Club car Carryall 550 2015 Manual

2015Carryall550

MaintenanceandService

Manual

GasolineVehiclewithSubaruEX40Engine

ElectricVehiclewithQuiQ™ ™

™Charger

ManualNumber105157206

EditionCode0714A00000

FOREWORD

ClubCarvehiclesaredesignedandbuilttoprovidetheultimateinperformanceefciency;however,proper

maintenanceandrepairareessentialforachievingmaximumservicelifeandcontinuedsafeandreliableoperation.

Thismanualprovidesdetailedinformationforthemaintenanceandrepairofthe2015Carryall550vehicle,andshould

bethoroughlyreviewedpriortoservicingthevehicle.Theproceduresprovidedmustbeproperlyimplemented,andthe

DANGER,WARNING,andCAUTIONstatementsmustbeheeded.

Thismanualwaswrittenforthetrainedtechnicianwhoalreadypossessesknowledgeandskillsinelectricaland

mechanicalrepair.Ifthetechniciandoesnothavesuchknowledgeandskills,attemptedserviceorrepairstothe

vehiclemayrenderthevehicleunsafe.Forthisreason,ClubCaradvisesthatallrepairsand/orservicebeperformed

byanauthorizedClubCardistributor/dealerrepresentativeorbyaClubCarfactory-trainedtechnician.

ItisthepolicyofClubCartoassistitsdistributorsanddealersincontinuallyupdatingtheirserviceknowledgeand

facilitiessotheycanprovidepromptandefcientserviceforvehicleowners.Regionaltechnicalrepresentatives,

vehicleserviceseminars,periodicservicebulletins,maintenanceandservicemanuals,andotherservicepublications

alsorepresentClubCar’scontinuingcommitmenttocustomersupport.

ClubCaroffersafulllineoftrainingandcontinuingeducationclassesfortechnicianswhowanttolearnmoreabout

ourproducts.Formoreinformation,contactyourlocaldealerorClubCar’sTechnicalServicesdepartmentfora

listofupcomingclasses.

Thismanualcoversallaspectsoftypicalvehicleservice;however,uniquesituationssometimesoccurwhenservicinga

vehicle.Ifitappearsthataservicequestionisnotansweredinthismanual,pleasecontactyournearestauthorized

ClubCardealerordistributorforassistance.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.

Therearenowarrantiesexpressedorimpliedinthismanual.Seethelimitedwarrantyfoundinthevehicle

Owner’sManual.

ClubCar,Carryall,andArmorFlex

areregisteredtrademarksofClubCar,LLC

ThismanualeffectiveJuly14,2014

2015Carryall550MaintenanceandServiceManualPagei

CONTENTS

SECTION1–SAFETY......................................................................................................................................1-1

SafetyDetails................................................................................................................................................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–VEHICLESPECIFICATIONS........................................................................................................2-1

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

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

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

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

SECTION3–GENERALINFORMATION...........................................................................................................3-1

Carryall550Wheels......................................................................................................................................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........................................................................................................................4-3

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

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

HeavyDutyBumperInstallation..................................................................................................................4-6

CowlRemoval...........................................................................................................................................4-6

CowlInstallation........................................................................................................................................4-6

GrilleRemoval...........................................................................................................................................4-7

GrilleInstallation........................................................................................................................................4-9

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2015Carryall550MaintenanceandServiceManualPageiii

ElectricBedLift...........................................................................................................................................4-19

ElectricBedLiftRemoval.........................................................................................................................4-20

ElectricBedLiftInstallation......................................................................................................................4-20

FloorMat....................................................................................................................................................4-22

FloorMatRemoval..................................................................................................................................4-22

FloorMatInstallation................................................................................................................................4-22

TrailerHitch.................................................................................................................................................4-22

TrailerHitchRemoval...............................................................................................................................4-22

TrailerHitchInstallation............................................................................................................................4-22

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

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

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

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

Pageiv2015Carryall550MaintenanceandServiceManual

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

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

RackandPinionInstallation–Maintenance-FreeBallJoints.......................................................................7-12

TieRodandDragLink.................................................................................................................................7-13

TieRodandDragLinkRemoval–Maintenance-FreeBallJoints................................................................7-13

TieRodandDragLinkInstallation–Maintenance-FreeBallJoints..............................................................7-13

FrontSuspension........................................................................................................................................7-14

Lubrication..............................................................................................................................................7-14

WheelAlignment.....................................................................................................................................7-14

