Club car Carryall 300 2018 Manual

2018Carryall300

MaintenanceandService

Manual

GasolineVehiclewithSubaruEX40Engine

ElectricVehiclewithERICChargingSystem

ManualNumber105344220

EditionCodeB

FOREWORD

ClubCarvehiclesaredesignedandbuilttoprovidetheultimateinperformanceefciency;however,proper

maintenanceandrepairareessentialforachievingmaximumservicelifeandcontinuedsafeandreliableoperation.

Thismanualprovidesdetailedinformationforthemaintenanceandrepairofthe2018Carryall300vehicle,andshould

bethoroughlyreviewedpriortoservicingthevehicle.Theproceduresprovidedmustbeproperlyimplemented,andthe

DANGER,WARNING,andCAUTIONstatementsmustbeheeded.

Thismanualwaswrittenforthetrainedtechnicianwhoalreadypossessesknowledgeandskillsinelectricaland

mechanicalrepair.Ifthetechniciandoesnothavesuchknowledgeandskills,attemptedserviceorrepairstothe

vehiclemayrenderthevehicleunsafe.Forthisreason,ClubCaradvisesthatallrepairsand/orservicebeperformed

byanauthorizedClubCardistributor/dealerrepresentativeorbyaClubCarfactory-trainedtechnician.

ItisthepolicyofClubCartoassistitsdistributorsanddealersincontinuallyupdatingtheirserviceknowledgeand

facilitiessotheycanprovidepromptandefcientserviceforvehicleowners.Regionaltechnicalrepresentatives,

vehicleserviceseminars,periodicservicebulletins,maintenanceandservicemanuals,andotherservicepublications

alsorepresentClubCar’scontinuingcommitmenttocustomersupport.

ClubCaroffersafulllineoftrainingandcontinuingeducationclassesfortechnicianswhowanttolearnmoreabout

ourproducts.Formoreinformation,contactyourlocaldealerorClubCar'sT echnicalServicesdepartmentfora

listofupcomingclasses.

Thismanualcoversallaspectsoftypicalvehicleservice;however,uniquesituationssometimesoccurwhenservicinga

vehicle.Ifitappearsthataservicequestionisnotansweredinthismanual,pleasecontactyournearestauthorized

ClubCardealerordistributorforassistance.

TondyourlocalauthorizedClubCardealer,visitwww.clubcardealer.com,call1-800-ClubCar(258–2227),orscan

thisQuickResponse(QR)codetobetakentotheClubCardealerlocator.RefertoFigure1.DownloadaQRcode

readersuchasRedLaserorBarcodeScannertoyourcellphoneortablet.

Ifyouwouldprefertowritetous,directyourletterto:ClubCarLLC,Attention:MarketingServices,P .O.Box204658,

Augusta,Georgia30917-4658USA.

DealerLocatorQRCode

ClubCarisaregisteredtrademarkofClubCar,LLC

ThismanualeffectiveJune,2018

2018Carryall300MaintenanceandServiceManualPagei

FOREWORD

TECHNICALPUBLICATIONCUSTOMERSATISFACTIONONLINESURVEY

Letyourvoicebeheard!

PleaseparticipateintheTechnicalPublicationcustomersatisfactiononlinesurvey.

Thissurveytakeslessthanveminutestocompleteandyourresponseswillhelpexaminecurrentperformance

andidentifyareasforfutureimprovement.

Ourtoppriorityistoprovidetimely,accurate,anduserfriendlymanuals.

Theonlinesurveycanbefoundathttp://bit.ly/1w9uFMhorusingtheQRCodebelow.

OnlineSurveyQRCode

WARNING

•ReadSafetyonpage1-1beforeattemptinganyserviceonthevehicle.

•Beforeservicingvehicle,readcompletesection(s)andanyreferencedinformationthatmaybe

relevanttotheserviceorrepairtobeperformed.

MAINTENANCEITEMS

BatteryTerminalProtectorSpray

CCPN1014305

DryMolyLube

CCPN1012151

ChassisLube

EPNLGIGrade2(commerciallyavailable)

EngineAirFilter(404cc)

CCPN102558201

DeionizerFilterReplacementCartridge(SPWS)

CCPN104005901

SparkPlugO.H.C.(404cc)

CCPN105017801

DeionizerFilterReplacementCartridge(non-SPWS)

CCPNAM10975

NOTE:Thismanualrepresentsthemostcurrentinformationatthetimeofpublication.ClubCariscontinuallyworking

tofurtherimproveitsvehiclesandotherproducts.Theseimprovementsmayaffectservicingprocedures.

Anymodicationand/orsignicantchangeinspecicationsorprocedureswillbeforwardedtoallClubCar

dealersandwill,whenapplicable,appearinfutureeditionsofthismanual.

ClubCarreservestherighttochangespecicationsanddesignsatanytimewithoutnoticeandwithoutthe

obligationofmakingchangestounitspreviouslysold.

Therearenowarrantiesexpressedorimpliedinthismanual.Seethelimitedwarrantyfoundinthevehicle

Owner’sManual.

CONTENTS

SECTION1—Safety.........................................................................................................................................1-1

SafetyDetails................................................................................................................................................1-1

PersonalSafety.........................................................................................................................................1-1

MachineSafety..........................................................................................................................................1-1

Information................................................................................................................................................1-1

GeneralWarnings..........................................................................................................................................1-1

DisablingtheVehicle..................................................................................................................................1-3

DisconnectingtheBattery-GasolineVehicles..............................................................................................1-3

ConnectingtheBattery-GasolineVehicles..................................................................................................1-3

DisconnectingtheBatteries–ElectricVehicles............................................................................................1-4

ConnectingtheBatteries–ElectricVehicles................................................................................................1-4

RecyclingLead-AcidBatteries....................................................................................................................1-4

Internationalsafetysymbolsonbatteries.....................................................................................................1-5

SECTION2—VehicleSpecications..................................................................................................................2-1

VehicleSpecications....................................................................................................................................2-1

VehicleSpecications–ElectricVehicles....................................................................................................2-1

E.R.I.C.BatteryChargerSpecications.......................................................................................................2-3

VehicleSpecications–GasolineVehicles..................................................................................................2-4

SECTION3—GeneralInformation.....................................................................................................................3-1

ModelIdentication........................................................................................................................................3-1

Storage–ElectricVehicles.............................................................................................................................3-2

PreparingtheElectricVehicleforExtendedStorage.....................................................................................3-2

ReturningtheStoredElectricVehicletoService..........................................................................................3-3

Storage–GasolineVehicles...........................................................................................................................3-4

