made by external instruments Since the Monitor menu is updated while the vehicle is in operation the trained technician has the ability to monitor the status of several components in conditions or locatio...

Page 143: ...M pulse width modulation The range of pulse width modulation is 0 to 100 When the vehicle is operating at full speed the pulse width modulation should be at 100 FIELD PWM Displays motor field PWM pulse width modulation The range of pulse width modulation is 0 to 100 When the vehicle is in operation the pulse width modulation will fluctuate in response to the terrain and throttle input FOOT INPUT I...

Page 144: ... the speed controller will permanently lock out access to Mode 2 In the event that Mode 2 is locked out the controller must be removed and shipped to Club Car before Mode 2 can be activated NOTE The lower portion of the monitor menu contains the fault counter information Each fault is listed in the left hand column and the number of occurances will be listed in the right hand column CIR BRKR OPEN ...

Page 145: ...umber of times the MAIN DRVR OFF fault has been detected See Fault Descriptions on page 11 20 RELAY DNC Displays the number of times the RELAY DNC fault has been detected Did not close See Fault Descriptions on page 11 20 CURRENT SENSE Displays the number of times the CURRENT SENSE fault has been detected See Fault Descriptions on page 11 20 M SHORTED Displays the number of times the M SHORTED fau...

Page 146: ...e controller does not drive inhibited the handset indicates ON When the charger is not connected and the controller is allowed to drive the handset indicates OFF LED DRIVER Displays the present state of pin 11 in the controller 16 pin connector that operates the charge indicator light on the dash When pin 11 is activated power is provided to the light and the handset indicates that the LED Driver ...

Page 147: ...driving the vehicle this displays either the current being pulled out of the batteries or the current being returned to the batteries during regenerative motor braking It has a range from negative 300 amps to positive 300 amps Amp Hours Displays total accumulated amp hours removed from batteries since initial vehicle start up Regen Amp Hours Displays total accumulated amp hours returned to the bat...

Page 148: ...11 Monitor Menu CONTROLLER DIAGNOSTIC TOOL CDT Charger Additional Page 11 16 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 149: ... a passenger in the vehicle Failure to heed this warning could result in severe personal injury or death PRESENT ERRORS FOLDER The Fault History folder displays all existing faults in chronological order An item in this folder can only be removed by remedying the fault As long as the fault exists it will be included in the Present Errors folder The number number in the upper right corner of the sc...

Page 150: ...ds to the fault by limiting the vehicle speed to 1 2 of its normal top speed If the technician reaches the conclusion that the vehicle is running slowly because batteries are heavily discharged he has made an improper diagnosis of the problem The vehicle speed controller should be checked for fault codes before any service is performed The speed controller after detecting a fault will respond in o...

Page 151: ... FAULT Throttle Applied Arm PWM 50 4 Speed pulses appear 10 MAIN DRIVER ON Continuous while KSI is ON 4 Condition clears 11 MAIN COIL OPEN Continuous while KSI is ON 3 Condition clears 12 MAIN DROPOUT Throttle applied 3 12 Throttle applied 13 MOTOR STALL Throttle applied 6 Speed pulses appear 14 MAIN DRIVER OFF Throttle applied 3 10 Condition clears 15 RELAY DNC WalkAway 2 13 Throttle applied 16 K...

Page 152: ...lready depressed when the key switch is turned to the ON position This fault when not caused by the operator can indicate that the pedal limit switch has failed closed 07 MAIN WELDED If the speed controller detects that the solenoid contacts are welded closed a main welded fault is detected 08 RELAY WELDED If the speed controller detects that the external Walk Away relay contacts are welded closed...

Page 153: ...d on or off with an CDT Factory default setting is off 17 CURRENT SENSE If there are problems with the armature current sensor circuitry a current sense fault is detected 18 M SHORTED If an uncontrolled current path is detected from the motor to B bypassing the MOSFETs an M shorted fault is detected 20 DRIVER OVERCURRENT If the current on the relay driver exceeds 120 mA or the current on the solen...

Page 154: ...o What to do Clear the Fault History in the CDT Ensure wiring is connected and inspect for damaged wires If the vehicle is not or no longer going to be equipped with these services change Control Mode setting to zero 0 LOCKOUT FAULT If the controller receives a signal that the charger interlock is activated while the vehicle is being driven the controller registers a lockout fault and may prevent ...

Page 155: ...cess Level Only on page 11 12 FAULT HISTORY The fault history menu can be useful in determining the cause of a vehicle problem however the fault history alone should not be the factor that determines when a component is replaced Some faults detected by the speed controller are not the result of a failed component and are instead the result of vehicle operator error If a fault appears in the fault ...

Page 156: ...that cannot be seen at the OEM level It is recommended to enable Advanced Cloning FAVORITES The Favorites menu is accessed by pressing the Favorites key 9 Figure 11 1 Page 11 1 This menu can also be accessed by using the arrow keys to highlight Favorites and pressing the Select softkey to activate the menu Return to the Main Menu at any time by pressing the Main Menu key 6 The Favorites menu selec...

Page 157: ...by the controller Exit menus with left arrow The left arrow key is used to navigate backwards within menus When set to Yes you can use the left arrow key to leave the presently displayed screen and return to the next higher i e previous screen using the left arrow key will eventually return you to the Main Menu When set to No you must use the appropriate softkeys Exit Cancel and the Main Menu key ...

Page 158: ...n the CDT display screen or with the Log program to create a log file of variable values to view later in a spreadsheet program on a PC The first step is to add the desired items to the Plot Variable List or the Log Variable List While in the Monitor menu or Parameters menu highlight an item and press the Add to softkey In the next screen highlight Plot or Log and press the Select softkey to view ...

Page 159: ...us Electric Vehicles Handset cord has failed Test Procedure 1 Handset Cord on page 11 28 Handset cord adaptor has failed Test Procedure 2 Handset Cord Adaptor on page 11 29 CDT port mounted under instrument panel assembly has failed Test Procedure 3 CDT Ports on page 11 29 Contrast Setting is too light See Backlight under HHP Settings menu Controller is in power down mode vehicle unused and not ch...

Page 160: ...conds and reconnect the handset to the vehicle Vehicle batteries loose terminals or corrosion Section 14 Batteries IQ Plus Electric Vehicles Vehicle batteries improperly wired Section 14 Batteries IQ Plus Electric Vehicles Vehicle batteries batteries failed Section 14 Batteries IQ Plus Electric Vehicles Vehicle batteries batteries not fully charged Section 14 Batteries IQ Plus Electric Vehicles Ha...

Page 161: ...lug TEST PROCEDURE 3 CDT Ports Inspect the CDT ports for damage or corrosion 3A CDT PORT LOCATED UNDER INSTRUMENT PANEL See General Warnings on page 1 1 1 Turn the key switch to the OFF position place the Forward Reverse switch in the NEUTRAL position and lock the park brake 2 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles Section 1 Page 1 4...

Page 162: ...es not function during Test Procedure 3A but does function when connected directly to the speed controller the handset cord adapter and vehicle wire harness should be thoroughly tested See Test Procedure 2 Handset Cord Adaptor on page 11 29 The CDT ports and connections should also be thoroughly checked Section 12 Electrical System Troubleshooting IQ Plus Electric Vehicles Figure 11 3 Disconnect F...

Page 163: ...w 10 Charging Confirmation The light will flash three times and the reverse buzzer simultaneously will sound three times to indicate a battery charging session has begun See following NOTE NOTE The number of flashes and beeps can vary depending on the Beep Option setting See Beep Option Section 11 Page 11 9 KEY DIFFERENCES IQ PLUS WITH QUIQ CHARGER VS IQ PLUS CHARGER Utilizes the 1520L 5550 contro...

Page 164: ...that speed Motor braking is automatically disengaged when vehicle speed slows below the programmed top speed Pedal Up Motor Braking adjustable Speed settings are programmable for IQ Plus vehicles Motor braking is activated when the accelerator pedal is released at or above the programmed speed When the vehicle slows to the programmed lower speed motor braking will disengage If no speed settings ar...

Page 165: ...formation 12 If either situation arises an HPD fault is recorded by the speed controller and will be displayed on an CDT handset in the Diagnostic History menu See CDT Troubleshooting Section 11 Page 11 27 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12 3 ...

Page 166: ...2 Wiring Diagrams ELECTRICAL SYSTEM TROUBLESHOOTING IQ PLUS ELECTRIC VEHICLES WIRING DIAGRAMS WD1050496_L_DGM Figure 12 1 Wiring Diagram Page 12 4 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 167: ...ELECTRICAL SYSTEM TROUBLESHOOTING IQ PLUS ELECTRIC VEHICLES Wiring Diagrams 12 WD1050496_R_DGM Figure 12 2 Wiring Diagram Continued 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12 5 ...

Page 168: ... Wiring Diagrams ELECTRICAL SYSTEM TROUBLESHOOTING IQ PLUS ELECTRIC VEHICLES WD1050821_DGM_C1 Figure 12 3 Wiring Diagram Instrument Panel Page 12 6 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 169: ...ELECTRICAL SYSTEM TROUBLESHOOTING IQ PLUS ELECTRIC VEHICLES Wiring Diagrams 12 WD1050496_2_DGM Figure 12 4 Wiring Diagram Accessories 2017 Carryall 500 and 700 Maintenance and Service Manual Page 12 7 ...

Page 170: ...IQ Plus electrical system Troubleshooting Guide 1 is to be used in conjunction with the CDT handset Refer to the CDT Owner s Manual for operating instructions See following WARNING WARNING The vehicle operator should not monitor the CDT while the vehicle is in motion A technician can monitor the CDT while traveling as a passenger in the vehicle Failure to heed this warning could result in severe p...

Page 171: ... motor speed sensor Loose or disconnected 24 pin connector at speed controller or broken wire Repair and or connect the 24 pin connector to the speed controller Monitor Menu SPEED PULSES menu item indicates that speed pulses are OFF when the vehicle is in motion or Diagnostic Menu SPEED SENSOR fault code Failed motor speed sensor or failed magnet Test Procedure 13 Motor Speed Sensor on page 12 29 ...

Page 172: ... or broken wire Repair and or connect the three pin connector to the MCOR Loose or disconnected 24 pin connector at speed controller or broken wire Repair and or connect the 24 pin connector to the speed controller Diagnostic Menu THROTTLE FAULT 1 fault code Failed MCOR Test Procedure 12 MCOR Voltage on page 12 27 Armature drive FET s field effect transistors inside speed controller have failed Re...

Page 173: ...lected direction with the Forward Reverse switch Batteries require charging Place batteries on battery charger and allow them to fully charge Diagnostic Menu LOW BATTERY fault code Improperly maintained or failed batteries Section 14 Batteries IQ Plus Electric Vehicles Diagnostic Menu MOTOR STALL fault code Operator error Train operators to use the brake to hold the vehicle on a hill rather than h...

Page 174: ...Test Procedure 8 Forward Reverse Rocker Switch on page 12 24 Solenoid loose wires Test Procedure 9 Solenoid Activating Coil on page 12 25 Solenoid failed coil Test Procedure 9 Solenoid Activating Coil on page 12 25 Solenoid failed solenoid diode Test Procedure 9 Solenoid Activating Coil on page 12 25 Speed controller thermal cutback Allow controller to cool and ensure that vehicle is not over load...

Page 175: ...on Vehicle runs slowly Tires under inflated or flat tires See Wheels and Tires Section Wiring improperly wired Check vehicle wiring See Wiring Diagrams beginning on page 12 4 Vehicle operates but motor braking function does not Speed sensor disconnected or failed Test Procedure 13 Motor Speed Sensor on page 12 29 Forward Reverse rocker switch improperly wired Test Procedure 8 Forward Reverse Rocke...

Page 176: ...hite black wire in position 21 of the 24 pin connector and charge indicator light is powered by the controller with Run Tow switch in RUN The 2 amp fuse is powered directly by the batteries via the solenoid and carries BPV to the connected car device No switch is involved The term back probe refers to probing the side of a connector that the wire enters This is usually done when the connector must...

Page 177: ...vehicle 2 Access the Monitor menu and select BATT VOLTAGE by using the SCROLL DISPLAY buttons The CDT should indicate at least 48 volts See following NOTE If not check for loose battery connections or a battery installed in reverse polarity Refer to Batteries IQ Plus Electric Vehicles on page 14 1 for further details on battery testing NOTE The voltage displayed through the CDT shows what the cont...

Page 178: ... IQ PLUS ELECTRIC VEHICLES 1 2 3 4 6 5 7 8 Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to battery no 6 3072 Figure 12 5 Battery Voltage Test 500 550 700 Page 12 16 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 179: ...t the tester leads to the positive post of battery no 1 and negative post of battery no 8 Figure 12 6 Page 12 17 Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to battery no 8 2780a Figure 12 6 Battery Discharge Test TESTER Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to battery no 8 2781a Figure 12 7 Battery Discharge Test 4 Turn the d...

Page 180: ...ce to activate the onboard computer 4 If the vehicle will not operate proceed to Run Tow Switch Test without the CDT Handset 5 If the CDT display screen begins to work after the vehicle has been driven turn the key switch to the OFF position and proceed to step 6 otherwise perform Run Tow Switch Test without the CDT Handset 6 With the CDT still connected to the vehicle place the Run Tow Switch in ...

Page 181: ... amp fuse to connected car device Guardian Visage V3 Circuit and 15 amp fuse to electric powertrain Under Floorboard Near MCOR 20 amp fuse from DC DC converter to accessories Under Front Cowl 15 amp fuse to cab 10 amp fuse to brake lights horn and turn signals 7 5 amp fuse to headlights and taillights 10 amp fuse to 12 volt power strip and power point On Main Harness Near Controller Mounting Plate...

Page 182: ...se shows 12 5 to 13 5 volts do the following Check 15 amp ATC fuse on controller mounting plate that supplies power to DC DC converter If fuse is good check converter For ATM Fuses Under Front Cowl Check sonic weld_4 in main wire harness Check key switch Check lockout relay For All Fuses Powered by the DC DC Converter Check sonic weld_16 in main wire harness TEST PROCEDURE 5 Circuit Breaker See Ge...

