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TURF 252 2007
Club Car TURF 252 2007 Utility Vehicle Manuals
Manuals and User Guides for Club Car TURF 252 2007 Utility Vehicle. We have
2
Club Car TURF 252 2007 Utility Vehicle manuals available for free PDF download: Maintenance And Service Manual, Owner's Manual
Club Car TURF 252 2007 Maintenance And Service Manual (536 pages)
Brand:
Club Car
| Category:
Utility Vehicle
| Size: 79.58 MB
Table of Contents
Table of Contents
5
Section 1 - Safety
17
General Warning
17
Disabling the Vehicle
19
Disconnecting the Battery - Gasoline Vehicles
19
Connecting the Battery - Gasoline Vehicles
19
Disconnecting the Batteries - Electric Vehicles
20
Connecting the Batteries - Electric Vehicles
20
Section 2 - Vehicle Specifications
21
Vehicle Specifications - Gasoline Vehicles
21
Vehicle Specifications - Electric Vehicles
23
Section 3 - General Information
25
Serial Number Identification
25
Storage - Gasoline Vehicle
26
Preparing the Gasoline Vehicle for Extended Storage
27
Returning the Stored Gasoline Vehicle to Service
28
Storage - Electric Vehicle
29
Preparing the Electric Vehicle for Extended Storage
29
Returning the Stored Electric Vehicle to Service
30
Section 4 - Body and Trim
31
Cleaning the Vehicle
31
Front Body Repair
32
Stress Lines or Streaks
32
Minor Impact Damage/Deformations
32
Minor Scratches and Surface Blemishes
32
Small Scratches that Cannot be Buffed out
33
Touch-Up Paint Color Chart
33
Gouges, Punctures, Tears, Large Scratches, and Abrasions
33
Front Body
33
Front Body Removal
33
Front Body Installation
34
Tilt Bed
35
Tilt Bed Removal
35
Tilt Bed Installation
35
Rear Fender
37
Rear Fender Removal
37
Rear Fender Installation
38
Trailer Hitch (Optional on some Models)
38
Trailer Hitch Removal
38
Trailer Hitch Installation
39
Receiver Hitch (Optional on some Models)
39
Receiver Hitch Removal
39
Receiver Hitch Installation
39
Tailskirt
40
Tailskirt Removal
40
Tailskirt Installation
40
Floor Mat
41
Front Floor Mat Removal
41
Front Floor Mat Installation
41
Section 5 - Accelerator and Brake Pedal Group
43
Brake Pedal and Park Brake
43
Brake Pedal Removal
43
Brake Pedal Installation
45
Park Brake Removal
45
Park Brake Installation
46
Accelerator Pedal - Gasoline Vehicles
47
Accelerator Pedal Removal - Gasoline Vehicles
47
Accelerator Pedal Installation - Gasoline Vehicles
48
Accelerator Pedal - Electric Vehicles
49
Accelerator Pedal Removal - Electric Vehicles
49
Accelerator Pedal Installation - Electric Vehicles
52
Pedal Group Adjustment - Gasoline Vehicles
52
Pedal Group Adjustment - Electric Vehicles
57
Section 6 - Wheel Brake Assemblies
61
General Information
61
Brake Shoe Removal
61
Brake Assembly Cleaning (Manually-Adjusted Brakes)
63
Brake Shoe Installation (Manually-Adjusted Brakes)
65
Brake Adjustment (Manually-Adjusted Brakes)
67
Brake Cluster Adjustment
67
Brake Cable Equalization
71
Final Brake Cluster Adjustment
71
Test Drive Vehicle
72
Brake Cluster Removal and Installation
72
Rear Brake Cluster Removal
72
Rear Brake Cluster Installation
72
Front Brake Cluster Removal
73
Front Brake Cluster Installation
74
Front Brake Cables
74
Front Brake Cable Removal
74
Front Brake Cable Installation
75
Rear Brake Cables
77
Rear Brake Cable Removal
77
Rear Brake Cable Installation
78
Section 7 - Steering and Front Suspension
79
General Information
79
Steering Wheel
79
Steering Wheel Removal
79