PreparingtheGasolineVehicleforExtendedStorage..................................................................................3-4

ReturningtheStoredGasolineVehicletoService........................................................................................3-5

SECTION4—BodyandTrim............................................................................................................................4-1

CleaningtheVehicle......................................................................................................................................4-1

SeatCleaning............................................................................................................................................4-1

FrontBodyRepair.........................................................................................................................................4-2

LightScratches..........................................................................................................................................4-2

AbrasionsandHaze..................................................................................................................................4-2

LargeScratchesandAbrasions..................................................................................................................4-2

Touch-UpPaintColorChart........................................................................................................................4-2

FrontBody....................................................................................................................................................4-3

HeavyDutyBumperRemoval.....................................................................................................................4-3

HeavyDutyBumperInstallation..................................................................................................................4-3

CowlRemoval...........................................................................................................................................4-5

CowlInstallation........................................................................................................................................4-5

GrilleRemoval...........................................................................................................................................4-6

GrilleInstallation........................................................................................................................................4-7

FrontBumperandSideFenderRemoval....................................................................................................4-9

FrontBumperandSideFenderInstallation..................................................................................................4-9

InstrumentPanelRemoval.......................................................................................................................4-10

InstrumentPanelInstallation....................................................................................................................4-10

DashRemoval..........................................................................................................................................4-11

DashInstallation.......................................................................................................................................4-11

TiltBed.......................................................................................................................................................4-13

TiltBedRemoval.....................................................................................................................................4-14

TiltBedInstallation..................................................................................................................................4-14

BedLatchAssemblyRemoval..................................................................................................................4-15

BedLatchAssemblyInstallation...............................................................................................................4-15

RearFendersandTailskirt............................................................................................................................4-17

2018Carryall300MaintenanceandServiceManualPageiii

RearFenderandTailskirtRemoval...........................................................................................................4-17

RearFenderandTailskirtInstallation........................................................................................................4-18

FloorMat....................................................................................................................................................4-18

FloorMatRemoval..................................................................................................................................4-18

FloorMatInstallation................................................................................................................................4-18

SECTION5—AcceleratorandBrakePedalGroup.............................................................................................5-1

BrakePedalandParkBrake(GasandElectricVehicles)..................................................................................5-1

BrakePedalRemoval(GasandElectricVehicles).......................................................................................5-1

BrakePedalInstallation(GasandElectricVehicles).....................................................................................5-1

ParkBrakeRemoval(GasandElectricVehicles).........................................................................................5-4

ParkBrakeInstallation(GasandElectricVehicles)......................................................................................5-4

AcceleratorPedal–GasolineVehicles............................................................................................................5-5

AcceleratorPedalRemoval–GasolineVehicles..........................................................................................5-5

AcceleratorPedalInstallation–GasolineVehicles.......................................................................................5-7

AcceleratorPedal–ElectricVehicles..............................................................................................................5-8

AcceleratorPedalRemoval–ElectricVehicles............................................................................................5-8

AcceleratorPedalInstallation–ElectricVehicles.......................................................................................5-10

PedalGroupAdjustment–GasolineVehicles................................................................................................5-10

PedalGroupAdjustment–ElectricVehicles..................................................................................................5-15

SECTION6—WheelBrakeAssemblies.............................................................................................................6-1

GeneralInformation.......................................................................................................................................6-1

BrakeShoeRemoval.....................................................................................................................................6-1

BrakeAssemblyCleaning..............................................................................................................................6-5

BrakeShoeInstallation..................................................................................................................................6-7

BrakeAdjustment..........................................................................................................................................6-9

BrakeAssemblyRemovalandInstallation.....................................................................................................6-10

BrakeAssemblyRemoval........................................................................................................................6-10

BrakeAssemblyInstallation......................................................................................................................6-10

BrakeCableRemovalandInstallation............................................................................................................6-11

BrakeCableRemoval...............................................................................................................................6-11

BrakeCableInstallation............................................................................................................................6-11

SECTION7—SteeringandFrontSuspension....................................................................................................7-1

GeneralInformation.......................................................................................................................................7-1

SteeringWheel..............................................................................................................................................7-1

SteeringWheelRemoval............................................................................................................................7-1

SteeringWheelInstallation.........................................................................................................................7-2

SteeringColumn............................................................................................................................................7-3

SteeringColumnRemoval..........................................................................................................................7-3

SteeringColumnDisassembly....................................................................................................................7-3

SteeringColumnAssembly........................................................................................................................7-3

SteeringColumnInstallation.......................................................................................................................7-5

SteeringAdjustment......................................................................................................................................7-6

RackandPinion............................................................................................................................................7-7

RackandPinionInspection........................................................................................................................7-7

RackandPinionRemoval–Maintenance-FreeBallJoints...........................................................................7-7

RackandPinionDisassembly....................................................................................................................7-8

RackandPinionAssembly.......................................................................................................................7-10

RackandPinionInstallation–Maintenance-FreeBallJoints.......................................................................7-13

TieRodandDragLink.................................................................................................................................7-14

TieRodandDragLinkRemoval–Maintenance-FreeBallJoints................................................................7-14

TieRodandDragLinkInstallation–Maintenance-FreeBallJoints..............................................................7-14

FrontSuspension........................................................................................................................................7-15

Lubrication..............................................................................................................................................7-15

WheelAlignment.....................................................................................................................................7-15

FrontSuspensionComponents.....................................................................................................................7-17

LeafSpringRemoval...............................................................................................................................7-17

LeafSpringInstallation.............................................................................................................................7-17

KingpinandSteeringSpindleRemoval–Maintenance-FreeBallJoints.......................................................7-17

Pageiv2018Carryall300MaintenanceandServiceManual

KingpinandSteeringSpindleInstallation–Maintenance-FreeBallJoints....................................................7-20

DeltaA-PlateRemoval.............................................................................................................................7-20

DeltaA-PlateInstallation..........................................................................................................................7-20

ShockAbsorberRemoval.........................................................................................................................7-20

ShockAbsorberInstallation......................................................................................................................7-20

FrontWheelBearingsandHubs...................................................................................................................7-21

FrontWheelFreePlayInspection.............................................................................................................7-21

FrontHubRemoval..................................................................................................................................7-21

FrontHubInstallation...............................................................................................................................7-21

SECTION8—WheelsandTires........................................................................................................................8-1

GeneralInformation.......................................................................................................................................8-1

Wheels.........................................................................................................................................................8-1

WheelRemoval.........................................................................................................................................8-1

WheelInstallation......................................................................................................................................8-1

Tires.............................................................................................................................................................8-2

TireRemoval.............................................................................................................................................8-2

