Club car Carryall 500 2015 Manual

2015Carryall500and700

MaintenanceandService

Manual

GasolineVehiclewithSubaruEX40Engine

ElectricVehiclewithQuiQ™ ™

™Charger

ManualNumber105157204

EditionCodeC

FOREWORD

ClubCarvehiclesaredesignedandbuilttoprovidetheultimateinperformanceefciency;however,proper

maintenanceandrepairareessentialforachievingmaximumservicelifeandcontinuedsafeandreliableoperation.

Thismanualprovidesdetailedinformationforthemaintenanceandrepairofthe2015Carryall500andCarryall700

vehicles,andshouldbethoroughlyreviewedpriortoservicingthevehicle.Theproceduresprovidedmustbeproperly

implemented,andtheDANGER,WARNING,andCAUTIONstatementsmustbeheeded.

Thismanualwaswrittenforthetrainedtechnicianwhoalreadypossessesknowledgeandskillsinelectricaland

mechanicalrepair.Ifthetechniciandoesnothavesuchknowledgeandskills,attemptedserviceorrepairstothe

vehiclemayrenderthevehicleunsafe.Forthisreason,ClubCaradvisesthatallrepairsand/orservicebeperformed

byanauthorizedClubCardistributor/dealerrepresentativeorbyaClubCarfactory-trainedtechnician.

ItisthepolicyofClubCartoassistitsdistributorsanddealersincontinuallyupdatingtheirserviceknowledgeand

facilitiessotheycanprovidepromptandefcientserviceforvehicleowners.Regionaltechnicalrepresentatives,

vehicleserviceseminars,periodicservicebulletins,maintenanceandservicemanuals,andotherservicepublications

alsorepresentClubCar’scontinuingcommitmenttocustomersupport.

ClubCaroffersafulllineoftrainingandcontinuingeducationclassesfortechnicianswhowanttolearnmoreabout

ourproducts.Formoreinformation,contactyourlocaldealerorClubCar'sT echnicalServicesdepartmentfora

listofupcomingclasses.

Thismanualcoversallaspectsoftypicalvehicleservice;however,uniquesituationssometimesoccurwhenservicinga

vehicle.Ifitappearsthataservicequestionisnotansweredinthismanual,pleasecontactyournearestauthorized

ClubCardealerordistributorforassistance.Youmayalsowritetousat:ClubCar,LLC,P .O.Box204658;Augusta,

GA30917-4658USA,Attention:T echnicalServices.

WARNING

•ReadSafetyonpage1-1beforeattemptinganyserviceonthevehicle.

•Beforeservicingvehicle,readcompletesection(s)andanyreferencedinformationthatmaybe

relevanttotheserviceorrepairtobeperformed.

MAINTENANCEITEMS

BatteryTerminalProtectorSpray

CCPN1014305

DryMolyLube

CCPN1012151

ChassisLube

EPNLGIGrade2(commerciallyavailable)

EngineAirFilter(404cc)

CCPN102558201

DeionizerFilterReplacementCartridge(SPWS)

CCPN104005901

SparkPlugO.H.C.(404cc)

CCPN105017801

DeionizerFilterReplacementCartridge(non-SPWS)

CCPNAM10975

NOTE:Thismanualrepresentsthemostcurrentinformationatthetimeofpublication.ClubCariscontinuallyworking

tofurtherimproveitsvehiclesandotherproducts.Theseimprovementsmayaffectservicingprocedures.

Anymodicationand/orsignicantchangeinspecicationsorprocedureswillbeforwardedtoallClubCar

dealersandwill,whenapplicable,appearinfutureeditionsofthismanual.

ClubCarreservestherighttochangespecicationsanddesignsatanytimewithoutnoticeandwithoutthe

obligationofmakingchangestounitspreviouslysold.

ClubCarisaregisteredtrademarkofClubCar,LLC

ThismanualeffectiveJuly,2018

2015Carryall500and700MaintenanceandServiceManualPagei

FOREWORD

Therearenowarrantiesexpressedorimpliedinthismanual.Seethelimitedwarrantyfoundinthevehicle

Owner’sManual.

