Club car Carryall 550 2019 Manual

2019Carryall550

MaintenanceandService

Manual

GasolineVehiclewithKohlerECH440Engine

ElectricVehiclewithQuiQ™ ™

™Charger

ManualNumber105355107

EditionCodeC

FOREWORD

ClubCarvehiclesaredesignedandbuilttoprovidetheultimateinperformanceefciency;however,proper

maintenanceandrepairareessentialforachievingmaximumservicelifeandcontinuedsafeandreliableoperation.

Thismanualprovidesdetailedinformationforthemaintenanceandrepairofthe2019Carryall550vehicle,andshould

bethoroughlyreviewedpriortoservicingthevehicle.Theproceduresprovidedmustbeproperlyimplemented,andthe

DANGER,WARNING,andCAUTIONstatementsmustbeheeded.

Thismanualwaswrittenforthetrainedtechnicianwhoalreadypossessesknowledgeandskillsinelectricaland

mechanicalrepair.Ifthetechniciandoesnothavesuchknowledgeandskills,attemptedserviceorrepairstothe

vehiclemayrenderthevehicleunsafe.Forthisreason,ClubCaradvisesthatallrepairsand/orservicebeperformed

byanauthorizedClubCardistributor/dealerrepresentativeorbyaClubCarfactory-trainedtechnician.

ItisthepolicyofClubCartoassistitsdistributorsanddealersincontinuallyupdatingtheirserviceknowledgeand

facilitiessotheycanprovidepromptandefcientserviceforvehicleowners.Regionaltechnicalrepresentatives,

vehicleserviceseminars,periodicservicebulletins,maintenanceandservicemanuals,andotherservicepublications

alsorepresentClubCar’scontinuingcommitmenttocustomersupport.

ClubCaroffersafulllineoftrainingandcontinuingeducationclassesfortechnicianswhowanttolearnmoreabout

ourproducts.Formoreinformation,contactyourlocaldealerorClubCar'sT echnicalServicesdepartmentfora

listofupcomingclasses.

Thismanualcoversallaspectsoftypicalvehicleservice;however,uniquesituationssometimesoccurwhenservicinga

vehicle.Ifitappearsthataservicequestionisnotansweredinthismanual,pleasecontactyournearestauthorized

ClubCardealerordistributorforassistance.

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

thisQuickResponse(QR)codetobetakentotheClubCardealerlocator.RefertoFigure1.DownloadaQRcode

readersuchasRedLaserorBarcodeScannertoyourcellphoneortablet.

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

Augusta,Georgia30917-4658USA.

DealerLocatorQRCode

Club Car is a registered trademark of Club Car, LLC

This manual effective March, 2020

2019Carryall550MaintenanceandServiceManualPagei

FOREWORD

TECHNICALPUBLICATIONCUSTOMERSATISFACTIONONLINESURVEY

Letyourvoicebeheard!

PleaseparticipateintheTechnicalPublicationcustomersatisfactiononlinesurvey.

Thissurveytakeslessthanveminutestocompleteandyourresponseswillhelpexaminecurrentperformance

andidentifyareasforfutureimprovement.

Ourtoppriorityistoprovidetimely,accurate,anduserfriendlymanuals.

Theonlinesurveycanbefoundathttp://bit.ly/1w9uFMhorusingtheQRCodebelow.

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WARNING

•ReadSafetyonpage1-1beforeattemptinganyserviceonthevehicle.

•Beforeservicingvehicle,readcompletesection(s)andanyreferencedinformationthatmaybe

relevanttotheserviceorrepairtobeperformed.

NOTE:Thismanualrepresentsthemostcurrentinformationatthetimeofpublication.ClubCariscontinuallyworking

tofurtherimproveitsvehiclesandotherproducts.Theseimprovementsmayaffectservicingprocedures.

Anymodicationand/orsignicantchangeinspecicationsorprocedureswillbeforwardedtoallClubCar

dealersandwill,whenapplicable,appearinfutureeditionsofthismanual.

ClubCarreservestherighttochangespecicationsanddesignsatanytimewithoutnoticeandwithoutthe

obligationofmakingchangestounitspreviouslysold.

Therearenowarrantiesexpressedorimpliedinthismanual.Seethelimitedwarrantyfoundinthevehicle

Owner’sManual.

CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2019Carryall550MaintenanceandServiceManualPageiii

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

RearFenderandTailskirtInstallation........................................................................................................4-16

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

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

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

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

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

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..................................................................................................5-16

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

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

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

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

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

BrakeAdjustment..........................................................................................................................................6-7

BrakeClusterAdjustment...........................................................................................................................6-8

BrakeCableEqualization.........................................................................................................................6-10

FinalBrakeClusterAdjustment..................................................................................................................6-11

TestDriveVehicle.....................................................................................................................................6-11

BrakeClusterRemovalandInstallation.........................................................................................................6-12

FrontBrakeClusterRemoval....................................................................................................................6-12

FrontBrakeClusterInstallation.................................................................................................................6-12

RearBrakeClusterRemoval....................................................................................................................6-14

RearBrakeClusterInstallation.................................................................................................................6-14

FrontBrakeCables......................................................................................................................................6-15

FrontBrakeCableRemoval.....................................................................................................................6-16

FrontBrakeCableInstallation...................................................................................................................6-16

RearBrakeCables......................................................................................................................................6-17

RearBrakeCableRemoval......................................................................................................................6-18

RearBrakeCableInstallation...................................................................................................................6-18

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

Pageiv2019Carryall550MaintenanceandServiceManual

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2019Carryall550MaintenanceandServiceManualPagev

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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.........................................................................................................................................11-11

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Pagevi2019Carryall550MaintenanceandServiceManual

MainCoilOPN#.....................................................................................................................................11-13

MainDropout#.......................................................................................................................................11-13

MotorStall#...........................................................................................................................................11-13

MainDRVROff#.....................................................................................................................................11-13

RelayDNC#..........................................................................................................................................11-13

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

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

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

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

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

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

DRVROvercur#.....................................................................................................................................11-14

RLYDRVROn#.....................................................................................................................................11-14

RLYDRVROff#.....................................................................................................................................11-14

VminI...................................................................................................................................................11-14

SignedBatteryCurrent............................................................................................................................11-14

BDIPercent............................................................................................................................................11-14

ChargerInhibit........................................................................................................................................11-14

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

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

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

BatteryMonitor.......................................................................................................................................11-15

ChargingTotals......................................................................................................................................11-15

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

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

DiagnosticsMenu.......................................................................................................................................11-17

PresentErrorsFolder..............................................................................................................................11-17

FaultHistoryFolder................................................................................................................................11-17

SystemFaults........................................................................................................................................11-17

FaultRecovery.......................................................................................................................................11-19

FaultDescriptions.......................................................................................................................................11-20

01ThrottleFault1..................................................................................................................................11-20

02LowBatteryVoltage...........................................................................................................................11-20

03Overvoltage.......................................................................................................................................11-20

04ThermalCutback...............................................................................................................................11-20

06HPD..................................................................................................................................................11-20

07MainWelded.....................................................................................................................................11-20

08RelayWelded....................................................................................................................................11-20

09SpeedSensor....................................................................................................................................11-20

10MainDriverOn..................................................................................................................................11-20

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

12MainDropout.....................................................................................................................................11-21

13MotorStall.........................................................................................................................................11-21

14MainDriverOff...................................................................................................................................11-21

15RelayDNC........................................................................................................................................11-21

16KeyswitchSRO..................................................................................................................................11-21

17CurrentSense...................................................................................................................................11-21

18M-Shorted........................................................................................................................................11-21

20DriverOvercurrent.............................................................................................................................11-21

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

22FieldMissing.....................................................................................................................................11-21

23RelayDriverOn.................................................................................................................................11-21

24HWFailsafe.......................................................................................................................................11-21

25IncorrectPassword............................................................................................................................11-22

26CircuitBRKROpen............................................................................................................................11-22

27MaxPasswordTries...........................................................................................................................11-22

29RelayDRVROff.................................................................................................................................11-22

30RelayCoilFault.................................................................................................................................11-22

Anti-TamperFault...................................................................................................................................11-22

LockoutFault.........................................................................................................................................11-22

LowSOC...............................................................................................................................................11-22

MainCONTDNC....................................................................................................................................11-23

MainCoilFault.......................................................................................................................................11-23

PROC/Wiring.........................................................................................................................................11-23

2019Carryall550MaintenanceandServiceManualPagevii

OpenArmature.......................................................................................................................................11-23

IncorrectPassword(OEMAccessLevelOnly)..........................................................................................11-23

FaultHistory...........................................................................................................................................11-23

ClearingFaultHistory.............................................................................................................................11-23

Programming.............................................................................................................................................11-24

Cloning..................................................................................................................................................11-24

Favorites....................................................................................................................................................11-24

HHPSettings.............................................................................................................................................11-25

Plot&Log..................................................................................................................................................11-26

Plot........................................................................................................................................................11-26

Log........................................................................................................................................................11-26

CDTTroubleshooting..................................................................................................................................11-27

