102190013, M&S, 2001-2002, Carryall Service Manual

102190013, M&S, 2001-2002, Carryall Service Manual Electric Vehicles, 284 Pages, $55.95

 

 

102190013, M&S, 2001-2002, Carryall Service Manual Electric Vehicles, 284 Pages, $55.95

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CONTENTS
SECTION 1 – SAFETY
General Warning
SECTION 2 – VEHICLE SPECIFICATIONS
SECTION 3 – GENERAL INFORMATION
Serial Number Identification
Storage
Preparing the Vehicle for Extended Storage
Returning the Stored Vehicle to Service
SECTION 4 – BODY AND TRIM
Cleaning the Vehicle
Seat
Seat Removal
Seat Installation
Seat Support
Seat Support Removal
Seat Support Installation
Armrest Removal
Armrest Installation
Front Body Repair
Stress Lines or Streaks
Minor Impact Damage/Deformations
Minor Scratches and Surface Blemishes
Small Scratches that Cannot be Buffed out
Touch-up Paint Color Chart
Gouges, Punctures, Tears, Large Scratches, and Abrasions
Front Body
Front Body Removal
Front Body Installation
Tilt Bed – Carryall 1 and Carryall 2
Tilt Bed Removal
Tilt Bed Installation
Flat Bed – Carryall 6
Flat Bed Removal
Flat Bed Installation
Flat Bed Trim – Carryall 6
Flat Bed Trim Removal
Flat Bed Trim Installation
Access Door – Carryall 6
Access Door Removal
Access Door Installation
Side Door – Carryall 6
Side Door Removal
Side Door Installation
Rear Fender
Rear Fender Removal
Rear Fender Installation
Trailer Hitch – Optional on Some Models
Trailer Hitch Removal
Trailer Hitch Installation
Tailskirt
Tailskirt Removal
Tailskirt Installation
Bumper
Bumper Removal
Bumper Installation
Floor Mat
Front Floor Mat Removal
Front Floor Mat Installation
Rear Floor Mat Removal – Carryall 6 Only
Rear Floor Mat Installation – Carryall 6 Only
SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP
General Information
Accelerator Pedal
Accelerator Pedal Removal
Accelerator Pedal Installation
Brake Pedal – Carryall 1
Brake Pedal Removal – Carryall 1
Brake Pedal Installation – Carryall 1
Brake Pedal – Carryall 2 and Carryall 6
Brake Pedal Removal – Carryall 2 and Carryall 6
Brake Pedal Installation – Carryall 2 and Carryall 6
Brake Pedal Height Adjustment
Brake Pedal Free Play Adjustment – Carryall 1 Only
Accelerator Pedal Height Adjustment
SECTION 6 – PARK BRAKE SYSTEM AND WHEEL BRAKE ASSEMBLIES
General Information
Park Brake System Inspection
Park Brake System
Park Brake Cable Removal
Park Brake Cable Installation
Park Brake Handle Removal
Park Brake Handle Installation
Park Brake Adjustment
Wheel Brake Assemblies – Carryall 1
Brake Shoe Removal – Carryall 1
Brake Assembly Cleaning – Carryall 1
Brake Shoe Installation – Carryall 1
Brake Adjustment – Carryall 1
Brake Cluster – Carryall 1
Brake Cluster Removal
Brake Cluster Installation
Brake Cables – Carryall 1
Brake Cable Removal
Brake Cable Installation
Wheel Brake Assemblies – Carryall 2 and Carryall 6
Brake Shoe Removal – Carryall 2 and Carryall 6
Brake Assembly Cleaning – Carryall 2 and Carryall 6
Brake Shoe Installation – Carryall 2 and Carryall 6
Rear Brake Cluster – Carryall 2 and Carryall 6
Rear Brake Cluster Removal
Rear Brake Cluster Installation
Front Brake Cluster – Carryall 2 and Carryall 6
Front Brake Cluster Removal
Front Brake Cluster Installation
Front Brake Cables – Carryall 2 and Carryall 6
Front Brake Cable Removal