CONTENTS

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

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

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

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

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

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

DisablingtheVehicle..................................................................................................................................1-4

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

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

DisconnectingtheBattery–GasolineVehicles............................................................................................1-4

ConnectingtheBattery–GasolineVehicles................................................................................................1-4

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

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

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

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

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

QuiQBatteryChargerSpecications...........................................................................................................2-3

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

HeavyDutyBumperInstallation..................................................................................................................4-5

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

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

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

GrilleInstallation........................................................................................................................................4-8

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

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

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

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

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

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

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

TiltBedRemoval.....................................................................................................................................4-12

TiltBedInstallation..................................................................................................................................4-12

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

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

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

2015Carryall500and700MaintenanceandServiceManualPageiii

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

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

ElectricBedLift...........................................................................................................................................4-18

ElectricBedLiftRemoval.........................................................................................................................4-19

ElectricBedLiftInstallation......................................................................................................................4-19

FloorMat....................................................................................................................................................4-21

FloorMatRemoval..................................................................................................................................4-21

FloorMatInstallation................................................................................................................................4-21

TrailerHitch.................................................................................................................................................4-21

TrailerHitchRemoval...............................................................................................................................4-21

TrailerHitchInstallation............................................................................................................................4-21

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

AcceleratorPedal–ElectricVehicles..............................................................................................................5-7

AcceleratorPedalRemoval–ElectricVehicles............................................................................................5-7

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

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

PedalGroupAdjustment–ElectricVehicles..................................................................................................5-16

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

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

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

BrakeAssemblyCleaning..............................................................................................................................6-3

BrakeShoeInstallation..................................................................................................................................6-5

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

BrakeClusterAdjustment...........................................................................................................................6-7

BrakeCableEqualization...........................................................................................................................6-9

FinalBrakeClusterAdjustment.................................................................................................................6-10

TestDriveVehicle....................................................................................................................................6-10

BrakeClusterRemovalandInstallation..........................................................................................................6-11

FrontBrakeClusterRemoval.....................................................................................................................6-11

FrontBrakeClusterInstallation..................................................................................................................6-11

RearBrakeClusterRemoval....................................................................................................................6-13

RearBrakeClusterInstallation.................................................................................................................6-13

FrontBrakeCables......................................................................................................................................6-14

FrontBrakeCableRemoval.....................................................................................................................6-14

FrontBrakeCableInstallation...................................................................................................................6-14

RearBrakeCables......................................................................................................................................6-16

RearBrakeCableRemoval......................................................................................................................6-16

RearBrakeCableInstallation...................................................................................................................6-16

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

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

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

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

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

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

SteeringColumnRemoval..........................................................................................................................7-4

SteeringColumnDisassembly....................................................................................................................7-4

SteeringColumnAssembly........................................................................................................................7-4

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

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

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

Pageiv2015Carryall500and700MaintenanceandServiceManual

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

FrontHubandWheelBearingsRemoval...................................................................................................7-21

FrontHubandWheelBearingsInstallation................................................................................................7-22

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

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

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

Multi-LeafSpringInstallation......................................................................................................................9-3

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

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

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

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

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

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

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

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

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

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

PluggingtheCDTintotheVehicle..................................................................................................................11-2

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

QuickReferenceGuide–IQPluswithQuiqCharger......................................................................................11-4

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

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

2015Carryall500and700MaintenanceandServiceManualPagev

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

AccessCodes..........................................................................................................................................11-9

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

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

SpeedIn................................................................................................................................................11-10

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

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

HeatsinkTemp.......................................................................................................................................11-10

Mode.....................................................................................................................................................11-10

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

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

ArmPWM..............................................................................................................................................11-10

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

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

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

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

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

ModeSwitch..........................................................................................................................................11-11

WKAwayRelay......................................................................................................................................11-11

MainCont..............................................................................................................................................11-11

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

CirBRKROpen#...................................................................................................................................11-11

THRTLFault#........................................................................................................................................11-12

Undervoltage#.......................................................................................................................................11-12

Overvoltage#.........................................................................................................................................11-12

TempCutback#.....................................................................................................................................11-12

HPD#....................................................................................................................................................11-12

