Name: Club Car Carryall 700 2016
Brand: Club Car
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2016Carryall500and700

MaintenanceandService

Manual

GasolineVehiclewithSubaruEX40Engine

ElectricVehiclewithQuiQ™ ™

™

Charger

ManualNumber105334704

EditionCode0515F0616E

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
Side-Post Battery: Disconnecting the Battery-Gasoline Vehicles21
Side-Post Battery: Connecting the Battery-Gasoline Vehicles21
Top-Post Battery: Disconnecting the Battery-Gasoline Vehicles21
Top-Post Battery: Connecting the Battery-Gasoline Vehicles21
Recycling Lead-Acid Batteries22
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 Installation41
Front Bumper and Side Fender Removal43
Front Bumper and Side Fender Installation43
Instrument Panel Removal44
Instrument Panel Installation44
Dash Removal45
Dash Installation45
Tilt Bed47
Tilt Bed Removal47
Tilt Bed Installation47
Bed Latch Assembly Removal49
Bed Latch Assembly Installation49
Rear Fenders and Tailskirt51
Rear Fender and Tailskirt Removal51
Rear Fender and Tailskirt Installation52
Electric Bed Lift53
Electric Bed Lift Removal53
Electric Bed Lift Installation53
Floor Mat56
Floor Mat Removal56
Floor Mat Installation56
Trailer Hitch56
Trailer Hitch Removal56
Trailer Hitch Installation56
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 Removal91
Front Brake Cable Installation91
Rear Brake Cables92
Rear Brake Cable Removal93
Rear Brake Cable Installation93
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 Inspection126
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
Battery Monitor147
Charging Totals147
Amp Hours Display147
Lin147
Diagnostics Menu149
Present Errors Folder149
Fault History Folder149
System Faults149
Fault Recovery151
Fault Descriptions152
02 Low Battery Voltage152
03 Overvoltage152
04 Thermal Cutback152
06 Hpd152
07 Main Welded152
08 Relay Welded152
09 Speed Sensor152
10 Main Driver on152
11 Main Coil Open152
12 Main Dropout153
13 Motor Stall153
14 Main Driver off153
15 Relay Dnc153
16 Keyswitch Sro153
17 Current Sense153
18 M- Shorted153
20 Driver Overcurrent153
21 Precharge Fault153
22 Field Missing153
25 Incorrect Password154
26 Circuit Brkr Open154
27 Max Password Tries154
29 Relay Drvr off154
30 Relay Coil Fault154
Anti-Tamper Fault154
Lockout Fault154
Low SOC154
Main CONT DNC155
Main Coil Fault155
Proc/Wiring155
Open Armature155
Incorrect Password (OEM Access Level Only)155
Fault History155
Clearing Fault History155
Programming156
Cloning156
Favorites156
HHP Settings157
Plot & Log158
Plot158
Log158
CDT Troubleshooting159
Connection Tests160
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 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
Tow/Run Switch209
Tow/Run Switch Removal210
Tow/Run 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
The Charge Circuit235
Onboard Charger Operation235
Charger Displays237
AC Power Connection239
Charging Batteries239
Maintenance240
Troubleshooting241
Test Procedures242
Charger Repairs243
Onboard Charger Removal and Installation243
Onboard Charger Removal243
Onboard Charger Installation244
SECTION 16 - Motor (Model DA5-4006): Electric Vehicles245
General Information245
External Motor Testing245
Motor Removal246
Motor Disassembly248
Motor Component Testing and Inspection251
Armature Inspection and Testing251
Motor Frame and Field Windings Inspection252
Motor Brush, Spring, and Terminal Insulator Inspection252
Reconditioning the Motor255
Motor Specifications255
Motor Assembly255
Motor Installation257
SECTION 17 - Transaxle: Electric Vehicles261
Lubrication261
Axle Bearing and Shaft261
Axle Shaft261
Axle Bearing264
Transaxle265
Transaxle Removal265
Transaxle Disassembly, Inspection, and Assembly268
Transaxle Disassembly and Inspection268
Transaxle Assembly270
Transaxle Installation272
SECTION 18 - Troubleshooting and Electrical System: Pedal-Start Gas Vehicle273
General Information273
Accessories273
Low Oil Warning Light273
Ground Locations273
Features of the Electronic Fuel Injection (EFI) System274
Troubleshooting Guide274
ECU Error Codes (Displayed by the Low Oil Warning Light)274

Club Car Carryall 700 2016 User Manual

Table of Contents

Questions and Answers:

Club Car Carryall 700 2016 Specifications

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Brand	Club Car
Model	Carryall 700 2016
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Language	English