Front Brake Cable Installation
Rear Brake Cables – Carryall 2 and Carryall 6
Rear Brake Cable Removal
Rear Brake Cable Installation
Brake Adjustment – Carryall 2 and Carryall 6
Brake Cluster Adjustment
Equalizing Brake Cables
Final Brake Cluster Adjustment
Test Drive Vehicle
Tires
Tire Removal
Tire Repair
Tire Installation
SECTION 9 – REAR SUSPENSION
General Information
Shock Absorbers
Shock Absorber Inspection and Removal
Shock Absorber Installation
Multi-Leaf Springs
Multi-Leaf Spring Removal
Multi-Leaf Spring Installation
Jounce Bumpers
Removal
Installation
SECTION 10 – PERIODIC MAINTENANCE
General Information
Pre-Operation and Daily Safety Checklist
Performance Inspection
Periodic Service Schedule
Periodic Lubrication Schedule
SECTION 11 – ELECTRICAL SYSTEM AND TESTING
General Information
Troubleshooting Guide
Wiring Diagrams
Electrical Circuits
Control Circuit
Power Circuit
Speed Control Circuit
Charge Circuit
Battery Warning Light
Test Procedures
Index of Test Procedures
Communication Display Module (CDM)
Using the CDM to Retrieve Data from the Onboard Computer
CDM Troubleshooting Guide
SECTION 12 – ELECTRICAL COMPONENTS
Electrical Component Cover
Main Power Fuse
Control Wiring Fuse
Key Switch
Battery Condition Indicator
Plug Diode
Emergency Stop Switch
Forward/Reverse Switch
Forward/Reverse Limit Switches
Reverse Buzzer
Solenoid
Diode – Solenoid
Resistor – Solenoid
Onboard Computer (OBC)
Solid State Speed Controller
Charger Receptacle
Receptacle Fuse Link
Motor Controller Output Regulator (MCOR)
Headlight Switch
Horn
Horn Switch
Brake Pedal Limit Switch
Battery Warning Light
Seat Switch
DC/DC Converter
SECTION 13 – BATTERIES
General Information
Common Misconceptions About Batteries
Battery Replacement
Battery Care
Preventive Maintenance
Self-Discharge
Electrolyte Level
Mineral Content
Vibration Damage
Battery Charging
Charger Shuts Off After 16 Hours
Deep-Discharge
Early Excessive Discharging
Incoming AC Service
Fleet Rotation
Numbering Vehicles and Chargers
Battery Troubleshooting Chart
Battery Testing
Battery Charger Test
On-Charge Voltage Test
Hydrometer Test
Discharge Test
Battery Troubleshooting Examples
Battery Storage
Battery Tray
Charging a Battery Pack that has Low Voltage
SECTION 14 – EUROPEAN POWERDRIVE BATTERY CHARGER
General Information
PowerDrive Charger Features
Battery Warning Light
The Charge Circuit
Charger Installation and Operation
DC Cord and Plug Inspection
Checking Battery Condition
Troubleshooting
Test Procedures
Index of Test Procedures
Charger Repairs
DC Cord
Heatsink
Transformer
Ammeter
Fuse Link
Voltage Suppressor
Charger Relay
Charger AC Circuit Breakers
AC Charger Receptacle
Charging a Battery Pack that has Low Voltage
Battery Charger Specifications
SECTION 15 – MOTOR
General Information
External Motor Testing
Motor
Motor Component Testing and Inspection
Armature
Field Windings Inspection
Motor Components
Bearing Inspection
Bearing Removal
Bearing Installation
Reconditioning the Motor
Motor Assembly
Motor Installation
SECTION 16 – TRANSAXLE (TYPE G)
Lubrication
Axle Bearing and Shaft
Axle Shaft
Axle Bearing
Transaxle
Transaxle Removal
Transaxle Disassembly, Inspection, and Assembly
Transaxle Disassembly and Inspection
Transaxle Assembly
Transaxle Installation

 

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