Steering Wheel Installation
80
Steering Column
80
Steering Column Removal
80
Steering Column Disassembly
82
Steering Column Assembly
82
Steering Column Installation
82
Steering Adjustment
83
Rack and Pinion
84
Rack and Pinion Removal
84
Rack and Pinion Disassembly
85
Rack and Pinion Assembly
87
Rack and Pinion Installation
89
Tie Rod and Drag Link
90
Tie Rod and Drag Link Removal
90
Tie Rod and Drag Link Installation
90
Front Suspension
91
Lubrication
91
Wheel Alignment
91
Front Suspension Components
93
Leaf Spring Removal
93
Leaf Spring Installation
93
Kingpin and Steering Spindle Removal
93
Kingpin and Steering Spindle Installation
97
Delta A-Plate Removal
97
Delta A-Plate Installation
97
Shock Absorber Removal
97
Shock Absorber Installation
97
Front Wheel Bearings and Hubs - 4-Wheel Brake Vehicles
98
Front Wheel Free Play Inspection
98
Front Wheel Bearings and Hub Removal
98
Front Wheel Bearings and Hub Installation
99
Section 8 - Wheels and Tires
101
General Information
101
Wheels
101
Wheel Removal
101
Wheel Installation
101
Tires
102
Tire Removal
102
Tire Repair
102
Tire Installation
103
Section 9 - Rear Suspension
105
General Information
105
Shock Absorbers
105
Shock Absorber Inspection and Removal
105
Shock Absorber Installation
105
Multi-Leaf Springs
106
Multi-Leaf Spring Removal
106
Multi-Leaf Spring Installation
107
Snubber
109
Snubber Removal
109
Snubber Installation
109
Stabilizer Bar
110
Stabilizer Bar Removal
110
Stabilizer Bar Installation
110
Section 10 - Periodic Maintenance
113
General Information
113
Pre-Operation and Daily Safety Checklist
113
Performance Inspection
114
Periodic Service Schedules
115
Periodic Lubrication Schedules
118
Engine Oil - Gasoline Vehicle
119
Engine Oil Level Check
120
Engine Oil and Filter Change
120
Section 11 - Troubleshooting and Electrical System: Key-Start with Neutral Rev Gas Vehicle
123
General Information
123
Troubleshooting Guide
123
Electrical System
128
Wiring Diagrams
129
Test Procedures
131
Section 12 - Troubleshooting and Electrical System: Pedal-Start Gas Vehicle
161
General Information
161
Troubleshooting Guide
161
Wiring Diagram
166
Electrical System
169
Test Procedures
169
Section 13 - Electrical Components: Key-Start with Neutral Rev Gas Vehicle
203
Starter/Generator
203
Testing the Starter/Generator
203
Starter/Generator Removal
203
Disassembly of the Starter/Generator to Service the Brushes
204
Brush Inspection and Replacement
204
Brush Spring Inspection and Replacement
205
Starter/Generator Assembly
205
Disassembly of the Starter/Generator to Service the Armature/Commutator
206
Bearing Cleaning and Inspection
206
Bearing Removal
207
Field Coil Removal
208
Visual Inspection of Armature and Commutator
209
Commutator Cleaning and Inspection
209
Armature Ground Test
210
Visual Inspection of Field Coils
210
Starter/Generator Rework
211
Starter/Generator Assembly
211
Starter/Generator Installation
212
Belt Tension Adjustment
214
Voltage Regulator
215
Voltage Regulator Removal
215
Voltage Regulator Installation
215
Diode
217
Diode Removal
217
Diode Installation
217
Key Switch
219
Key Switch Removal
219
Key Switch Installation
220
Solenoid
221
Solenoid Removal
221
Solenoid Installation
221
Fuse
222
Fuse Removal
222
Fuse Installation
222
Neutral Lockout Limit Switch
223
Neutral Lockout Limit Switch Removal
223
Neutral Lockout Limit Switch Installation
224
Reverse Warning Buzzer
225
Reverse Warning Buzzer Removal
