Club Car Carryall 300 2021 User Manual

2021Carryall300
MaintenanceandService
Manual
GasolineVehiclewithKohlerECH440Engine
ElectricVehiclewithERICChargingSystem
ManualNumber86753090054
EditionCodeA

Club Car Carryall 300 2021 Specifications

General

Model Year	2021
Type	Utility Vehicle
Seating Capacity	2
Drive	Rear-Wheel Drive
Overall Height (with Sun Canopy)	70 inches
Batteries	Six 8-Volt (Electric)
Battery Type	Lead-Acid
Battery Voltage	48V
Charger	Onboard
Transaxle	Continuously Variable Transmission
Brakes	Hydraulic Drum
Rear Suspension	Leaf Springs with Hydraulic Shock Absorbers
Frame	Steel
Body	ArmorFlex with automotive paint
Payload Capacity	800 lb (363 kg)
Overall Width	48 inches (122 cm)

Summary

Foreword

Technical Publication Customer Satisfaction Online Survey

Customer satisfaction survey for technical publications to gather feedback for improvement.

SECTION 5 — Accelerator and Brake Pedal Group

Brake Pedal and Park Brake (Gas and Electric Vehicles)

Procedures for brake pedal and park brake removal and installation.

Accelerator Pedal – Gasoline Vehicles

Details on accelerator pedal removal and installation for gasoline models.

Accelerator Pedal – Electric Vehicles

Details on accelerator pedal removal and installation for electric models.

Pedal Group Adjustment – Gasoline Vehicles

Procedure for adjusting accelerator and brake pedal group for gasoline vehicles.

Pedal Group Adjustment – Electric Vehicles

Procedure for adjusting accelerator and brake pedal group for electric vehicles.

SECTION 6 — Wheel Brake Assemblies

GENERAL INFORMATION

Overview of the self-adjusting, mechanically expanding shoe drum brakes.

BRAKE SHOE REMOVAL

Step-by-step instructions for removing brake shoes.

BRAKE ASSEMBLY CLEANING

Procedure for cleaning brake assembly components, including safety precautions.

BRAKE SHOE INSTALLATION

Step-by-step instructions for installing brake shoes.

BRAKE ADJUSTMENT

Procedure for adjusting the brake system for proper operation.

BRAKE ASSEMBLY REMOVAL AND INSTALLATION

Procedure for removing and installing the complete brake assembly.

BRAKE CABLE REMOVAL AND INSTALLATION

Procedure for removing and installing the brake cables.

SECTION 7 — Steering and Front Suspension

STEERING WHEEL

Information and procedures for steering wheel removal and installation.

STEERING COLUMN

Procedures for steering column removal, disassembly, assembly, and installation.

RACK AND PINION

Inspection, removal, and installation procedures for the rack and pinion assembly.

TIE ROD AND DRAG LINK

Procedures for removing and installing tie rod and drag link components.

FRONT SUSPENSION

Information on front suspension components, lubrication, and wheel alignment.

CAMBER ADJUSTMENT

Procedure for adjusting the camber angle of the front wheels.

SECTION 8 — Wheels and Tires

GENERAL INFORMATION

General information regarding wheel and tire care for maximum life and handling.

WHEELS

Procedures for wheel removal and installation.

TIRES

Procedures for tire removal, repair, and installation.

SECTION 9 — Rear Suspension

GENERAL INFORMATION

Overview of the rear suspension system components and operation.

SHOCK ABSORBERS

Procedures for shock absorber inspection, removal, and installation.

MULTI-LEAF SPRINGS

Procedures for multi-leaf spring removal and installation.

JOUNCE BUMPERS

Procedures for jounce bumper removal and installation.

SECTION 10 — Periodic Maintenance

GENERAL INFORMATION

Importance of preventive maintenance for vehicle performance and longevity.

PRE-OPERATION AND DAILY SAFETY CHECKLIST

Daily checklist for ensuring vehicle is in proper working condition.

PERFORMANCE INSPECTION

Procedure for inspecting vehicle performance through a test drive.

MAINTENANCE

General maintenance instructions and safety warnings.

PERIODIC SERVICE SCHEDULES

Schedules for regular maintenance intervals for electric and gasoline vehicles.

PERIODIC LUBRICATION SCHEDULES

Schedules for lubrication points and recommended lubricants for electric vehicles.

AIR FILTER

Procedure for air filter removal and installation.

ENGINE OIL

Information on engine oil viscosity, level inspection, and replacement.

REFUEL

Procedure for safely refueling the vehicle, including danger warnings.

LIFT THE VEHICLE

Procedures for safely lifting the front and rear of the vehicle.

SPARK PLUG

Procedure for spark plug removal, inspection, gap adjustment, and installation.

VALVE CLEARANCE CHECK AND ADJUSTMENT

Procedure for checking and adjusting valve clearance.

SECTION 11 — Controller Diagnostic Tool (CDT)

General Information

Overview of the CDT's purpose and capabilities.

