Club Car Turf 252 2007 Maintenance And Service Manual
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Club Car Turf 252 2007 Maintenance And Service Manual

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Table of Contents

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2007-2009 Turf 252, Carryall 252
and XRT 900 Maintenance and
Service Manual
Gasoline and Electric Vehicles
Manual Number 103209112
Edition Code 1008C0312B

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Summary of Contents for Club Car Turf 252 2007

  • Page 1 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual Gasoline and Electric Vehicles Manual Number 103209112 Edition Code 1008C0312B...
  • Page 3 If it appears that a service question is not answered in this manual, please contact your nearest authorized Club Car dealer or distributor for assistance. You may also write to us at: Club Car, Inc., P.O. Box 204658; Augusta, GA 30917–4658 USA, Attention: Technical Services.

  • Page 5: Table Of Contents

    CONTENTS SECTION 1 – SAFETY ............................1-1 General Warning ............................1-1 Disabling the Vehicle..........................1-3 Disconnecting the Battery – Gasoline Vehicles .................... 1-3 Connecting the Battery – Gasoline Vehicles ....................1-3 Disconnecting the Batteries – Electric Vehicles .................... 1-4 Connecting the Batteries – Electric Vehicles ....................1-4 SECTION 2 –...
  • Page 6 Brake Pedal Installation ..........................5-3 Park Brake Removal ..........................5-3 Park Brake Installation ..........................5-4 Accelerator Pedal – Gasoline Vehicles ......................5-5 Accelerator Pedal Removal – Gasoline Vehicles ..................5-5 Accelerator Pedal Installation – Gasoline Vehicles ..................5-6 Accelerator Pedal – Electric Vehicles ......................5-7 Accelerator Pedal Removal –...
  • Page 7 Delta A-Plate Installation .......................... 7-19 Shock Absorber Removal......................... 7-19 Shock Absorber Installation ........................7-19 Front Wheel Bearings and Hubs – 4-Wheel Brake Vehicles ................7-20 Front Wheel Free Play Inspection ......................7-20 Front Wheel Bearings and Hub Removal....................7-20 Front Wheel Bearings and Hub Installation ....................7-21 SECTION 8 –...
  • Page 8 SECTION 13 – ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE ....13-1 Starter/Generator............................13-1 Testing the Starter/Generator........................13-1 Starter/Generator Removal ........................13-1 Disassembly of the Starter/Generator to Service the Brushes ..............13-2 Brush Inspection and Replacement......................13-2 Brush Spring Inspection and Replacement ....................13-3 Starter/Generator Assembly ........................
  • Page 9 Voltage Limiter ............................13-34 Voltage Limiter Removal .........................13-34 Voltage Limiter Installation........................13-34 Light Switch..............................13-35 Light Switch Removal ..........................13-35 Light Switch installation ...........................13-35 Battery ...............................13-35 General Information ..........................13-36 Testing the Battery ..........................13-36 Preventive Maintenance..........................13-36 Self-Discharge............................13-37 Water Level ............................13-37 Vibration Damage ...........................13-38 Mineral Content ............................13-38 Battery Removal .............................13-39 Charging the Battery ..........................13-39 Battery Installation ..........................13-39...
  • Page 10 Reverse Buzzer Limit Switch Installation ....................14-21 Low Oil Warning Light ..........................14-22 Low Oil Warning Light Removal .......................14-22 Low Oil Warning Light Installation ......................14-22 Fuel Gauge/Hour Meter ..........................14-23 General Information ..........................14-23 Fuel Gauge/Hour Meter Removal ......................14-23 Fuel Gauge/Hour Meter Installation......................14-24 Fuel Level Sending Unit ..........................14-24 RPM Limiter ...............................14-24 RPM Limiter Removal ..........................14-24 RPM Limiter Installation ..........................14-25...
  • Page 11 Adjustments and Settings........................15-11 SECTION 16 – S27 FE 350 ENGINE ........................ 16-1 General Information ............................. 16-1 Before Servicing ............................16-1 Engine Rotation............................16-1 Spark Plug .............................. 16-1 Cylinder Head ............................. 16-3 General Information ..........................16-3 Breather Valve (Reed Valve)........................16-3 Valve Clearance Check and Adjustment....................
  • Page 12 Fuel Tank Storage ..........................17-23 Fuel Tank Installation ..........................17-24 Fuel Lines ..............................17-25 Fuel Shut-Off Valve.............................17-26 Fueling Instructions.............................17-26 SECTION 18 – S27 FE 350 FUEL SYSTEM...................... 18-1 General Information ............................. 18-1 Carburetor..............................18-1 Main Jet Elevation/Size Chart........................18-2 Changing the Main Jet ..........................18-3 Engine Control Linkage ..........................
  • Page 13 Axle Shaft ..............................20-3 Axle Shaft and Oil Seal Removal ......................20-3 Axle Bearing............................20-4 Axle Shaft Installation ..........................20-6 Unitized Transaxle Removal ......................... 20-7 Unitized Transaxle Installation ........................20-14 Forward/Reverse Shifter Cable........................20-20 Forward/Reverse Shifter Cable Removal....................20-20 Forward/Reverse Shifter Cable Installation ....................20-20 Forward/Reverse Shifter Cable Adjustment ....................20-22 SECTION 21 –...
  • Page 14 Reverse Input............................23-6 Mode Switch ............................23-6 WK Away Relay............................23-6 Main Cont ............................... 23-6 Password Tries (IQDM-P only) ......................... 23-6 Cir BRKR Open # ............................ 23-6 THRTL Fault #............................23-6 Undervoltage # ............................23-6 Overvoltage #............................23-7 Temp Cutback # ............................23-7 HPD #..............................
  • Page 15 Tow/Run Switch Installation ........................24-4 Circuit Breaker ............................24-5 Circuit Breaker Removal .......................... 24-5 Circuit Breaker Installation........................24-5 Motor Controller Output Regulator (MCOR) ....................24-6 MCOR Removal ............................24-6 MCOR Installation ........................... 24-6 Reverse Buzzer............................24-7 Reverse Buzzer Removal......................... 24-7 Reverse Buzzer Installation ........................
  • Page 16 SECTION 26 – BATTERY CHARGER ......................26-1 SECTION 27 – MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES ............... 27-1 General Information ............................. 27-1 External Motor Testing ..........................27-1 Motor ................................27-2 Motor Removal ............................27-2 Motor Disassembly ..........................27-4 Motor Component Testing and Inspection...................... 27-7 Armature Inspection and Testing.......................