Page 183: ...ge at the number 3 pin of the 24 pin connector 12 If there is voltage at the number 3 pin 12 1 Replace the controller NOTE Make sure the correct controller is used Early 2006 model year to 2013 model year with onboard computer and Villager 6 8 use controller model number 1520 Mid model year 2014 models without onboard computer OBC onboard charger Delta Quiq use controller model number 1520L 13 If ...

Page 184: ... 12 9 Page 12 22 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 1 VOM Black Le...

Page 185: ...on properly in order to test the MCOR limit switch with the CDT handset 5 Test the MCOR limit switch 5 1 Select FOOT INPUT on the Monitor menu by using the SCROLL DISPLAY buttons on the CDT 5 2 The CDT should indicate that FOOT INPUT is OFF when the accelerator pedal is not pressed regardless of the key switch position 5 3 With the key switch in the ON position press the accelerator pedal The CDT ...

Page 186: ...nnector It should show zero 0 volts with the accelerator pedal at rest Press the accelerator pedal and the green wire should show BPV passing through the MCOR to the controller for FOOT INPUT From the MCOR the blue wire supplies voltage BPV to pin 8 If not replace MCOR See MCOR Removal on page 13 6 TEST PROCEDURE 8 Forward Reverse Rocker Switch See General Warnings on page 1 1 NOTE This is a volta...

Page 187: ...spade terminal connection and related wiring 4 2 Brown Wire The brown wire should show BPV in FORWARD The brown wire should show zero 0 volts in NEUTRAL and REVERSE If the brown wire shows voltage in NEUTRAL the switch may have corrosion across the contacts or the switch has failed CLOSED and must be replaced See Forward Reverse Rocker Switch Removal on page 13 3 If the brown wire does not show BP...

Page 188: ... with a chain hoist or floor jack Position jack stands under the frame crossmember between the spring mount and side stringer just forward of each rear wheel See WARNING Lift only one end in General Warnings on page 1 1 2 Turn the key switch to the ON position and place the Forward Reverse switch in the FORWARD position 3 Set a multimeter to 200 volts Place the black probe on the battery no 8 nega...

Page 189: ... 10k ohm resistor If the reading is approximately 42 to 46 volts check continuity of circuit wires 5 Check 10k ohm resistor Set multimeter to 20k ohms Remove the 15 amp fuse With the red probe with insulation piercing probe still on the light blue wire pin 2 of the 24 pin connector place the black probe to the pink wire terminal in the 15 amp fuse holder The reading should be approximately 10 0k o...

Page 190: ...and lift the rear of the vehicle with a chain hoist or floor jack Position jack stands under the frame rails just forward of each spring mount See WARNING Lift only one end in General Warnings See also following WARNING WARNING The key switch should be placed in the OFF position and left in the OFF position for the duration of this test 2 With the batteries connected place Run Tow switch in RUN Us...

Page 191: ...stance about 3 feet 1 meter The reverse buzzer should sound and motor braking should engage while the vehicle is rolling 4 If the reverse buzzer does not sound and motor braking does not engage while the vehicle is rolling replace the Motor Speed Sensor Motor Speed Sensor Test with the CDT Handset CAUTION Perform the following procedure only on a level surface To avoid injury or property damage en...

Page 192: ...ctor at the motor speed sensor If the continuity is correct replace the speed controller Figure 12 11 Test 13 Speed Sensor Black White Wire 4 Check voltage at the red motor speed sensor wire 4 1 With Run Tow switch in the RUN position and using a multimeter set to 20 volts DC place the black probe on the battery no 8 negative post and place red probe on red wire terminal socket in three pin connec...

Page 193: ...n wire from the 24 pin connector at the speed controller to the three pin connector at the motor speed sensor If the continuity is correct replace the speed controller 5 3 If reading is below 3 50 volts check the continuity of the wires and plug and replace the speed controller if necessary Figure 12 13 Test 13 Speed Sensor Light Green Wire 6 Reconnect the three pin connector at the motor speed se...

Page 194: ... or floor jack Position jack stands under the frame crossmember between the spring mount and side stringer just forward of each rear wheel See WARNING Lift only one end in General Warnings on page 1 1 See also following WARNING WARNING Keep people and equipment clear from rotating rear wheels Do not allow persons under the car Contact with rotating rear wheels could result in serious personal inju...

Page 195: ... and discharge the controller See Disconnecting the Batteries Electric Vehicles Section 1 Page 1 4 2 Disconnect the 24 pin connector from the speed controller Inspect terminal ends inside plug to ensure they are in position and seated in plug housing If any terminals look like they are not pushed all the way into the connector gently push the terminals until they are firmly seated in the 24 pin co...

Page 196: ...in 14 Purple White 18 gauge Pin 15 Yellow 18 gauge Test continuity of each wire and perform Pin 16 Open no wire Pin 17 Blue White 18 gauge Pin 18 Open no wire Pin 19 Orange White 18 gauge Pin 20 Purple 18 gauge Pin 21 White Black 18 gauge Supplies approximately 13 volts to the Guardian Visage unit CONNECTED CAR OUTPUT Approximately 13 volts measured between pin 1 and B terminal on controller Key s...

Page 197: ...e multimeter should read approximately 1k ohms 6 Slowly press the accelerator pedal while monitoring the multimeter The resistance should rise as the pedal is pressed When the pedal is all the way to the floor the multimeter should indicate between 5 67k ohms and 7 43k ohms 7 Set a multimeter to 20k ohms Insert the red probe of the multimeter into pin 15 yellow wire at the 24 pin connector Connect...

Page 198: ...icles Section 1 Page 1 4 5 Set a multimeter to 200 volts DC insert the red probe of the multimeter into pin 8 green wire of the 24 pin connector See following CAUTION Connect the black probe to the B terminal of the speed controller or negative post of battery no 8 Figure 12 17 Page 12 36 CAUTION Do not fully insert probes into the 24 pin plug Doing so can result in a poor connection A Detail A Fr...

Page 199: ...l See WARNING Lift only one end in General Warnings on page 1 1 3 Disconnect the 24 pin connector at the speed controller 4 Place a jumper wire with an alligator clip between the B terminal of the speed controller use alligator clip for this connection and pin 19 orange white wire of the 24 pin connector Figure 12 18 Page 12 38 See following CAUTION CAUTION Do not fully insert probes into the 24 p...

Page 200: ...g mount and side stringer just forward of each rear wheel See WARNING Lift only one end in General Warnings on page 1 1 3 Disconnect the 24 pin connector at the speed controller 4 Set a multimeter to 200 volts DC insert the red probe of the multimeter into pin 10 brown wire of the 24 pin connector See following CAUTION Using an alligator clip connect the black probe to the B terminal of the speed ...

Page 201: ... of the wires in the wire harness Forward Reverse switch for proper operation See Forward Reverse Rocker Switch on page 12 24 Run Tow switch for proper operation See Run Tow Switch on page 12 18 A Detail A Front of 24 Pin Connector Figure 12 19 Test Pin 10 Black Wires Pin 1 See General Warnings on page 1 1 Pin 1 in the 24 pin connector provides a connection point for the key switch to the speed co...

Page 202: ...ey switch in the ON position the multimeter should indicate full battery voltage approximately 48 volts With the key switch in the OFF position the reading should be zero volts 9 If any other reading is obtained check the following items Continuity of the wires in the wire harness Run Tow switch for proper operation See Run Tow Switch on page 12 18 Key switch for proper operation See Key Switch an...

Page 203: ... With an alligator clip connect the black probe to the negative terminal of battery 8 CAUTION Do not fully insert probes into the 24 pin plug Doing so can result in a poor connection 3 The reading should be 48 volts If the reading is zero volts replace the circuit breaker Pin 20 Smart Key Switch Only Voltage is supplied to Pin 20 when it is in the Mode position 1 With a multimeter set for 200 volt...

Page 204: ...full battery voltage 6 1 If the voltage reading is correct replace the reverse buzzer 6 2 If reading is zero volts check orange white wire continuity and connection at Pin 19 in 24 Pin connector 6 3 If there is no continuity in the orange white wire or the Pin 19 terminal in the 24 Pin connector is not properly seated repair or replace as required 6 4 If the orange white wire continuity and 24 Pin...

Page 205: ...T should quickly display ON just once while the dash mounted charge indicator light flashes three times See following NOTE NOTE The CDT will still flash ON even with a failed or missing charge indicator light 7 If the CDT quickly displays ON but the charge indicator light still does not flash check the following items Condition of the blue yellow wire terminal in the 16 pin connector Condition of ...

Page 206: ... Run Tow switch in either position 4 Probe pin 4 white black wire It should show approximately 13 volts supplied by the controller If not check wiring and then controller See following NOTE NOTE The white black wire only has voltage with the Run Tow switch in the RUN position If pin 4 has no voltage the controllers LIN Local Interconnect bus may have failed The vehicle can be driven if it is not u...

Page 207: ...ch 4 From the back of the instrument panel push down on the retaining tabs surrounding the key switch 4 and remove the key switch cap 8 Using a 1 inch socket hold the key switch and remove the switch retaining nut 6 from the outside of the instrument panel Figure 13 1 Page 13 2 KEY SWITCH INSTALLATION 1 Position the key switch 3 and key switch washer 1 in the instrument panel then install and tigh...

Page 208: ...13 Key Switch ELECTRICAL COMPONENTS IQ PLUS ELECTRIC VEHICLES 6 5 1 2 3 4 Figure 13 1 Key Switch Page 13 2 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 209: ...ect the 18 gauge brown orange and red green wires to the rocker switch exactly as shown in the wiring diagram See Wiring Diagrams Section 12 Page 12 4 3 Install instrument panel See Instrument Panel Installation on page 4 10 4 Connect the batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 5 Place the Run Tow switch in the RUN position 6 Inspect the vehicle for proper opera...

Page 210: ...Test Procedure 5 Circuit Breaker on page 12 20 CIRCUIT BREAKER REMOVAL 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles Section 1 Page 1 4 2 Remove the plastic nut 1 from the circuit breaker Figure 13 2 Page 13 5 3 Remove circuit breaker and metal nut 2 from bracket 3 4 Disconnect tan and green wires from the spade connectors 4 on the back o...

Page 211: ...ELECTRICAL COMPONENTS IQ PLUS ELECTRIC VEHICLES Circuit Breaker 13 3 1 2 4 Figure 13 2 Circuit Breaker 2017 Carryall 500 and 700 Maintenance and Service Manual Page 13 5 ...

Page 212: ... with a chain hoist or floor jack Place jack stands under the round tube crossmember of the frame to support vehicle 3 Disconnect the two pin and three pin connectors 1 from the MCOR 2 Figure 13 3 Page 13 6 4 Remove the two torx screws 3 securing the MCOR 2 to the plastic housing 4 on the chassis 5 Detach the two tabs from the plastic housing 4 and remove the MCOR 2 from vehicle GO 1 2 3 4 5 2646 ...

Page 213: ...e two screws from the reverse buzzer Remove the reverse buzzer from the center dash panel REVERSE BUZZER INSTALLATION 1 Install the reverse buzzer in the reverse order of removal Tighten screws to 4 in lb 0 45 N m 2 Connect the batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 SPEED CONTROLLER COVER REMOVING THE SPEED CONTROLLER COVER 1 Use a flathead screwdriver to pry u...

Page 214: ... remove the two screws 1 that hold the solenoid 2 to the component mounting plate 5 Lift the solenoid 2 up and off of the component mounting plate 2 1 Figure 13 4 Solenoid SOLENOID INSTALLATION 1 Mount solenoid 2 onto component mounting plate with screws 1 Figure 13 4 Page 13 8 2 Tighten screws 1 to 60 in lb 6 8 N m 3 Using the wiring diagram install the wires washers and nuts onto the large mount...

Page 215: ...3 5 Page 13 10 2 Using the wiring diagram install the multi pin connectors and all wires as illustrated See Wiring Diagrams Section 12 Page 12 4 Tighten bolts 8 to 13 5 ft lb 18 3 N m Tighten bolts 22 to 11 ft lb 14 9 N m Figure 13 5 Page 13 10 3 Install the speed controller cover See Installing the Speed Controller Cover on page 13 7 4 Connect the batteries See Connecting the Batteries Electric V...

Page 216: ...r ELECTRICAL COMPONENTS IQ PLUS ELECTRIC VEHICLES 7 20 8 12 23 17 22 18 2 13 3 24 1 6 4 21 10 15 16 14 5 9 19 25 11 11 2998 Figure 13 5 Speed Controller Page 13 10 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 217: ...les Section 1 Page 1 4 2 Remove instrument panel See Instrument Panel Removal on page 4 10 3 Disconnect the wires at the warning light 4 Press the two retaining tabs and remove the light from the instrument panel CHARGE INDICATOR LIGHT INSTALLATION 1 Install light into instrument panel 2 Connect wires to the warning light 3 Install the instrument panel See Instrument Panel Installation on page 4 1...

Page 218: ...Pagination Page 13 Charge Indicator Light ELECTRICAL COMPONENTS IQ PLUS ELECTRIC VEHICLES Page 13 12 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 219: ...minutes Call a physician immediately WARNING Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubber gloves when working on or near batteries Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Ensure battery connections are clean and properly ...

Page 220: ...d downs Incorrect orientation of batteries i e terminal posts Poor fair or proper cleanliness of batteries Added electric accessories Use of a single point watering system SPWS MEASURING VOLTAGE OF BATTERY SET Set the multimeter to 200 volts DC Place the red probe on the positive post of battery no 1 and the black probe on the negative post of battery no 8 Record the reading BATTERY CELL NUMBERING...

Page 221: ...rithm specific to the battery installed Regrouping is now Club Car s standard battery replacement method Regrouping is the practice of placing batteries of similar condition together in one vehicle For example if there was an issue with the batteries in two cars and the battery test indicated three failed batteries in each car after removing the failed batteries there will be six good batteries re...

Page 222: ...14 Battery Regrouping BATTERIES IQ PLUS ELECTRIC VEHICLES 3104 Figure 14 2 Battery Regrouping Process Flow Page 14 4 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 223: ...at may have occurred in transit New batteries will not deliver their full capabilities until they have been discharged and recharged 50 to 70 times To obtain the maximum service life from new batteries restrict vehicles with new batteries to one hour of operation between charges for the first two months vehicle is in service Batteries should be fully charged before first use of new vehicle before ...

