Club car Carryall 300 2021 Manual

2021Carryall300

MaintenanceandService

Manual

GasolineVehiclewithKohlerECH440Engine

ElectricVehiclewithERICChargingSystem

ManualNumber86753090054

EditionCodeA

FOREWORD

ClubCarvehiclesaredesignedandbuilttoprovidetheultimateinperformanceefciency;however,proper

maintenanceandrepairareessentialforachievingmaximumservicelifeandcontinuedsafeandreliableoperation.

Thismanualprovidesdetailedinformationforthemaintenanceandrepairofthe2019Carryall300vehicle,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'sTechnicalServicesdepartmentfora

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

ThismanualeffectiveJuly,2020

2021Carryall300MaintenanceandServiceManualPagei

FOREWORD

TECHNICALPUBLICATIONCUSTOMERSATISFACTIONONLINESURVEY

Letyourvoicebeheard!

PleaseparticipateintheTechnicalPublicationcustomersatisfactiononlinesurvey.

Thissurveytakeslessthanveminutestocompleteandyourresponseswillhelpexaminecurrentperformance

andidentifyareasforfutureimprovement.

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WARNING

•ReadSafetyonpage1-1beforeattemptinganyserviceonthevehicle.

•Beforeservicingvehicle,readcompletesection(s)andanyreferencedinformationthatmaybe

relevanttotheserviceorrepairtobeperformed.

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

DisableTheVehicle...................................................................................................................................1-3

DisconnecttheBattery-GasolineVehicles..................................................................................................1-4

ConnecttheBattery-GasolineVehicles.......................................................................................................1-4

DisconnecttheBatteries–ElectricVehicles................................................................................................1-5

ConnecttheBatteries–ElectricVehicles....................................................................................................1-5

RecyclingLead-AcidBatteries....................................................................................................................1-5

Internationalsafetysymbolsonbatteries.....................................................................................................1-6

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

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

BrushguardRemoval.................................................................................................................................4-3

BrushguardInstallation..............................................................................................................................4-3

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

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

GrilleRemoval...........................................................................................................................................4-5

GrilleInstallation........................................................................................................................................4-5

FrontBumperandSideFenderRemoval....................................................................................................4-8

FrontBumperandSideFenderInstallation..................................................................................................4-8

InstrumentPanelRemoval.........................................................................................................................4-9

InstrumentPanelInstallation......................................................................................................................4-9

DashRemoval.........................................................................................................................................4-10

DashInstallation......................................................................................................................................4-10

TiltBed.......................................................................................................................................................4-12

TiltBedRemoval.....................................................................................................................................4-13

TiltBedInstallation..................................................................................................................................4-13

BedLatchAssemblyRemoval..................................................................................................................4-14

BedLatchAssemblyInstallation...............................................................................................................4-14

RearFendersandTailskirt............................................................................................................................4-16

RearFenderandTailskirtRemoval...........................................................................................................4-16

2021Carryall300MaintenanceandServiceManualPageiii

RearFenderandTailskirtInstallation........................................................................................................4-17

RearTriangleReector................................................................................................................................4-18

RearTriangleReectorRemoval..............................................................................................................4-18

RearTriangleReectorInstallation...........................................................................................................4-18

FloorMat....................................................................................................................................................4-19

FloorMatRemoval..................................................................................................................................4-19

FloorMatInstallation................................................................................................................................4-19

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

Pageiv2021Carryall300MaintenanceandServiceManual

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

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

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

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

PeriodicServiceSchedules..........................................................................................................................10-3

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

AirFilter......................................................................................................................................................10-9

AirFilterRemoval....................................................................................................................................10-9

AirFilterInstallation.................................................................................................................................10-9

EngineOil..................................................................................................................................................10-10

EngineOilViscosity................................................................................................................................10-10

EngineOilLevelInspection.....................................................................................................................10-10

EngineOilReplacement..........................................................................................................................10-11