  • Page 17: Section 1 - Safety

    SECTION 1 – SAFETY To ensure the safety of those servicing Club Car vehicles, and to protect the vehicles from possible damage resulting from improper service or maintenance, the procedures in this manual must be followed. It is important to note that throughout this manual there are statements labeled DANGER, WARNING, or CAUTION.
  • Page 18 General Warning SAFETY DANGER • Gasoline – Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. Service only in a well-ventilated area. • Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison.

  • Page 19: Disabling The Vehicle

    SAFETY General Warning WARNING • Any modification or change to the vehicle that affects the stability or handling of the vehicle, or increases maximum vehicle speed beyond factory specifications, could result in severe personal injury or death. • Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic floor jack) with 1000 lb.

  • Page 20: Disconnecting The Batteries - Electric Vehicles

    General Warning SAFETY (–) (Viewed from passenger side of vehicle) (Viewed from driver side of vehicle) 1. Remove negative battery cable. 1. Place TOW/RUN Switch in TOW before disconnecting or connecting 2. Remove positive battery cable. battery cables. Connect battery cables in reverse order. 2.

  • Page 21: Section 2 - Vehicle Specifications

    SECTION 2 – VEHICLE SPECIFICATIONS VEHICLE SPECIFICATIONS – GASOLINE VEHICLES TURF 252 XRT 900 SPECIFICATIONS CARRYALL 252 GASOLINE GASOLINE POWER SOURCE Engine: 4 cycle, OHV, 351 cc, 11.5 maximum hp @ 3600 RPM (per SAE J 1940/1349), • • single cylinder, air cooled, with pressure lubrication system Fuel system: Side-draft carburetor with float bowl, fixed jets, fuel filters, and impulse •...
  • Page 22 Vehicle Specifications – Gasoline Vehicles VEHICLE SPECIFICATIONS TURF 252 XRT 900 SPECIFICATIONS CARRYALL 252 GASOLINE GASOLINE Ground clearance (under foot platform) 11.0 in. (27.9 cm) Front wheel tread 36.5 in. (92 cm) Rear wheel tread 41.3 in. (104 cm) Weight (standard vehicle with off-road tires (dry)) 937 lb.