MainWelded#.......................................................................................................................................11-12

RelayWelded#......................................................................................................................................11-12

SPDSensor#........................................................................................................................................11-12

MainDRVOn#......................................................................................................................................11-12

MainCoilOPN#.....................................................................................................................................11-12

MainDropout#.......................................................................................................................................11-12

MotorStall#...........................................................................................................................................11-12

MainDRVROff#.....................................................................................................................................11-12

RelayDNC#..........................................................................................................................................11-12

CurrentSense#.....................................................................................................................................11-13

M-Shorted#...........................................................................................................................................11-13

RelayCoil#............................................................................................................................................11-13

Precharge#...........................................................................................................................................11-13

FLDMissing#........................................................................................................................................11-13

HWFailsafe#.........................................................................................................................................11-13

DRVROvercur#.....................................................................................................................................11-13

RLYDRVROn#.....................................................................................................................................11-13

RLYDRVROff#.....................................................................................................................................11-13

VminI...................................................................................................................................................11-13

SignedBatteryCurrent............................................................................................................................11-13

BDIPercent............................................................................................................................................11-13

ChargerInhibit........................................................................................................................................11-13

LEDDriver.............................................................................................................................................11-14

Odometer...............................................................................................................................................11-14

BDIInfo.................................................................................................................................................11-14

BatteryMonitor.......................................................................................................................................11-14

ChargingTotals......................................................................................................................................11-14

Pagevi2015Carryall500and700MaintenanceandServiceManual

AmpHoursDisplay.................................................................................................................................11-15

LIN........................................................................................................................................................11-15

DiagnosticsMenu.......................................................................................................................................11-16

PresentErrorsFolder..............................................................................................................................11-16

FaultHistoryFolder................................................................................................................................11-16

SystemFaults........................................................................................................................................11-16

FaultRecovery.......................................................................................................................................11-18

FaultDescriptions.......................................................................................................................................11-19

01ThrottleFault1..................................................................................................................................11-19

02LowBatteryVoltage...........................................................................................................................11-19

03Overvoltage.......................................................................................................................................11-19

04ThermalCutback...............................................................................................................................11-19

06HPD..................................................................................................................................................11-19

07MainWelded.....................................................................................................................................11-19

08RelayWelded....................................................................................................................................11-19

09SpeedSensor....................................................................................................................................11-19

10MainDriverOn..................................................................................................................................11-19

11MainCoilOpen..................................................................................................................................11-19

12MainDropout.....................................................................................................................................11-20

13MotorStall.........................................................................................................................................11-20

14MainDriverOff...................................................................................................................................11-20

15RelayDNC........................................................................................................................................11-20

16KeyswitchSRO..................................................................................................................................11-20

17CurrentSense...................................................................................................................................11-20

18M-Shorted........................................................................................................................................11-20

20DriverOvercurrent.............................................................................................................................11-20

21PrechargeFault.................................................................................................................................11-20

22FieldMissing.....................................................................................................................................11-20

23RelayDriverOn.................................................................................................................................11-20

24HWFailsafe.......................................................................................................................................11-20

25IncorrectPassword............................................................................................................................11-21

26CircuitBRKROpen............................................................................................................................11-21

27MaxPasswordTries...........................................................................................................................11-21

29RelayDRVROff.................................................................................................................................11-21

30RelayCoilFault.................................................................................................................................11-21

Anti-TamperFault...................................................................................................................................11-21

LockoutFault.........................................................................................................................................11-21

LowSOC...............................................................................................................................................11-21

MainCONTDNC....................................................................................................................................11-22

MainCoilFault.......................................................................................................................................11-22

PROC/Wiring.........................................................................................................................................11-22

OpenArmature.......................................................................................................................................11-22

IncorrectPassword(OEMAccessLevelOnly)..........................................................................................11-22

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

ClearingFaultHistory.............................................................................................................................11-22

Programming.............................................................................................................................................11-23

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

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

HHPSettings.............................................................................................................................................11-24

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

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

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

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

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

SECTION12—ElectricalSystemTroubleshooting:IQPlusElectricVehicles......................................................12-1