AddEngineOil.......................................................................................................................................10-14

Refuel........................................................................................................................................................10-15

LiftTheVehicle...........................................................................................................................................10-16

LiftTheFrontOfTheVehicle...................................................................................................................10-16

LiftTheRearOfTheVehicle...................................................................................................................10-17

LowerTheFrontOfTheVehicle..............................................................................................................10-18

LowerTheRearOfTheVehicle...............................................................................................................10-19

SparkPlug.................................................................................................................................................10-20

SparkPlugRemoval...............................................................................................................................10-20

SparkPlugInspection.............................................................................................................................10-21

SparkPlugGap......................................................................................................................................10-21

SparkPlugInstallation............................................................................................................................10-22

ValveClearanceCheckandAdjustment.......................................................................................................10-22

2021Carryall300MaintenanceandServiceManualPagev

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

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

Pagevi2021Carryall300MaintenanceandServiceManual

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

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—ElectricVehicle-ElectricalSystemTroubleshooting..................................................................12-1

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

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

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

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

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

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

SonicWeld,Diode,and10kOhmResistorLocations.....................................................................................12-4

Troubleshooting...........................................................................................................................................12-5

TroubleshootingtheVehiclewiththeCDT.................................................................................................12-5

TroubleshootingGuide1..........................................................................................................................12-5

TroubleshootingGuide2..........................................................................................................................12-8

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

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

SECTION13—ElectricVehicle-ElectricalComponents...................................................................................13-1

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

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

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

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

Forward/Neutral/Reversecontrol(FNR)........................................................................................................13-2

TestingtheForward/Neutral/Reversecontrol(FNR)...................................................................................13-2

Forward/Neutral/Reversecontrol(FNR)Removal......................................................................................13-2

Forward/Neutral/Reversecontrol(FNR)Installation...................................................................................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

2021Carryall300MaintenanceandServiceManualPagevii

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

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

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

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

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

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

USBReceptacle.........................................................................................................................................13-15

USBReceptacleRemoval.......................................................................................................................13-15

USBReceptacleInstallation...................................................................................................................13-15

SECTION14—ElectricVehicle-Batteries.......................................................................................................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

Pageviii2021Carryall300MaintenanceandServiceManual

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

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

SECTION15—ElectricVehicle-BatteryCharger.............................................................................................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

BatteryCharging........................................................................................................................................15-10

ChargingWithExternalCharger..............................................................................................................15-11

ChargingWithOnboardCharger..............................................................................................................15-12

Algorithm...................................................................................................................................................15-14

ExternalBatteryCharger.........................................................................................................................15-14

OnboardBatteryCharger........................................................................................................................15-19

UpdateBatteryChargerWithUSB...........................................................................................................15-21

ChargerMaintenance.................................................................................................................................15-22

USBServicePortCleaningandCare.......................................................................................................15-22

ChargerTroubleshooting.............................................................................................................................15-23

NumberingVehiclesandChargers...........................................................................................................15-23

USBServicePort....................................................................................................................................15-23

IncomingACService..............................................................................................................................15-23

TerminalBlockCover..............................................................................................................................15-24

ResettingPower–ExternalCharger........................................................................................................15-24

ResettingPower–OnboardCharger.......................................................................................................15-24

ExternalChargerTroubleshootingIndicators............................................................................................15-25

OnboardChargerFaultCodes.................................................................................................................15-27

TestProcedures.........................................................................................................................................15-29

ExternalChargerRepairs............................................................................................................................15-32

TerminalBlockCoverRemoval................................................................................................................15-32

TerminalBlockCoverInstallation.............................................................................................................15-33

DCCordandStrainReliefRemoval.........................................................................................................15-33

DCCordandStrainReliefInstallation......................................................................................................15-33

HandleRemoval.....................................................................................................................................15-33

HandleInstallation..................................................................................................................................15-34

FootRemoval.........................................................................................................................................15-34