Page 224: ... with the Single Point Watering System SPWS CC P N 105166801 for vehicles without SPWS CC P N 105166801 used in combination with AM10818 Battery Watering Nozzle Gun Alternate Methods Reverse Osmosis Reverse osmosis involves forcing water through a membrane that allows water to pass while trapping solids The choice of membrane used determines the amount of solids or impurities that get trapped and ...

Page 225: ... strainer on all supply hoses Be sure to replace the deionizer filter cartridge as indicated by the water quality light The CC P N 105166801 Deionizer system has a battery powered water quality light Deionizer filters have a limited life cycle and are disposable Life cycle of the filter will vary based on incoming water quality and water usage If the deionizer system is equipped with a water quali...

Page 226: ...tion off of the batteries Do not allow this solution to enter the battery Be sure terminals are tight Let the terminals dry and then coat with Battery Terminal Protector Spray See following NOTE NOTE Dispose of waste water properly 2 The battery hold downs should be tight enough so that the batteries do not move while the vehicle is in motion but not so tight as to crack or buckle the battery case...

Page 227: ...working condition follow this maintenance program on a regular basis 1 Keep the batteries clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water use 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse solution off of the batteries Do not allow this solution to enter the battery Be sure terminals are tight Let the terminals dry and then coat...

Page 228: ...s or hydrometer to drip onto the front or rear body of the vehicle Battery acid will cause permanent damage Wash immediately Add water only after charging unless the electrolyte is below the level of the plates If the electrolyte level is below the level of the plates add just enough water to cover the plates and then charge the batteries After charging fill with water to the level indicator Filli...

Page 229: ...ered water quality indicator light Replacement cartridge 104005901 Bottled distilled water with hand pump Club Car Part Number 104006101 is recommended for private consumer applications INITIAL MAINTENANCE OF THE SPWS After six weeks of operation remove the valves from the batteries and manually check the battery water level to ensure that the SPWS is not leaving any cells dry This initial electro...

Page 230: ...e following NOTE NOTE This step also eliminates any trapped air from the water hose The water flow rate must be at least 2 gallons per minute 7 6 L per minute and the water pressure must be no more than 100 psig 689 5 kPa when static no flow for the SPWS to function properly 5 Check the water quality light on the deionizer to make sure the light is green in color indicating acceptable water qualit...

Page 231: ...ill coupling into the space between the batteries and the car body Leaving the fill coupling on top of the battery bank or tucked between the batteries can result in coupling damage 5 Turn the water faucet off when finished filling the vehicle s BATTERY STORAGE See Storage Electric Vehicles Section 3 Page 3 2 FLEET ROTATION Rotate vehicle usage It is very hard on batteries if the last vehicles in ...

Page 232: ...use provided 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 EARLY EXCESSIVE DISCHARGING When vehicle batteries are new they do not reach their full capacity until they have been discharged and recharged 50 to 70 times If they are excessively di...

Page 233: ...revents the possibility of driving the vehicle while the charger is plugged in and potentially damaging the vehicle and charger Long Term Storage Charge This charger is designed to be left connected to AC power during off season or long term storage Be sure to check the charger monthly to ensure the charger is operating correctly during storage The charger will enter maintenance mode if supported ...

Page 234: ...l of the charger lights will turn on and then off 4 2 The AC on symbol will turn on 4 3 The current algorithm will display for 11 seconds 2388B Figure 15 1 80 Charge Light 5 If the 80 charge light flashes the current algorithm is 72 Figure 15 1 NOTE The 80 charge light will flash 7 times pause then flash 2times 2387B Figure 15 2 Number 3 Light 6 If the number 3 light flashes the current algorithm ...

Page 235: ...y wire to the battery post until the batteries start to charge 7 2 When the batteries start to charge disconnect the main positive battery wire 8 Disconnect the AC cord 9 Connect the main positive battery wire 10 If equipped connect the DC DC converter connector 11 Set the Run Tow switch to RUN THE CHARGE CIRCUIT The charge circuit consists of the onboard charger batteries and charger information ...

Page 236: ...ir work to the manufacturer or qualified personnel This appliance is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety Children should be supervised to ensure that they do not play w...

Page 237: ...arts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death Do not operate the charger if it has received a sharp blow was dropped or otherwise damaged in any way Have worn cut or damaged power cords or wires replaced immediately Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical components in the...

Page 238: ...bulk phase Ammeter Amber Flashing High internal charger temperature Output reduced Also displays algorithm 1 through 6 for 11 seconds if no battery is connected Solid Bulk charge phase complete 80 charged In Absorption phase 80 Charge Amber Flashing 1 With no battery connecte indicates algorithm selected by number of flashes 2 With battery connected indicates battery being charged TABLE CONTINUED ...

Page 239: ...ower good AC on Amber Flashing Low AC Voltage Check Voltage and power cord length refer to guidelines See AC Power Connection on page 15 8 Fault Red Flashing 1 Solid Red Charger Hardware Failure requires charger to be replaced 2 Flashing Red Charge Cycle Caution AC Voltage DC Voltage Ambient Temperature Charge Cycle Timers 2017 Carryall 500 and 700 Maintenance and Service Manual Page 15 7 ...

Page 240: ...cle has been driven and recharged from 20 to 50 times Vehicles should be restricted to 40 to 50 amp hours of discharge between charges until the batteries 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 amp hours of discharge or each night in order to avoid deep discharging the batteries Charg...

Page 241: ...nd annual periodic service WARNING If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal injury or death Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the charger Do not expose charger to oil dirt mud or direct h...

Page 242: ...er interrupt AC power for 15 seconds Battery Low Voltage Ensure battery set is rated 48 volts and composed of 24 cells Also check the voltage of each individual battery See Battery Voltage Using Multimeter on page 15 11 If not replace with correct battery set Reset charger interrupt AC power for 15 seconds Charge Timeout caused by battery pack not reaching required voltage Charger output was reduc...

Page 243: ... poor performance may indicate a problem in the vehicle electrical system brakes or battery charger If the problem is not found in the vehicle or charging system proceed to the on charge voltage test If the green battery icon does not change to a slow flash the batteries should be tested further using the on charge voltage test TEST PROCEDURE 3 On Charge Battery Voltage Using Charger And Multimete...

Page 244: ...ler 10 gauge black wire See following NOTE NOTE The 10 gauge red wire from the charger to the solenoid has an in line 30 amp fuse 3 When finished connect DC cord plug to the charger lead CHARGER REPAIRS See General Warnings on page 1 1 NOTE The high frequency charger offers no replacement parts If necessary the charger must be replaced See Onboard Charger Removal And Installation on page 15 12 ONB...

Page 245: ...l the four lock nuts 5 securing charger to charger mounting plate Tighten to 40 in lb 5 4 N m 3 Connect the AC and DC connector 4 Connect 8 pin grey connector 5 Install wire ties to secure connectors to the charger P clip 6 Connect the batteries See Connecting the Batteries Electric Vehicles on page 1 4 2017 Carryall 500 and 700 Maintenance and Service Manual Page 15 13 ...

Page 246: ...Pagination Page 15 Onboard Charger Removal And Installation QUIQ HIGH FREQUENCY CHARGER Page 15 14 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 247: ...ee General Warnings on page 1 1 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles Section 1 Page 1 4 2 Disconnect wires from terminals on motor using two wrenches to prevent posts from turning 3 With a multimeter set to 200 ohms place black probe on motor housing Scratch through paint to ensure a good connection Place red probe on A1 A2 F1 an...

Page 248: ...pen field coil or bad connections at the terminals may be the cause The motor will need to be removed from the vehicle and repaired by a qualified technician See Motor Removal on page 16 2 3 Connect the batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 MOTOR REMOVAL See General Warnings on page 1 1 1 Disconnect the batteries and discharge the controller See Disconnecting ...

Page 249: ...les 8 To gain easier access to the motor lower the transaxle as low as it will go If more room is needed remove the jack from beneath the transaxle and allow the springs to rest on the floor Figure 16 3 Page 16 3 Figure 16 3 Lower Axle 9 Remove the four bolts that mount the motor to the transaxle Figure 16 21 Page 16 16 See following CAUTION CAUTION Do not position fingers under motor when sliding...

Page 250: ...ve speed sensor 10 and magnet 12 3 1 Remove the two screws 11 and clamp that secure the speed sensor 10 to the end cap 20 3 2 Remove the bolt 13 securing the magnet 12 to the armature shaft 15 Hold the back of the armature assembly to keep it from turning as you remove the bolt 3 3 Inspect the speed sensor magnet See Speed Sensor Magnet Inspection on page 16 9 Figure 16 6 Brush Springs Positioning...

Page 251: ...o reduce tension during removal of the armature Figure 16 6 Page 16 4 8 2 Place the end cap in a press with the armature facing down 8 3 Place a bearing press tool with an outer diameter smaller than that of the armature shaft between the press ram and the armature shaft Figure 16 7 Page 16 4 8 4 Have an assistant support the armature while the press is activated 9 Inspect the armature for wear an...

Page 252: ...16 Motor Disassembly MOTOR MODEL DA5 4006 ELECTRIC VEHICLES Figure 16 8 Brush Rigging Removal Figure 16 9 Retaining Ring Removal Page 16 6 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 253: ... help determine original cause of failure Slight roughness of the commutator can be polished smooth with 400 grit or finer sandpaper See following CAUTION and NOTE CAUTION Do not use emery cloth to polish the commutator Particles of emery are conductive and may short circuit the commutator bars Do not use oil or lubricants on the commutator or brushes NOTE Oil on the commutator may indicate a faul...

Page 254: ...3 Inspect the brush springs 18 Figure 16 13 Page 16 10 Replace springs that are discolored from heat light gold or blue tinted 4 Test the brush springs for proper tension 4 1 Place a C shaped steel plate 1 on a scale 2 4 2 Place the end of the C shaped plate 1 so that it is between the spring and the brush 4 3 Gently pull the scale 2 to obtain the spring tension reading See following CAUTION CAUTI...

Page 255: ...sulators as required Bearing Inspection NOTE Replacement of the end cap bearing is highly recommended if the end cap is removed from the motor The following procedure is provided as a guideline for determining general bearing failure 1 Remove the motor from the vehicle See Motor Removal Section 16 Page 16 2 2 Remove the bearing by performing steps 1 through 13 of Motor Disassembly on page 16 4 3 U...

Page 256: ...omponent Testing and Inspection MOTOR MODEL DA5 4006 ELECTRIC VEHICLES 22 2 4 1 23 13 10 11 9 12 18 16 21 14 15 17 7 6 19 20 Figure 16 13 Motor Page 16 10 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 257: ...oid damaging the bearing apply pressure only to the outer race when installing the bearing 1 2 Install the retaining ring to secure the bearing 2 Install the brushes and brush rigging See following NOTE NOTE When installing new brushes remove and replace brushes one at a time This method ensures the terminals and brushes will be properly positioned in the rigging When replacing brushes replace all...

Page 258: ... the end of each brush 5 Align the match marks on the end cap 20 and the motor frame 14 and secure with four bolts Figure 16 13 Page 16 10 Tighten bolts to 130 in lb 14 7 N m 6 Install the speed sensor magnet 12 with bolt 13 Tighten to 65 in lb 7 3 N m 7 Install the speed sensor 1 with one screw 2 finger tight Figure 16 16 Page 16 13 8 Install clamp 3 onto sensor wires 4 and secure with other scre...

Page 259: ...haft 2 1 Squeeze approximately 1 2 inch 1 3 cm of moly teflon lubricant CCI P N 102243403 from tube onto a putty knife as shown Figure 16 17 Page 16 14 2 2 Rotate wheels to rotate input shaft 2 3 Apply motor coupling grease evenly to the rotating input shaft starting at approximately 1 8 inch 3 1 mm from the end of the shaft and working back toward the transaxle away from the end of the shaft Figu...

Page 260: ... 16 Continue tightening by hand until the motor is seated in the transaxle housing See following CAUTION and NOTE CAUTION Make sure the motor is properly seated in the transaxle housing NOTE Failure to install and tighten the motor mounting bolts in the proper sequence and to the proper tightness may result in motor noise during operation 3 4 Tighten the right bolt 1 to 65 in lb 7 3 N m Figure 16 ...

Page 261: ...ghten the lug nuts 8 Lift vehicle and remove jack stands Lower vehicle to the floor and tighten lug nuts using a crisscross pattern See Wheel Installation Section 8 Page 8 1 9 Connect the batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 10 Place the Run Tow switch in the RUN position 11 Inspect the vehicle for proper operation See following WARNING WARNING Make sure that...

Page 262: ...16 Motor Installation MOTOR MODEL DA5 4006 ELECTRIC VEHICLES 2 3 1 4 Viewed From Driver Side Figure 16 21 Motor Tightening Sequence Page 16 16 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 263: ... chocks at the front wheels Loosen lug nuts on rear wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to support the vehicle See WARNING Lift only one end in General Warnings on page 1 1 3 Remove the rear wheel and brake drum See Wheel Brake Assemblies Section and Wheels and Tires Section 4 Use 90 internal snap ring pliers to remove the...

Page 264: ...ng 5 Figure 17 5 Page 17 3 If the bearing in a Type G transaxle is worn or damaged the entire axle shaft assembly 1 or 2 must be replaced 1 2 Figure 17 1 Remove Internal Retaining Ring Figure 17 2 Axle Seal and Adapter Ring Removal 15 39 A A Adapter Ring Lip Figure 17 3 Axle Seal and Adapter Ring Figure 17 4 Axle Seal and Adapter Ring Installation Page 17 2 2017 Carryall 500 and 700 Maintenance an...

Page 265: ...earing and Shaft 17 1 3 6 5 14 15 24 26 13 33 36 32 8 10 11 12 20 18 19 16 16 16 17 23 21 25 36 22 35 13 27 30 31 29 2 5 3 8 36 15 27 30 28 Figure 17 5 Transaxle Type G 2017 Carryall 500 and 700 Maintenance and Service Manual Page 17 3 ...

Page 266: ...rotate it to align the shaft splines with the splined bore of the differential side gear 27 Figure 17 5 Page 17 3 Continue advancing the shaft until the bearing on the axle is firmly seated within the axle tube hub seat 2 2 Use a pair of snap ring pliers to install the retaining ring 6 inside axle tube hub so that it seats against the axle bearing assembly and into the machined slot in the inside ...