TireRepair................................................................................................................................................8-2

TireInstallation..........................................................................................................................................8-3

SECTION9—RearSuspension........................................................................................................................9-1

GeneralInformation.......................................................................................................................................9-1

ShockAbsorbers...........................................................................................................................................9-1

ShockAbsorberInspectionandRemoval...................................................................................................9-1

ShockAbsorberInstallation........................................................................................................................9-2

Multi-LeafSprings..........................................................................................................................................9-2

Multi-LeafSpringRemoval........................................................................................................................9-2

Multi-LeafSpringInstallation......................................................................................................................9-5

JounceBumpers...........................................................................................................................................9-5

JounceBumperRemoval...........................................................................................................................9-5

JounceBumperInstallation........................................................................................................................9-5

SECTION10—PeriodicMaintenance..............................................................................................................10-1

GeneralInformation.....................................................................................................................................10-1

Pre-OperationandDailySafetyChecklist......................................................................................................10-1

PerformanceInspection...........................................................................................................................10-2

Maintenance...............................................................................................................................................10-3

PeriodicServiceSchedules..........................................................................................................................10-4

PeriodicLubricationSchedules.....................................................................................................................10-7

SECTION11—ControllerDiagnosticT ool(CDT)...............................................................................................11-1

GeneralInformation......................................................................................................................................11-2

Features..................................................................................................................................................11-2

PluggingtheCDTintotheVehicle..................................................................................................................11-3

IntroductoryDisplay..................................................................................................................................11-3

QuickReferenceGuide–ExcelwithERICChargingSystem...........................................................................11-4

SystemInfo..................................................................................................................................................11-5

ModelNumber..........................................................................................................................................11-5

SerialNumber..........................................................................................................................................11-5

HardwareVersion.....................................................................................................................................11-5

ProtocolVersion.......................................................................................................................................11-5

ParamBlockVersion.................................................................................................................................11-5

MFGDateCode.......................................................................................................................................11-5

OSVersion...............................................................................................................................................11-5

SMVersion..............................................................................................................................................11-5

VCLAppVersion......................................................................................................................................11-5

Parameters..................................................................................................................................................11-5

Settings...................................................................................................................................................11-6

AmpHours...............................................................................................................................................11-8

AccessCodes..........................................................................................................................................11-8

2018Carryall300MaintenanceandServiceManualPagev

VehicleID................................................................................................................................................11-9

MonitorMenu...............................................................................................................................................11-9

BattVoltage............................................................................................................................................11-10

VminI...................................................................................................................................................11-10

SignedBatteryCurrent............................................................................................................................11-10

BDIPercent............................................................................................................................................11-10

Speed....................................................................................................................................................11-10

Throttle..................................................................................................................................................11-10

Temperature...........................................................................................................................................11-10

ArmCurrent...........................................................................................................................................11-10

FieldCurrent..........................................................................................................................................11-10

ArmaturePWM.......................................................................................................................................11-10

FieldPWM.............................................................................................................................................11-11

SpeedPulses.........................................................................................................................................11-11

FootInput..............................................................................................................................................11-11

KeyInput...............................................................................................................................................11-11

ForwardInput.........................................................................................................................................11-11

ReverseInput.........................................................................................................................................11-11

ModeSwitchInput..................................................................................................................................11-11

ChargerInhibit........................................................................................................................................11-11

MainContDriver....................................................................................................................................11-11

LEDDriver.............................................................................................................................................11-11

PasswordTries(OEMAccessLevelOnly)................................................................................................11-11

Odometer...............................................................................................................................................11-12

BDIInfo.................................................................................................................................................11-12

BatteryMonitor.......................................................................................................................................11-12

ChargingTotals......................................................................................................................................11-12

AmpHoursDisplay.................................................................................................................................11-13

LIN........................................................................................................................................................11-13

VehicleSpeeds.......................................................................................................................................11-13

PedalCounters.......................................................................................................................................11-13

FaultCounters........................................................................................................................................11-13

FaultCountOdometers...........................................................................................................................11-13

DiagnosticsMenu.......................................................................................................................................11-14

PresentErrorsFolder..............................................................................................................................11-14

FaultHistoryFolder................................................................................................................................11-14

CausesofFaults....................................................................................................................................11-15

FaultRecovery.......................................................................................................................................11-17

FaultDescriptions.......................................................................................................................................11-18

IncorrectPassword(OEMAccessLevelOnly)..........................................................................................11-18

MaxPasswordTries(OEMAccessLevelOnly)........................................................................................11-18

ThrottleFault..........................................................................................................................................11-18

LowBatteryVoltage(Undervoltage).........................................................................................................11-18

Overvoltage............................................................................................................................................11-18

ThermalCutback....................................................................................................................................11-19

Anti-TamperFault...................................................................................................................................11-19

HPD......................................................................................................................................................11-19

MainDrvrOverCurrent............................................................................................................................11-19

LockoutFault.........................................................................................................................................11-19

LowSOC...............................................................................................................................................11-19

MainWelded..........................................................................................................................................11-20

HighSpeedWalkAway............................................................................................................................11-20

Speedsensor.........................................................................................................................................11-20

MainDriverOn.......................................................................................................................................11-20

MainCoilOpen.......................................................................................................................................11-20

MainDropout(1or2)..............................................................................................................................11-21

MotorStall..............................................................................................................................................11-21

MainDriverOff.......................................................................................................................................11-21

CurrentSenseFault................................................................................................................................11-21

M–Shorted............................................................................................................................................11-21

FLD(Field)Missing.................................................................................................................................11-22

HWFailsafe...........................................................................................................................................11-22

FaultHistory...........................................................................................................................................11-22

ClearFaultHistory..................................................................................................................................11-22

Pagevi2018Carryall300MaintenanceandServiceManual

Programming.............................................................................................................................................11-22

Cloning..................................................................................................................................................11-23

Favorites....................................................................................................................................................11-23

HHPSettings.............................................................................................................................................11-23

Plot&Log..................................................................................................................................................11-25

Plot........................................................................................................................................................11-25

Log........................................................................................................................................................11-25

CDTTroubleshooting..................................................................................................................................11-26

ConnectionTests........................................................................................................................................11-27

SECTION12—ExcelSystemTroubleshooting:withERICCharging..................................................................12-1

GeneralInformation.....................................................................................................................................12-1

Accessories.............................................................................................................................................12-1

ChargeIndicatorLight..............................................................................................................................12-1

AttributesoftheExcelSystem..................................................................................................................12-1

KeyDifferences:ExcelwithERICChargingSystemvs.PowerDriveChargers............................................12-2

Features.................................................................................................................................................12-2