FootInstallation......................................................................................................................................15-34

SECTION16—ElectricVehicle-Motor............................................................................................................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

2021Carryall300MaintenanceandServiceManualPageix

SECTION17—ElectricVehicle-Transaxle......................................................................................................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—GasolineVehicle-TroubleshootingandElectricalSystem..........................................................18-1

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

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

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

MalfunctionIndicatorLight........................................................................................................................18-2

GroundLocations....................................................................................................................................18-3

FeaturesoftheElectronicFuelInjection(EFI)System...............................................................................18-3

TroubleshootingGuide.................................................................................................................................18-3

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

ElectricalSystem.........................................................................................................................................18-6

TestProcedures..........................................................................................................................................18-7

TestingBasics.........................................................................................................................................18-7

SECTION19—GasolineVehicle-ElectricalComponents.................................................................................19-1

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

Starter/Generator.........................................................................................................................................19-1

Starter/GeneratorRemoval......................................................................................................................19-1

DisassemblyoftheStarter/GeneratortoServicetheBrushes.....................................................................19-2

BrushInspectionandReplacement...........................................................................................................19-3

BrushSpringInspectionandReplacement................................................................................................19-3

Starter/GeneratorAssembly.....................................................................................................................19-4

DisassemblyoftheStarter/GeneratortoServicetheArmature/Commutator................................................19-5

BearingCleaningandInspection..............................................................................................................19-6

BearingRemoval.....................................................................................................................................19-7

FieldCoilAssembly.................................................................................................................................19-7

VisualInspectionofArmature...................................................................................................................19-7

CommutatorCleaningandInspection.......................................................................................................19-8

ArmatureGroundTest..............................................................................................................................19-9

VisualInspectionofFieldCoils................................................................................................................19-10

Starter/GeneratorRework.......................................................................................................................19-10

Starter/GeneratorAssembly....................................................................................................................19-10

Starter/GeneratorInstallation...................................................................................................................19-13

BeltTensionInspectionForEFIEngines..................................................................................................19-14

BeltTensionAdjustmentforEFIEngines..................................................................................................19-15

BeltTensionToolModication..................................................................................................................19-18

VoltageRegulator.......................................................................................................................................19-19

VoltageRegulatorRemoval.....................................................................................................................19-19

VoltageRegulatorInstallation..................................................................................................................19-19

KeySwitch.................................................................................................................................................19-20

KeySwitchRemoval...............................................................................................................................19-20

KeySwitchInstallation............................................................................................................................19-21

Maintenance/OperateSwitch.......................................................................................................................19-22

Maintenance/OperateSwitchRemoval.....................................................................................................19-22

Maintenance/OperateSwitchInstallation..................................................................................................19-22

NeutralLockoutLimitSwitch.......................................................................................................................19-23

NeutralLockoutLimitSwitchRemoval.....................................................................................................19-23

NeutralLockoutLimitSwitchInstallation...................................................................................................19-25

Solenoid.....................................................................................................................................................19-26

SolenoidRemoval..................................................................................................................................19-26

Pagex2021Carryall300MaintenanceandServiceManual

SolenoidInstallation................................................................................................................................19-27

Fuse..........................................................................................................................................................19-28

FuseRemoval........................................................................................................................................19-29

FuseInstallation.....................................................................................................................................19-29

AcceleratorPedalLimitSwitch....................................................................................................................19-30

AcceleratorPedalLimitSwitchRemoval..................................................................................................19-30

AcceleratorPedalLimitSwitchInstallation................................................................................................19-30

KillLimitSwitch..........................................................................................................................................19-31

KillLimitSwitchRemoval........................................................................................................................19-31

KillLimitSwitchInstallation.....................................................................................................................19-31

ReverseWarningBuzzer.............................................................................................................................19-32

ReverseWarningBuzzerRemoval..........................................................................................................19-32

ReverseWarningBuzzerInstallation........................................................................................................19-32