225
Reverse Warning Buzzer Installation
225
Reverse Buzzer Limit Switch
226
Reverse Buzzer Limit Switch Removal
226
Reverse Buzzer Limit Switch Installation
226
Oil Warning Light
227
Oil Warning Light Removal
227
Oil Warning Light Installation
227
Fuel Gauge/Hour Meter
228
Fuel Gauge/Hour Meter Removal
228
Fuel Gauge/Hour Meter Installation
229
Fuel Level Sending Unit
229
RPM Limiter
229
RPM Limiter Removal
229
RPM Limiter Installation
230
Ignition Coil
231
Ignition Coil Removal
231
Ignition Coil Installation
232
Oil Level Sensor
234
Oil Level Sensor Removal
234
Oil Level Sensor Installation
234
Headlights
234
Headlight Bulb Removal
235
Headlight Bulb Installation
235
Voltage Limiter
236
Voltage Limiter Removal
236
Voltage Limiter Installation
236
Light Switch
237
Light Switch Removal
237
Light Switch Installation
237
Battery
237
General Information
238
Testing the Battery
238
Preventive Maintenance
238
Self-Discharge
239
Water Level
239
Vibration Damage
240
Mineral Content
240
Battery Removal
241
Charging the Battery
241
Battery Installation
241
Battery Storage
242
Charging a Dead Battery
242
Ground Cables
242
Section 14 - Electrical Components: Pedal-Start Gas Vehicle
243
Starter/Generator
243
Starter/Generator Removal
243
Disassembly of the Starter/Generator to Service the Brushes
244
Brush Inspection and Replacement
244
Brush Spring Inspection and Replacement
245
Starter/Generator Assembly
245
Disassembly of the Starter/Generator to Service the Armature/Commutator
246
Bearing Cleaning and Inspection
247
Bearing Removal
247
Field Coil Removal
248
Visual Inspection of Armature
248
Commutator Cleaning and Inspection
249
Armature Ground Test
250
Visual Inspection of Field Coils
251
Starter/Generator Rework
251
Starter/Generator Assembly
251
Starter/Generator Installation
252
Belt Tension Adjustment
254
Voltage Regulator
254
Voltage Regulator Removal
254
Voltage Regulator Installation
255
Key Switch
255
Key Switch Removal
255
Key Switch Installation
257
Solenoid
257
Solenoid Removal
257
Solenoid Installation
257
Fuse
258
Fuse Removal
258
Fuse Installation
258
Kill Limit Switch
258
Kill Limit Switch Removal
258
Kill Limit Switch Installation
259
Neutral Lockout Limit Switch
260
Neutral Lockout Limit Switch Removal
260
Neutral Lockout Limit Switch Installation
261
Reverse Warning Buzzer
261
Reverse Warning Buzzer Removal
261
Reverse Warning Buzzer Installation
261
Reverse Buzzer Limit Switch
263
Reverse Buzzer Limit Switch Removal
263
Reverse Buzzer Limit Switch Installation
263
Low Oil Warning Light
264
Low Oil Warning Light Removal
264
Low Oil Warning Light Installation
264
Fuel Gauge/Hour Meter
265
General Information
265
Fuel Gauge/Hour Meter Removal
265
Fuel Gauge/Hour Meter Installation
266
Fuel Level Sending Unit
266
RPM Limiter
266
RPM Limiter Removal
266
RPM Limiter Installation
267
Ignition Coil
268
Ignition Coil Removal
268
Ignition Coil Installation
269
Oil Level Sensor
270
Oil Level Sensor Removal
271
Oil Level Sensor Installation
271
Headlights
271
Headlight Bulb Removal
271
Headlight Bulb Installation
272
Voltage Limiter
272
Voltage Limiter Removal
272
Voltage Limiter Installation
272
Headlight Switch
273
Headlight Switch Removal
273
Headlight Switch Installation
273
Battery
274
General Information
274
Testing the Battery
274
Preventive Maintenance
275
Water Level
275
Self-Discharge
275
Vibration Damage
276
Mineral Content