  • Page 23: Vehicle Specifications - Electric Vehicles

    VEHICLE SPECIFICATIONS Vehicle Specifications – Electric Vehicles VEHICLE SPECIFICATIONS – ELECTRIC VEHICLES TURF 252 XRT 900 SPECIFICATIONS CARRYALL 252 ELECTRIC ELECTRIC POWER SOURCE Drive motor: Direct drive, 48 volts DC, shunt wound, 3.7 hp • • Transaxle: Double reduction helical gear with 12.3:1 direct drive axle •...
  • Page 24 Vehicle Specifications – Electric Vehicles VEHICLE SPECIFICATIONS TURF 252 XRT 900 SPECIFICATIONS CARRYALL 252 ELECTRIC ELECTRIC 17-19 mph 15-17 mph Forward speed (27-31 km/h) (24-27 km/h) 21 ft.-8 in. Curb clearance circle (diameter) (660 cm) 130 in. Turning radius per SAE J 695 (330 cm) 31.5 in.

  • Page 25: Section 3 - General Information

    • See General Warning on page 1-1. Important features unique to the different models covered in this manual are highlighted. Club Car, Inc. recommends the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s).

  • Page 26: Storage - Gasoline Vehicle

    Storage – Gasoline Vehicle GENERAL INFORMATION SERIAL NUMBER Club Car AQ0601-123456 P O BOX 204658 AUGUST A GA 30917 Rear of center dash viewed from the front of the vehicle (front body removed). Figure 3-1 Serial Number Decal Figure 3-2 Serial Number Decal Behind Dash STORAGE –...

  • Page 27: Preparing The Gasoline Vehicle For Extended Storage

    GENERAL INFORMATION Storage – Gasoline Vehicle PREPARING THE GASOLINE VEHICLE FOR EXTENDED STORAGE Unload the vehicle so that tires are supporting only the weight of the vehicle. Store vehicle in a cool, dry place. This will minimize battery self-discharge. If the battery appears to be weak, have it charged by a trained technician.

  • Page 28: Returning The Stored Gasoline Vehicle To Service

    Storage – Gasoline Vehicle GENERAL INFORMATION 1. Vent 2. Fuel Shut-off Valve 3. Fuel Vent Line 4. Fuel Tank Figure 3-5 Fuel Tank, Vent, and Lines Disconnect battery. See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3. Batteries should be clean and free of corrosion. Wash tops and terminals of batteries with a solution of baking soda and water (1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water).

  • Page 29: Storage - Electric Vehicle

    GENERAL INFORMATION Storage – Electric Vehicle Adjust tires to recommended tire pressure. See Vehicle Specifications – Gasoline Vehicles on page 2-1. Perform the Pre-Operation and Daily Safety Checklist and the Performance Inspection. See Pre-Operation and Daily Safety Checklist, Section 10, Page 10-1. STORAGE –...

  • Page 30: Returning The Stored Electric Vehicle To Service

    Storage – Electric Vehicle GENERAL INFORMATION NOTE: The OBC keeps track of the time spent in storage mode. When the OBC detects that the storage charge cycles may have depleted the available electrolyte, it will stop the charger from further operation. Disconnecting then reconnecting the DC cord (stationary charger) or AC cord (onboard charger) indicates the electrolyte levels have been maintained and allows the OBC to resume operation.

  • Page 31: Section 4 - Body And Trim

    (no. 00) steel wool. Club Car does not recommend any type of pressure washing or steam cleaning. Such a process will expose electrical components to moisture. Moisture entering electrical components can result in water damage and subsequent component failure.

  • Page 32: Front Body Repair

    Front Body Repair BODY AND TRIM CAUTION • To prevent damage to the vehicle when removing difficult stains or heavy soiling, remove the seat bottom from the vehicle first. FRONT BODY REPAIR See General Warning on page 1-1. STRESS LINES OR STREAKS Repeatedly flexing the front body may cause white stress lines or streaks in the finish.

  • Page 33: Small Scratches That Cannot Be Buffed Out

    Tears, Large Scratches, and Abrasions on page 4-3. Using the brush provided with the touch-up paint (available from Club Car Service Parts, see following color chart), apply paint to the scratch. Multiple layers of paint may be required to fill the scratch.

  • Page 34: Front Body Installation

    Front Body BODY AND TRIM 1.1. Vehicles without heavy-duty bumper: Remove blind rivets (10). Vehicles equipped with a heavy-duty front bumper (1): 2.1. Remove the two carriage bolts (5), lock nuts (3), and spacers (4) from the heavy-duty bumper mounting positions located on both sides of the front body.