FrontSuspensionComponents.....................................................................................................................7-16

LeafSpringRemoval...............................................................................................................................7-16

LeafSpringInstallation.............................................................................................................................7-16

KingpinandSteeringSpindleRemoval–Maintenance-FreeBallJoints.......................................................7-16

KingpinandSteeringSpindleInstallation–Maintenance-FreeBallJoints....................................................7-19

DeltaA-PlateRemoval.............................................................................................................................7-19

DeltaA-PlateInstallation..........................................................................................................................7-19

ShockAbsorberRemoval.........................................................................................................................7-19

ShockAbsorberInstallation......................................................................................................................7-19

FrontWheelBearingsandHubs...................................................................................................................7-20

FrontWheelFreePlayInspection.............................................................................................................7-20

FrontHubandWheelBearingsRemoval...................................................................................................7-20

FrontHubandWheelBearingsInstallation................................................................................................7-21

SECTION8–WHEELSANDTIRES..................................................................................................................8-1

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

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

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

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

Tires.............................................................................................................................................................8-3

TireRemoval.............................................................................................................................................8-3

TireRepair................................................................................................................................................8-3

TireInstallation..........................................................................................................................................8-4

SECTION9–REARSUSPENSION...................................................................................................................9-1

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

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

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

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

Multi-LeafSprings..........................................................................................................................................9-4

Multi-LeafSpringRemoval.........................................................................................................................9-4

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

SECTION10–PERIODICMAINTENANCE......................................................................................................10-1

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

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

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

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

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

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

SECTION11–CONTROLLERDIAGNOSTICTOOL(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

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

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

2015Carryall550MaintenanceandServiceManualPagev

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

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

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

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

SMVersion..............................................................................................................................................11-6

VCLAppVersion......................................................................................................................................11-6

Parameters..................................................................................................................................................11-6

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

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

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

VehicleID..............................................................................................................................................11-10

MonitorMenu.............................................................................................................................................11-10

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

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

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

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

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

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

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

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

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

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

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

ForwardInput.........................................................................................................................................11-12

ReverseInput.........................................................................................................................................11-12

ModeSwitch..........................................................................................................................................11-12

WKAwayRelay......................................................................................................................................11-12

MainCont..............................................................................................................................................11-12

PasswordTries(OEMAccessLevelOnly)................................................................................................11-12

CirBRKROpen#...................................................................................................................................11-12

THRTLFault#........................................................................................................................................11-13

Undervoltage#.......................................................................................................................................11-13

Overvoltage#.........................................................................................................................................11-13

TempCutback#.....................................................................................................................................11-13

HPD#....................................................................................................................................................11-13

MainWelded#.......................................................................................................................................11-13

RelayWelded#......................................................................................................................................11-13

SPDSensor#........................................................................................................................................11-13

MainDRVOn#......................................................................................................................................11-13

MainCoilOPN#.....................................................................................................................................11-14

MainDropout#.......................................................................................................................................11-14

MotorStall#...........................................................................................................................................11-14

MainDRVROff#.....................................................................................................................................11-14

RelayDNC#..........................................................................................................................................11-14

CurrentSense#.....................................................................................................................................11-14

M-Shorted#...........................................................................................................................................11-14

RelayCoil#............................................................................................................................................11-14

Precharge#...........................................................................................................................................11-14

FLDMissing#........................................................................................................................................11-15

HWFailsafe#.........................................................................................................................................11-15

DRVROvercur#.....................................................................................................................................11-15

RLYDRVROn#.....................................................................................................................................11-15

RLYDRVROff#.....................................................................................................................................11-15

VminI...................................................................................................................................................11-15

SignedBatteryCurrent............................................................................................................................11-15

BDIPercent............................................................................................................................................11-15

ChargerInhibit........................................................................................................................................11-15

LEDDriver.............................................................................................................................................11-16

Odometer...............................................................................................................................................11-16

BDIInfo.................................................................................................................................................11-16

BatteryMonitor.......................................................................................................................................11-16

ChargingTotals......................................................................................................................................11-16

AmpHoursDisplay.................................................................................................................................11-17

LIN........................................................................................................................................................11-17

Pagevi2015Carryall550MaintenanceandServiceManual

DiagnosticsMenu.......................................................................................................................................11-18

PresentErrorsFolder..............................................................................................................................11-18

FaultHistoryFolder................................................................................................................................11-18

SystemFaults........................................................................................................................................11-18

FaultRecovery.......................................................................................................................................11-20