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

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

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

KeyDifferences:IQPluswithQuiQChargervs.IQPlusCharger...............................................................12-1

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

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

Troubleshooting...........................................................................................................................................12-8

2015Carryall500and700MaintenanceandServiceManualPagevii

TroubleshootingtheVehiclewiththeCDT.................................................................................................12-8

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

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

TestProcedures.........................................................................................................................................12-14

TestingBasics........................................................................................................................................12-14

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

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

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

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

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

Forward/ReverseRockerSwitch...................................................................................................................13-3

Forward/ReverseRockerSwitchRemoval.................................................................................................13-3

Forward/ReverseRockerSwitchInstallation..............................................................................................13-3

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

Run/TowSwitchRemoval.........................................................................................................................13-4

Run/TowSwitchInstallation......................................................................................................................13-4

CircuitBreaker............................................................................................................................................13-4

CircuitBreakerRemoval..........................................................................................................................13-4

CircuitBreakerInstallation........................................................................................................................13-4

MotorControllerOutputRegulator(MCOR)...................................................................................................13-6

TestingtheMCOR...................................................................................................................................13-6

MCORRemoval......................................................................................................................................13-6

MCORInstallation...................................................................................................................................13-6

ReverseBuzzer...........................................................................................................................................13-7

ReverseBuzzerRemoval.........................................................................................................................13-7

ReverseBuzzerInstallation......................................................................................................................13-7

Speedcontrollercover.................................................................................................................................13-7

RemovingtheSpeedControllerCover......................................................................................................13-7

InstallingtheSpeedControllerCover........................................................................................................13-7

Solenoid......................................................................................................................................................13-8

SolenoidRemoval...................................................................................................................................13-8

SolenoidInstallation.................................................................................................................................13-8

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

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

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

ChargeIndicatorLight.................................................................................................................................13-11

TestingtheChargeIndicatorLight............................................................................................................13-11

ChargeIndicatorLightRemoval...............................................................................................................13-11

ChargeIndicatorLightInstallation............................................................................................................13-11

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

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

BatteryTestingBasics–6Volt......................................................................................................................14-2

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

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

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

BatteryTesting–6Volt................................................................................................................................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..............................................................................................................14-11

WateringBatterieswiththeSPWS...........................................................................................................14-11

BatteryStorage..........................................................................................................................................14-13

Pageviii2015Carryall500and700MaintenanceandServiceManual

FleetRotation.............................................................................................................................................14-13

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

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

SECTION15—QuiQHighFrequencyCharger.................................................................................................15-1

GeneralInformation.....................................................................................................................................15-1

Features.................................................................................................................................................15-1

ULandCSAListing.................................................................................................................................15-1

CECompliance.......................................................................................................................................15-1

IP(IngressProtection)Rating...................................................................................................................15-1

HowToIdentifyChargeAlgorithmNumber................................................................................................15-2

HowToChangeTheAlgorithm.................................................................................................................15-3

TheChargeCircuit...................................................................................................................................15-3

OnboardChargerOperation.........................................................................................................................15-4

ChargerDisplays.....................................................................................................................................15-6

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

ChargingBatteries...................................................................................................................................15-8

Maintenance...............................................................................................................................................15-9

Troubleshooting..........................................................................................................................................15-10

TestProcedures.........................................................................................................................................15-11

ChargerRepairs.........................................................................................................................................15-12

OnboardChargerRemovalAndInstallation..................................................................................................15-12

OnboardChargerRemoval.....................................................................................................................15-12

OnboardChargerInstallation...................................................................................................................15-13

SECTION16—Motor(ModelDA5-4006):ElectricVehicles...............................................................................16-1

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

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

MotorRemoval............................................................................................................................................16-2

MotorDisassembly......................................................................................................................................16-4

MotorComponentTestingandInspection......................................................................................................16-7

ArmatureInspectionandTesting...............................................................................................................16-7

MotorFrameandFieldWindingsInspection..............................................................................................16-8

MotorBrush,Spring,andTerminalInsulatorInspection..............................................................................16-8

ReconditioningtheMotor............................................................................................................................16-11

MotorSpecications...............................................................................................................................16-11