276
Battery Removal
277
Charging the Battery
277
Battery Installation
277
Battery Storage
278
Charging a Dead Battery
278
Ground Cables
278
Section 15 - S10 Fe 350 Engine
279
General Information
279
Before Servicing
279
Engine Rotation
279
Spark Plug
279
Cylinder Head
281
General Information
281
Breather Valve (Reed Valve)
281
Crankcase
281
Engine Removal
281
Crankcase Cover Removal
282
Oil Level Sensor
283
Crankcase Cover Installation
284
Ignition Coil and Flywheel
285
Ignition Coil and Flywheel Removal
285
Flywheel Installation
286
Ignition Coil Inspection and Repair
287
Ignition Coil Installation
287
Crankcase Cover Installation
287
Engine Installation
287
Torque Specifications
288
Adjustments and Settings
289
Section 16 - S27 Fe 350 Engine
291
General Information
291
Before Servicing
291
Engine Rotation
291
Spark Plug
291
Cylinder Head
293
General Information
293
Breather Valve (Reed Valve)
293
Valve Clearance Check and Adjustment
293
Crankcase
294
Engine Removal
294
Crankcase Cover Removal
294
Oil Level Sensor
296
Crankcase Cover Installation
297
Ignition Coil and Flywheel
298
Ignition Coil and Flywheel Removal
298
Flywheel Installation
299
Ignition Coil Inspection and Repair
300
Ignition Coil Installation
300
Crankcase Cover Installation
300
Engine Installation
300
Torque Specifications
301
Adjustments and Settings
302
Section 17 - S10 Fe 350 Fuel System
303
General Information
303
Carburetor
303
Main Jet Elevation/Size Chart
304
Changing the Main Jet
305
Engine Control Linkage
308
General Information
308
Accelerator Rod
308
Governor Cable
310
Accelerator Cable
312
Closed Throttle or Idle Adjustment
312
Engine RPM Adjustment
313
Choke and Air Intake System
314
General Information
314
Choke Cable Removal
314
Choke Cable Installation
314
Air Box Removal
314
Air Box Installation
315
Intake Duct Removal
315
Intake Duct Installation
316
Intake Duct Repair
318
Air Filter
318
Fuel Filters
318
Fuel Filter Removal
318
Fuel Filter Installation
319
Fuel Pump
321
General Information
321
Fuel Pump Removal
321
Fuel Pump Disassembly
321
Fuel Pump Cleaning and Inspection
322
Fuel Pump Assembly
322
Fuel Pump Installation
323
Fuel Tank
324
General Information
324
Fuel Tank Removal
324
Fuel Tank Disposal
325
Fuel Tank Storage
325
Fuel Tank Installation
326
Fuel Lines
327
Fuel Shut-Off Valve
328
Fueling Instructions
328
Section 18 - S27 Fe 350 Fuel System
331
General Information
331
Carburetor
331
Main Jet Elevation/Size Chart
332
Changing the Main Jet
333
Engine Control Linkage
335
General Information
336
Accelerator Rod
336
Governor Cable
338
Accelerator Cable
339
Closed Throttle or Idle Adjustment
340
Engine RPM Adjustment
341
Choke and Air Intake System
341
General Information
341
Choke Cable Removal
342
Choke Cable Installation
342
Air Box Removal
344
Air Box Installation
344
Intake Duct Removal
344
Intake Duct Installation
345
Intake Duct Repair
345
Air Filter
345
Fuel Filters
347
General Information
347
Fuel Filter Removal
347
Fuel Filter Installation
347
Fuel Pump
349
General Information
349
Fuel Pump Removal
349
Fuel Pump Disassembly
350
Fuel Pump Cleaning and Inspection
350
Fuel Pump Assembly
351
Fuel Pump Installation
351
Fuel Tank
353
General Information
353
Fuel Tank Removal
353
Fuel Tank Disposal
354
Fuel Tank Storage
354
Fuel Tank Installation
354
Fuel Lines
356
Fuel Shut-Off Valve
356
Section 19 - Exhaust System: Gasoline Vehicles
357
Muffler
357