WiringDiagrams..........................................................................................................................................12-4

Troubleshooting...........................................................................................................................................12-9

TroubleshootingtheVehiclewiththeCDT.................................................................................................12-9

TroubleshootingGuide1..........................................................................................................................12-9

TroubleshootingGuide2.........................................................................................................................12-12

TestProcedures.........................................................................................................................................12-15

TestingBasics........................................................................................................................................12-15

SECTION13—ElectricalComponents:ElectricVehicles..................................................................................13-1

KeySwitch..................................................................................................................................................13-1

TestingtheKeySwitch.............................................................................................................................13-1

KeySwitchRemoval................................................................................................................................13-1

KeySwitchInstallation.............................................................................................................................13-1

Forward/ReverseRockerSwitch...................................................................................................................13-2

TestingtheForward/ReverseRockerSwitch..............................................................................................13-2

Forward/ReverseRockerSwitchRemoval.................................................................................................13-2

Forward/ReverseRockerSwitchInstallation..............................................................................................13-2

Run/TowSwitch...........................................................................................................................................13-3

TestingtheRun/TowSwitch......................................................................................................................13-3

Run/TowSwitchRemoval.........................................................................................................................13-3

Run/TowSwitchInstallation......................................................................................................................13-3

MotorControllerOutputRegulator(MCOR)...................................................................................................13-4

TestingtheMCOR...................................................................................................................................13-4

MCORRemoval......................................................................................................................................13-4

MCORInstallation...................................................................................................................................13-4

ReverseBuzzer...........................................................................................................................................13-5

ReverseBuzzerRemoval.........................................................................................................................13-5

ReverseBuzzerInstallation......................................................................................................................13-5

Solenoid......................................................................................................................................................13-6

TestingtheSolenoid................................................................................................................................13-6

SolenoidRemoval...................................................................................................................................13-6

SolenoidInstallation.................................................................................................................................13-6

SpeedController.........................................................................................................................................13-7

TestingtheSolidStateSpeedController...................................................................................................13-7

SpeedControllerRemoval.......................................................................................................................13-7

SpeedControllerInstallation.....................................................................................................................13-8

ChargerReceptacle.....................................................................................................................................13-9

TestingtheChargerReceptacle................................................................................................................13-9

ChargerReceptacleInspection.................................................................................................................13-9

ChargerReceptacleRemoval...................................................................................................................13-9

ChargerReceptacleInstallation...............................................................................................................13-10

ChargeIndicatorLight.................................................................................................................................13-10

TestingtheChargeIndicatorLight............................................................................................................13-10

ChargeIndicatorLightRemoval...............................................................................................................13-10

ChargeIndicatorLightInstallation............................................................................................................13-10

2018Carryall300MaintenanceandServiceManualPagevii

DC/DCConverter.......................................................................................................................................13-10

DC/DCConverterRemoval.....................................................................................................................13-10

DC/DCConverterInstallation...................................................................................................................13-11

FuseBlock.................................................................................................................................................13-11

FuseBlockRemoval...............................................................................................................................13-11

FuseBlockInstallation............................................................................................................................13-11

HeadlightSwitch.........................................................................................................................................13-12

HeadlightSwitchRemoval.......................................................................................................................13-12

HeadlightSwitchInstallation....................................................................................................................13-12

Headlights..................................................................................................................................................13-12

HeadlightBezelRemoval........................................................................................................................13-12

HeadlightBezelInstallation.....................................................................................................................13-12

HeadlightBulbRemoval(Halogen)..........................................................................................................13-13

HeadlightBulbInstallation(Halogen).......................................................................................................13-13

HeadlightBulbRemoval(LED)................................................................................................................13-13

HeadlightBulbInstallation(LED).............................................................................................................13-13

SECTION14—Batteries:ElectricVehiclewithERICCharging..........................................................................14-1

GeneralInformation.....................................................................................................................................14-1

BatteryTestingBasics–8Volt......................................................................................................................14-2

Observation.............................................................................................................................................14-2

MeasuringVoltageofBatterySet..............................................................................................................14-2

BatteryCellNumbering............................................................................................................................14-2

BatteryTesting–8Volt................................................................................................................................14-3

BatteryRegrouping......................................................................................................................................14-3

BatteryReplacement...................................................................................................................................14-5

BatteryCare................................................................................................................................................14-6

WaterQuality..........................................................................................................................................14-6

Deionizer................................................................................................................................................14-7

BatteryCare–VehiclesEquippedwiththeSingle-PointWateringSystem(SPWS)......................................14-8

BatteryCare–VehiclesWithouttheSingle-PointWateringSystem(SPWS)................................................14-9

Self-Discharge........................................................................................................................................14-10

ElectrolyteLevel.....................................................................................................................................14-10

VibrationDamage...................................................................................................................................14-11

SinglePointWateringSystem(SPWS).........................................................................................................14-11

InitialMaintenanceoftheSPWS..............................................................................................................14-12

WateringBatterieswiththeSPWS...........................................................................................................14-12

BatteryStorage..........................................................................................................................................14-14

FleetRotation.............................................................................................................................................14-14

Deep-Discharge.........................................................................................................................................14-14

EarlyExcessiveDischarging.......................................................................................................................14-14

SECTION15—BatteryCharger:forERICChargingSystem.............................................................................15-1

GeneralInformation.....................................................................................................................................15-2

USBServicePort.....................................................................................................................................15-3

ULandCSAListing.................................................................................................................................15-3

CECompliance.......................................................................................................................................15-3

PlugandReceptacle................................................................................................................................15-3

ChargerPowerConnectionFuse..............................................................................................................15-3

ChargerInterlock.....................................................................................................................................15-3

ACInputVoltageDetection......................................................................................................................15-4

ThermalCutback.....................................................................................................................................15-4

ChargeIndicatorLight..............................................................................................................................15-4

ExternalChargerStatusIndicators............................................................................................................15-4

OnboardChargerStatusIndicators...........................................................................................................15-5

Long-termStorage...................................................................................................................................15-6

ExternalChargerMounting...........................................................................................................................15-7

ACPowerConnection..................................................................................................................................15-8

TheChargeCircuit.......................................................................................................................................15-9

ChargerOperation......................................................................................................................................15-10

ChargingBatteries..................................................................................................................................15-10

ChargerMaintenance.................................................................................................................................15-13

Pageviii2018Carryall300MaintenanceandServiceManual

USBServicePortCleaningandCare.......................................................................................................15-13

ChargerTroubleshooting.............................................................................................................................15-14

NumberingVehiclesandChargers...........................................................................................................15-14