Page 267: ... spring mount and the side stringer just forward of each rear wheel Lower the vehicle to let the jack stands support the vehicle Figure 17 6 Page 17 5 See WARNING Lift only one end of the vehicle in General Warnings on page 1 1 4 Remove the rear wheels then thread one lug nut onto a stud on each rear hub This will keep the brake drums on the hubs 5 Remove the bow tie pins 1 brake cable clevis pins...

Page 268: ...s used to raise the vehicle lift the vehicle high enough to permit easy access and clearance for removal of the motor If a floor jack was used to raise the vehicle lower the transaxle enough to permit easy access and clearance for removal of the motor 10 Remove the three motor mounting bolts Figure 17 11 Page 17 7 and the motor positioning bolt Figure 17 12 Page 17 7 mounting the motor to the tran...

Page 269: ... to rest on the floor 13 Remove the U bolts attaching the transaxle to the leaf springs Figure 17 10 Page 17 7 14 Carefully lift each end of the transaxle off its positioning pin on the leaf spring and slide the transaxle to the rear and out of the vehicle 15 Drain the lubricant from the transaxle and remove the axle shafts See Axle Shaft and Oil Seal Removal on page 17 1 See following NOTE NOTE R...

Page 270: ...ar assembly 19 Lift intermediate gear assembly and differential gear case unit out simultaneously Figure 17 5 Page 17 3 See following CAUTION CAUTION Do not damage gears Use extreme care when handling them 5 Use a bearing puller or arbor press to remove bearings 16 from the input pinion gear If the oil seal 10 is damaged replace it Figure 17 5 Page 17 3 See also Figure 17 13 Page 17 8 See followin...

Page 271: ...ential pin 31 by pushing pin through differential gear case from one side Figure 17 5 Page 17 3 See also Figure 17 15 Page 17 9 8 5 Remove the idler gears 1 and 2 and thrust plates 3 and 4 Figure 17 16 Page 17 9 1 5 6 26 2 8 7 3 4 Figure 17 15 Differential Pin Figure 17 16 Left Differential 8 6 Remove the differential gears 5 and 6 and thrust plates 7 and 8 8 7 Inspect the bearings 13 of the diffe...

Page 272: ...ing surface of housing 8 2 Install left half of transaxle housing 20 Figure 17 5 Page 17 3 8 3 Install eleven bolts 24 in the case housing and tighten to 19 ft lb 25 7 N m Type G transaxles have no shims or gasket 8 4 Install axle tube 14 and 35 with bolts 8 Figure 17 5 Page 17 3 Tighten the bolts to 37 ft lb 50 2 N m 9 Install the brake assemblies as instructed See Wheel Brake Assemblies Section ...

Page 273: ...and other components Loss of vehicle control could result in severe personal injury or death 12 Make sure the drain plug 22 is installed in the transaxle and tightened to 23 ft lb 31 N m Fill the transaxle through the level indicator hole with 22 ounces of SAE 30 API Class SE SF or SG oil a higher grade may also be used Install and tighten the level indicator plug 21 to 23 ft lb 31 N m 2017 Carrya...

Page 274: ...ged when disconnected refer to the wiring diagram for proper connection See Wiring Diagrams Section 12 Page 12 4 7 Insert bolts through the spring shackles and bushings in the leaf spring eyes Secure bolts with locknuts Tighten to 15 ft lb 20 3 N m 8 Connect the brake cables using new bow tie pins 1 Figure 17 7 Page 17 5 9 Install the shock absorbers Tighten shock absorber retaining nuts until the...

Page 275: ...is added to correct the issue the Low Oil Warning Light will still remain ON Cycle the key switch OFF and ON to reset the Low Oil Warning Light The gasoline vehicle is equipped with a low oil warning light 4 located at the top of the instrument panel If the warning light comes on oil should be checked and added to the engine as necessary before continuing to use the vehicle See following CAUTION T...

Page 276: ...ties should they occur The guides include the symptom probable cause s and suggested checks The procedures used in making these checks can be found in the referenced sections of the maintenance and service manual ECU ERROR CODES DISPLAYED BY THE LOW OIL WARNING LIGHT Failure Mode Table When Ignition Is Initially Switched ON DISPLAY MODE CONDITION LAMP CONTROL Step 1 Lamp ON Two Seconds Step 2 Lamp...

Page 277: ... module If connection is made and no corrosion is present replace ECU and Throttle Module 31 Fuel Pump Open Connection Check fuel pump and fuel system Check electrical connections at ECU Throttle module and fuel pump 41 Fuel Injector Open Connection Check connector at ECU Throttle module If connection is made and no corrosion is present replace ECU and Throttle Module 51 Ignition Pulse Open Connec...

Page 278: ...Section 23 Fuel System Gasoline Vehicles Low cylinder compression Section 22 Engine Subaru EX40 Cylinder head bolts not tighten properly Check and retighten Section 22 Engine Subaru EX40 Intake or exhaust valve not sealing Repair Section 22 Engine Subaru EX40 Incorrect valve clearance Adjust Section 22 Engine Subaru EX40 Vacuum leak Retighten hardware or replace gasket s Engine does not start easi...

Page 279: ...k EFI Section 23 Fuel System Gasoline Vehicles Overloading Reduce to rated load Engine overheats Poor quality engine oil Replace Excessive carbon deposits on piston head or in combustion chamber Section 22 Engine Subaru EX40 Spark plug heat range is incorrect Section 22 Engine Subaru EX40 Engine pre ignites Unsuitable or contaminated fuel Section 23 Fuel System Gasoline Vehicles Exhaust valve is r...

Page 280: ...olenoid Accelerator pedal limit switch failed Test Procedure 7 Accelerator Pedal Limit Switch Pedal Start Vehicles Only Key switch failed Test Procedure 5 Key Switch Start Circuit Neutral lockout limit switch failed Test Procedure 10 Neutral Lockout Limit Switch Pedal Start Vehicles Only Loose or broken wire in starter generator circuit Section 20 Electrical Components Pedal Start Gas Vehicle Star...

Page 281: ...s Damaged drive clutch Section 25 Clutches Gasoline Vehicles Damaged starter generator pulley Section 20 Electrical Components Pedal Start Gas Vehicle Starter Generator on page 20 1 Excessive vehicle vibration RPM setting is incorrect Section 23 Fuel System Gasoline Vehicles Engine RPM Adjustment on page 23 13 Drive belt is worn cracked glazed or frayed Section 25 Clutches Gasoline Vehicles Drive ...

Page 282: ...ROUBLESHOOTING AND ELECTRICAL SYSTEM PEDAL START GAS VEHICLE WIRING DIAGRAMS WD1050077_DGM_D L Figure 18 1 Wiring Diagram for Pedal Start Gasoline Vehicle Page 18 8 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 283: ...ND ELECTRICAL SYSTEM PEDAL START GAS VEHICLE Wiring Diagrams 18 WD1050077_DGM_D R Figure 18 2 Wiring Diagram for Pedal Start Gasoline Vehicle Continued 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18 9 ...

Page 284: ...ms TROUBLESHOOTING AND ELECTRICAL SYSTEM PEDAL START GAS VEHICLE S M M 2 1 WD1050951_DGM_A Figure 18 3 Wiring Diagram Instrument Panel and FNR Shifter Page 18 10 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 285: ...OUBLESHOOTING AND ELECTRICAL SYSTEM PEDAL START GAS VEHICLE Wiring Diagrams 18 WD1050081_DGM_D Figure 18 4 Wiring Diagram EFI and Engine 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18 11 ...

Page 286: ...ams TROUBLESHOOTING AND ELECTRICAL SYSTEM PEDAL START GAS VEHICLE 3022 Figure 18 5 Sonic Weld and Diode Locations Approximate CA500 550 Cafe Express Page 18 12 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 287: ...ESHOOTING AND ELECTRICAL SYSTEM PEDAL START GAS VEHICLE Wiring Diagrams 18 3020 Figure 18 6 Sonic Weld and Diode Locations Approximate CA700 2017 Carryall 500 and 700 Maintenance and Service Manual Page 18 13 ...

Page 288: ...il Warning Light Circuit Neutral Lockout Circuit Fuel Pump Circuit Fuel Gauge and Sending Unit Circuit Hour Meter Circuit Lighting Circuit Recognizing and understanding the function of each of these circuits will help to quickly isolate the source of an electrical problem Use the appropriate test procedure to correct the electrical problem See Test Procedures on page 18 15 For a complete wiring di...

Page 289: ...ery voltage is accessed in Test Procedure 1 Battery on page 18 17 The MAINTENANCE OPERATE switch in the MAINTENANCE position grounds and kills the ignition if the FNR shifter is placed in FORWARD or REVERSE The key switch powers the ECU fuel pump solenoid lights and the connected car device The 2 amp fuse is powered by the key switch via the 10 amp ATM fuse and carries battery voltage to the conne...

Page 290: ...icles Only 11 Starter Generator Generator Function 12 Starter Generator Starter Function 13 Voltage Regulator 14 Kill Limit Switch Pedal Start Vehicles Only 15 Ignition Spark 16 Ignition Coil 17 Reverse Buzzer and Reverse Buzzer Limit Switch 18 Low Oil Warning Light LED 19 Oil Level Sensor 20 Battery Test Under Load 21 Fuel Pump 22 Fuel Level Sending Unit 23 Fuel Gauge 24 Hour Meter 25 Light Switc...

Page 291: ...cal Components Pedal Start Gas Vehicle on page 20 1 of this manual See Battery on page 20 33 1 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position Chock the wheels 2 Check for loose or corroded battery terminal connections Remove the negative cable first and clean tighten and replace connections as necessary Voltage Test 1 Take a volt...

Page 292: ...bove 9 6 V 60 F 16 C 9 5 V 50 F 10 C 9 4 V 40 F 4 C 9 3 V 30 F 1 C 9 1 V 20 F 7 C 8 9 V 10 F 12 C 8 7 V 0 F 18 C 8 5 V 4 If the battery is found to be good or if the electrical problem continues after the battery has been replaced with a good one test the electrical circuits Page 18 18 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 293: ...ct or check using a continuity test ATC style blade fuses are located inside the electrical component box near the battery ATM style blade fuses are located on the main wire harness in front of the engine The ABC style glass fuse is located on the main wire harness underneath the front cowl 2784 Figure 18 7 Testing the ATC and ATM style Blade Fuse 1 If necessary see Testing Basics on page 18 15 2 ...

Page 294: ...voltage inspect the following locations 12 pin dash wire harness connector key switch and sonic weld 3 5 2 amp ABC Glass Fuse Only With the key switch in the ON position 5 1 Probe the wire on each side of the fuse with insulation piercing probes 5 2 Each probe should show battery voltage 5 3 If only one side shows battery voltage replace fuse 5 4 If neither side of a fuse shows battery voltage ins...

Page 295: ...gure 18 8 Page 18 21 Check the starter generator ground cable black wire from A1 terminal to chassis Check the battery ground cable from the disconnected terminal to chassis Check the engine ground cable from engine block to chassis 4 The reading should be continuity If the reading is incorrect clean and tighten cable connections If the connections are good and the reading is incorrect repair or r...

Page 296: ... VEHICLE TEST PROCEDURE 4 EFI System ECU and Sensors See General Warnings on page 1 1 WARNING This procedure involves testing voltage resistance and continuity If necessary see Testing Basics on page 18 15 Page 18 22 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 297: ...y Pin 10 Red White and Ground Battery Voltage Plug connected to ECU and Key ON 13 Gray MAP Sensor Input Voltage ECU Gray Pin 13 Green Yellow and Ground Approx 3 9 volts sea level engine OFF 3 0 volts engine running Voltage decreases as pressure decreases Key ON and engine running 15 Gray Engine Temperature Sensor Ground Continuity ECU Gray Pin 15 Black Blue and Ground Meter should beep Key OFF 16 ...

Page 298: ...ge ECU Black Pin 9 Red and ECU Black Pin 10 Black Battery Voltage Key ON Continuity ECU Black Pin 10 Black and Ground Meter should beep Key OFF 10 Black Ground for ECU Power Voltage ECU Black Pin 10 Black and Battery Terminal Battery Voltage Key OFF 11 Black Diagnosis low oil Lamp Control Voltage ECU Black Pin 11 Yellow Black and Ground Less than 1 Volt initially 7 to 8 volts after lamp is OFF Key...

Page 299: ...Removal on page 4 10 3 With the key switch in the OFF position The green wire should show battery voltage coming to the switch The brown white wire should show zero 0 volts If it shows battery voltage the switch has failed CLOSED and must be replaced 4 With the key switch in the ON position The brown white wire should show battery voltage passing through the key switch to sonic weld 3 the 5 amp fu...

Page 300: ...V V V A COM 200nA MAX 1000 750V FUSED 1 M 2 M 1 1 200 Ohm Setting 1337 Figure 18 9 Key Switch Test Engine Kill Circuit TEST PROCEDURE 7 Accelerator Pedal Limit Switch Pedal Start Vehicles Only See General Warnings on page 1 1 NOTE This is a continuity test The accelerator pedal limit switch is the top switch located in the electrical component box There is a green wire and a pink wire connected to...

Page 301: ...nce across the small posts of the solenoid The reading should be 14 to 16 ohms If the reading is not within limits replace the solenoid 5 Contact Side Remove the 6 gauge white wire the 16 gauge red wire and 16 gauge white wire from the large post of the solenoid Do not allow the wires to touch the frame or other components of the vehicle Figure 18 10 Page 18 27 Cover the other large post 5 1 Place...

Page 302: ...ontinuity between terminals T2 and T3 4 With switch in position 2 OPERATE 4 1 Check for no continuity between terminals T2 and T3 4 2 Check for continuity between terminals T1 and T2 T1 T3 T2 2 1 1 Position 1 MAINT closes T2 to T3 Toggle Position Operates 2 Position 2 OP closes T1 to T2 3 T1 Black Pink Stripe T2 Black T3 Black Yellow Stripe 478 Figure 18 12 Maintenance Operate Switch Test for Peda...

Page 303: ...limit switch as the Forward Reverse shifter is being shifted The limit switch should make an audible click as it is pressed If it does not check for wear on the cam lobe and replace shift lever if necessary 5 Check the following terminals for no continuity with the lever released and continuity with the lever engaged Figure 18 13 Page 18 29 PROBE BETWEEN LOCATIONS TEST RESULT With lever released N...