Muffler Removal
357
Muffler Installation
357
Section 20 - Unitized Transaxle: Dash-Mounted Shifter
359
General Information
359
Shifter Lever
359
Neutral Lockout
359
Governor System
360
Unitized Transaxle Service
360
Tools Required for this Section
361
Lubrication
361
Axle Shaft
361
Axle Shaft and Oil Seal Removal
361
Axle Bearing
362
Axle Shaft Installation
364
Unitized Transaxle Removal
365
Unitized Transaxle Installation
372
Forward/Reverse Shifter Cable
378
Forward/Reverse Shifter Cable Removal
378
Forward/Reverse Shifter Cable Installation
378
Forward/Reverse Shifter Cable Adjustment
380
Section 21 - Torque Converter: Gasoline Vehicles
381
General Information
381
Troubleshooting
381
Drive Belt
382
Drive Belt Removal
383
Drive Belt Installation
383
Drive Clutch
384
Drive Clutch Removal
384
Drive Clutch Cleaning and Inspection
385
Drive Clutch Disassembly
387
Inspection of Drive Clutch Parts
389
Drive Clutch Assembly
390
Drive Clutch Installation
391
Driven Clutch
392
Driven Clutch Removal
392
Driven Clutch Disassembly
392
Driven Clutch Inspection
393
Driven Clutch Assembly
393
Driven Clutch Installation
396
Section 22 - Electrical System and Testing: Electric Vehicles
397
General Information
397
Wiring Diagrams
398
Troubleshooting
400
Troubleshooting the Vehicle with the IQDM
400
Troubleshooting Guide 1
401
Troubleshooting Guide 2
404
Test Procedures
406
Communication Display Module (CDM)
432
Using the CDM to Retrieve Data from the Onboard Computer
433
CDM Troubleshooting Guide
434
Section 23 - Iq Display Module (Iqdm) Series 2 and Iqdm-P Diagnostics
435
Plugging the Handset into the Vehicle
435
Introductory Display
436
Menu Navigation
436
Program (IQDM-P Only)
437
Monitor Menu
438
Speed in
438
Throttle
438
Batt Voltage
438
Heatsink Temp
438
Mode
439
Arm Current
439
Field Current
439
Arm PWM
439
Field PWM
439
Foot Input
439
Key Input
439
Forward Input
439
Reverse Input
440
Mode Switch
440
WK Away Relay
440
Main Cont
440
Password Tries (IQDM-P Only)
440
Cir BRKR Open
440
THRTL Fault
440
Undervoltage
440
Overvoltage
441
Temp Cutback
441
Hpd
441
Main Welded
441
Relay Welded
441
SPD Sensor
441
Main DRV on
441
Main Coil OPN
441
Main Dropout
441
Motor Stall
442
Main DRVR off
442
Relay DNC
442
Current Sense
442
M-Shorted
442
Relay Coil
442
Precharge
442
FLD Missing
442
HW Failsafe
442
DRVR Overcur
443
RLY DRVR on
443
RLY DRVR off
443
Miles X 1000
443
Miles X 1
443
Faults Menu
443
System Faults
444
Fault Recovery
445
Fault Descriptions
446
Functions Menu
448
Get Settings from Controller
448
Write Settings to Controller
450
Reset All Settings
451
Information
452
Model Number
452
Serial Number
452
MFG Date
452
Software Version
452
Programmer Setup
452
Program
452
Faults
452
Information
453
IQDM and IQDM-P Handset Troubleshooting
453
Test Procedures
454
Section 24 - Electrical Components: Electric Vehicles
459
Key Switch
459
Key Switch Removal
459
Key Switch Installation
460
Forward/Reverse Rocker Switch
461
Forward/Reverse Rocker Switch Removal
461
Forward/Reverse Rocker Switch Installation
461
Tow/Run Switch
462
Tow/Run Switch Removal
462
Tow/Run Switch Installation
462
Circuit Breaker
463
Circuit Breaker Removal
463
Circuit Breaker Installation
463
Motor Controller Output Regulator (MCOR)
464
MCOR Removal
464
MCOR Installation
464
Reverse Buzzer
465
Reverse Buzzer Removal
465
Reverse Buzzer Installation
466
Speed Controller Cover
466
Removing the Speed Controller Cover