ReverseBuzzerLimitSwitch.......................................................................................................................19-33

ReverseBuzzerLimitSwitchRemoval.....................................................................................................19-33

ReverseBuzzerLimitSwitchInstallation..................................................................................................19-33

LowOilWarningLight.................................................................................................................................19-34

LowOilWarningLightRemoval...............................................................................................................19-34

LowOilWarningLightInstallation............................................................................................................19-34

MalfunctionIndicatorLight...........................................................................................................................19-35

MalfunctionIndicatorLightRemoval.........................................................................................................19-35

MalfunctionIndicatorLightInstallation......................................................................................................19-35

FuelGauge/HourMeter..............................................................................................................................19-35

GeneralInformation................................................................................................................................19-35

FuelGauge/HourMeterRemoval............................................................................................................19-36

FuelGauge/HourMeterInstallation..........................................................................................................19-36

FuelLevelSendingUnit..............................................................................................................................19-36

VoltageLimiter...........................................................................................................................................19-37

VoltageLimiterRemoval.........................................................................................................................19-37

VoltageLimiterInstallation.......................................................................................................................19-37

HeadlightSwitch.........................................................................................................................................19-38

HeadlightSwitchRemoval.......................................................................................................................19-38

HeadlightSwitchinstallation....................................................................................................................19-38

Headlights..................................................................................................................................................19-39

HeadlightBezelRemoval........................................................................................................................19-39

HeadlightBezelInstallation.....................................................................................................................19-39

HalogenHeadlightBulbRemoval............................................................................................................19-40

HalogenHeadlightBulbInstallation..........................................................................................................19-40

HalogenHeadlightLensRemoval............................................................................................................19-41

HalogenHeadlightLensInstallation.........................................................................................................19-41

LEDHeadlightRemoval..........................................................................................................................19-42

LEDHeadlightInstallation.......................................................................................................................19-42

Battery.......................................................................................................................................................19-42

GeneralInformation................................................................................................................................19-43

PreventiveMaintenance..........................................................................................................................19-43

Self-Discharge........................................................................................................................................19-43

VibrationDamage...................................................................................................................................19-44

BatteryRemoval.....................................................................................................................................19-44

ChargingtheBattery...............................................................................................................................19-44

BatteryInstallation..................................................................................................................................19-44

BatteryStorage......................................................................................................................................19-45

ChargingaDeadBattery.........................................................................................................................19-45

OxygenSensor...........................................................................................................................................19-46

OxygenSensorRemoval........................................................................................................................19-46

OxygenSensorInstallation......................................................................................................................19-46

GroundCables...........................................................................................................................................19-46

ChargingDioded(Key-StartOnly)................................................................................................................19-47

ChargingDiodeRemoval........................................................................................................................19-47

ChargingDiodeInstallation.....................................................................................................................19-48

USBReceptacle.........................................................................................................................................19-49

USBReceptacleRemoval.......................................................................................................................19-49

USBReceptacleInstallation...................................................................................................................19-49

2021Carryall300MaintenanceandServiceManualPagexi

SECTION20—GasolineVehicle-Engine........................................................................................................20-1

GeneralInformation.....................................................................................................................................20-1

BeforeServicing......................................................................................................................................20-1

LouverArm.................................................................................................................................................20-2

EngineRemoval..........................................................................................................................................20-3

EngineInstallation.......................................................................................................................................20-6

Snubber......................................................................................................................................................20-9

SnubberRemoval....................................................................................................................................20-9

SnubberInstallation.................................................................................................................................20-9

SECTION21—GasolineVehicle-FuelSystem................................................................................................21-1

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

EFISystemFeatures/Specications..........................................................................................................21-1

EngineControlLinkages..............................................................................................................................21-1

GeneralInformation.................................................................................................................................21-2

GroundSpeed.........................................................................................................................................21-2

AcceleratorRod.......................................................................................................................................21-2