USBServicePort....................................................................................................................................15-14

IncomingACService..............................................................................................................................15-14

TerminalBlockCover..............................................................................................................................15-15

ResettingPower–ExternalCharger........................................................................................................15-15

ResettingPower–OnboardCharger.......................................................................................................15-15

ExternalChargerTroubleshootingIndicators............................................................................................15-16

OnboardChargerFaultCodes.................................................................................................................15-18

TestProcedures.........................................................................................................................................15-20

ExternalChargerRepairs............................................................................................................................15-23

TerminalBlockCoverRemoval................................................................................................................15-23

TerminalBlockCoverInstallation.............................................................................................................15-24

DCCordandStrainReliefRemoval.........................................................................................................15-24

DCCordandStrainReliefInstallation......................................................................................................15-24

HandleRemoval.....................................................................................................................................15-24

HandleInstallation..................................................................................................................................15-25

FootRemoval.........................................................................................................................................15-25

FootInstallation......................................................................................................................................15-25

SECTION16—Motor(ModelEJ8-4001A):ElectricVehicle................................................................................16-1

GeneralInformation.....................................................................................................................................16-1

ExternalMotorTesting.................................................................................................................................16-1

MotorRemoval............................................................................................................................................16-4

MotorDisassembly......................................................................................................................................16-6

MotorComponentTestingandInspection......................................................................................................16-8

ArmatureInspectionandTesting...............................................................................................................16-8

MotorFrameandFieldWindingsInspection.............................................................................................16-10

MotorBrush,Spring,andTerminalInsulatorInspection.............................................................................16-10

ReconditioningtheMotor............................................................................................................................16-13

MotorSpecications...............................................................................................................................16-13

MotorAssembly..........................................................................................................................................16-13

MotorInstallation........................................................................................................................................16-15

SECTION17—Transaxle(TypeG):ElectricVehicles........................................................................................17-1

Lubrication..................................................................................................................................................17-1

AxleBearingandShaft................................................................................................................................17-1

AxleShaft...............................................................................................................................................17-1

AxleBearing............................................................................................................................................17-4

Transaxle....................................................................................................................................................17-5

TransaxleRemoval..................................................................................................................................17-5

TransaxleDisassembly,Inspection,andAssembly.........................................................................................17-8

TransaxleDisassemblyandInspection......................................................................................................17-8

TransaxleAssembly................................................................................................................................17-10

TransaxleInstallation..................................................................................................................................17-12

SECTION18—TroubleshootingandElectricalSystem:Pedal-StartGasVehicle................................................18-1

GeneralInformation.....................................................................................................................................18-1

Accessories.............................................................................................................................................18-1

LowOilWarningLight..............................................................................................................................18-1

GroundLocations....................................................................................................................................18-1

FeaturesoftheElectronicFuelInjection(EFI)System...............................................................................18-2

TroubleshootingGuide.................................................................................................................................18-2

ECUErrorCodes(DisplayedbytheLowOilWarningLight).......................................................................18-2

GasolinePowertrain................................................................................................................................18-4

WiringDiagrams..........................................................................................................................................18-8

ElectricalSystem........................................................................................................................................18-13

TestProcedures.........................................................................................................................................18-14

TestingBasics........................................................................................................................................18-14

2018Carryall300MaintenanceandServiceManualPageix

SECTION19—TroubleshootingandElectricalSystem:Key-StartGasVehicle...................................................19-1

GeneralInformation.....................................................................................................................................19-1

WiringDiagrams..........................................................................................................................................19-2

TestProcedures..........................................................................................................................................19-6

SECTION20—ElectricalComponents:Pedal-StartGasVehicle.......................................................................20-1

Starter/Generator.........................................................................................................................................20-1

Starter/GeneratorRemoval......................................................................................................................20-1

DisassemblyoftheStarter/GeneratortoServicetheBrushes.....................................................................20-1

BrushInspectionandReplacement...........................................................................................................20-2

BrushSpringInspectionandReplacement................................................................................................20-2

Starter/GeneratorAssembly.....................................................................................................................20-3

DisassemblyoftheStarter/GeneratortoServicetheArmature/Commutator................................................20-4

BearingCleaningandInspection..............................................................................................................20-5

BearingRemoval.....................................................................................................................................20-6

FieldCoilAssembly.................................................................................................................................20-6

VisualInspectionofArmature...................................................................................................................20-6

CommutatorCleaningandInspection.......................................................................................................20-7

ArmatureGroundTest..............................................................................................................................20-8

VisualInspectionofFieldCoils.................................................................................................................20-9

Starter/GeneratorRework........................................................................................................................20-9

Starter/GeneratorAssembly.....................................................................................................................20-9

Starter/GeneratorInstallation...................................................................................................................20-12

BeltTensionAdjustmentforEFIEngines..................................................................................................20-13

VoltageRegulator.......................................................................................................................................20-15

VoltageRegulatorRemoval.....................................................................................................................20-15

VoltageRegulatorInstallation..................................................................................................................20-16

EngineControlUnit(ECU)..........................................................................................................................20-17

EngineControlUnitRemoval...................................................................................................................20-17

EngineControlUnitInstallation................................................................................................................20-17

KeySwitch.................................................................................................................................................20-18

KeySwitchRemoval...............................................................................................................................20-18

KeySwitchInstallation............................................................................................................................20-18

Maintenance/OperateSwitch.......................................................................................................................20-19

Maintenance/OperateSwitchRemoval.....................................................................................................20-19

Maintenance/OperateSwitchInstallation..................................................................................................20-19

NeutralLockoutLimitSwitch.......................................................................................................................20-19

NeutralLockoutLimitSwitchRemoval.....................................................................................................20-19

NeutralLockoutLimitSwitchInstallation...................................................................................................20-19

Solenoid.....................................................................................................................................................20-20

SolenoidRemoval..................................................................................................................................20-20

SolenoidInstallation................................................................................................................................20-20

Fuse..........................................................................................................................................................20-20

FuseRemoval........................................................................................................................................20-21

FuseInstallation.....................................................................................................................................20-21

KillLimitSwitch..........................................................................................................................................20-22

KillLimitSwitchRemoval........................................................................................................................20-22

KillLimitSwitchInstallation.....................................................................................................................20-22

ReverseWarningBuzzer.............................................................................................................................20-23

ReverseWarningBuzzerRemoval..........................................................................................................20-23

ReverseWarningBuzzerInstallation........................................................................................................20-23

ReverseBuzzerLimitSwitch.......................................................................................................................20-25

ReverseBuzzerLimitSwitchRemoval.....................................................................................................20-25

