Name: Club Car Carryall 500 2015
Brand: Club Car
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2015Carryall500and700

MaintenanceandService

Manual

GasolineVehiclewithSubaruEX40Engine

ElectricVehiclewithQuiQ™ ™

™

Charger

ManualNumber105157204

EditionCodeC

Table of Contents5
SECTION 1 - Safety17
Safety Details17
Personal Safety17
Machine Safety17
Information17
General Warnings17
Disabling the Vehicle20
Disconnecting the Batteries - Electric Vehicles20
Connecting the Batteries - Electric Vehicles20
Disconnecting the Battery - Gasoline Vehicles20
Connecting the Battery - Gasoline Vehicles20
Recycling Lead-Acid Batteries21
International Safety Symbols on Batteries22
SECTION 2 - Vehicle Specifications24
Vehicle Specifications24
Quiq Battery Charger Specifications25
Vehicle Specifications - Gasoline Vehicles26
SECTION 3 - General Information29
Model Identification29
Storage - Electric Vehicles30
Preparing the Electric Vehicle for Extended Storage30
Returning the Stored Electric Vehicle to Service31
Storage - Gasoline Vehicles32
Preparing the Gasoline Vehicle for Extended Storage32
Returning the Stored Gasoline Vehicle to Service33
SECTION 4 - Body and Trim35
Cleaning the Vehicle35
Seat Cleaning35
Front Body Repair36
Light Scratches36
Abrasions and Haze36
Large Scratches and Abrasions36
Touch-Up Paint Color Chart36
Front Body37
Heavy Duty Bumper Removal37
Heavy Duty Bumper Installation39
Cowl Removal39
Cowl Installation39
Grille Removal40
Grille Installation42
Front Bumper and Side Fender Removal42
Front Bumper and Side Fender Installation42
Instrument Panel Removal43
Instrument Panel Installation43
Dash Removal44
Dash Installation44
Tilt Bed46
Tilt Bed Removal46
Tilt Bed Installation46
Bed Latch Assembly Removal48
Bed Latch Assembly Installation48
Rear Fenders and Tailskirt50
Rear Fender and Tailskirt Removal50
Rear Fender and Tailskirt Installation51
Electric Bed Lift52
Electric Bed Lift Removal53
Electric Bed Lift Installation53
Floor Mat55
Floor Mat Removal55
Floor Mat Installation55
Trailer Hitch55
Trailer Hitch Removal55
Trailer Hitch Installation55
SECTION 5 - Accelerator and Brake Pedal Group57
Brake Pedal and Park Brake (Gas and Electric Vehicles)57
Brake Pedal Removal (Gas and Electric Vehicles)57
Brake Pedal Installation (Gas and Electric Vehicles)57
Park Brake Removal (Gas and Electric Vehicles)60
Park Brake Installation (Gas and Electric Vehicles)60
Accelerator Pedal - Gasoline Vehicles61
Accelerator Pedal Removal - Gasoline Vehicles61
Accelerator Pedal Installation - Gasoline Vehicles62
Accelerator Pedal - Electric Vehicles63
Accelerator Pedal Removal - Electric Vehicles63
Accelerator Pedal Installation - Electric Vehicles66
Pedal Group Adjustment - Gasoline Vehicles66
Pedal Group Adjustment - Electric Vehicles72
SECTION 6 - Wheel Brake Assemblies77
General Information77
Brake Shoe Removal77
Brake Assembly Cleaning79
Brake Shoe Installation81
Brake Adjustment82
Brake Cluster Adjustment83
Brake Cable Equalization85
Final Brake Cluster Adjustment86
Test Drive Vehicle86
Brake Cluster Removal and Installation87
Front Brake Cluster Removal87
Front Brake Cluster Installation87
Rear Brake Cluster Removal89
Rear Brake Cluster Installation89
Front Brake Cables90
Front Brake Cable Removal90
Front Brake Cable Installation90
Rear Brake Cables92
Rear Brake Cable Removal92
Rear Brake Cable Installation92
SECTION 7 - Steering and Front Suspension95
General Information95