Features

Description of the CDT's key features and functionalities.

Plugging the CDT into the Vehicle

Procedure for connecting the CDT to the vehicle's diagnostic port.

System Info

Information regarding controller model, serial, hardware, protocol, MFG date, OS, and SM versions.

Parameters

Overview of adjustable parameters and how to navigate the menu.

Settings

Details on various settings like Speed Setting, Fast Accel, and Pedal Up Mode.

Diagnostics Menu

Accessing and understanding diagnostic menus, including Present Errors and Fault History folders.

SECTION 12 — Electric Vehicle - Electrical System Troubleshooting

General Information

Overview of the Excel vehicle's electrical system and features.

KEY DIFFERENCES: EXCEL WITH ERIC CHARGING SYSTEM VS. POWERDRIVE CHARGERS

Comparison of key differences between ERIC and PowerDrive charging systems.

Troubleshooting the Vehicle with the CDT

Using the CDT handheld programmer for vehicle troubleshooting.

TROUBLESHOOTING GUIDE 1

Troubleshooting guide for use with CDT, detailing symptoms, causes, and corrective actions.

TEST PROCEDURES

Procedures for testing the electrical system without major disassembly.

SECTION 13 — Electric Vehicle - Electrical Components

KEY SWITCH

Procedures for key switch removal, installation, and testing.

FORWARD/NEUTRAL/REVERSE CONTROL (FNR)

Procedures for FNR control removal, installation, and testing.

RUN/TOW SWITCH

Procedures for run/tow switch removal, installation, and testing.

MOTOR CONTROLLER OUTPUT REGULATOR (MCOR)

Procedures for MCOR removal, installation, and testing.

SOLENOID

Procedures for solenoid removal, installation, and testing.

SPEED CONTROLLER

Procedures for speed controller removal and installation.

HEADLIGHT SWITCH

Procedures for headlight switch removal and installation.

HEADLIGHTS

Procedures for headlight bezel and bulb removal/installation.

USB RECEPTACLE

Procedures for USB receptacle removal and installation.

SECTION 14 — Electric Vehicle - Batteries

BATTERY TESTING BASICS – 8 VOLT

Basics of battery testing, including observation and voltage measurement.

BATTERY REGROUPING

Procedure for regrouping batteries to optimize performance and life.

BATTERY REPLACEMENT

Step-by-step instructions for replacing batteries, including safety warnings.

BATTERY CARE

Maintenance program for keeping batteries in good working condition.

SINGLE POINT WATERING SYSTEM (SPWS)

Maintenance procedures for vehicles equipped with the SPWS.

BATTERY STORAGE

Procedures for storing batteries correctly to maintain their life.

SECTION 15 — Electric Vehicle - Battery Charger

GENERAL INFORMATION

Overview of the high-frequency battery charger, its features, and differences from PowerDrive chargers.

EXTERNAL CHARGER MOUNTING

Guidelines for securely mounting the charger and ensuring adequate ventilation.

AC POWER CONNECTION

Instructions and warnings for connecting the charger to AC power.

BATTERY CHARGING

Procedures and safety warnings for charging batteries with external and onboard chargers.

ALGORITHM

Information on managing charging algorithms for external and onboard chargers.

CHARGER MAINTENANCE

Procedures for maintaining the charger, including cleaning and cord care.

CHARGER TROUBLESHOOTING

Guide for troubleshooting charger issues based on status indicators and fault codes.

TEST PROCEDURES

Various test procedures to diagnose battery charger issues.

SECTION 16 — Electric Vehicle - Motor

GENERAL INFORMATION

Overview of the 48-volt DC shunt-wound traction motor.

EXTERNAL MOTOR TESTING

Tests for motor continuity, internal shorts, and circuit opens using a multimeter.

Motor Removal

Step-by-step procedure for removing the motor from the vehicle.

Motor Disassembly

Procedure for disassembling the motor, including end cap and brush removal.

Motor Component Testing and Inspection

Inspection and testing procedures for motor components like armature, brushes, and bearings.

Armature Inspection and Testing

Visual inspection and testing of the armature for wear or damage.

Armature Ground Test

Procedure to test the armature for ground faults using a multimeter.

Motor Frame and Field Windings Inspection

Inspection of motor frame and field windings for signs of overheating or damage.

Motor Brush, Spring, and Terminal Insulator Inspection

Inspection of brush springs, brushes, and terminal insulators for wear or damage.

Bearing Inspection

Procedure for inspecting bearings for noise, smoothness, and play.

SECTION 17 — Electric Vehicle - Transaxle

General Information

Overview of the transaxle's function and service requirements.

Lubrication

Instructions for checking and maintaining lubricant levels in the transaxle.

Axle Bearing and Shaft

Procedures for axle shaft and oil seal removal and installation.

Transaxle Removal

Step-by-step procedure for removing the transaxle from the vehicle.

Transaxle Disassembly, Inspection, and Assembly

Comprehensive procedures for disassembling, inspecting, and assembling the transaxle.