Page 304: ...should show the voltage rising on the meter If the voltage rises above 15 3 volts DC test the voltage regulator See Voltage Regulator on page 18 32 If the voltage does not rise a tear down inspection of the starter generator will be necessary See Starter Generator Removal on page 20 1 6 Remove jumper wire 7 Reconnect yellow wire to DF terminal on starter generator 2 1 F1 DF F2 1 Yellow Wire 2 Jump...

Page 305: ... F2 reading is incorrect it indicates a possible grounded F1 or F2 terminal or a grounded field coil If the DF reading is incorrect it indicates a possible grounded DF terminal or a grounded field coil 4 Using a multimeter set to 200 ohms place the red probe on the A1 terminal and the black probe on the A2 terminal The reading should be continuity If the reading is incorrect a possible open or poo...

Page 306: ...he engine Using a multimeter set to 20 volts DC place the red probe on the large post of the solenoid with the red wire from the voltage regulator attached Place the black probe on the negative battery post Figure 18 16 Page 18 32 Turn the key switch to the ON position Press the accelerator to start the engine and run it at full governed speed If the reading is between 14 7 and 15 3 volts the regu...

Page 307: ...s See Wiring Diagrams on page 18 8 5 Disconnect the wires from the lower of the two limit switches and test the limit switch for continuity Place the red probe of the multimeter on the common COM terminal white black wire of the limit switch Place the black probe on the normally open NO terminal blue wire of the limit switch Without the lever pressed the reading should be no continuity Press the l...

Page 308: ... SE Small Engine Setting on the Thexton 404 tool Connect the tester to the spark plug wire and connect the alligator clip to a solid engine ground 3 2 Start the engine There should be a strong blue spark between the probes of the spark gap tester If there is no spark or if the spark is a faint yellow or red color test components of the ignition circuit See Ignition Coil on page 18 35 4 If the spar...

Page 309: ...perly keep the new coil in the circuit NOTE Resistance value ranges given in these tests reflect a tolerance of 40 Please note that these values are rough standard and it is impossible to reach an exact conclusion with the resistance reading 1 If necessary see Testing Basics on page 18 15 2 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 5 3 At en...

Page 310: ...en the black orange wire and ground With Forward Reverse handle still in the FORWARD position there should be no continuity If either reading is incorrect replace limit switch See Reverse Buzzer Limit Switch Removal on page 20 25 8 If limit switch is operating properly replace buzzer See Reverse Warning Buzzer Removal Section 20 Page 20 23 TEST PROCEDURE 18 Low Oil Warning Light LED See General Wa...

Page 311: ...y connected while performing this test procedure 1 If necessary see Testing Basics on page 18 15 2 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position Chock the wheels 3 Set a multimeter to 20 volts DC and place the red probe on the F2 white wire terminal on the starter generator Place the black probe on the negative battery post 4 Tu...

Page 312: ...essary see Testing Basics on page 18 15 2 Disconnect the 5 pin connector from the top of the fuel pump module 3 Check that battery voltage is present between ground and the red wire of the 5 pin connector immediately after the key switch is placed in the ON position NOTE The fuel pump and low oil warning light operate for a few seconds when key switch is turned to the ON position it stops if no en...

Page 313: ...should be obtained depending on the position of the float inside the fuel tank The resistance reading will vary according to the exact position of the float The chart below may be used as a guideline to determine if the fuel level sending unit is operating correctly Make sure the float is at the surface of the fuel in the tank _ FLOAT POSITION RESISTANCE READING FUEL GAUGE READINGS Lower position ...

Page 314: ...ed probe of the multimeter on the positive post of the battery Place the black probe on the negative post of the battery Record the voltage reading 7 Set a multimeter to 20 volts DC and place the red probe on the 2 terminal of the fuel gauge hour meter with the red white wire is connected Place the black probe on the 1 terminal of the fuel gauge hour meter with the black wire Figure 18 21 Page 18 ...

Page 315: ... key switch OFF check the hour meter display It is powered by an internal battery and should always be on even with the engine off and the key removed 4 Start the engine and let it idle See following DANGER DANGER Do not operate vehicle in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison 5 With engine idling the hour glass icon shou...

Page 316: ...e wires and fuse show continuity and the readings are still incorrect replace the switch See Headlight Switch Removal Section 20 Page 20 30 TEST PROCEDURE 26 Voltage at Headlight Socket See General Warnings on page 1 1 NOTE This is a voltage test 1 If necessary see Testing Basics on page 18 15 2 Inspect the wires at the light bulb socket Make sure the wires are securely fastened to the contacts in...

Page 317: ... 4 5 4 Disconnect green wire from positive terminal of voltage limiter and black wire from negative terminal 5 Using a multimeter on diode setting test voltage limiter as shown Figure 18 24 Page 18 43 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAV...

Page 318: ... welds no 4 10 and 14 3 Probe pin 2 red wire It should show battery voltage with the key switch in the ON position If not check 2 amp fuse near 4 pin connector See following NOTE NOTE The red wire only has battery voltage with the key switch in the ON position 4 Probe pin 4 blue wire It should show approximately 11 8 volts supplied by pin 8 blue white wire of the black 18 pin connector on the ECU ...

Page 319: ...Electrical System Pedal Start Gas Vehicle section Most components are shared between the two systems except for the following items unique to the key start vehicle Key Switch Only way to start and shut off the engine Accelerator Pedal Is not linked to the accelerator pedal limit switch and kill limit switch in the electrical component box because these switches are omitted for key start applicatio...

Page 320: ... TROUBLESHOOTING AND ELECTRICAL SYSTEM KEY START GAS VEHICLE WIRING DIAGRAMS WD1050080_DGM_B L Figure 19 1 Wiring Diagram for Key Start Gasoline Vehicle Page 19 2 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 321: ... AND ELECTRICAL SYSTEM KEY START GAS VEHICLE Wiring Diagrams 19 WD1050080_DGM_B R Figure 19 2 Wiring Diagram for Key Start Gasoline Vehicle Continued 2017 Carryall 500 and 700 Maintenance and Service Manual Page 19 3 ...

Page 322: ...ams TROUBLESHOOTING AND ELECTRICAL SYSTEM KEY START GAS VEHICLE S M M 2 1 WD1050951_DGM_A Figure 19 3 Wiring Diagram Instrument Panel and FNR Shifter Page 19 4 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 323: ...ROUBLESHOOTING AND ELECTRICAL SYSTEM KEY START GAS VEHICLE Wiring Diagrams 19 WD1050081_DGM_D Figure 19 4 Wiring Diagram EFI and Engine 2017 Carryall 500 and 700 Maintenance and Service Manual Page 19 5 ...

Page 324: ...eted be sure to replace the cover See following CAUTION CAUTION Exposure to water and the elements may damage electrical components Do not operate vehicle without the cover properly installed Index of Test Procedures 1 EFI System ECU and Sensors 2 Key Switch ON Position 3 Key Switch START Position 4 Solenoid 5 Maintenance Operate Switch Key Start Vehicles 6 Charging Diode Generator Circuit Key Sta...

Page 325: ...he solenoid and the 4 pin connected car plug If it does not show battery voltage the switch has failed OPEN and must be replaced TEST PROCEDURE 3 Key Switch START Position See General Warnings on page 1 1 NOTE This is a voltage test The key switch START position provides power to the starter generator 1 If necessary see Testing Basics on page 18 15 2 Remove instrument panel to access the back of t...

Page 326: ...ce across the small posts of the solenoid The reading should be 14 to 16 ohms If the reading is not within limits replace the solenoid 5 Contact Side Remove the 4 gauge white wire the 10 gauge white wire the 18 gauge red wire and 18 gauge white wire from the large post of the solenoid Do not allow the wires to touch the frame or other components of the vehicle Figure 19 5 Page 19 8 Cover the other...

Page 327: ...or continuity between terminals T2 and T3 4 With switch in position 2 OPERATE 4 1 Check for no continuity between terminals T2 and T3 4 2 Check for continuity between terminals T1 and T2 T1 T3 T2 2 1 1 Position 1 MAINT closes T2 to T3 Toggle Position Operates 2 Position 2 OP closes T1 to T2 3 T1 Blue White Stripe T2 Black 478 Figure 19 7 Maintenance Operate Switch Test for Key Start Vehicles 5 If ...

Page 328: ...he white lead of the diode and the red probe of the multimeter to the red lead of the diode Figure 19 8 Page 19 10 The reading should indicate an overload no continuity A diode is designed to conduct current in one direction only If a diode conducts current shows continuity with the meter probes as described the diode has failed and must be replaced See Charging Diode Removal Section 21 Page 21 4 ...

Page 329: ...Y START GAS VEHICLE Test Procedures 19 WARNING Diode and solenoid connections must have correct polarity Keep all persons clear of engine belts when making final connections 2017 Carryall 500 and 700 Maintenance and Service Manual Page 19 11 ...

Page 330: ...Pagination Page 19 Test Procedures TROUBLESHOOTING AND ELECTRICAL SYSTEM KEY START GAS VEHICLE Page 19 12 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 331: ...port the starter generator so that when the pivot bolts 5 are removed the starter generator will not fall Remove the two pivot nuts 7 and bolts 5 from the mounting bracket 7 Remove the starter generator DISASSEMBLY OF THE STARTER GENERATOR TO SERVICE THE BRUSHES 1 Remove the two bolts 20 and pull commutator end cover 23 free of starter generator housing 24 Figure 20 1 Page 20 2 See following NOTE ...

Page 332: ... Figure 20 3 Page 20 2 0 1 1 2 1 2 Figure 20 3 Inspect Brushes and Measure Length BRUSH SPRING INSPECTION AND REPLACEMENT 1 Visually inspect springs Replace all four springs if any spring is discolored from heat straw or bluish in color 2 Install the four brushes 27 into their holders and insert the four brush springs 28 Figure 20 2 Page 20 2 Using a spring scale test brush spring tension If any s...

Page 333: ...ossible damage to the brushes lift the brush springs and pull the brushes back from the center of the commutator end cover The springs will rest on the sides of the brushes and help prevent them from sliding towards the center of the cover Figure 20 5 Page 20 4 3 Install the commutator end cover 23 onto the armature shaft Align the locating pin with the pin hole in the cover Install two M6 x 180 m...

Page 334: ...utput end cover assembly from the field coil housing first remove the two securing bolts 43 Carefully remove armature and output end cover assembly from the field coil housing so components are not damaged 3 To separate armature 33 from output end cover 36 remove nut 41 lock washer 40 pulley 39 It may be necessary to use the wedge attachment tool P N 1012812 to remove the pulley from the shaft 4 R...

Page 335: ...al A and radial B play Figure 20 7 Page 20 5 2 Replace the bearing if it is noisy does not spin smoothly or has excessive play Check the bearings and replace if rusted worn cracked or if there is an abnormal color change in the metal of the bearing Bearings should be replaced if there is extensive wear or pitting on the balls or on the rolling surfaces Do not remove the bearings unless they are to...

Page 336: ... pipe 6 Press against armature shaft 7 Use bearing puller if a press is not available 494 Figure 20 8 Bearing Removal FIELD COIL ASSEMBLY Replace entire field coil housing assembly if coils pole shoes or terminals are damaged Figure 20 9 Page 20 7 VISUAL INSPECTION OF ARMATURE Obvious defects can be seen by examining the armature If an armature has frayed or charred insulation broken wires or thro...

Page 337: ...commutator can be polished away with 400 grit or finer sandpaper See following CAUTION CAUTION Do not use emery cloth on the commutator Particles of emery are conductive and may short circuit the commutator bars Do not use oil or lubricants on the commutator or brushes 2 Using a micrometer measure the outside diameter at two points along the commutator If the commutator outside diameter is less th...

Page 338: ...TE Before testing wipe the armature with a clean cloth and remove carbon dust and metal particles from between commutator bars Using a multimeter set on 200 ohms place the positive probe on the commutator bars and the negative probe on the armature core The reading should be no continuity If the reading is incorrect replace the armature and the two bearings Figure 20 11 Page 20 9 Page 20 8 2017 Ca...

Page 339: ...g STARTER GENERATOR REWORK Any rework must be performed by a qualified technician Starter generator service specifications are listed in the following table _ ITEM SERVICE LIMIT Commutator diameter minimum 1 60 in 41 mm Concentric with armature shaft within 0 002 in 0 051 mm Minimum commutator diameter for reslotting 1 65 in 42 mm Undercut Commutator must have a minimum diameter of 1 65 in 42 mm f...

Page 340: ... towards the center of the cover Figure 20 5 Page 20 4 6 Install the commutator end cover 23 onto the armature shaft Use the tapped mounting holes to align housing to the cover rotate and orient as shown Install the two M6 x 180 mm bolts 20 and tighten to 60 in lb 6 8 N m Figure 20 1 Page 20 2 7 Push the brushes down into the holders Place springs into the notches in the brushes Install the brush ...

Page 341: ...Starter Generator 20 1 2 F1 DF 3 90 F2 1 Jumper Wire 2 1 inch 25 4 mm Minimum Radius 3 Jumper Wire Not Allowed in this Area 2687 Figure 20 12 A1 to F1 Terminal Jumper Wire Routing 2017 Carryall 500 and 700 Maintenance and Service Manual Page 20 11 ...

Page 342: ...e starter generator Install a lock washer 6 and nut 4 onto adjustment bolt 1 finger tight Figure 20 13 Page 20 12 4 Install starter generator belt 2 and adjust belt tension as instructed See Belt Tension Adjustment for EFI Engines on page 20 13 5 Connect the yellow wire 2 from the voltage regulator to the DF terminal on the starter generator Figure 20 14 Page 20 13 Install a flat washer lock washe...

Page 343: ...ator belt is tensioned varies between a used and new belt EFI engines have higher starting torque demands that require consistent belt tension to prevent slipping Belt tension should be checked periodically Locate gauge midway between pulleys 2724 Figure 20 15 Belt Tension Gauge 2725 Figure 20 16 Belt Tensioning Tool Installation 1 Disconnect battery and spark plug wire s See Disconnecting the Bat...