  • Page 35: Tilt Bed

    BODY AND TRIM Tilt Bed NOTE: If installing a new front body, two 5/16-inch holes must be drilled after the body has been placed on the vehicle. Use the body trim (13) as a guide for drilling the holes. Tighten screws (18) holding front body trim against front body to 17 in-lb (1.9 N·m). Vehicles equipped with headlights: Reconnect the light wiring harness to the headlight assemblies.
  • Page 36 Tilt Bed BODY AND TRIM TYPICAL 2 PLACES Figure 4-2 Tilt Bed – Turf, Carryall, and XRT Page 4-6 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual...

  • Page 37: Rear Fender

    BODY AND TRIM Rear Fender REAR FENDER See General Warning on page 1-1. REAR FENDER REMOVAL Vehicles with taillights: Remove taillight assembly. 1.1. Remove the two screws that secure taillight to the rear fender. 1.2. Disconnect the three taillight wires. All vehicles: Remove two nylon lock nuts (3), flat washers (1), and 1/4 x 1 bolts (2) from front of fender (6) (Figure 4-3, Page 4-8).

  • Page 38: Rear Fender Installation

    Trailer Hitch (Optional on Some Models) BODY AND TRIM TYPICAL 2 PLACES Figure 4-3 Rear Fender, Trailer Hitch, and Tailskirt – Turf, Carryall, and XRT REAR FENDER INSTALLATION Install rear fender in the reverse order of removal. Tighten lock nuts (3) to 35 in-lb (4.0 N·m). TRAILER HITCH (OPTIONAL ON SOME MODELS) See General Warning on page 1-1.

  • Page 39: Trailer Hitch Installation

    BODY AND TRIM Receiver Hitch (Optional On Some Models) Where the hitch (7) is mounted to frame, remove two nuts (12), lock washers (11), flat washers (10), and bolts (9) (Figure 4-3, Page 4-8). Where the hitch (7) is mounted to hitch brace (8), remove the nut (12), lock washer (11), flat washer (10), and bolt (9).

  • Page 40: Tailskirt

    Tailskirt BODY AND TRIM Figure 4-4 Receiver Hitch TAILSKIRT See General Warning on page 1-1. TAILSKIRT REMOVAL Remove two thread-forming screws (5) and flat washers (13) from tailskirt (4) and lift tailskirt from vehicle frame (Figure 4-3, Page 4-8). TAILSKIRT INSTALLATION Insert upper edge of tailskirt (4) under, and in front of, back edge of rear body (Figure 4-3, Page 4-8).

  • Page 41: Floor Mat

    BODY AND TRIM Floor Mat Align holes in tailskirt (4) with holes in vehicle frame. Position tailskirt flush against frame. Install two thread-forming screws (5) and flat washers (13) in tailskirt and tighten to 80 in-lb (9.0 N·m). FLOOR MAT See General Warning on page 1-1.

  • Page 43: Section 5 - Accelerator And Brake Pedal Group

    SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP DANGER • See General Warning on page 1-1. WARNING • See General Warning on page 1-1. BRAKE PEDAL AND PARK BRAKE See General Warning on page 1-1. BRAKE PEDAL REMOVAL Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s). See Disconnecting the Batteries –...
  • Page 44 Brake Pedal and Park Brake ACCELERATOR AND BRAKE PEDAL GROUP Figure 5-1 Brake and Park Brake Pedal Assembly and Mounting – Four-Wheel Brake Vehicles Page 5-2 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual...

  • Page 45: Brake Pedal Installation

    ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake BRAKE PEDAL INSTALLATION From the top side of the floorboard, insert the brake pedal assembly (10) (Figure 5-1, Page 5-2) through the opening in the floor as shown (Figure 5-2, Page 5-3) and install the brake pedal stop bumper (24) (Figure 5-1, Page 5-2) on the brake pedal assembly, but do not tighten the jam nut (25) at this time.

  • Page 46: Park Brake Installation

    Brake Pedal and Park Brake ACCELERATOR AND BRAKE PEDAL GROUP 3.1. To remove the park brake rod and pawl assembly (17 through 20), remove the push nut (19) and disconnect the ball joint sleeve (21) from the park brake pedal (35) (Figure 5-1, Page 5-2). See following NOTE. NOTE: New push nuts (19) and (32) must be used when reassembling the park brake (Figure 5-3, Page 5-3).