Transaxle Installation

Step-by-step procedure for installing the transaxle into the vehicle.

Shifter Cable

Procedures for shifter cable removal, installation, and adjustment.

SECTION 18 — Gasoline Vehicle - Troubleshooting and Electrical System

GENERAL INFORMATION

Overview of the gasoline vehicle's electrical system and its circuits.

Troubleshooting Guide

Guides for identifying operating difficulties, including symptoms, causes, and checks.

Gasoline Powertrain

Troubleshooting guide for gasoline powertrain issues.

Electrical System

Information on the 12-volt DC electrical system and its circuits.

Test Procedures

Procedures for testing the entire electrical system without major disassembly.

SECTION 19 — Gasoline Vehicle - Electrical Components

STARTER/GENERATOR

Procedures for starter/generator removal, disassembly, inspection, and installation.

Voltage Regulator

Procedures for voltage regulator removal and installation.

Key Switch

Procedures for key switch removal, installation, and testing.

Maintenance/Operate Switch

Procedures for maintenance/operate switch removal, installation, and testing.

Neutral Lockout Limit Switch

Procedures for neutral lockout limit switch removal, installation, and testing.

Reverse Warning Buzzer

Procedures for reverse warning buzzer removal, installation, and testing.

Malfunction Indicator Light

Procedures for malfunction indicator light removal and installation.

Fuel Gauge/Hour Meter

Procedures for fuel gauge/hour meter removal and installation.

Fuel Level Sending Unit

Information and testing procedures for the fuel level sending unit.

Voltage Limiter

Procedures for voltage limiter removal and installation.

Headlight Switch

Procedures for headlight switch removal and installation.

Headlights

Procedures for headlight bezel and bulb removal/installation.

Battery

Information and procedures related to the vehicle's battery.

SECTION 20 — Gasoline Vehicle - Engine

GENERAL INFORMATION

Overview of the Kohler engine and its specifications.

BEFORE SERVICING

Important safety and procedural information before beginning engine service.

LOUVER ARM

Information on the louver assembly and its function for engine temperature control.

ENGINE REMOVAL

Step-by-step procedure for removing the engine from the chassis.

ENGINE INSTALLATION

Step-by-step procedure for installing the engine into the chassis.

SNUBBER

Procedures for snubber removal and installation.

SECTION 21 — Gasoline Vehicle - Fuel System

GENERAL INFORMATION

Overview of the EFI gasoline engine and its systems.

EFI SYSTEM FEATURES/SPECIFICATIONS

Features and specifications of the Electronic Fuel Injection system.

ENGINE CONTROL LINKAGES

Information on accelerator pedal, governor linkage, and throttle adjustments.

RELIEVING FUEL PRESSURE

Procedures to safely relieve fuel pressure before servicing the EFI fuel system.

FUEL LINE

Information and procedures for fuel line removal and installation.

FUEL PUMP MODULE

Information and procedures for fuel pump module removal and installation.

FUEL TANK

Information and procedures for fuel tank removal, disposal, storage, and installation.

FUEL FILTER

Procedures for fuel filter removal and installation.

SECTION 22 — Gasoline Vehicle - Exhaust System

MUFFLER

Procedures for muffler removal and installation.

SECTION 23 — Gasoline Vehicle - Clutches

GENERAL INFORMATION

Overview of the torque converter system, including drive clutch, driven clutch, and drive belt.

TROUBLESHOOTING

Troubleshooting tips for torque converter issues.

Drive Belt

Procedures for drive belt inspection, removal, and installation.

Drive Clutch

Procedures for drive clutch removal, cleaning, inspection, disassembly, and assembly.

Driven Clutch

Procedures for driven clutch removal, disassembly, inspection, and assembly.

SECTION 24 — Gasoline Vehicle - Transaxle

General Information

Overview of the transaxle, its components, and service requirements.

FORWARD/NEUTRAL/REVERSE CONTROL (FNR)

Information on the FNR shifter and its operation.

MAINTENANCE/OPERATE SWITCH

Information on the Maintenance/Operate switch and its positions.

GOVERNOR SYSTEM

Information on the governor system and linkage adjustment.

TRANSAXLE SERVICE

Information on transaxle durability and lubrication requirements.

Rear Hubs

Procedures for rear hub removal and installation.

Axle Tubes, Axle Shafts, Differential Guard, and Wheel Bearings

Procedures for axle tubes, shafts, differential guard, and wheel bearings.

Transaxle Removal

Step-by-step procedure for removing the transaxle from the vehicle.

Transaxle Installation

Step-by-step procedure for installing the transaxle into the vehicle.

Shifter Cable

Procedures for shifter cable removal, installation, and adjustment.

SECTION 26 — Wiring Diagrams

General Information

Information regarding wire descriptions and colors used in wiring diagrams.

Pedal-Start Connector Pinouts

Pinout details for pedal-start connector and main harness.

Key-Start Connector Pinouts

Pinout details for key-start connector and main harness.