102907721, M&S, 2006-2008, Carryall 232 Service Manual

102907721, M&S, 2006-2008, Carryall 232 Service Manual

 

102907721, M&S, 2006-2008, Carryall 232 Service Manual Gasoline and Electric Vehicles, 412 Pages, $69.95

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SECTION 1 – SAFETY
General Warning
SECTION 2 – VEHICLE SPECIFICATIONS
SECTION 3 – GENERAL INFORMATION
Serial Number Identification
Storage – Gasoline Vehicle
Preparing the Gasoline Vehicle for Extended Storage
Returning the Stored Gasoline Vehicle to Service
Storage – Electric Vehicle
Preparing the Electric Vehicle for Extended Storage
Returning the Stored Electric Vehicle to Service
SECTION 4 – BODY AND TRIM
Cleaning the Vehicle
Seat Cleaning
Front and Rear Body Repair
Minor Scratches and Surface Blemishes
Small Scratches That Cannot Be Buffed Out
Gouges, Punctures, Tears, Large Scratches, and Abrasions
Front Body
Bumper Removal
Bumper Installation
Brush Guard Removal
Brush Guard Installation
Front Body Removal
Dash Removal
Dash Installation
Front Body Installation
Cargo Bed
Cargo Bed Removal
Cargo Bed Installation
Bed Latch Assembly
Bed Latch Assembly Installation
Page iv 2006-2008 Carryall 232 Maintenance and Service Manual
Seat Back Support Brackets
Seat Back Support Bracket Removal
Seat Back Support Bracket Installation
Rear Body and Fenders
Rear Body Removal
Rear Fender Removal
Rear Fender Installation
Rear Body Installation
Floor Mat
Floor Mat Removal
Floor Mat Installation
SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP
Brake Pedal and Park Brake
Brake Pedal Removal
Brake Pedal Installation
Park Brake Removal
Park Brake Installation
Accelerator Pedal – Gasoline Vehicles
Accelerator Pedal Removal
Accelerator Pedal Installation
Accelerator Pedal – Electric Vehicles
Accelerator Pedal Removal
Accelerator Pedal Installation
Pedal Group Adjustment – Gasoline Vehicle
Pedal Group Adjustment – Electric Vehicles
SECTION 6 – WHEEL BRAKE ASSEMBLIES
Brake Shoe Removal
Brake Assembly Cleaning
Brake Shoe Installation
Brake Adjustment
Brake Cluster Removal and Installation
Brake Cluster Installation
Brake Cable Removal and Installation
SECTION 7 – STEERING AND FRONT SUSPENSION
General Information
2006-2008 Carryall 232 Maintenance and Service Manual Page v
Steering Wheel
Steering Wheel Removal
Steering Wheel Installation
Steering Column
Steering Column Removal
Steering Column Disassembly
Steering Column Assembly
Steering Column Installation
Steering Adjustment
Rack and Pinion
Rack and Pinion Removal
Rack and Pinion Disassembly
Rack and Pinion Assembly
Rack and Pinion Installation
Tie Rod and Drag Link
Tie Rod and Drag Link Removal
Tie Rod and Drag Link Installation
Front Suspension
Lubrication
Wheel Alignment
Front Suspension Components
Tapered Leaf Spring Removal
Tapered Leaf Spring Installation
Kingpin and Steering Spindle Removal
Kingpin and Steering Spindle Installation
Delta A-Plate Removal
Delta A-Plate Installation
Shock Absorber Removal
Shock Absorber Installation
Front Wheel Bearings and Hubs
Front Wheel Free Play Inspection
Front Hub Removal
Front Hub Installation
SECTION 8 – WHEELS AND TIRES
General Information
Wheels
Wheel Removal
Wheel Installation
Page vi 2006-2008 Carryall 232 Maintenance and Service Manual
Tires
Tire Removal