FaultDescriptions.......................................................................................................................................11-21

01ThrottleFault1..................................................................................................................................11-21

02LowBatteryVoltage...........................................................................................................................11-21

03Overvoltage.......................................................................................................................................11-21

04ThermalCutback...............................................................................................................................11-21

06HPD..................................................................................................................................................11-21

07MainWelded.....................................................................................................................................11-21

08RelayWelded....................................................................................................................................11-21

09SpeedSensor....................................................................................................................................11-22

10MainDriverOn..................................................................................................................................11-22

11MainCoilOpen..................................................................................................................................11-22

12MainDropout.....................................................................................................................................11-22

13MotorStall.........................................................................................................................................11-22

14MainDriverOff...................................................................................................................................11-22

15RelayDNC........................................................................................................................................11-22

16KeyswitchSRO..................................................................................................................................11-22

17CurrentSense...................................................................................................................................11-23

18M-Shorted........................................................................................................................................11-23

20DriverOvercurrent.............................................................................................................................11-23

21PrechargeFault.................................................................................................................................11-23

22FieldMissing.....................................................................................................................................11-23

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

24HWFailsafe.......................................................................................................................................11-23

25IncorrectPassword............................................................................................................................11-23

26CircuitBRKROpen............................................................................................................................11-24

27MaxPasswordTries...........................................................................................................................11-24

29RelayDRVROff.................................................................................................................................11-24

30RelayCoilFault.................................................................................................................................11-24

Anti-TamperFault...................................................................................................................................11-24

LockoutFault.........................................................................................................................................11-24

LowSOC...............................................................................................................................................11-24

MainCONTDNC....................................................................................................................................11-25

MainCoilFault.......................................................................................................................................11-25

PROC/Wiring.........................................................................................................................................11-25

OpenArmature.......................................................................................................................................11-25

IncorrectPassword(OEMAccessLevelOnly)..........................................................................................11-25

FaultHistory...........................................................................................................................................11-25

ClearingFaultHistory.............................................................................................................................11-26

Programming.............................................................................................................................................11-27

Cloning..................................................................................................................................................11-27

Favorites....................................................................................................................................................11-27

HHPSettings.............................................................................................................................................11-28

Plot&Log..................................................................................................................................................11-29

Plot........................................................................................................................................................11-29

Log........................................................................................................................................................11-29

CDTTroubleshooting..................................................................................................................................11-30

ConnectionTests........................................................................................................................................11-31

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

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

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

2015Carryall550MaintenanceandServiceManualPagevii

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

Tow/RunSwitch...........................................................................................................................................13-3

Tow/RunSwitchRemoval.........................................................................................................................13-4

Tow/RunSwitchInstallation......................................................................................................................13-4

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

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

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

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

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

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

MCORInstallation...................................................................................................................................13-7

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

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

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

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

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

InstallingtheSpeedControllerCover........................................................................................................13-8

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

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

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

Pageviii2015Carryall550MaintenanceandServiceManual

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

SECTION15–QUIQHIGHFREQUENCYCHARGER......................................................................................15-1

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

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

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

CECompliance.......................................................................................................................................15-2

IP(IngressProtection)Rating...................................................................................................................15-2

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

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

OnboardChargerOperation.........................................................................................................................15-3

ChargerDisplays.....................................................................................................................................15-5

ACPowerConnection..............................................................................................................................15-7

ChargingBatteries...................................................................................................................................15-7

Maintenance...............................................................................................................................................15-8

Troubleshooting...........................................................................................................................................15-9

TestProcedures.........................................................................................................................................15-10

ChargerRepairs.........................................................................................................................................15-11

OnboardChargerRemovalAndInstallation..................................................................................................15-11

OnboardChargerRemoval.....................................................................................................................15-11

OnboardChargerInstallation...................................................................................................................15-12

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

TransaxleDisassemblyandInspection......................................................................................................17-7

TransaxleAssembly.................................................................................................................................17-9

TransaxleInstallation..................................................................................................................................17-11

SECTION18–TROUBLESHOOTINGANDELECTRICALSYSTEM:PEDAL-STARTGASVEHICLE................18-1

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

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

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

GroundLocations....................................................................................................................................18-2

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

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

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

GasolinePowertrain................................................................................................................................18-3

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

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

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

2015Carryall550MaintenanceandServiceManualPageix

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

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..............................................................................................................20-4

BearingRemoval.....................................................................................................................................20-5

FieldCoilRemoval...................................................................................................................................20-5