ReverseBuzzerLimitSwitchInstallation..................................................................................................20-25

LowOilWarningLight.................................................................................................................................20-27

LowOilWarningLightRemoval...............................................................................................................20-27

LowOilWarningLightInstallation............................................................................................................20-27

FuelGauge/HourMeter..............................................................................................................................20-27

GeneralInformation................................................................................................................................20-27

FuelGauge/HourMeterRemoval............................................................................................................20-27

FuelGauge/HourMeterInstallation..........................................................................................................20-28

FuelLevelSendingUnit..............................................................................................................................20-28

Pagex2018Carryall300MaintenanceandServiceManual

OilLevelSensor.........................................................................................................................................20-28

OilLevelSensorRemoval.......................................................................................................................20-28

OilLevelSensorInstallation....................................................................................................................20-28

VoltageLimiter...........................................................................................................................................20-28

VoltageLimiterRemoval.........................................................................................................................20-29

VoltageLimiterInstallation.......................................................................................................................20-29

HeadlightSwitch.........................................................................................................................................20-30

HeadlightSwitchRemoval.......................................................................................................................20-30

HeadlightSwitchinstallation....................................................................................................................20-30

Headlights..................................................................................................................................................20-30

HeadlightBezelRemoval........................................................................................................................20-30

HeadlightBezelInstallation.....................................................................................................................20-30

HeadlightBulbRemoval(Halogen)..........................................................................................................20-31

HeadlightBulbInstallation(Halogen).......................................................................................................20-31

HeadlightBulbRemoval(LED)................................................................................................................20-31

HeadlightBulbInstallation(LED).............................................................................................................20-31

Battery.......................................................................................................................................................20-33

GeneralInformation................................................................................................................................20-33

TestingtheBattery..................................................................................................................................20-33

PreventiveMaintenance..........................................................................................................................20-33

Self-Discharge........................................................................................................................................20-34

VibrationDamage...................................................................................................................................20-34

BatteryRemoval.....................................................................................................................................20-35

ChargingtheBattery...............................................................................................................................20-35

BatteryInstallation..................................................................................................................................20-35

BatteryStorage......................................................................................................................................20-36

ChargingaDeadBattery.........................................................................................................................20-36

GroundCables...........................................................................................................................................20-36

SECTION21—ElectricalComponents:Key-StartGasVehicle..........................................................................21-1

GeneralInformation.....................................................................................................................................21-1

KeySwitch..................................................................................................................................................21-1

KeySwitchRemoval................................................................................................................................21-1

KeySwitchInstallation.............................................................................................................................21-2

Maintenance/OperateSwitch........................................................................................................................21-3

Maintenance/OperateSwitchRemoval.....................................................................................................21-3

Maintenance/OperateSwitchInstallation...................................................................................................21-3

Solenoid......................................................................................................................................................21-3

SolenoidRemoval...................................................................................................................................21-3

SolenoidInstallation.................................................................................................................................21-3

ChargingDiode...........................................................................................................................................21-4

ChargingDiodeRemoval.........................................................................................................................21-4

ChargingDiodeInstallation......................................................................................................................21-5

SECTION22—Engine(SubaruEX40).............................................................................................................22-1

GeneralInformation.....................................................................................................................................22-1

BeforeServicing......................................................................................................................................22-1

EngineRotation.......................................................................................................................................22-1

TorqueSpecications...............................................................................................................................22-2

AdjustmentsandSettings.........................................................................................................................22-2

EngineOil–GasolineVehicle...................................................................................................................22-2

SparkPlug..............................................................................................................................................22-5

Breather..................................................................................................................................................22-6

ValveClearanceCheckandAdjustment....................................................................................................22-7

EngineRemoval..........................................................................................................................................22-8

EngineInstallation.......................................................................................................................................22-9

Flywheel....................................................................................................................................................22-10

FlywheelRemoval..................................................................................................................................22-10

FlywheelInstallation...............................................................................................................................22-11

OilLevelSensor.........................................................................................................................................22-12

TestingtheOilLevelSensor....................................................................................................................22-12

OilLevelSensorRemoval.......................................................................................................................22-12

2018Carryall300MaintenanceandServiceManualPagexi

OilLevelSensorInstallation....................................................................................................................22-12

IgnitionCoil................................................................................................................................................22-13

TestingtheIgnitionCoil...........................................................................................................................22-13

IgnitionCoilRemoval..............................................................................................................................22-13

IgnitionCoilInstallation...........................................................................................................................22-13

Snubber.....................................................................................................................................................22-14

SnubberRemoval...................................................................................................................................22-14

SnubberInstallation................................................................................................................................22-14

SECTION23—FuelSystem:GasolineVehicles...............................................................................................23-1

GeneralInformation.....................................................................................................................................23-1

EFISystemFeatures/Specications..........................................................................................................23-1

RelievingFuelPressure...............................................................................................................................23-2

ToRelieveFuelPressure.........................................................................................................................23-2

ThrottleBody...............................................................................................................................................23-3

ThrottleBodyRemoval.............................................................................................................................23-3

ThrottleBodyInstallation..........................................................................................................................23-4

EngineControlLinkages..............................................................................................................................23-6

GeneralInformation.................................................................................................................................23-6

GroundSpeed.........................................................................................................................................23-7

AcceleratorRod.......................................................................................................................................23-7

GovernorCable.......................................................................................................................................23-9

AcceleratorCable...................................................................................................................................23-10

ClosedThrottleorIdleAdjustment–Pedal-StartVehicles.........................................................................23-11

ClosedThrottleorIdleAdjustment–Key-StartVehicles............................................................................23-11

HowtoMeasureGroundSpeed...............................................................................................................23-12

EngineRPMAdjustment.........................................................................................................................23-12

AirIntakeSystem.......................................................................................................................................23-13

AirFilter.................................................................................................................................................23-14

AirCleanerRemoval...............................................................................................................................23-14

AirCleanerInstallation............................................................................................................................23-14

FuelLine....................................................................................................................................................23-15

FuelLineRemoval..................................................................................................................................23-15

FuelLineInstallation...............................................................................................................................23-16

FuelPumpModule......................................................................................................................................23-17

GeneralInformation................................................................................................................................23-17

FuelPumpModuleRemoval...................................................................................................................23-17

FuelPumpModuleInstallation.................................................................................................................23-17

FuelTank...................................................................................................................................................23-20

GeneralInformation................................................................................................................................23-20

FuelTankRemoval.................................................................................................................................23-20

FuelTankDisposal.................................................................................................................................23-21

FuelTankStorage..................................................................................................................................23-21

FuelTankInstallation..............................................................................................................................23-21