Tire Repair
Tire Installation
SECTION 9 – REAR SUSPENSION
General Information
Shock Absorbers
Shock Absorber Removal and Inspection
Shock Absorber Installation
Leaf Springs
Leaf Spring Removal
Leaf Spring Installation
SECTION 10 – PERIODIC MAINTENANCE
General Information
Periodic Service Schedules
Periodic Lubrication Schedules
Batteries – Electric Vehicles
Battery Care
Battery Charger – Electric Vehicles
Charging Batteries
Plug and Receptacle
Receptacle Fuse Link
Battery – Gasoline Vehicles
Engine Oil – Gasoline Vehicles
Engine Oil Level Check
Engine Oil and Filter Change
Oil Viscosity
Fueling Instructions – Gasoline Vehicles
SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLE
General Information
Troubleshooting Guide
Electrical System
Lockout Cam
Wiring Diagrams
Test Procedures
Index of Test Procedures
2006-2008 Carryall 232 Maintenance and Service Manual Page vii
SECTION 12 – ELECTRICAL COMPONENTS: GASOLINE VEHICLES
Starter/Generator
Voltage Regulator
Diode
Key Switch
Forward/Reverse Shifter
Solenoid
Fuse
Lockout Cam Limit Switch
Lockout Cam
Reverse Warning Buzzer
Reverse Buzzer Limit Switch
Oil Warning Light
Fuel Gauge/Hour Meter
Fuel Level Sending Unit
RPM Limiter
Ignition Coil
Oil Level Sensor
Headlights
Headlight Diode
Light Switch
Battery
Ground Cables
SECTION 13 – FE290 ENGINES
General Information
Before Servicing
Engine Rotation
Spark Plug
Cylinder Head
General Information
Breather Valve (Reed Valve)
Crankcase
Engine Removal
Crankcase Cover Removal
Oil Level Sensor
Crankcase Cover Installation
Ignition Coil and Flywheel
Flywheel Installation
Page viii 2006-2008 Carryall 232 Maintenance and Service Manual
Engine Installation
Torque Specifications
Adjustments and Settings
SECTION 14 – FUEL SYSTEM: GASOLINE VEHICLE
General Information
Carburetor
Main Jet Elevation/Size Chart
Changing the Main Jet
Engine Control Linkage
General Information
Accelerator Rod
Governor Cable
Accelerator Cable
Closed Throttle or Idle Adjustment
Engine RPM Adjustment
Choke and Air Intake System
Choke Button Removal
Choke Button Installation
Air Box Removal
Air Box Installation
Intake Duct Removal
Intake Duct Installation
Air Filter
Fuel Filters
Fuel Filter Removal
Fuel Filter Installation
Fuel Pump
General Information
Fuel Pump Removal
Fuel Pump Disassembly
Fuel Pump Cleaning and Inspection
Fuel Pump Assembly
Fuel Pump Installation
Fuel Tank
General Information
Fuel Tank Removal
Fuel Tank Disposal
Fuel Tank Storage
Fuel Tank Installation
Fuel Lines
2006-2008 Carryall 232 Maintenance and Service Manual Page ix
Fuel Shut-Off Valve
SECTION 15 – EXHAUST SYSTEM: GASOLINE VEHICLES
Muffler
Muffler Removal
Muffler Installation
SECTION 16 – UNITIZED TRANSAXLE: GASOLINE VEHICLE
General Information
Lubrication
Axle Shaft
Axle Shaft and Oil Seal Removal
Axle Bearing
Axle Shaft Installation
Unitized Transaxle Removal
Unitized Transaxle Installation
Forward/Reverse Shifter Cable
Forward/Reverse Shifter Cable Removal
Forward/Reverse Shifter Cable Installation
Forward/Reverse Shifter Cable Adjustment
SECTION 17 – TORQUE CONVERTER: GASOLINE VEHICLE
General Information
Troubleshooting
Drive Belt
Drive Belt Removal
Drive Belt Installation
Drive Clutch
Drive Clutch Removal
Drive Clutch Cleaning and Inspection
Drive Clutch Disassembly