Page 344: ...gure 20 13 Page 20 12 6 Install belt tension tool P N 102570401 6 1 Carefully insert pry bar between starter generator and bracket 6 2 Carefully lift starter up until tension tool can be installed as shown over the slotted adjustment bracket Figure 20 16 Page 20 13 Note orientation of tension tool on the slotted adjustment bracket and how the threaded J bolt is inserted into the slot under the sta...

Page 345: ... 4 Engage starter and crank engine a minimum of 5 seconds and a maximum of 15 seconds to fully seat the belt into pulleys and help eliminate any slack 9 Repeat step 7 10 Maintain tension and tighten adjustment nut 4 to 15 to 18 ft lb 20 to 24 5 N m Tighten hex nuts 7 to 20 to 25 ft lb 27 to 34 N m Figure 20 13 Page 20 12 11 Remove belt tension tool 12 Confirm proper belt tension with a final measu...

Page 346: ... the yellow wire 4 at the bullet connector and the black wire 7 at the battery frame ground Figure 20 18 Page 20 16 3 Install snap on electrical component box cover Be sure to firmly press down all corners Install screw and tighten to 18 in lb 2 N m 4 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 5 5 Place Forward Reverse handle in NEUTRAL and place t...

Page 347: ...ect battery See Disconnecting the Battery Gasoline Vehicles on page 1 5 2 Remove ECU mounting plate bolts 3 Disconnect gray and black wire connectors ENGINE CONTROL UNIT INSTALLATION WARNING To prevent damage to the ECU never mix the black and gray connectors that attach to it The black connector is tethered to the ECU mounting plate to help prevent accidentally installing it in the gray port 1 Mo...

Page 348: ...ng the key switch 3 and remove the key switch cap 6 Using a 1 inch socket hold the key switch 3 and remove the switch retaining nut 5 from the outside of the instrument panel Figure 20 19 Page 20 18 KEY SWITCH INSTALLATION 1 Position the key switch 3 and key switch washer 1 in the instrument panel then install and tighten the key switch nut 5 to 35 to 45 in lb 4 to 5 N m Install key switch cap 6 i...

Page 349: ...ge 1 1 TESTING THE NEUTRAL LOCKOUT LIMIT SWITCH See Test Procedure 10 Neutral Lockout Limit Switch Pedal Start Vehicles Only on page 18 29 NEUTRAL LOCKOUT LIMIT SWITCH REMOVAL 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in the NEUTRAL position Chock the wheels 2 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 5 3 ...

Page 350: ...ng Diagrams on page 18 8 2 1 Connect the 4 gauge white wire from the starter generator the 18 gauge white wire from the fuel gauge hour meter and the 18 gauge red wire from the voltage regulator to the large post on the solenoid 2 2 Connect the 4 gauge red wire from the positive battery terminal and the 10 gauge red wire and 16 gauge orange wire from the fuse blocks to the other large post on the ...

Page 351: ...wing WARNING WARNING If a fuse is blown determine the cause of the failure and make necessary repairs before installing a new fuse Use the appropriately rated fuse if a fuse with a higher amp rating is used damage to the vehicle electrical system may occur 2 ATC Fuse Only Install the snap on electrical box cover by pressing down firmly on all corners and install the screw tightening to 18 in lb 2 ...

Page 352: ... common COM terminal and the blue wire to the normally open NO terminal of the kill limit switch 12 and place the switch on the mounting screws located in the electrical component box Figure 20 20 Page 20 23 Place the accelerator limit switch 11 on the mounting screws located in the electrical component box 2 Secure the switches using two washers 10 and two nuts 9 Tighten to 5 in lb 0 6 N m See fo...

Page 353: ...20 21 Page 20 24 Do not allow wires to touch 4 Remove the mounting screws 1 securing the buzzer 2 to the instrument panel REVERSE WARNING BUZZER INSTALLATION 1 Install the screws 1 through the buzzer 2 mounting tabs and tighten to 3 5 in lb 0 40 N m Figure 20 21 Page 20 24 2 Connect the black wire from the key switch to the negative terminal on the buzzer 3 Connect the orange white wire from the w...

Page 354: ...20 Reverse Warning Buzzer ELECTRICAL COMPONENTS PEDAL START GAS VEHICLE 2 1 9 4 6 5 8 3 7 3003 Figure 20 21 Instrument Panel Switches Page 20 24 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 355: ...the reverse buzzer switch 3 and slide the reverse buzzer switch off of the screws 2 REVERSE BUZZER LIMIT SWITCH INSTALLATION 1 Install the reverse buzzer switch 3 with two screws 2 Figure 20 22 Page 20 26 that attach the buzzer to the shifter assembly Install washers 5 and tighten nuts 4 to 5 in lb 0 6 N m See following CAUTION CAUTION Do not overtighten the retaining nuts If the nuts are over tig...

Page 356: ... Reverse Buzzer Limit Switch ELECTRICAL COMPONENTS PEDAL START GAS VEHICLE 2 3 1 5 4 3001 Figure 20 22 Forward Reverse Assembly Switches Page 20 26 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 357: ...hat panel is properly seated and snapped in place 4 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 5 FUEL GAUGE HOUR METER See General Warnings on page 1 1 TESTING THE FUEL GAUGE HOUR METER See Test Procedure 23 Fuel Gauge on page 18 40 Also see Test Procedure 24 Hour Meter on page 18 41 GENERAL INFORMATION With the key switch in the OFF position the f...

Page 358: ...ed in place 4 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 5 FUEL LEVEL SENDING UNIT See General Warnings on page 1 1 The fuel level sending unit is an integral part of the fuel pump module and is not replaceable Thoroughly test the fuel level sending unit before replacing the fuel pump module TESTING THE FUEL LEVEL SENDING UNIT See Test Procedure 22...

Page 359: ...connect wires from the voltage limiter 1 Do not allow wires to touch Figure 20 23 Page 20 29 6 Remove the mounting hardware 2 from the voltage limiter and remove from vehicle VOLTAGE LIMITER INSTALLATION 1 Mount the voltage limiter to the driver side frame using the mounting hardware and tighten to 25 in lb 2 8 N m Figure 20 23 Page 20 29 2 Connect the black wire from harness to the black wire fro...

Page 360: ...e Battery Gasoline Vehicles on page 1 5 HEADLIGHTS See General Warnings on page 1 1 TESTING THE HEADLIGHT SOCKET See Test Procedure 26 Voltage at Headlight Socket on page 18 42 HEADLIGHT BEZEL REMOVAL 1 Disconnect the batteries and discharge the controller Disconnecting the Batteries Electric Vehicles on page 1 4 2 Remove the cowl See Cowl Removal Section 4 Page 4 5 3 Remove the front fenders See ...

Page 361: ...ge 1 4 3 Install front fenders See Front Bumper and Side Fender Installation Section 4 Page 4 9 4 Install cowl See Cowl Installation Section 4 Page 4 5 HEADLIGHT BULB REMOVAL LED 1 Disconnect the batteries 2 Remove cowl See Cowl Removal Section 4 Page 4 5 3 Remove front fenders See Front Bumper and Side Fender Removal Section 4 Page 4 9 4 Remove the three screws 2 and pull bulb assembly 6 out of b...

Page 362: ...20 Headlights ELECTRICAL COMPONENTS PEDAL START GAS VEHICLE 1 3 1 3 3 1 2 5 6 4 1 2 2 1 2993 Figure 20 24 Headlight Assembly Page 20 32 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 363: ...tes Call a physician immediately WARNING Do not jump start a dead battery using another battery and jumper cables GENERAL INFORMATION See preceding DANGER and WARNING statements Gasoline vehicles are equipped with 12 volt top post battery When changing a 12 volt battery in any gasoline powered vehicle the same size battery with adequate amperage ratings should be used as a replacement A group 26 t...

Page 364: ...ate of charge See Charging the Battery on page 20 35 4 Keep battery hold down clamp tight See Vibration Damage on page 20 34 SELF DISCHARGE Dirt and battery acid can provide a path for a small current draw that slowly discharges the battery To prevent self discharge the battery should always be kept clean Hot weather also has an effect on a battery s self discharge rate The higher the temperature ...

Page 365: ...arger cable to the negative battery post 4 The battery may be charged with a slow charge 3 to 10 amps or a fast charge 20 to 30 amps Charge until the battery voltage is greater than 12 4 volts See following WARNING WARNING If the battery case feels hot approximately 125 F 52 C or more emits gases or fluid boils from vents stop charging immediately Failure to stop charging battery when any of these...

Page 366: ...lged discard battery A frozen battery can explode 6 The frequency of recharging required depends on the temperature of the storage area but it is recommended that the battery be monitored for state of charge every month Also if the storage area is unheated in a cold climate and recharging is required it is recommended that the area be heated to at least 60 F 16 C prior to charging The battery will...

Page 367: ... Pedal Is not linked to the accelerator pedal limit switch and kill limit switch in the electrical component box because these switches are omitted for key start applications Charging Diode Is connected to the solenoid in the electrical component box Forward Reverse Shifter Is not linked to the neutral lockout limit switch on the transaxle because this switch is omitted for key start applications ...

Page 368: ... 3 and key switch washer 1 in the instrument panel then install and tighten the key switch nut 5 to 35 to 45 in lb 4 to 5 N m Install key switch cap 6 into instrument panel align the bent washer tab with the slot in the plastic Figure 21 1 Page 21 2 2 Refer to the wiring diagram to connect the wires to the key switch terminals See Wiring Diagrams Section 19 Page 19 2 3 Install instrument panel See...

Page 369: ...ID REMOVAL 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 5 2 Remove electrical component box cover Figure 20 20 Page 20 23 3 Disconnect all the wires from the solenoid 4 Remove the two screws securing the solenoid in place Remove the solenoid SOLENOID INSTALLATION 1 Install the solenoid in the electrical component box Use two screws to secure ...

Page 370: ...Forward Reverse handle in the NEUTRAL position Chock the wheels 2 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 5 3 Remove the screw 1 and electrical component box cover 2 Figure 21 2 Page 21 5 4 Remove the nuts 3 from the two large solenoid posts and disconnect the charging diode wires 4 and 5 from the solenoid 4 1 Observe color orientation of ...

Page 371: ... power handling capability of the diode causing it to overheat and damage the electrical system 3 Mount the charging diode 6 using the new thermal transfer pad 12 and mounting nut 11 Tighten nut 11 to 25 in lb 2 8 N m Figure 21 2 Page 21 5 4 Route and connect the red 4 and white 5 diode wires to the solenoid posts in the electrical component box See following WARNING WARNING Incorrect wiring could...

Page 372: ...the voltage regulator and white wire 10 from the starter generator Tighten nut 3 to 55 in lb 6 2 N m 5 Replace the electrical component box cover 2 and screw 1 and tighten the screw to 18 in lb 2 0 N m 6 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 5 Page 21 6 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 373: ...on using a standard compression tester Low compression would normally indicate a problem in the cylinder assembly such as defective rings gaskets etc Compression should be At a normal cranking speed of 1050 to 1100 RPM the compression should typically be approximately 167 psig 1151 kPa This value could vary slightly depending on wear of components affecting compression See the Subaru EX40 Engine R...

Page 374: ...er screws M6 25 in lb 2 8 N m Bolts marked with 4 when used with nuts M8 M6 M5 130 in lb 15 N m 50 in lb 5 9 N m 30 in lb 3 4 N m ADJUSTMENTS AND SETTINGS _ ITEM VALUES Spark plug gap 0 024 to 0 028 in 0 6 to 0 7 mm Valve clearance Intake Exhaust cold 0 0047 to 0 0059 in 0 12 to 0 15 mm Ignition coil air gap 0 012 to 0 020 in 0 3 to 0 5 mm Compression pressure 167 psig 1151 kPa Allowable Lower Pre...

Page 375: ... 22 1 Engine Oil Level Check Engine Oil Change Engine oil should be changed after the first 100 hours of operation After that it should be changed every 200 hours of operation or annually whichever comes first 1 Turn the key switch to the OFF position then remove the key Place the Forward Reverse handle in the NEUTRAL position Chock the front wheels 2 Access the engine compartment and place the Ma...

Page 376: ...oil drain plug and oil drain pan 6 Clean the oil drain plug threads with solvent to remove oil and oil residue Make sure that the compression washer remains on the drain plug 7 Use a 14 mm socket or wrench and replace the oil drain plug turning it clockwise and tighten to 18 ft lb 24 4 N m 8 Remove the dipstick and add engine oil into the dipstick port Use a funnel or pour spout to direct the oil ...

Page 377: ...r spark plug wrench to loosen the plug Spark Plug Cleaning Inspection and Repair Examine the plug Figure 22 4 Page 22 6 The deposits on the plug base and electrode are an indication of the correct heat range and efficiency as well as a guide to the general condition of the engine fuel and air mixture and ignition system If all of the above conditions are proper the spark plug should be a light bro...

Page 378: ...ary Use a high temperature anti seize lubricant on the threads of the spark plug to reduce friction when installing a new plug and reduce gauling and thread seizing for future replacements Install the spark plug by threading it in until finger tight then tighten the spark plug to the following torque New 120 in lb 13 5 N m Re tightening 216 in lb 24 5 N m BREATHER The function of the breather is t...

Page 379: ...t 2 and turn the adjuster 3 up or down to adjust the clearance to 0 0047 in 0 12 mm for both intake and exhaust Once clearance is correct tighten the lock nut 2 to 52 in lb 6 N m 6 After adjusting valve clearances rotate the crankshaft several full revolutions and verify that the intake and exhaust valve clearance are still correct At TDC the two punch marks on cam sprocket are parallel with the c...

Page 380: ... 4 7 10 11 14 16 13 12 15 14 21 2 3036a Figure 22 7 EX40 Engine and Mounting Brackets CAUTION Before removal and disassembly clean the engine 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 5 Page 22 8 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 381: ...e General Warnings on page 1 1 1 If replacing engine 1 install starter generator mounting weldment 10 on engine with screws 11 bolts 12 washers 13 and locknuts 14 Figure 22 7 Page 22 8 Tighten locknuts 14 only finger tight at this time 2 Install oil drain plug and tighten to 18 ft lb 24 4 N m 3 Place engine 1 onto engine pan 9 and secure with mounting hardware 4 5 and 6 Leave flange nuts 4 loose a...