MotorAssembly..........................................................................................................................................16-11

MotorInstallation........................................................................................................................................16-13

SECTION17—Transaxle:ElectricVehicles.....................................................................................................17-1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2015Carryall500and700MaintenanceandServiceManualPageix

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

ElectricalSystem........................................................................................................................................18-14

TestProcedures.........................................................................................................................................18-15

TestingBasics........................................................................................................................................18-15

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

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

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

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

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

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

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

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

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

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

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

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

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

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

FieldCoilRemoval...................................................................................................................................20-6

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

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

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

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

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

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

Starter/GeneratorInstallation...................................................................................................................20-11

BeltTensionAdjustment..........................................................................................................................20-13

VoltageRegulator.......................................................................................................................................20-14

VoltageRegulatorRemoval.....................................................................................................................20-14

VoltageRegulatorInstallation..................................................................................................................20-14

EngineControlUnit(ECU)..........................................................................................................................20-15

EngineControlUnitRemoval...................................................................................................................20-15

EngineControlUnitInstallation................................................................................................................20-15

KeySwitch.................................................................................................................................................20-15

KeySwitchRemoval...............................................................................................................................20-16

KeySwitchInstallation............................................................................................................................20-16

Maintenance/OperateSwitch.......................................................................................................................20-17

Maintenance/OperateSwitchRemoval.....................................................................................................20-17

Maintenance/OperateSwitchInstallation..................................................................................................20-17

NeutralLockoutLimitSwitch.......................................................................................................................20-17

NeutralLockoutLimitSwitchRemoval.....................................................................................................20-17

NeutralLockoutLimitSwitchInstallation...................................................................................................20-17

Solenoid.....................................................................................................................................................20-18

SolenoidRemoval..................................................................................................................................20-18

SolenoidInstallation................................................................................................................................20-18

Fuse..........................................................................................................................................................20-18

FuseRemoval........................................................................................................................................20-19

FuseInstallation.....................................................................................................................................20-19

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

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

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

ReverseWarningBuzzer.............................................................................................................................20-21

ReverseWarningBuzzerRemoval..........................................................................................................20-21

ReverseWarningBuzzerInstallation........................................................................................................20-21

ReverseBuzzerLimitSwitch.......................................................................................................................20-23

ReverseBuzzerLimitSwitchRemoval.....................................................................................................20-23

ReverseBuzzerLimitSwitchInstallation..................................................................................................20-23

LowOilWarningLight.................................................................................................................................20-25

LowOilWarningLightRemoval...............................................................................................................20-25

LowOilWarningLightInstallation............................................................................................................20-25

Pagex2015Carryall500and700MaintenanceandServiceManual

FuelGauge/HourMeter..............................................................................................................................20-25

GeneralInformation................................................................................................................................20-25

FuelGauge/HourMeterRemoval............................................................................................................20-25

FuelGauge/HourMeterInstallation..........................................................................................................20-26

FuelLevelSendingUnit..............................................................................................................................20-26

OilLevelSensor.........................................................................................................................................20-26

OilLevelSensorRemoval.......................................................................................................................20-26

OilLevelSensorInstallation....................................................................................................................20-26

VoltageLimiter...........................................................................................................................................20-26

VoltageLimiterRemoval.........................................................................................................................20-27

VoltageLimiterInstallation.......................................................................................................................20-27

HeadlightSwitch.........................................................................................................................................20-28

HeadlightSwitchRemoval.......................................................................................................................20-28

HeadlightSwitchinstallation....................................................................................................................20-28

Headlights..................................................................................................................................................20-29

HeadlightBezelRemoval........................................................................................................................20-29

HeadlightBezelInstallation.....................................................................................................................20-29

HeadlightBulbRemoval(Halogen)..........................................................................................................20-29

HeadlightBulbInstallation(Halogen).......................................................................................................20-29

HeadlightBulbRemoval(LED)................................................................................................................20-29

HeadlightBulbInstallation(LED).............................................................................................................20-30

Battery.......................................................................................................................................................20-32

GeneralInformation................................................................................................................................20-32

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

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

WaterLevel............................................................................................................................................20-33