Inspection of Drive Clutch Parts
Drive Clutch Assembly
Drive Clutch Installation
Driven Clutch
Driven Clutch Removal
Driven Clutch Disassembly
Driven Clutch Inspection
Driven Clutch Assembly
Driven Clutch Installation
Page x 2006-2008 Carryall 232 Maintenance and Service Manual
SECTION 18 – ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE
General Information
Wiring Diagram
Troubleshooting
Troubleshooting the Vehicle with the Diagnostic Handset
Troubleshooting Guide 1
Troubleshooting Guide 2
Test Procedures
Index of Test Procedures
Communication Display Module (CDM)
Using the CDM to Retrieve Data from the Onboard Computer
CDM Troubleshooting Guide
SECTION 19 – IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS
Plugging the Handset into the Vehicle
Introductory Display
Menu Navigation
Monitor Menu
Faults Menu
Functions Menu
Get Settings from Controller
Write Settings to Controller
Reset All Settings
Information
Programmer Setup
Program
Faults
Information
IQDM and IQDM-P Handset Troubleshooting
Test Procedures
Index of Test Procedures
SECTION 20 – ELECTRICAL COMPONENTS: ELECTRIC VEHICLE
Key Switch
Forward/Reverse Switch
Tow/Run Switch
Motor Controller Output Regulator (MCOR)
Reverse Buzzer
Solenoid
2006-2008 Carryall 232 Maintenance and Service Manual Page xi
Onboard Computer (OBC)
Solid State Speed Controller
Charger Receptacle
Receptacle Fuse Link
Battery Warning Light
Pin 9 Diode
SECTION 21 – BATTERIES: ELECTRIC VEHICLES
General Information
Battery Replacement
Battery Care
Preventive Maintenance
Self-Discharge
Electrolyte Level
Mineral Content
Vibration Damage
Battery Charger
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
Charging a Battery Pack that has Low Voltage
SECTION 22 – BATTERY CHARGER: ELECTRIC VEHICLE
Refer to the appropriate Battery Charger Maintenance and Service Manual.
SECTION 23A – MOTOR (MODEL 5BC59JBS6390)
General Information
Motor Identification
External Motor Testing
Page xii 2006-2008 Carryall 232 Maintenance and Service Manual
Motor
Motor Component Testing and Inspection
Armature
Field Windings Inspection
Motor Components
Bearing Inspection
Bearing Removal
Bearing Installation
Speed Sensor Magnet Inspection
Speed Sensor Magnet Removal
Speed Sensor Magnet Installation
Reconditioning the Motor
Motor Assembly
Motor Installation
Motor Speed Sensor
SECTION 23B – MOTOR (MODEL EJ4-4001)
General Information
Motor Identification
External Motor Testing
Motor
Motor Removal
Motor Disassembly
Motor Component Testing and Inspection
Armature Inspection and Testing
Motor Frame and Field Windings Inspection
Motor Brush, Spring, and Terminal Insulator Inspection
Reconditioning the Motor
Motor Assembly
Motor Installation
SECTION 24 – TRANSAXLE (TYPE G): ELECTRIC VEHICLE
Transaxle Identification
Lubrication
Axle Bearing and Shaft
Axle Shaft
Axle Bearing
Transaxle
Transaxle Removal
2006-2008 Carryall 232 Maintenance and Service Manual Page xiii
Transaxle Disassembly, Inspection, and Assembly
Transaxle Disassembly and Inspection
Transaxle Assembly
Transaxle Installation
SECTION 25 – IQ DISPLAY MODULE (IQDM-P) PROGRAMMING
Plugging the Handset into the Vehicle
Program Menu
Speed Setting
Fast Accel
Pedal Up Mode
Speed Cal
Code A, Code B, and Code C

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