Page 382: ...e Connecting the Battery Gasoline Vehicles on page 1 5 17 Adjust the engine RPM setting See Engine RPM Adjustment on page 23 13 18 Test drive vehicle to ensure all systems are functional and correctly adjusted FLYWHEEL See General Warnings on page 1 1 1 3 6 8 1 7 9 2 4 10 3037 Figure 22 8 Flywheel Fan and Fan Housing EX40 FLYWHEEL REMOVAL 1 Remove screws 1 and fan housing 2 Figure 22 8 Page 22 10 ...

Page 383: ... F 3 4 8 1 532 Figure 22 9 Flywheel Nut Removal 533 Figure 22 10 Fan and Flywheel Installation FLYWHEEL INSTALLATION 1 Wipe off any oil on tapered portions of crankshaft and flywheel 4 Figure 22 8 Page 22 10 2 Insert woodruff key 10 into keyway of crankshaft Then align groove in flywheel 4 to woodruff key 10 and push flywheel onto crankshaft until it seats Install and fan 7 flat washer 9 and nut 8...

Page 384: ...nsor 5 out of engine OIL LEVEL SENSOR INSTALLATION 1 Lubricate oil level sensor o ring with oil and carefully insert sensor 5 into engine until fully seated 2 Secure sensor 5 to engine with two bolts 4 and tighten to 80 in lb 9 N m Figure 22 11 Page 22 12 3 Connect oil level sensor wire 3 to wire harness 4 Secure oil sensor wire 3 with clamp 2 and bolt 1 Tighten bolt to 80 in lb 9 N m 5 Install fl...

Page 385: ...012 Inch 0 304 mm 6 510 Figure 22 12 Ignition Coil 512 Figure 22 13 Adjust Ignition Coil Air Gap IGNITION COIL INSTALLATION 1 Position ignition coil 11 onto engine and tighten two mounting bolts 10 finger tight at this time Figure 22 12 Page 22 13 2 Rotate flywheel until its magnet is positioned directly under ignition coil 11 Use a bronze feeler gauge to set air gap between ignition coil and flyw...

Page 386: ...2 14 2 Remove the two bolts 3 and two lock nuts 4 securing the snubber bracket 5 to the engine pan 1 3 Slide snubber 2 and bracket 5 assembly toward battery to remove it from vehicle 4 Slide snubber 2 off bracket 5 SNUBBER INSTALLATION 1 Slide snubber 2 onto bracket 5 Figure 22 14 Page 22 14 2 Install bracket and snubber assembly onto engine pan 1 3 Tighten lock nuts 4 from 20 to 25 ft lb 27 1 to ...

Page 387: ...ld Absolute Pressure MAP sensor engine block temperature sensor and ignition timing EFI SYSTEM FEATURES SPECIFICATIONS NOTE This manual covers ECU software version F6i33051 The ECU and throttle body fuel injector assembly are matched pairs and are not available separately Fuel pump and low oil warning light operates for a few seconds when key switch is turned to the ON position it stops if no engi...

Page 388: ...oline at the connection To prevent possible serious injury or death fuel pressure must be relieved before disconnecting or removing the pump hose and throttle body Either of these suggested procedures MUST be followed before attempting ANY service work on the EFI fuel system Following these will relieve any pressure in the fuel hose prior to opening the fuel system TO RELIEVE FUEL PRESSURE Shut of...

Page 389: ...y See Disconnecting the Battery Gasoline Vehicles on page 1 5 3 If equipped remove air deflector from top of engine 4 If necessary remove fuel tank to increase access to the throttle body 1 See Fuel Tank Removal Section 23 Page 23 21 5 Clean the throttle body 1 and surrounding area Figure 23 2 Page 23 4 6 Disconnect breather hose 2 from air intake adapter 3 7 Disconnect governor cable from bracket...

Page 390: ... on page 1 1 1 Install throttle body 1 and its related components onto threaded studs in order as shown Figure 23 2 Page 23 4 2 Install two flange nuts 7 and tighten to 53 to 71 in lb 6 to 8 N m 3 Connect fuel line 6 and vent hose 5 Secure with spring clamps 4 Connect fuel injector and MAP sensor Page 23 4 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 391: ...Battery Gasoline Vehicles on page 1 5 12 Place the Forward Reverse handle in the NEUTRAL position chock the wheels and the neutral lockout switch in the MAINTENANCE position Figure 26 1 Page 26 1 13 Turn the key switch to the ON position and check for fuel leaks Repeat as necessary to build fuel pressure Any leaks found must be fixed DANGER Repair all fuel leaks before returning the vehicle to ser...

Page 392: ...isconnect battery cables negative cable first Disconnect the spark plug wire from the spark plug See Disconnecting the Battery Gasoline Vehicles on page 1 5 GENERAL INFORMATION For proper vehicle operation it is important the accelerator pedal governor linkage and throttle adjustments are done correctly and in the proper sequence See following CAUTION CAUTION Improper adjustment can result in poor...

Page 393: ...3 3 539 Figure 23 4 Accelerator Rod 1345 Figure 23 5 Accelerator Rod Pull Spring Release to Attach Bottom View Accelerator Rod Installation and Adjustment 1 Before installing the accelerator rod adjust accelerator pedal position See Pedal Group Adjustment Gasoline Vehicles in the Accelerator and Brake Pedal Group Section 2 Install the ball joint 1 on the ball stud 2 at the accelerator pedal Figure...

Page 394: ...g the engine prior to the throttle body lever moving _ EVENT APPROXIMATE PEDAL TRAVEL Park brake release 0 to 4 Solenoid activation and engine start 4 to 15 Throttle body actuation 15 and greater 9 While holding the accelerator ball joint with pliers tighten the jam nuts against the ball joints accelerator ball joint first at each end of the accelerator rod 10 Check rod adjustment for proper switc...

Page 395: ... Page 23 8 1 2 Connect Z fitting of governor cable 1 to throttle lever 2 1 3 If equipped install air deflector on top of engine 2 At transaxle 2 1 Slide bellows off threaded end of cable housing separate jam nuts and place threaded end into governor bracket 5 Figure 23 8 Page 23 10 2 2 Finger tighten jam nuts 2 3 Push bellows back onto threaded end of cable housing 2 4 Connect Z fitting of governo...

Page 396: ...STEM GASOLINE VEHICLES 4 5 1 9 8 13 A 0 055 in 0 039 1 4 mm 1 3110 Figure 23 8 Governor and Accelerator Cables At Governor Arm 3111 Figure 23 9 Throttle Stop Screw Gap Page 23 10 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 397: ...able 8 from vehicle 8 12 11 10 3046 Figure 23 10 Accelerator Cable At Electrical Component Box Accelerator Cable Installation 1 At transaxle 1 1 Hook spring fitting of accelerator cable 8 to governor arm 4 Figure 23 8 Page 23 10 1 2 Snap accelerator cable 8 into FNR accelerator cable bracket 9 1 3 Push dust shield 13 onto end of cable housing 2 At electrical component box 2 1 Insert barrel fitting...

Page 398: ...ottle valve as follows 1 Loosen the throttle body idle screw so that it is not touching the throttle lever Figure 23 11 Page 23 12 2 Slowly tighten the idle screw until it lightly touches the throttle lever then tighten it an additional 1 whole turn 360 degrees 3047 Figure 23 11 Idle Screw CLOSED THROTTLE OR IDLE ADJUSTMENT KEY START VEHICLES Adjust the idle screw until idle RPM is 1200 25 Figure ...

Page 399: ... produces carbon monoxide which is an odorless deadly poison 1 If governor is adjusted proceed to step 2 otherwise adjust governor See Governor Cable Installation and Adjustment on page 23 9 2 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 5 3 Measure vehicle ground speed See How to Measure Ground Speed on page 23 13 4 Compare measured ground speed wit...

Page 400: ... GASOLINE VEHICLES AIR INTAKE SYSTEM See General Warnings on page 1 1 10 5 6 7 8 9 3 2 1 4 3048 Figure 23 12 Air Intake System CA 500 550 700 TRANSPORTER Cafe Express Page 23 14 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 401: ...Fasten wire latches 1 Make sure latches are securely engage See following CAUTION CAUTION Engine damage will occur if the air cleaner cap is not properly secured If air cleaner is extremely dirty remove air cleaner from vehicle and clean thoroughly Use only Club Car replacement air filters The use of other air filters could result in engine damage and void the warranty AIR CLEANER REMOVAL 1 Turn k...

Page 402: ...onto hot engine See Relieving Fuel Pressure on page 23 2 FUEL LINE REMOVAL 1 Turn the key switch to the OFF position and remove the key place the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Disconnect battery See Disconnecting the Battery Gasoline Vehicles on page 1 5 3 Clean the top of the fuel tank and fuel pump module 4 At engine 4 1 Remove spring clamp securing fuel l...

Page 403: ...2 At engine 2 1 Connect fuel line to throttle body and secure with spring clamp See following DANGER DANGER Ensure line is connected properly to avoid a leak that can cause a fire 3 Clean spilled and remove any drained gasoline from the area 4 Connect battery See Connecting the Battery Gasoline Vehicles on page 1 5 5 Place the Forward Reverse handle in the NEUTRAL position chock the wheels and the...

Page 404: ...RNING Fuel may be under pressure Use extreme caution when disconnecting fuel line to prevent the spray of fuel onto hot engine See Relieving Fuel Pressure on page 23 2 Carefully drain any fuel remaining in the hose or pump module into an approved container Add drained fuel back into fuel tank or dispose of properly 7 Loosen fuel tank retaining strap 4 to allow tank to move and provide access to al...

Page 405: ...eak that can cause a fire 7 Connect wire harness plug 2 to fuel pump module 1 8 Clean spilled and remove any drained gasoline from the area 9 Connect battery See Connecting the Battery Gasoline Vehicles on page 1 5 10 Place the Forward Reverse handle in the NEUTRAL position chock the wheels and the neutral lockout switch in the MAINTENANCE position Figure 26 1 Page 26 1 11 Turn key switch to the O...

Page 406: ...23 Fuel Pump Module FUEL SYSTEM GASOLINE VEHICLES 3052 Figure 23 15 Fuel System Side Fill Exploded View Page 23 20 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 407: ...e NEUTRAL position chock the wheels and the neutral lockout switch in the MAINTENANCE position 2 Turn key switch to OFF position and remove key 3 Disconnect battery See Disconnecting the Battery Gasoline Vehicles on page 1 5 4 Clean the top of the fuel tank 10 and fuel pump module 1 Figure 23 15 Page 23 20 5 Remove gas cap and siphon all fuel from tank into an approved container See following DANG...

Page 408: ...ilated area flush the fuel tank with water to remove any remaining fuel 3 In a well ventilated area set the tank upside down so that the water can drain out of it To make sure that the tank dries completely allow the tank to sit for 24 hours 4 Completely drain gas from fuel pump module and allow to module to dry 5 After module is completely dry install in fuel tank See Fuel Pump Module Installatio...

Page 409: ...e OPERATE position Figure 26 1 Page 26 1 FUEL FILTER See General Warnings on page 1 1 GENERAL INFORMATION The fuel filter is located in the fuel tank It is part of the fuel pump module assembly and should last the life of the vehicle however it is replaceable if the need should arise In addition the module assembly features a fuel pickup screen to catch larger particles before entering the fuel fi...

Page 410: ... NEUTRAL position chock the wheels and the neutral lockout switch in the MAINTENANCE position Figure 26 1 Page 26 1 6 Start the engine and check for fuel leaks See following DANGER DANGER Repair all fuel leaks before operating the vehicle 7 If no leaks are found place the neutral lockout switch in the OPERATE position Figure 26 1 Page 26 1 FUELING INSTRUCTIONS GASOLINE VEHICLE See General Warnings...

Page 411: ...o start a vehicle when the fuel pump is dry no gas in tank Doing so can damage the fuel pump NOTE Whenever possible avoid using oxygenated fuels and fuels that are blended with alcohol Vehicles to be stored for extended periods should be prepared for storage as instructed See Preparing the Gasoline Vehicle for Extended Storage on page 3 4 1 Remove the fuel cap located on the passenger side panel a...

Page 412: ...Pagination Page 23 Fueling Instructions Gasoline Vehicle FUEL SYSTEM GASOLINE VEHICLES Page 23 26 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 413: ...t lb 68 N m Figure 24 1 Page 24 2 2 Replace exhaust gasket 5 on the cylinder head exhaust port studs with a new gasket For exhaust gasket with raised port opening orient gasket 5 with raised section of gasket up against the flange of the muffler 3 Place muffler 2 into position and loosely secure it to mounting bracket with locknut 1 and to cylinder head with lock washers 4 and hex nuts 3 4 Tighten...

Page 414: ...24 Muffler EXHAUST SYSTEM GASOLINE VEHICLES 3 4 2 1 6 5 5 7 8 9 3112a Figure 24 1 Exhaust System Page 24 2 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 415: ...vice on the driven clutch This device overcomes the force of the centrifugal weights to close the driven clutch and open the drive clutch thus increasing axle torque with little or no change in engine RPM The engine and torque converter rotate counter clockwise as viewed from the clutch side of the engine To provide optimum performance for the engine and powertrain the vehicle uses a pair of tuned...

Page 416: ... Page 25 4 CC P N 1014496 CC P N 1014507 CC P N 101809101 CC P N 1014497 CC P N 105072501 CC P N 101808401 CC P N 1014508 WARNING 1 2 3 7 5 4 6 1 Drive Clutch Hub Puller 2 Driven Clutch Cam Puller 3 Driven Clutch Cam Press Tool 4 Drive Clutch Holder Tool 5 Driven Clutch Puller Plug 6 Cam Installation Tool 7 Drive Clutch Puller 2963 Figure 25 1 Clutch Tools Page 25 2 2017 Carryall 500 and 700 Maint...

Page 417: ...ift upward on the belt to force the sheaves of the driven clutch 1 apart then roll the belt off the driven clutch by rotating the clutch counterclockwise Figure 25 2 Page 25 3 See following CAUTION CAUTION Make sure fingers are not underneath the belt when rolling the belt off the driven clutch 3 Remove the belt from the drive clutch 2 1 2 594 Figure 25 2 Drive Belt Removal DRIVE BELT INSTALLATION...