ConnectionTests........................................................................................................................................11-28

SECTION12—ElectricVehicle-ElectricalSystemTroubleshooting..................................................................12-1

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

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

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

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

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

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

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

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

TroubleshootingGuide1..........................................................................................................................12-6

TroubleshootingGuide2..........................................................................................................................12-9

TestProcedures.........................................................................................................................................12-11

TestingBasics........................................................................................................................................12-11

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Solenoid......................................................................................................................................................13-7

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

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

SpeedController.........................................................................................................................................13-8

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

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

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

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

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

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

Pageviii2019Carryall550MaintenanceandServiceManual

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

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

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

HalogenHeadlightBulbRemoval............................................................................................................13-13

HalogenHeadlightBulbInstallation..........................................................................................................13-13

HalogenHeadlightLensRemoval............................................................................................................13-14

HalogenHeadlightLensInstallation.........................................................................................................13-14

LEDHeadlightRemoval..........................................................................................................................13-15

LEDHeadlightInstallation.......................................................................................................................13-15

LockoutRelay............................................................................................................................................13-15

LockoutRelayRemoval..........................................................................................................................13-16

LockoutRelayInstallation........................................................................................................................13-16

WalkAwayRelay........................................................................................................................................13-17

WalkAwayRelayRemoval......................................................................................................................13-17

WalkAwayRelayInstallation...................................................................................................................13-17

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

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

SECTION15—ElectricVehicle-BatteryCharger.............................................................................................15-1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2019Carryall550MaintenanceandServiceManualPageix

SECTION16—ElectricVehicle-Motor............................................................................................................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—ElectricVehicle-Transaxle......................................................................................................17-1

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

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

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

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

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

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

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

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

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

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

SECTION18—GasolineVehicle-TroubleshootingandElectricalSystem..........................................................18-1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Pagex2019Carryall550MaintenanceandServiceManual

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2019Carryall550MaintenanceandServiceManualPagexi

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Pagexii2019Carryall550MaintenanceandServiceManual

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2019Carryall550MaintenanceandServiceManualPagexiii

SECTION1—SAFETY1

Safety

SAFETYDETAILS

ToensurethesafetyofthoseservicingClubCarvehicles,andtoprotectthevehiclesfrompossibledamageresulting

fromimproperserviceormaintenance,theproceduresinthismanualmustbefollowed.

ItisimportanttonotethatthroughoutthismanualtherearestatementslabeledDANGER,WARNING,orCAUTION.

Thesespecialstatementsrelatetospecicsafetyissues,andmustberead,understood,andheededbefore

proceedingwithprocedures.TherearestatementslabeledNOTE,whichprovideotheressentialserviceor

maintenanceinformation.

PERSONALSAFETY

DANGER

•ADANGERindicatesanimmediatehazardthatwillresultinseverepersonalinjuryordeath.The

colorassociatedwithDangerisRED.

WARNING

•AWARNINGindicatesanimmediatehazardthatcouldresultinseverepersonalinjuryordeath.

ThecolorassociatedwithWarningisORANGE.

CAUTION

•ACAUTIONwiththesafetyalertsymbolindicatesahazardorunsafepracticethatcouldresultin

minorpersonalinjury.ThecolorassociatedwithCautionisYELLOW.

MACHINESAFETY

CAUTION

•ACAUTIONwithoutthesafetyalertsymbolindicatesapotentiallyhazardoussituationthatcould

resultinpropertydamage.

ACAUTION,withoutthesafetyalertsymbol,isintendedformachineandpropertysafety.Itisusedthroughoutthis

manualfollowedbyspecicinstructionstopreventmachineorpropertydamage.FailuretofollowtheseCAUTION

messagescouldresultinmachineorpropertydamage.

INFORMATION

NOTE:Instructionsthatclarifysteps,procedures,orotherinformationinthismanual.

GENERALWARNINGS

Thefollowingsafetystatementsmustbeheededwheneverthevehicleisbeingoperated,repaired,orserviced.Other

specicsafetystatementsappearthroughoutthismanualandonthevehicle.

2019Carryall550MaintenanceandServiceManualPage1-1

1GeneralWarningsSAFETY

DANGER

•Battery–Explosivegases!Donotsmoke.Keepsparksandamesawayfromthevehicleandservice

area.Ventilatewhenchargingoroperatingvehicleinanenclosedarea.Wearafullfaceshieldand

rubbergloveswhenworkingonornearbatteries.

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

servicearea.Serviceonlyinawell-ventilatedarea.

•Donotoperateengineinanenclosedareawithoutproperventilation.Theengineproducescarbon

monoxide,whichisanodorless,deadlypoison.