  • Page 47: Accelerator Pedal - Gasoline Vehicles

    ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles ACCELERATOR PEDAL – GASOLINE VEHICLES See General Warning on page 1-1. ACCELERATOR PEDAL REMOVAL – GASOLINE VEHICLES Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3.

  • Page 48: Accelerator Pedal Installation - Gasoline Vehicles

    Accelerator Pedal – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP Figure 5-5 Accelerator Pedal – Gasoline Vehicles ACCELERATOR PEDAL INSTALLATION – GASOLINE VEHICLES If the accelerator pivot rod supports were replaced, position the supports (21) on the vehicle frame and install the four bolts (22), flat washers (19), and lock nuts (18).

  • Page 49: Accelerator Pedal - Electric Vehicles

    ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles Install the ball stud (8) through the pivot rod. Install the spring retainer (11) onto the ball stud. Secure these parts with the nut (10) (Figure 5-5, Page 5-6). Tighten the nut to 50 in-lb (5.7 N·m). Press the brake pedal slightly, and with the park brake ratchet oriented so that the tip of the ratchet is pointed toward the rear of vehicle, slide the ratchet onto the pivot rod (do not slide the ratchet onto the pivot rod splines).
  • Page 50 Accelerator Pedal – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP Remove the MCOR (2) and drive bar (3) as instructed (Figure 5-7, Page 5-9). See MCOR Removal on page 24-6. Use a 9/16-inch socket and 9/16-inch wrench to remove the nut (7), two washers (5), and bolt (4) securing the accelerator pedal (1) to the pivot rod (6) (Figure 5-7, Page 5-9).
  • Page 51 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles Figure 5-7 Accelerator Pedal – Electric Vehicle 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual Page 5-9...

  • Page 52: Accelerator Pedal Installation - Electric Vehicles

    Pedal Group Adjustment – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP ACCELERATOR PEDAL INSTALLATION – ELECTRIC VEHICLES If the accelerator pivot rod supports were replaced, position the supports (21) on the vehicle frame and install the four bolts (22), flat washers (16), and lock nuts (15) (Figure 5-7, Page 5-9). Finger-tighten nuts at this time. Insert the lower end of the accelerator pedal (1) through the floorboard and install the accelerator pivot rod (6) through the uppermost hole in the pedal.
  • Page 53 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles Figure 5-8 Loosen Rear Brake Equalizer Rod Nuts Figure 5-9 Loosen Front Brake Equalizer Rod Nuts 2.4. Loosen the brake stop jam nut (31), then relieve pedal pressure on the stop by pushing down slightly on the pedal.
  • Page 54 Pedal Group Adjustment – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP becomes larger as the park brake pedal is pressed, move the pivot rod supports slightly forward until gap is consistent. See following NOTE. NOTE: The accelerator rod must also be checked if the ratchet/pawl gap is adjusted. See step 5 of Pedal Group Adjustment –...
  • Page 55 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles 3.8. Check for proper brake operation prior to driving the vehicle. 1. 1/2-Inch Socket 2. 1/2-Inch Wrench Figure 5-15 Brake Rod Adjustment Figure 5-16 Accelerator Pedal Height Adjustment Adjust accelerator pedal height. 4.1.
  • Page 56 Pedal Group Adjustment – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP 5.1. Remove the electrical box screw and cover. See preceding DANGER. 5.2. Loosen the jam nuts (25) and disconnect the accelerator rod (17) at the accelerator pedal (Figure 5-5, Page 5-6).

  • Page 57: Pedal Group Adjustment - Electric Vehicles

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles 5.7. Install the electrical box cover and screw. Adjust the brakes. See Brake Adjustment (Manually-Adjusted Brakes) on page 6-7. PEDAL GROUP ADJUSTMENT – ELECTRIC VEHICLES See General Warning on page 1-1. Disconnect the batteries and discharge the controller.
  • Page 58 Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP Correct pedal position is 6 inches (15.2 cm)from floormat to back of brake pedal. Figure 5-21 Brake Pedal Height Adjustment Figure 5-22 Brake Pedal Height Measurement Adjust park brake ratchet/pawl gap and pawl engagement. 3.1.
  • Page 59 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles 1. Locked Position 2. Ratchet (B) Tooth Length 3. Make sure pawl (A) engages at least 75% of ratchet tooth length (B). Figure 5-24 Accelerator Pedal Height Measurement Figure 5-25 Ratchet/Pawl Tooth Engagement 3.5.
  • Page 60 Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP 1. Accelerator Pedal Adjustment Tool (CCI P/N 101871001) 2. Rubber Strap Figure 5-28 Accelerator Pedal Height Adjustment Adjust the brakes. See Brake Adjustment (Manually-Adjusted Brakes), Section 6, Page 6-7. Page 5-18 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual...