Page 418: ...tainer 2 Washer Hard M10 11 Ring Spiral Backup 3 Washer 3 8 Type A Flat 12 Bushing Split Drive Clutch 4 Cap Plug 13 Sheave Moveable Drive 5 Drive Hub Assy Drive Clutch 14 Spacer Fixed Face Shaft 6 Ring 0 810 in 20 5 mm Internal Retaining 15 Spring Drive Clutch 7 Drive Clutch Button 16 No Item to Show Page 25 4 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 419: ...2 Loosen starter generator mounting and adjusting hardware and remove starter belt See WARNING Moving parts Do not in General Warnings on page 1 1 CCI P N 1014496 2 1 2962 Figure 25 4 Loosen Retaining Bolt 596 Figure 25 5 Drive Clutch Removal 3 Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the chassis to support the vehic...

Page 420: ...Lubricate the threaded portion of the clutch puller tool 1 with a light oil and thread the clutch puller tool into the clutch retaining bolt hole Figure 25 5 Page 25 5 6 Use a 1 2 in drive air wrench to tighten the clutch puller tool The drive clutch 2 will pull free of the crankshaft 7 Support the drive clutch assembly in your hand and back the clutch puller tool out of the crankshaft CAUTION Do ...

Page 421: ... clutch until the stop nut touches the clutch then back the bolt out one half turn Figure 25 7 Page 25 7 2 3 Thread the three small bolts of the puller into corresponding holes in the clutch Tighten bolts evenly making sure the face of the puller plate is parallel to the face of the clutch Figure 25 7 Page 25 7 2 4 Unscrew the puller center bolt out of the clutch to pull drive clutch hub off CCI P...

Page 422: ...ts 3 as shown Figure 25 9 Page 25 8 5 2 Pull the weight assemblies 3 with pins from slots 4 in the clutch See following NOTE NOTE Before removing note the orientation of the wave washer 1 and secondary weight 2 on the primary weight 3 Figure 25 10 Page 25 9 5 3 Remove the plastic washers weights 2 and 3 and wave washer 1 from the pin 4 Retain all parts Page 25 8 2017 Carryall 500 and 700 Maintenan...

Page 423: ...e bore in the fixed sheave Figure 25 3 Page 25 4 See also Figure 25 11 Page 25 9 Discard the rings 605 Figure 25 11 Spiral Back up Rings INSPECTION OF DRIVE CLUTCH PARTS 1 Inspect the idler spacer 17 for smoothness Figure 25 3 Page 25 4 2 Inspect the bore of the moveable sheave 13 for scarring or wear The moveable sheave must be replaced if the bore is worn to a diameter of 0 883 in 22 4 mm or lar...

Page 424: ...the retaining ring 6 Figure 25 3 Page 25 4 5 Install the primary weights 3 on the mounting pins 4 Figure 25 10 Page 25 9 6 Install a wave washer 1 on each mounting pin 4 Make sure that the concave side of the washer faces the side of the primary weight 3 with the small guide pin protruding from it Figure 25 10 Page 25 9 7 Install the secondary weights 2 onto the mounting pins 4 with the weight pin...

Page 425: ... plugs 4 into the holes Figure 25 3 Page 25 4 3054 Figure 25 13 Correct Orientation of Drive Button Take up Springs DRIVE CLUTCH INSTALLATION 1 Place the drive clutch assembly on the crankshaft taper Position the mounting washers 2 and 3 on the bolt 1 and start the bolt into the crankshaft Figure 25 3 Page 25 4 See following NOTE NOTE The drive clutch retaining bolt has right hand threads The manu...

Page 426: ...page 1 1 1 Screw 5 16 18 X 3 4 Hex Head with Patch 7 Screw 8 32 X 3 4 Socket Head Cap 2 Washer Driven Clutch 8 Button Drive 3 Ring Retaining 9 Sheave Movable Driven 4 Key Driven Clutch 10 Washer Acetal Driven Clutch Page 25 12 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 427: ...xed sheave and moveable sheave so they can be reassembled in the same positions 1 Make match marks on the driven clutch fixed sheave and on the moveable sheave to maintain balance upon reassembly 2 Using external snap ring pliers remove the retaining ring 4 Figure 25 15 Page 25 14 See following WARNING WARNING Do not place fingers under the cam when removing the cam The moveable face may spin when...

Page 428: ...ave if it is worn scratched or damaged DRIVEN CLUTCH ASSEMBLY 1 Place the three drive buttons 8 in position Apply one drop of Loctite 222 to each of the socket head cap screws 7 and then install and tighten them to 8 in lb 0 9 N m Figure 25 14 Page 25 12 2 Slide the acetal washer 10 and moveable sheave 9 onto the fixed sheave 11 3 Place the end of the spring 6 into the hole in the moveable sheave ...

Page 429: ...Process NOTE This process is for field assembly requirements where hydraulic and pneumatic press equipment is not available Use the cam installation tool CC P N 101808401 for this process 5 2 1 With the clutch loosely assembled set the edge of the clutch body 5 on a clean flat surface Figure 25 18 Page 25 15 5 2 2 Assemble the threaded bolt 1 through the washer 2 the thrust bearing assembly 3 the ...

Page 430: ...4 NOTE The retaining ring 4 can be reused if the O D does not exceed 1 607 in 40 82 mm otherwise it must be replaced with a new ring CC P N 1014080 DRIVEN CLUTCH INSTALLATION 1 To install the driven clutch reverse the removal procedure Make sure that the washer 2 is mounted with the flat portion of the washer against the driven clutch Figure 25 14 Page 25 12 Secure with a new bolt 1 See following ...

Page 431: ...SE R Bring the vehicle to a complete stop before changing FORWARD or REVERSE direction NEUTRAL LOCKOUT For the convenience of the trained technician there is a neutral lockout switch located on the seat support panel under the seat Figure 26 1 Page 26 1 The neutral lockout switch has two positions MAINTENANCE and OPERATE which are clearly marked 81 Figure 26 1 MAINTENANCE OPERATE Switch Pedal Star...

Page 432: ...tes vehicle ground speed It is mounted inside the transaxle and is driven by transaxle gears If any of the governor linkages are removed in order to service other components readjustment of the governor linkage is required See Governor Cable Installation and Adjustment on page 23 9 TRANSAXLE SERVICE The transaxle is extremely durable and should require very little service under normal operating co...

Page 433: ...rque wrench 3 8 in drive 1 2 in combination wrench Jack stands 2 one ton capacity 3 8 in socket 3 8 in drive 9 16 in combination wrench Standard slip joint pliers 7 16 in socket 3 8 in drive Small flat blade screwdriver External snap ring pliers 0 047 in tip 1 2 in socket 3 8 in drive Medium flat blade screwdrivers 2 90 Internal snap ring pliers 0 090 in tip 9 16 in socket 3 8 in drive No 2 philli...

Page 434: ...rt the rear of vehicle 8 Remove the lug nuts and wheel 9 Slide brake drum off hub 10 Remove hub nut 4 and large flat washer 5 and pull hub 6 off axle shaft See following NOTE NOTE If the hub 6 does not slide easily off the axle shaft use a two or four jaw wheel puller to remove the hub 6 1 3 4 5 2 3056 Figure 26 3 Rear Hub Exploded View REAR HUB INSTALLATION 1 Inspect brake shoes for wear and repl...

Page 435: ...cap 3 on hub nut 4 and install new cotter pin 2 If necessary tighten hub nut 4 further 177 ft lb 240 N m max until the locking cap 3 and new cotter pin 2 can be installed 11 Deform cotter pin 2 as shown Figure 26 4 Page 26 5 Either way is acceptable No part of the cotter pin 2 should protrude beyond the perimeter of the locking cap 3 12 Install rubber dust cap 1 13 Tighten lug nuts to 65 ft lb 88 ...

Page 436: ... it can be done one side at a time without removing the transaxle 1 Clean debris from drain plug and area around it at the bottom of the transaxle Drain oil Install plug after draining 2 If removing entire transaxle from vehicle remove the transaxle and clean it in preparation for disassembly See Transaxle Removal on page 26 9 See following NOTE NOTE After cleaning move transaxle to a clean locati...

Page 437: ...ge 26 2 REAR WHEEL BEARING REMOVAL 1 Remove hub See Rear Hub Removal on page 26 4 2 Remove axle tube 2 from transaxle See Axle Tube and Axle Shaft Removal on page 26 6 3 Remove the snap ring 5 that is in front of the bearing 6 and discard Figure 26 5 Page 26 6 4 Drive axle shaft 3 and bearing 6 from outer end of axle tube 2 as an assembly 5 Use a puller to remove bearing 6 from axle shaft 3 See fo...

Page 438: ... seal 7 will sit Figure 26 5 Page 26 6 2 Using an appropriate sized seal driver drive in new oil seal 7 until 0 0393 in 1 mm below surface not fully seated 3 Clean end of axle shaft 3 and carefully install axle tube 2 to avoid damaging new oil seal 7 with splines of axle shaft See Axle Tube and Axle Shaft Installation on page 26 7 4 Refill transaxle with appropriate type and volume of oil See Oil ...

Page 439: ... wire plug from limit switch on transaxle 8 Disconnect three wires of main wire harness from starter generator Figure 20 14 Page 20 13 9 Loosen jam nuts 1 securing shifter cable 2 to FNR accelerator cable mounting bracket Then remove bowtie clip 3 to disconnect shifter cable end 4 from transaxle shift lever 5 and set shifter cable 2 aside Figure 26 14 Page 26 14 10 Remove bolts 1 securing governor...

Page 440: ...Stands 17 Continue raising vehicle until chassis is higher than the top of the transaxle i e enough to allow powertrain to be rolled out from under vehicle Figure 26 10 Page 26 10 Position jack stands adjusted to support the vehicle at this height under the frame crossmember between the leaf spring mounts and side stringers just forward of each rear wheel Lower the floor jack to allow the jack sta...

Page 441: ...l from transaxle Dispose of gear oil properly 23 Remove driven clutch See Driven Clutch Removal Section 25 Page 25 13 24 Remove eight bolts 1 total that secure transaxle to powertrain Figure 26 12 Page 26 12 at the following locations Four bolts 1 at engine pan 2 Two bolts 1 at clutch plate 3 Two bolts 1 at muffler bracket 25 Roll transaxle from engine pan 2 See following NOTE NOTE The transaxle w...

Page 442: ...26 Transaxle Removal TRANSAXLE ED65 GASOLINE VEHICLES 1 1 3 2 3063 Figure 26 12 Transaxle Mounting Bolts Page 26 12 2017 Carryall 500 and 700 Maintenance and Service Manual ...

Page 443: ...secure wires and cables could result in vehicle malfunction property damage or personal injury 4 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 5 5 Check governor adjustment and correct if necessary See Governor Cable Installation and Adjustment Section 23 Page 23 9 6 Check engine RPM setting Adjust if necessary See Engine RPM Adjustment Section 23 Pag...

Page 444: ...d secure with bowtie clip 3 4 Feed front of cable 2 through its mounting hole and push the plastic anchor into hole until tangs 4 snap into place Figure 26 13 Page 26 14 5 Snap cable end socket 1 onto stud 3 of Forward Reverse shifter handle 6 Secure shifter cable along chassis with wire ties 7 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 5 SHIFTER C...

Page 445: ... charger 14 1 self discharge 14 10 storage 14 13 testing 14 3 basics 14 2 voltage test 12 15 voltage test under load 12 17 vibration damage 14 11 battery installation 20 35 storage 20 36 testing 18 17 testing under load 18 17 18 37 voltage test 18 17 bearing axle see transaxle type g axle bearing 17 4 bearing motor see motor bearing 16 9 bed tilt see tilt bed 4 13 belt drive see drive belt 25 3 bo...

Page 446: ...ion 21 5 removal 21 4 testing 19 10 circuit breaker installation 13 4 removal 13 4 circuit breaker testing 12 20 cleaning brake assembly 6 3 vehicle body 4 1 clutch torque converter troubleshooting 25 1 clutch drive see drive clutch 25 4 clutch driven see driven clutch 25 12 column steering see steering column 7 3 commutator see starter generator 20 1 connector 18 pin see test procedures 18 22 19 ...

Page 447: ...ilter installation 23 24 removal 23 23 fuel gauge hour meter 20 27 fuel gauge circuit testing 18 40 fuel level sending unit 20 28 fuel level sending unit testing 18 39 hour meter circuit testing 18 41 installation 20 28 removal 20 27 fuel gauge hour meter gasoline vehicles operation 20 27 fuel injector testing 18 22 19 6 fuel level sending unit 20 28 fuel level sending unit testing 18 39 fuel line...

Page 448: ... 33 kill limit switch installation 20 22 removal 20 22 kill limit switch engine testing 18 33 L leaf spring see suspension front and suspension rear 9 2 light switch testing 18 42 low oil warning light installation 20 27 removal 20 27 testing 18 36 lubrication front suspension 7 15 transaxle type g 17 1 M magnet motor speed sensor see motor speed sensor magnet 16 9 maintenance operate switch testi...

Page 449: ...w switch 12 2 installation 13 4 removal 13 4 testing 12 18 S safety 1 1 schematic diagram key start gasoline vehicle 19 2 pedal start gasoline vehicle 18 8 service tools torque converter kit 25 1 transaxle 26 3 shock absorber see suspension front and suspension rear 9 1 shock absorber front installation 7 20 removal 7 20 single point watering system SPWS 14 11 solenoid installation 13 8 20 20 21 3...

Page 450: ...dures charger AC power and continuity test of AC circuit 15 12 DC circuit continuity test 15 12 test procedures electric vehicle 15 amp fuse 12 19 24 pin connector 12 33 4 pin connector 12 43 batteries voltage check 12 15 battery pack voltage under load 12 17 charge indicator light 12 42 charger interlock 12 26 circuit breaker 12 20 Forward Reverse rocker switch 12 24 key switch MCOR limit switch ...

Page 451: ... 26 3 torque converter troubleshooting 25 1 transaxle installation 26 13 lubrication 26 2 removal 26 9 service 26 2 transaxle type g assembly 17 10 axle bearing 17 4 axle shaft installation 17 4 removal 17 1 disassembly 17 8 inspection 17 8 installation 17 12 lubrication 17 1 oil seal installation 17 4 removal 17 1 removal 17 5 troubleshooting 12 8 CDT handheld programmer 11 27 torque converter 25...

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