FuelFilter...................................................................................................................................................23-22

GeneralInformation................................................................................................................................23-22

FuelFilterRemoval.................................................................................................................................23-22

FuelFilterInstallation..............................................................................................................................23-23

FuelingInstructions–GasolineVehicle........................................................................................................23-23

SECTION24—ExhaustSystem:GasolineVehicles.........................................................................................24-1

Mufer........................................................................................................................................................24-1

MuferRemoval......................................................................................................................................24-1

MuferInstallation....................................................................................................................................24-1

SECTION25—Clutches:GasolineVehicles.....................................................................................................25-1

GeneralInformation.....................................................................................................................................25-1

Troubleshooting...........................................................................................................................................25-1

DriveBelt....................................................................................................................................................25-3

DriveBeltRemoval..................................................................................................................................25-3

DriveBeltInstallation...............................................................................................................................25-3

Pagexii2018Carryall300MaintenanceandServiceManual

DriveClutch................................................................................................................................................25-4

DriveClutchRemoval..............................................................................................................................25-5

DriveClutchCleaningandInspection........................................................................................................25-6

DriveClutchDisassembly.........................................................................................................................25-7

InspectionofDriveClutchParts................................................................................................................25-9

DriveClutchAssembly............................................................................................................................25-10

DriveClutchInstallation..........................................................................................................................25-11

DrivenClutch.............................................................................................................................................25-12

DrivenClutchRemoval...........................................................................................................................25-13

DrivenClutchDisassembly......................................................................................................................25-13

DrivenClutchInspection.........................................................................................................................25-14

DrivenClutchAssembly..........................................................................................................................25-14

DrivenClutchInstallation.........................................................................................................................25-16

SECTION26—Transaxle(ED65):GasolineVehicles........................................................................................26-1

GeneralInformation.....................................................................................................................................26-1

ShifterLever............................................................................................................................................26-1

NeutralLockout.......................................................................................................................................26-1

GovernorSystem.....................................................................................................................................26-2

TransaxleService....................................................................................................................................26-2

Lubrication..............................................................................................................................................26-2

ToolsRequiredForThisSection...............................................................................................................26-3

RearHubs...................................................................................................................................................26-4

RearHubRemoval..................................................................................................................................26-4

RearHubInstallation...............................................................................................................................26-4

AxleTubes,AxleShaftsandWheelBearings................................................................................................26-6

AxleTubeandAxleShaftRemoval...........................................................................................................26-6

AxleTubeandAxleShaftInstallation........................................................................................................26-7

RearWheelBearingRemoval..................................................................................................................26-7

RearWheelBearingInstallation................................................................................................................26-7

AxleShaftOilSealRemoval.....................................................................................................................26-7

AxleShaftOilSealInstallation..................................................................................................................26-8

TransaxleRemoval......................................................................................................................................26-9

TransaxleInstallation..................................................................................................................................26-13

ShifterCable..............................................................................................................................................26-13

ShifterCableRemoval............................................................................................................................26-13

ShifterCableInstallation.........................................................................................................................26-14

ShifterCableAdjustment.........................................................................................................................26-14

Index..........................................................................................................................................................Index-1

2018Carryall300MaintenanceandServiceManualPagexiii

SECTION1—SAFETY1

Safety

SAFETYDETAILS

ToensurethesafetyofthoseservicingClubCarvehicles,andtoprotectthevehiclesfrompossibledamageresulting

fromimproperserviceormaintenance,theproceduresinthismanualmustbefollowed.

ItisimportanttonotethatthroughoutthismanualtherearestatementslabeledDANGER,WARNING,orCAUTION.

Thesespecialstatementsrelatetospecicsafetyissues,andmustberead,understood,andheededbefore

proceedingwithprocedures.TherearestatementslabeledNOTE,whichprovideotheressentialserviceor

maintenanceinformation.

PERSONALSAFETY

DANGER

•ADANGERindicatesanimmediatehazardthatwillresultinseverepersonalinjuryordeath.The

colorassociatedwithDangerisRED.

WARNING

•AWARNINGindicatesanimmediatehazardthatcouldresultinseverepersonalinjuryordeath.

ThecolorassociatedwithWarningisORANGE.

CAUTION

•ACAUTIONwiththesafetyalertsymbolindicatesahazardorunsafepracticethatcouldresultin

minorpersonalinjury.ThecolorassociatedwithCautionisYELLOW.

MACHINESAFETY

CAUTION

•ACAUTIONwithoutthesafetyalertsymbolindicatesapotentiallyhazardoussituationthatcould

resultinpropertydamage.

ACAUTION,withoutthesafetyalertsymbol,isintendedformachineandpropertysafety.Itisusedthroughoutthis

manualfollowedbyspecicinstructionstopreventmachineorpropertydamage.FailuretofollowtheseCAUTION

messagescouldresultinmachineorpropertydamage.

INFORMATION

NOTE:Instructionsthatclarifysteps,procedures,orotherinformationinthismanual.

GENERALWARNINGS

Thefollowingsafetystatementsmustbeheededwheneverthevehicleisbeingoperated,repaired,orserviced.Other

specicsafetystatementsappearthroughoutthismanualandonthevehicle.

2018Carryall300MaintenanceandServiceManualPage1-1

1GeneralWarningsSAFETY

DANGER

•Battery–Explosivegases!Donotsmoke.Keepsparksandamesawayfromthevehicleandservice

area.Ventilatewhenchargingoroperatingvehicleinanenclosedarea.Wearafullfaceshieldand

rubbergloveswhenworkingonornearbatteries.

•Gasoline–Flammable!Explosive!Donotsmoke.Keepsparksandamesawayfromthevehicleand

servicearea.Serviceonlyinawell-ventilatedarea.

•Donotoperateengineinanenclosedareawithoutproperventilation.Theengineproducescarbon

monoxide,whichisanodorless,deadlypoison.

•Thevehiclewillnotprovideprotectionfromlightning,yingobjects,orotherstorm-relatedhazards.If

caughtinastormwhiledrivingaClubCarvehicle,exitthevehicleandseekshelterinaccordancewith

applicablesafetyguidelinesforyourlocation.

WARNING

•Followtheproceduresexactlyasstatedinthismanual,andheedallDANGER,WARNING,and

CAUTIONstatementsinthismanualaswellasthoseonthevehicleandbatterycharger.

•Donotleavechildrenunattendedinvehicleatanytime.

•Priortoleavingthevehicleunattendedorservicingthevehicle,settheparkbrake,placethe

Forward/ReversehandleorswitchintheNEUTRALposition,turnthekeyswitchtotheOFFposition,

andremovethekey.Chockthewheelswhenservicingthevehicle.