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

CommutatorCleaningandInspection.......................................................................................................20-6

ArmatureGroundTest..............................................................................................................................20-7

VisualInspectionofFieldCoils.................................................................................................................20-8

Starter/GeneratorRework........................................................................................................................20-8

Starter/GeneratorAssembly.....................................................................................................................20-8

Starter/GeneratorInstallation....................................................................................................................20-9

BeltTensionAdjustment..........................................................................................................................20-11

VoltageRegulator.......................................................................................................................................20-12

VoltageRegulatorRemoval.....................................................................................................................20-12

VoltageRegulatorInstallation..................................................................................................................20-12

EngineControlUnit(ECU)..........................................................................................................................20-13

EngineControlUnitRemoval...................................................................................................................20-13

EngineControlUnitInstallation................................................................................................................20-13

KeySwitch.................................................................................................................................................20-13

KeySwitchRemoval...............................................................................................................................20-14

KeySwitchInstallation............................................................................................................................20-14

Maintenance/OperateSwitch.......................................................................................................................20-15

Maintenance/OperateSwitchRemoval.....................................................................................................20-15

Maintenance/OperateSwitchInstallation..................................................................................................20-15

NeutralLockoutLimitSwitch.......................................................................................................................20-15

NeutralLockoutLimitSwitchRemoval.....................................................................................................20-15

NeutralLockoutLimitSwitchInstallation...................................................................................................20-16

Solenoid.....................................................................................................................................................20-16

SolenoidRemoval..................................................................................................................................20-16

SolenoidInstallation................................................................................................................................20-16

Fuse..........................................................................................................................................................20-17

FuseRemoval........................................................................................................................................20-17

FuseInstallation.....................................................................................................................................20-17

KillLimitSwitch..........................................................................................................................................20-18

KillLimitSwitchRemoval........................................................................................................................20-18

KillLimitSwitchInstallation.....................................................................................................................20-18

ReverseWarningBuzzer.............................................................................................................................20-19

ReverseWarningBuzzerRemoval..........................................................................................................20-19

ReverseWarningBuzzerInstallation........................................................................................................20-19

ReverseBuzzerLimitSwitch.......................................................................................................................20-21

ReverseBuzzerLimitSwitchRemoval.....................................................................................................20-21

ReverseBuzzerLimitSwitchInstallation..................................................................................................20-21

LowOilWarningLight.................................................................................................................................20-23

LowOilWarningLightRemoval...............................................................................................................20-23

LowOilWarningLightInstallation............................................................................................................20-23

FuelGauge/HourMeter..............................................................................................................................20-23

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

FuelGauge/HourMeterRemoval............................................................................................................20-24

Pagex2015Carryall550MaintenanceandServiceManual

FuelGauge/HourMeterInstallation..........................................................................................................20-24

FuelLevelSendingUnit..............................................................................................................................20-24

OilLevelSensor.........................................................................................................................................20-24

OilLevelSensorRemoval.......................................................................................................................20-24

OilLevelSensorInstallation....................................................................................................................20-25

VoltageLimiter...........................................................................................................................................20-25

VoltageLimiterRemoval.........................................................................................................................20-25

VoltageLimiterInstallation.......................................................................................................................20-25

HeadlightSwitch.........................................................................................................................................20-26

HeadlightSwitchRemoval.......................................................................................................................20-26

HeadlightSwitchinstallation....................................................................................................................20-26

Headlights..................................................................................................................................................20-27

HeadlightBezelRemoval........................................................................................................................20-27

HeadlightBezelInstallation.....................................................................................................................20-27

HeadlightBulbRemoval(Halogen)..........................................................................................................20-27

HeadlightBulbInstallation(Halogen).......................................................................................................20-27

HeadlightBulbRemoval(LED)................................................................................................................20-28

HeadlightBulbInstallation(LED).............................................................................................................20-28

Battery.......................................................................................................................................................20-30

GeneralInformation................................................................................................................................20-30

TestingtheBattery..................................................................................................................................20-30

PreventiveMaintenance..........................................................................................................................20-31

WaterLevel............................................................................................................................................20-31

Self-Discharge........................................................................................................................................20-31

VibrationDamage...................................................................................................................................20-32

MineralContent......................................................................................................................................20-32

BatteryRemoval.....................................................................................................................................20-34

ChargingtheBattery...............................................................................................................................20-34

BatteryInstallation..................................................................................................................................20-34

BatteryStorage......................................................................................................................................20-35