Steering Wheel95
Steering Wheel Removal95
Steering Wheel Installation96
Steering Column97
Steering Column Removal98
Steering Column Disassembly98
Steering Column Assembly98
Steering Column Installation99
Steering Adjustment100
Rack and Pinion101
Rack and Pinion Inspection101
Rack and Pinion Removal - Maintenance-Free Ball Joints101
Rack and Pinion Disassembly102
Rack and Pinion Assembly104
Rack and Pinion Installation - Maintenance-Free Ball Joints107
Tie Rod and Drag Link108
Tie Rod and Drag Link Removal - Maintenance-Free Ball Joints108
Tie Rod and Drag Link Installation - Maintenance-Free Ball Joints108
Front Suspension109
Lubrication109
Wheel Alignment109
Front Suspension Components111
Leaf Spring Removal111
Leaf Spring Installation111
Kingpin and Steering Spindle Removal - Maintenance-Free Ball Joints111
Kingpin and Steering Spindle Installation - Maintenance-Free Ball Joints114
Delta A-Plate Removal114
Delta A-Plate Installation114
Shock Absorber Removal114
Shock Absorber Installation114
Front Wheel Bearings and Hubs115
Front Wheel Free Play Inspection115
Front Hub and Wheel Bearings Removal115
Front Hub and Wheel Bearings Installation116
SECTION 8 - Wheels and Tires117
General Information117
Wheels117
Wheel Removal117
Wheel Installation117
Tires118
Tire Removal118
Tire Repair118
Tire Installation119
SECTION 9 - Rear Suspension121
General Information121
Shock Absorbers121
Shock Absorber Inspection and Removal121
Shock Absorber Installation121
Multi-Leaf Springs122
Multi-Leaf Spring Removal122
Multi-Leaf Spring Installation123
SECTION 10 - Periodic Maintenance125
General Information125
Pre-Operation and Daily Safety Checklist125
Performance Inspection125
Maintenance127
Periodic Service Schedules128
Periodic Lubrication Schedules131
SECTION 11 - Controller Diagnostic Tool (CDT)133
General Information134
Features134
Plugging the CDT into the Vehicle134
Introductory Display135
Quick Reference Guide - IQ Plus with Quiq Charger136
System Info137
Model Number137
Amp Hours Display147
Lin147
Diagnostics Menu148
Present Errors Folder148
Fault History Folder148
System Faults148
Fault Recovery150
Fault Descriptions151
Throttle Fault 1151
02 Low Battery Voltage151
03 Overvoltage151
04 Thermal Cutback151
06 Hpd151
07 Main Welded151
08 Relay Welded151
09 Speed Sensor151
10 Main Driver on151
12 Main Dropout152
13 Motor Stall152
14 Main Driver off152
15 Relay Dnc152
16 Keyswitch Sro152
17 Current Sense152
18 M- Shorted152
20 Driver Overcurrent152
21 Precharge Fault152
22 Field Missing152
25 Incorrect Password153
26 Circuit Brkr Open153
27 Max Password Tries153
29 Relay Drvr off153
30 Relay Coil Fault153
Anti-Tamper Fault153
Lockout Fault153
Low SOC153
Main CONT DNC154
Main Coil Fault154
Proc/Wiring154
Open Armature154
Incorrect Password (OEM Access Level Only)154
Fault History154
Clearing Fault History154
Programming155
Cloning155
Favorites155
HHP Settings156
Plot & Log157
Plot157
Log157
CDT Troubleshooting158
Connection Tests159
SECTION 12 - Electrical System Troubleshooting: IQ Plus Electric Vehicles163
General Information163
Accessories163
Charge Indicator Light163
Key Differences: IQ Plus with Quiq Charger Vs. IQ Plus Charger163
Features164
Wiring Diagrams166
Troubleshooting170
Troubleshooting the Vehicle with the CDT170
Troubleshooting Guide 1171
Troubleshooting Guide 2174
Test Procedures176
Testing Basics176
SECTION 13 - Electrical Components: IQ Plus Electric Vehicles207