466
Installing the Speed Controller Cover
466
Solenoid
467
Solenoid Removal
467
Solenoid Installation
468
Onboard Computer (OBC)
468
Onboard Computer Removal
468
Onboard Computer Installation
469
Solid State Speed Controller
470
Speed Controller Removal
470
Speed Controller Installation
470
Charger Receptacle
471
Charger Receptacle Inspection
471
Charger Receptacle Removal
472
Charger Receptacle Installation
472
Receptacle Fuse Link
473
Receptacle Fuse Link Removal
473
Receptacle Fuse Link Installation
474
Battery Warning Light
474
Battery Warning Light Removal
474
Battery Warning Light Installation
474
Section 25 - Batteries: Electric Vehicles
477
General Information
477
Battery Replacement
478
Battery Care
479
Preventive Maintenance
479
Self-Discharge
479
Electrolyte Level
479
Mineral Content
480
Vibration Damage
481
Battery Charging
481
Charger Shuts off after 16 Hours
481
Deep-Discharge
482
Early Excessive Discharging
482
Incoming AC Service
482
Fleet Rotation
482
Numbering Vehicles and Chargers
482
Battery Troubleshooting Chart
483
Battery Testing
484
Battery Charger Test
484
On-Charge Voltage Test
484
Hydrometer Test
484
Discharge Test
486
Battery Troubleshooting Examples
487
Battery Storage
488
Charging a Battery Pack that Has Low Voltage
488
Section 26 - Battery Charger
489
Section 27 - Motor (Model Da5-4006): Electric Vehicles
491
General Information
491
External Motor Testing
491
Motor
492
Motor Removal
492
Motor Disassembly
494
Motor Component Testing and Inspection
497
Armature Inspection and Testing
497
Motor Frame and Field Windings Inspection
498
Motor Brush, Spring, and Terminal Insulator Inspection
498
Reconditioning the Motor
501
Motor Specifications
501
Motor Assembly
501
Motor Installation
503
Section 28 - Transaxle (Type G): Electric Vehicles
507
Lubrication
507
Axle Bearing and Shaft
507
Axle Shaft
507
Axle Bearing
510
Transaxle
511
Transaxle Removal
511
Transaxle Disassembly, Inspection, and Assembly
513
Transaxle Disassembly and Inspection
513
Transaxle Assembly
515
Transaxle Installation
517
Section 29 - Iq Display Module (Iqdm-P) Series 2 Programming
519
Plugging the Handset into the Vehicle
519
Program Menu
520
M1/M2 Speed
520
M1/M2 Fast Accel
520
M1/M2 Pedal up
520
M1/M2 Speed Cal
521
Code A, Code B, and Code C
522
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Club Car TURF 252 2007 Owner's Manual (52 pages)
Gasoline
Brand:
Club Car
| Category:
Utility Vehicle
| Size: 2.51 MB
Table of Contents
Table of Contents
5
Vehicle Feature Identification
6
Practice Safety
10
Safety Details
11
General Warnings
12
General Information
13
Model Identification
13
Controls and Indicators
14
Accelerator Pedal
16
Brake Pedal
17
Pre-Operation and Daily Safety Checklist
18
Performance Inspection
19
Driving Instructions
20
Starting the Vehicle
21
Bed Latch
22
Prop Rod
22
Loading and Unloading
23
Towing with the Vehicle
24
Transporting on a Trailer
25
Storage
25
Preparing the Vehicle for Extended Storage
26
Returning the Stored Vehicle to Service
27
Maintenance
28
Periodic Service Schedule
28
Periodic Lubrication Schedule
30
Engine Oil
31
Fueling Instructions
33
Battery
34
Cleaning the Vehicle
36
Accessories
36
Subsequent Owner Registration
37
Vehicle Specifications
38
Rear Fender Installation
40
Wheel and Tire Installation
42
California Emission Control Warranty Statement
45
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