•Improperuseofthevehicleorfailuretoproperlymaintainitcanresultindecreasedvehicle

performance,severepersonalinjury,ordeath.

•Anymodicationorchangetothevehiclethataffectstheelectricalsystem,stabilityorhandlingof

thevehicle,orincreasesmaximumvehiclespeedbeyondfactoryspecications,canresultinsevere

personalinjuryordeath.

•Checkthevehicleforproperlocationofallvehiclesafetyandoperationdecalsandmakesuretheyare

inplaceandareeasytoread.

•Forvehicleswithcargobeds,removeallcargo(includingaccessories)beforeraisingthebedor

servicingthevehicle.Ifthevehicleisequippedwithaproprod,ensurethatitissecurelyengaged

whilebedisraised.Donotclosebeduntilallpersonsareclearofcargobedarea.Keephandsclearof

allcrushareas.Donotdropcargobed;lowergentlyandkeepentirebodyclear.Failuretoheedthis

warningcanresultinseverepersonalinjuryordeath.

•Onlytrainedtechniciansshouldserviceorrepairthevehicleorbatterycharger.Anyonedoingeven

simplerepairsorserviceshouldhaveknowledgeandexperienceinelectricalandmechanicalrepair.

Theappropriateinstructionsmustbeusedwhenperformingmaintenance,service,oraccessory

installation.

Electricvehiclesonly:

•Ensurebatteryconnectionsarecleanandproperlytightened.SeeBatteryCare–VehiclesEquipped

withtheSingle-PointWateringSystem(SPWS),Section14,Page14-8.

SeeBatteryCare–VehiclesWithouttheSingle-PointWateringSystem(SPWS),Section14,Page14-9.

•PlaceRun/TowswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failureto

heedthiswarningcanresultinabatteryexplosionorseverepersonalinjury.

WARNINGCONTINUEDONNEXTPAGE

Page1-22018Carryall300MaintenanceandServiceManual

SAFETYGeneralWarnings1

WARNING

•Toavoidunintentionallystartinganelectricvehicle,disconnectthebatteriesanddischargethe

controller.SeeDisconnectingtheBatteries–ElectricVehiclesonpage1-4.

Gasolinevehiclesonly:

•Toavoidunintentionallystartingagasolinevehicle,disconnectthebatteryandsparkplugwire.See

DisconnectingtheBattery-GasolineVehiclesonpage1-3.

•Frameground–Donotallowtoolsorothermetalobjectstocontactframewhendisconnectingbattery

cablesorotherelectricalwiring.Donotallowapositivewiretotouchthevehicleframe,engine,or

anyothermetalcomponent.

Allvehicles:

•Wearsafetyglassesorapprovedeyeprotectionwhenservicingthevehicleorbatterycharger.Weara

fullfaceshieldandrubbergloveswhenworkingonornearbatteries.

•Donotwearlooseclothingorjewelrysuchasrings,watches,chains,etc.,whenservicingthe

vehicleorbatterycharger.

•Useinsulatedtoolswhenworkingnearbatteriesorelectricalconnections.Useextremecautionto

avoidshortingofcomponentsorwiring.

DISABLINGTHEVEHICLE

1.Engageparkbraketolockwheels.

2.TurnthekeyswitchOFFandremovethekey.

3.PlacetheForward/ReversecontrolintheNEUTRALposition.

4.Inaddition,chockthewheelsifservicingorrepairingthevehicle.

DISCONNECTINGTHEBATTERY-GASOLINEVEHICLES

1.Disablethevehicle.SeeDisablingtheVehicleonpage1-3.

2.Removepositiveterminalcover.

3.Disconnectthebatterycables,negative(–)cablerst,asshown(Figure1-2).

4.Disconnectthesparkplugwire(s)fromthesparkplug(s).

CONNECTINGTHEBATTERY-GASOLINEVEHICLES

1.Connectthebatterycables,positive(+)cablerst.

2.Tightenbatteryterminalsto41in·lb(4.3N·m).

3.CoatterminalswithBatteryT erminalProtectorSpray(CCP/N1014305)tominimizecorrosion.

4.Attachpositiveterminalcover.

5.Connectthesparkplugwire(s)tothesparkplug(s).

2018Carryall300MaintenanceandServiceManualPage1-3

1GeneralWarningsSAFETY

(Viewedfromdriversideofvehicle)

1.PlaceRun/T owSwitchinTOWbeforedisconnectingorconnecting

batterycables.

2.Removenegativebatterycable.

3.Removepositivebatterycable.

Connectbatterycablesinreverseorder.

(Viewedfromdriversideofvehicle)

1.Removepositiveterminalcover.

2.Removenegativebatterycable.

3.Removepositivebatterycable.

Connectbatterycablesinreverseorder.

2779

Figure1-1BatteryCableRemoval-ElectricVehicle

3167

Figure1-2Top-PostBattery-BatteryCable

Removal-GasolineVehicles

DISCONNECTINGTHEBATTERIES–ELECTRICVEHICLES

1.Disablethevehicle.SeeDisablingtheVehicleonpage1-3.

2.PlaceRun/TowswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failuretoheed

thiswarningcanresultinabatteryexplosionorseverepersonalinjury.

3.Disconnectthebatteries,negative(–)cablerst,asshown(Figure1-1).

4.Afterdisconnectingthebatteries,wait90secondsforthecontrollercapacitorstodischarge.

CONNECTINGTHEBATTERIES–ELECTRICVEHICLES

1.EnsuretheRun/TowswitchisintheTOWposition.

2.Connectthebatterycables,positive(+)cablerst.

3.Tightenbatteryterminalsto110in·lb(12.4N·m).

4.CoatterminalswithBatteryT erminalProtectorSpray(CCPN1014305)tominimizecorrosion.

RECYCLINGLEAD-ACIDBATTERIES

WARNING

•Lead-acidbatteriescontainlead(Pb),othermetals,acidsandothercompounds.Ifimproperlyhandled,

theycancontaminatebothwaterandsoil,causingenvironmentaldamageandpersonalinjury.

Lead-acidbatteriesareidentiedbythesymbolshownbelowandshouldbeproperlyrecycled(Figure1-3).They

cannotbedisposedasmunicipalwasteandmustbecollectedseparately.Responsibilityforenvironmentalprotection

mustbeshared,notonlybythemanufacturersofthebatteries,butbypeoplewhousethebatteriesaswell.Please

contactyournearestClubCardealerordistributorforinformationonhowtoproperlyrecycleyourbatteries.

Page1-42018Carryall300MaintenanceandServiceManual

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