•Thevehiclewillnotprovideprotectionfromlightning,yingobjects,orotherstorm-relatedhazards.If

caughtinastormwhiledrivingaClubCarvehicle,exitthevehicleandseekshelterinaccordancewith

applicablesafetyguidelinesforyourlocation.

WARNING

•Followtheproceduresexactlyasstatedinthismanual,andheedallDANGER,WARNING,and

CAUTIONstatementsinthismanualaswellasthoseonthevehicleandbatterycharger.

•Donotleavechildrenunattendedinvehicleatanytime.

•Priortoleavingthevehicleunattendedorservicingthevehicle,settheparkbrake,placethe

Forward/Neutral/Reversecontrol(FNR)orswitchintheNEUTRALposition,turnthekeyswitchtothe

OFFposition,andremovethekey.Chockthewheelswhenservicingthevehicle.

•Improperuseofthevehicleorfailuretoproperlymaintainitcanresultindecreasedvehicle

performance,severepersonalinjury,ordeath.

•Anymodicationorchangetothevehiclethataffectstheelectricalsystem,stabilityorhandlingof

thevehicle,orincreasesmaximumvehiclespeedbeyondfactoryspecications,canresultinsevere

personalinjuryordeath.

•Checkthevehicleforproperlocationofallvehiclesafetyandoperationdecalsandmakesuretheyare

inplaceandareeasytoread.

•Forvehicleswithcargobeds,removeallcargo(includingaccessories)beforeraisingthebedor

servicingthevehicle.Ifthevehicleisequippedwithaproprod,ensurethatitissecurelyengaged

whilebedisraised.Donotclosebeduntilallpersonsareclearofcargobedarea.Keephandsclearof

allcrushareas.Donotdropcargobed;lowergentlyandkeepentirebodyclear.Failuretoheedthis

warningcanresultinseverepersonalinjuryordeath.

•Onlytrainedtechniciansshouldserviceorrepairthevehicleorbatterycharger.Anyonedoingeven

simplerepairsorserviceshouldhaveknowledgeandexperienceinelectricalandmechanicalrepair.

Theappropriateinstructionsmustbeusedwhenperformingmaintenance,service,oraccessory

installation.

Electricvehiclesonly:

•Ensurebatteryconnectionsarecleanandproperlytightened.

•PlaceRun/TowswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failureto

heedthiswarningcanresultinabatteryexplosionorseverepersonalinjury.

•Toavoidunintentionallystartinganelectricvehicle,disconnectthebatteriesanddischargethe

controller.

WARNINGCONTINUEDONNEXTPAGE

Page1-22019Carryall550MaintenanceandServiceManual

SAFETYGeneralWarnings1

WARNING

Gasolinevehiclesonly:

•Toavoidunintentionallystartingagasolinevehicle,disconnectthebatteryandsparkplugwire.

•Frameground–Donotallowtoolsorothermetalobjectstocontactframewhendisconnectingbattery

cablesorotherelectricalwiring.Donotallowapositivewiretotouchthevehicleframe,engine,or

anyothermetalcomponent.

Allvehicles:

•Wearsafetyglassesorapprovedeyeprotectionwhenservicingthevehicleorbatterycharger.Weara

fullfaceshieldandrubbergloveswhenworkingonornearbatteries.

•Donotwearlooseclothingorjewelrysuchasrings,watches,chains,etc.,whenservicingthe

vehicleorbatterycharger.

•Useinsulatedtoolswhenworkingnearbatteriesorelectricalconnections.Useextremecautionto

avoidshortingofcomponentsorwiring.

DISABLETHEVEHICLE

1.Parkthevehicleonasolidlevelsurface.

2.Engagetheparkbraketolockthewheels..

3.TurnthekeytoOFF .

NOTE:KeyOFFfor15secondsletstheECUdoapermanentmemorywrite.

4.Removethekey.

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

6.Putthechocksagainstthewheels.

2019Carryall550MaintenanceandServiceManualPage1-3

1GeneralWarningsSAFETY

DISCONNECTTHEBATTERY-GASOLINEVEHICLES

1.Disablethevehicle.

2.Removepositiveterminalcover.

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

Figure1-1Battery-GasolineVehicles

4.Disconnectthepositive(+)cable(2).

CONNECTTHEBATTERY-GASOLINEVEHICLES

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

2.Connectthenegative(-)cable(1).

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

4.CoatterminalswithBatteryT erminalProtectorSpraytominimizecorrosion.

5.Attachthepositiveterminalcover.

Page1-42019Carryall550MaintenanceandServiceManual

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