GovernorCable.......................................................................................................................................21-5

AcceleratorCable....................................................................................................................................21-7

ClosedThrottleorIdleAdjustment–Pedal-StartVehicles.........................................................................21-10

ClosedThrottleorIdleAdjustment–Key-StartVehicles............................................................................21-10

HowtoMeasureGroundSpeed...............................................................................................................21-10

EngineRPMAdjustment.........................................................................................................................21-10

AirIntakeSystem.......................................................................................................................................21-12

AirCleanerRemoval...............................................................................................................................21-13

AirCleanerInstallation............................................................................................................................21-13

RelievingFuelPressure..............................................................................................................................21-14

ToRelieveFuelPressure........................................................................................................................21-14

FuelLine....................................................................................................................................................21-14

FuelLineRemoval..................................................................................................................................21-15

FuelLineInstallation...............................................................................................................................21-16

FuelPumpModule......................................................................................................................................21-18

GeneralInformation................................................................................................................................21-18

FuelPumpModuleRemoval...................................................................................................................21-19

FuelPumpModuleInstallation.................................................................................................................21-20

FuelTank...................................................................................................................................................21-21

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

FuelTankRemoval.................................................................................................................................21-22

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

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

FuelTankInstallation..............................................................................................................................21-24

FuelFilter...................................................................................................................................................21-25

GeneralInformation................................................................................................................................21-25

FuelFilterRemoval.................................................................................................................................21-25

FuelFilterInstallation..............................................................................................................................21-25

SECTION22—GasolineVehicle-ExhaustSystem..........................................................................................22-1

Mufer........................................................................................................................................................22-1

MuferRemoval......................................................................................................................................22-1

MuferInstallation....................................................................................................................................22-2

SECTION23—GasolineVehicle-Clutches.....................................................................................................23-1

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

Troubleshooting...........................................................................................................................................23-1

DriveBelt....................................................................................................................................................23-3

DriveBeltRemoval..................................................................................................................................23-3

DriveBeltInstallation...............................................................................................................................23-3

DriveClutch................................................................................................................................................23-4

DriveClutchRemoval..............................................................................................................................23-5

DriveClutchCleaningandInspection........................................................................................................23-6

Pagexii2021Carryall300MaintenanceandServiceManual

DriveClutchDisassembly.........................................................................................................................23-7

InspectionofDriveClutchParts................................................................................................................23-9

DriveClutchAssembly............................................................................................................................23-10

DriveClutchInstallation..........................................................................................................................23-11

DrivenClutch.............................................................................................................................................23-12

DrivenClutchRemoval...........................................................................................................................23-13

DrivenClutchDisassembly......................................................................................................................23-13

DrivenClutchInspection.........................................................................................................................23-16

DrivenClutchAssembly..........................................................................................................................23-16

DrivenClutchInstallation.........................................................................................................................23-19

SECTION24—GasolineVehicle-Transaxle....................................................................................................24-1

GeneralInformation.....................................................................................................................................24-1

Forward/Neutral/Reversecontrol(FNR)....................................................................................................24-1

Maintenance/OperateSwitch....................................................................................................................24-1

GovernorSystem.....................................................................................................................................24-2

TransaxleService....................................................................................................................................24-2

Lubrication..............................................................................................................................................24-2

ToolsRequiredForThisSection...............................................................................................................24-3

RearHubs...................................................................................................................................................24-4

RearHubRemoval..................................................................................................................................24-4

RearHubInstallation...............................................................................................................................24-4

AxleTubes,AxleShafts,DifferentialGuard,andWheelBearings...................................................................24-6

DifferentialGuardRemoval......................................................................................................................24-6

DifferentialGuardInstallation....................................................................................................................24-6

AxleTubeandAxleShaftRemoval...........................................................................................................24-7

AxleTubeandAxleShaftInstallation........................................................................................................24-8

RearWheelBearingRemoval..................................................................................................................24-8