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

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

MineralContent......................................................................................................................................20-34

BatteryRemoval.....................................................................................................................................20-36

ChargingtheBattery...............................................................................................................................20-36

BatteryInstallation..................................................................................................................................20-36

BatteryStorage......................................................................................................................................20-37

ChargingaDeadBattery.........................................................................................................................20-37

GroundCables...........................................................................................................................................20-37

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2015Carryall500and700MaintenanceandServiceManualPagexi

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

AcceleratorCable...................................................................................................................................23-11

ClosedThrottleorIdleAdjustment–Pedal-StartVehicles.........................................................................23-12

ClosedThrottleorIdleAdjustment–Key-StartVehicles............................................................................23-12

HowtoMeasureGroundSpeed...............................................................................................................23-13

EngineRPMAdjustment.........................................................................................................................23-13

AirIntakeSystem.......................................................................................................................................23-14

AirFilter.................................................................................................................................................23-15

AirCleanerRemoval...............................................................................................................................23-15

AirCleanerInstallation............................................................................................................................23-15

FuelLine....................................................................................................................................................23-16

FuelLineRemoval..................................................................................................................................23-16

FuelLineInstallation...............................................................................................................................23-17

FuelPumpModule......................................................................................................................................23-18

GeneralInformation................................................................................................................................23-18

FuelPumpModuleRemoval...................................................................................................................23-18

FuelPumpModuleInstallation.................................................................................................................23-18

FuelTank...................................................................................................................................................23-21

GeneralInformation................................................................................................................................23-21

FuelTankRemoval.................................................................................................................................23-21

FuelTankDisposal.................................................................................................................................23-22

FuelTankStorage..................................................................................................................................23-22

FuelTankInstallation..............................................................................................................................23-22

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

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

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

FuelFilterInstallation..............................................................................................................................23-24

FuelingInstructions–GasolineVehicle........................................................................................................23-24

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

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

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

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

Pagexii2015Carryall500and700MaintenanceandServiceManual

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2015Carryall500and700MaintenanceandServiceManualPagexiii

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.

2015Carryall500and700MaintenanceandServiceManualPage1-1

1GeneralWarningsSAFETY

DANGER

•Battery–Explosivegases!Donotsmoke.Keepsparksandamesawayfromthevehicleandservice

area.Ventilatewhenchargingoroperatingvehicleinanenclosedarea.Wearafullfaceshieldand

rubbergloveswhenworkingonornearbatteries.

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

servicearea.Serviceonlyinawell-ventilatedarea.

•Donotoperateengineinanenclosedareawithoutproperventilation.Theengineproducescarbon

monoxide,whichisanodorless,deadlypoison.

•Thevehiclewillnotprovideprotectionfromlightning,yingobjects,orotherstorm-relatedhazards.If

caughtinastormwhiledrivingaClubCarvehicle,exitthevehicleandseekshelterinaccordancewith

applicablesafetyguidelinesforyourlocation.

WARNING

•Followtheproceduresexactlyasstatedinthismanual,andheedallDANGER,WARNING,and

CAUTIONstatementsinthismanualaswellasthoseonthevehicleandbatterycharger.

•Donotleavechildrenunattendedinvehicleatanytime.

•Priortoleavingthevehicleunattendedorservicingthevehicle,settheparkbrake,placethe

Forward/ReversehandleorswitchintheNEUTRALposition,turnthekeyswitchtotheOFFposition,

andremovethekey.Chockthewheelswhenservicingthevehicle.

•Improperuseofthevehicleorfailuretoproperlymaintainitcanresultindecreasedvehicle

performance,severepersonalinjury,ordeath.

•Anymodicationorchangetothevehiclethataffectstheelectricalsystem,stabilityorhandlingof

thevehicle,orincreasesmaximumvehiclespeedbeyondfactoryspecications,canresultinsevere

personalinjuryordeath.

•Checkthevehicleforproperlocationofallvehiclesafetyandoperationdecalsandmakesuretheyare

inplaceandareeasytoread.