ChargingaDeadBattery.........................................................................................................................20-35

GroundCables...........................................................................................................................................20-35

SECTION21–ELECTRICALCOMPONENTS:KEY-STARTGASVEHICLE.....................................................21-1

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

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

KeySwitchRemoval................................................................................................................................21-2

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

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

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

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

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

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

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

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

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

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

SECTION22–ENGINE(SUBARUEX40)........................................................................................................22-1

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

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

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

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

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

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

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

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

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

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

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

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

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

2015Carryall550MaintenanceandServiceManualPagexi

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

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

SECTION25–CLUTCHES:GASOLINEVEHICLES........................................................................................25-1

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

Pagexii2015Carryall550MaintenanceandServiceManual

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

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

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

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

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

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

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

DriveClutchDisassembly.........................................................................................................................25-6

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

DriveClutchAssembly.............................................................................................................................25-9

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

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

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

TransaxleInstallation..................................................................................................................................26-12

ShifterCable..............................................................................................................................................26-12

ShifterCableRemoval............................................................................................................................26-12

ShifterCableInstallation.........................................................................................................................26-13

ShifterCableAdjustment.........................................................................................................................26-13

SECTIONi–INDEX

2015Carryall550MaintenanceandServiceManualPagexiii

SECTION1–SAFETY1

SAFETYDETAILS

WARNING

•Thisowner’smanualshouldbereadcompletelybeforeattemptingtodriveorservicethevehicle.

Failuretofollowtheinstructionsinthismanualcanresultinpropertydamage,severepersonal

injury,ordeath.

Itisimportanttonotethatsomevitalstatementsthroughoutthismanualandonthedecalsafxedtothevehicleare

precededbythewordsDANGER,WARNING,orCAUTION.Foryourprotection,werecommendthatyoutakespecial

noticeofthesesafetyprecautions.Safetyprecautionsareessentialandmustbefollowed.

Ifanyoftheoperationorsafetydecalsonthevehiclebecomedamaged,havebeenremoved,orcannotbeeasily

read,theyshouldbereplacedimmediatelytoavoidpossiblepropertydamage,personalinjury,ordeath.Contactyour

distributor/dealer.

DANGER

•ADANGERindicatesanimmediatehazardthatwillresultinseverepersonalinjuryordeath.

WARNING

•AWARNINGindicatesanimmediatehazardthatcanresultinseverepersonalinjuryordeath.

CAUTION

•ACAUTIONwiththesafetyalertsymbolindicatesahazardorunsafepracticethatcanresultin

minorpersonalinjury.

CAUTION

•ACAUTIONwithoutthesafetyalertsymbolindicatesapotentiallyhazardoussituationthatcanresult

inpropertydamage.

GENERALWARNINGS

Thefollowingsafetystatementsmustbeheededwheneverthevehicleisbeingoperated,repaired,orserviced.Other

specicsafetystatementsappearthroughoutthismanualandonthevehicle.

2015Carryall550MaintenanceandServiceManualPage1-1

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.

•PlaceTow/RunswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failureto

heedthiswarningcanresultinabatteryexplosionorseverepersonalinjury.

•Toavoidunintentionallystartinganelectricvehicle,disconnectthebatteriesanddischargethe

controller.SeeDisconnectingtheBatteries–ElectricVehiclesonpage1-4.

WARNINGCONTINUEDONNEXTPAGE

Page1-22015Carryall550MaintenanceandServiceManual

SAFETYGeneralWarnings1

WARNING

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.

2015Carryall550MaintenanceandServiceManualPage1-3

1GeneralWarningsSAFETY

DISABLINGTHEVEHICLE

1.Engageparkbraketolockwheels.

2.TurnthekeyswitchOFFandremovethekey.

3.PlacetheForward/ReversecontrolintheNEUTRALposition.

4.Inaddition,chockthewheelsifservicingorrepairingthevehicle.

DISCONNECTINGTHEBATTERIES–ELECTRICVEHICLES

1.Disablethevehicle.SeeDisablingtheVehicleonpage1-4.

2.PlaceTow/RunswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failuretoheed

thiswarningcanresultinabatteryexplosionorseverepersonalinjury.

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

4.Afterdisconnectingthebatteries,wait90secondsforthecontrollercapacitorstodischarge.

CONNECTINGTHEBATTERIES–ELECTRICVEHICLES

1.EnsuretheTow/RunswitchisintheTOWposition.

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.

Page1-42015Carryall550MaintenanceandServiceManual

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