RearWheelBearingInstallation................................................................................................................24-9

AxleShaftOilSealRemoval.....................................................................................................................24-9

AxleShaftOilSealInstallation..................................................................................................................24-9

TransaxleRemoval.....................................................................................................................................24-10

TransaxleInstallation..................................................................................................................................24-14

ShifterCable..............................................................................................................................................24-14

ShifterCableRemoval............................................................................................................................24-14

ShifterCableInstallation.........................................................................................................................24-15

ShifterCableAdjustment.........................................................................................................................24-15

SECTION25—KohlerEngineServiceManual.................................................................................................25-1

SECTION26—WiringDiagrams......................................................................................................................26-1

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

Pedal-StartConnectorPinouts.....................................................................................................................26-2

Pedal-StartMainHarnessConnectorPinouts............................................................................................26-2

Key-StartConnectorPinouts........................................................................................................................26-7

Key-StartMainHarnessConnectorPinouts...............................................................................................26-7

EngineHarnessWiringDiagramTable.........................................................................................................26-12

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

2021Carryall300MaintenanceandServiceManualPagexiii

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.

2021Carryall300MaintenanceandServiceManualPage1-1

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/Neutral/Reversecontrol(FNR)orswitchintheNEUTRALposition,turnthekeyswitchtothe

OFFposition,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.

•PlaceRun/TowswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failureto

heedthiswarningcanresultinabatteryexplosionorseverepersonalinjury.

•Toavoidunintentionallystartinganelectricvehicle,disconnectthebatteriesanddischargethe

controller.

WARNINGCONTINUEDONNEXTPAGE

Page1-22021Carryall300MaintenanceandServiceManual

SAFETYGeneralWarnings1

WARNING

Gasolinevehiclesonly:

•Toavoidunintentionallystartingagasolinevehicle,disconnectthebatteryandsparkplugwire.

•Frameground–Donotallowtoolsorothermetalobjectstocontactframewhendisconnectingbattery

cablesorotherelectricalwiring.Donotallowapositivewiretotouchthevehicleframe,engine,or

anyothermetalcomponent.

Allvehicles:

•Wearsafetyglassesorapprovedeyeprotectionwhenservicingthevehicleorbatterycharger.Weara

fullfaceshieldandrubbergloveswhenworkingonornearbatteries.

•Donotwearlooseclothingorjewelrysuchasrings,watches,chains,etc.,whenservicingthe

vehicleorbatterycharger.

•Useinsulatedtoolswhenworkingnearbatteriesorelectricalconnections.Useextremecautionto

avoidshortingofcomponentsorwiring.

DISABLETHEVEHICLE

1.Parkthevehicleonasolidlevelsurface.

2.Engagetheparkbraketolockthewheels..

3.TurnthekeytoOFF .

NOTE:KeyOFFfor15secondsletstheECUdoapermanentmemorywrite.

4.Removethekey.

5.SettheForward/Neutral/Reversecontrol(FNR)toN.

6.Putthechocksagainstthewheels.

2021Carryall300MaintenanceandServiceManualPage1-3

1GeneralWarningsSAFETY

DISCONNECTTHEBATTERY-GASOLINEVEHICLES

1.Disablethevehicle.

2.Removepositiveterminalcover.

3.Disconnectthenegative(-)cable(1)(Figure1-1,Page1-4).

Figure1-1Battery-GasolineVehicles

4.Disconnectthepositive(+)cable(2).

CONNECTTHEBATTERY-GASOLINEVEHICLES

1.Connectthepositive(+)cable(2)(Figure1-1,Page1-4).

2.Connectthenegative(-)cable(1).

3.Tightenthebatteryterminalsto41in·lb(4.3N·m).

4.CoatterminalswithBatteryT erminalProtectorSpraytominimizecorrosion.

5.Attachthepositiveterminalcover.

Page1-42021Carryall300MaintenanceandServiceManual

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