•Forvehicleswithcargobeds,removeallcargo(includingaccessories)beforeraisingthebedor

servicingthevehicle.Ifthevehicleisequippedwithaproprod,ensurethatitissecurelyengaged

whilebedisraised.Donotclosebeduntilallpersonsareclearofcargobedarea.Keephandsclearof

allcrushareas.Donotdropcargobed;lowergentlyandkeepentirebodyclear.Failuretoheedthis

warningcanresultinseverepersonalinjuryordeath.

•Onlytrainedtechniciansshouldserviceorrepairthevehicleorbatterycharger.Anyonedoingeven

simplerepairsorserviceshouldhaveknowledgeandexperienceinelectricalandmechanicalrepair.

Theappropriateinstructionsmustbeusedwhenperformingmaintenance,service,oraccessory

installation.

Electricvehiclesonly:

•Ensurebatteryconnectionsarecleanandproperlytightened.SeeBatteryCare–VehiclesEquipped

withtheSingle-PointWateringSystem(SPWS)onpage14-8orBatteryCare–VehiclesWithoutthe

Single-PointWateringSystem(SPWS)onpage14-9.

•PlaceRun/TowswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failureto

heedthiswarningcanresultinabatteryexplosionorseverepersonalinjury.

WARNINGCONTINUEDONNEXTPAGE

Page1-22015Carryall500and700MaintenanceandServiceManual

SAFETYGeneralWarnings1

WARNING

•Toavoidunintentionallystartinganelectricvehicle,disconnectthebatteriesanddischargethe

controller.SeeDisconnectingtheBatteries–ElectricVehiclesonpage1-4.

Gasolinevehiclesonly:

•Toavoidunintentionallystartingagasolinevehicle,disconnectthebatteryandsparkplugwire.See

DisconnectingtheBattery–GasolineVehiclesonpage1-4.

•Frameground–Donotallowtoolsorothermetalobjectstocontactframewhendisconnectingbattery

cablesorotherelectricalwiring.Donotallowapositivewiretotouchthevehicleframe,engine,or

anyothermetalcomponent.

Allvehicles:

•Wearsafetyglassesorapprovedeyeprotectionwhenservicingthevehicleorbatterycharger.Weara

fullfaceshieldandrubbergloveswhenworkingonornearbatteries.

•Donotwearlooseclothingorjewelrysuchasrings,watches,chains,etc.,whenservicingthe

vehicleorbatterycharger.

•Useinsulatedtoolswhenworkingnearbatteriesorelectricalconnections.Useextremecautionto

avoidshortingofcomponentsorwiring.

2015Carryall500and700MaintenanceandServiceManualPage1-3

1GeneralWarningsSAFETY

DISABLINGTHEVEHICLE

1.Engageparkbraketolockwheels.

2.TurnthekeyswitchOFFandremovethekey.

3.PlacetheForward/ReversecontrolintheNEUTRALposition.

4.Inaddition,chockthewheelsifservicingorrepairingthevehicle.

DISCONNECTINGTHEBATTERIES–ELECTRICVEHICLES

1.Disablethevehicle.SeeDisablingtheVehicleonpage1-4.

2.PlaceRun/TowswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failuretoheed

thiswarningcanresultinabatteryexplosionorseverepersonalinjury.

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

4.Afterdisconnectingthebatteries,wait90secondsforthecontrollercapacitorstodischarge.

CONNECTINGTHEBATTERIES–ELECTRICVEHICLES

1.EnsuretheRun/TowswitchisintheTOWposition.

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

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

4.CoatterminalswithBatteryT erminalProtectorSpraytominimizecorrosion.

DISCONNECTINGTHEBATTERY–GASOLINEVEHICLES

1.Disablethevehicle.SeeDisablingtheVehicleonpage1-4.

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

3.Disconnectthesparkplugwirefromthesparkplug.

CONNECTINGTHEBATTERY–GASOLINEVEHICLES

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

2.Tightenbatteryterminalsto80in·lb(9N·m).

3.CoatterminalswithBatteryT erminalProtectorSpray(CCPN1014305)tominimizecorrosion.

4.Connectthesparkplugwiretothesparkplug.

Page1-42015Carryall500and700MaintenanceandServiceManual

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