Key Switch207
Testing the Key Switch207
Key Switch Removal207
Key Switch Installation207
Forward/Reverse Rocker Switch209
Forward/Reverse Rocker Switch Removal209
Forward/Reverse Rocker Switch Installation209
Run/Tow Switch209
Run/Tow Switch Removal210
Run/Tow Switch Installation210
Circuit Breaker210
Circuit Breaker Removal210
Circuit Breaker Installation210
Motor Controller Output Regulator (MCOR)212
Testing the MCOR212
MCOR Removal212
MCOR Installation212
Reverse Buzzer213
Reverse Buzzer Removal213
Reverse Buzzer Installation213
Speed Controller Cover213
Removing the Speed Controller Cover213
Installing the Speed Controller Cover213
Solenoid214
Solenoid Removal214
Solenoid Installation214
Speed Controller215
Speed Controller Removal215
Speed Controller Installation215
Charge Indicator Light217
Testing the Charge Indicator Light217
Charge Indicator Light Removal217
Charge Indicator Light Installation217
SECTION 14 - Batteries: IQ Plus Electric Vehicles219
General Information219
Battery Testing Basics - 6 Volt220
Observation220
Measuring Voltage of Battery Set220
Battery Cell Numbering220
Battery Testing - 6 Volt221
Battery Regrouping221
Battery Replacement223
Battery Care224
Water Quality224
Deionizer225
Battery Care - Vehicles Equipped with the Single-Point Watering System (SPWS)226
Battery Care - Vehicles Without the Single-Point Watering System (SPWS)227
Self-Discharge228
Electrolyte Level228
Vibration Damage229
Single Point Watering System (SPWS)229
Initial Maintenance of the SPWS229
Watering Batteries with the SPWS229
Battery Storage231
Fleet Rotation231
Deep-Discharge232
Early Excessive Discharging232
SECTION 15 - Quiq High Frequency Charger233
General Information233
Features233
UL and CSA Listing233
CE Compliance233
IP (Ingress Protection) Rating233
How to Identify Charge Algorithm Number234
How to Change the Algorithm235
The Charge Circuit235
Onboard Charger Operation236
Charger Displays238
AC Power Connection240
Charging Batteries240
Maintenance241
Troubleshooting242
Test Procedures243
Charger Repairs244
Onboard Charger Removal and Installation244
Onboard Charger Removal244
Onboard Charger Installation245
SECTION 16 - Motor (Model DA5-4006): Electric Vehicles247
General Information247
External Motor Testing247
Motor Removal248
Motor Disassembly250
Motor Component Testing and Inspection253
Armature Inspection and Testing253
Motor Frame and Field Windings Inspection254
Motor Brush, Spring, and Terminal Insulator Inspection254
Reconditioning the Motor257
Motor Specifications257
Motor Assembly257
Motor Installation259
SECTION 17 - Transaxle: Electric Vehicles263
Lubrication263
Axle Bearing and Shaft263
Axle Shaft263
Axle Bearing266
Transaxle267
Transaxle Removal267
Transaxle Disassembly, Inspection, and Assembly270
Transaxle Disassembly and Inspection270
Transaxle Assembly272
Transaxle Installation274
SECTION 18 - Troubleshooting and Electrical System: Pedal-Start Gas Vehicle275
General Information275
Accessories275
Low Oil Warning Light275
Ground Locations275
Features of the Electronic Fuel Injection (EFI) System276
Troubleshooting Guide276
ECU Error Codes (Displayed by the Low Oil Warning Light)276
Gasoline Powertrain278

Club Car Carryall 500 2015 User Manual

Table of Contents

Questions and Answers:

Club Car Carryall 500 2015 Specifications

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Brand	Club Car
Model	Carryall 500 2015
Category	Golf Cars
Language	English