  • Page 61: Section 6 - Wheel Brake Assemblies

    OSHA/29 CFR - 1910.1001. GENERAL INFORMATION The Club Car vehicles covered in this manual are equipped with four-wheel manually-adjusted brakes. See Vehicle Specifications on page 2-1. BRAKE SHOE REMOVAL See General Warning on page 1-1.
  • Page 62 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES Figure 6-1 Loosen Equalizer Nuts Remove the rear wheels and remove the brake drums. See following CAUTION. CAUTION • Worn or damaged brake drums cannot be machined to refinish them. Replace as necessary. Remove the axle shaft. 4.1.

  • Page 63: Brake Assembly Cleaning (Manually-Adjusted Brakes)

    WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning (Manually-Adjusted Brakes) CAUTION • The brake shoes are under spring pressure and can release suddenly when brake shoe retainers are removed. Figure 6-3 Rotate Clip Retainer Figure 6-4 Remove Shoes Grasp both brake shoes and pull them, with the springs, out of brake assembly (Figure 6-4, Page 6-3). BRAKE ASSEMBLY CLEANING (MANUALLY-ADJUSTED BRAKES) See General Warning on page 1-1.
  • Page 64 Brake Assembly Cleaning (Manually-Adjusted Brakes) WHEEL BRAKE ASSEMBLIES Figure 6-5 Lubricate Slide Figure 6-6 Lubricate Raised Bosses Use a small brush to carefully apply a light coat of white lithium NLGI #2 grease (Dow Corning BR2-Plus or equivalent) on each of the six raised bosses on brake backing plate (Figure 6-6, Page 6-4). See preceding WARNING.

  • Page 65: Brake Shoe Installation (Manually-Adjusted Brakes)

    WHEEL BRAKE ASSEMBLIES Brake Shoe Installation (Manually-Adjusted Brakes) BRAKE SHOE INSTALLATION (MANUALLY-ADJUSTED BRAKES) See General Warning on page 1-1. See also WARNING on page 6-1. NOTE: Components of the front wheel brake assembly are identical to the rear wheel manually-adjusted brake assembly.
  • Page 66 Brake Shoe Installation (Manually-Adjusted Brakes) WHEEL BRAKE ASSEMBLIES so the tips (1) of the shoes are positioned flush with the top surface of the shoe mounting blocks as shown (Figure 6-12, Page 6-6). See following CAUTION. Figure 6-11 Attach Springs and Install Other Shoe Figure 6-12 Position Shoes in Mounting Block CAUTION •...

  • Page 67: Brake Adjustment (Manually-Adjusted Brakes)

    WHEEL BRAKE ASSEMBLIES Brake Adjustment (Manually-Adjusted Brakes) BRAKE ADJUSTMENT (MANUALLY-ADJUSTED BRAKES) See General Warning on page 1-1. See also WARNING on page 6-1. CAUTION • Pedal group adjustment must be within specifications prior to beginning brake adjustment. Perform the appropriate pedal group adjustment. –...
  • Page 68 Figure 6-16 Rear Brake Adjustment Bolt Use a torque wrench and a 7-mm 8-point socket or Club Car brake adjustment tool (CCI P/N 1013582) to turn the brake adjustment bolt (5) on each brake clockwise until it is tightened to 15 ft-lb (20.3 N·m) and continue clockwise rotation to the point at which torque is released.
  • Page 69 WHEEL BRAKE ASSEMBLIES Brake Adjustment (Manually-Adjusted Brakes) Figure 6-17 Rear Manually-Adjusted Brake Assembly 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual Page 6-9...
  • Page 70 Brake Adjustment (Manually-Adjusted Brakes) WHEEL BRAKE ASSEMBLIES Figure 6-18 Front Manually-Adjusted Brake Assembly Page 6-10 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual...

  • Page 71: Brake Cable Equalization

    WHEEL BRAKE ASSEMBLIES Brake Adjustment (Manually-Adjusted Brakes) BRAKE CABLE EQUALIZATION Set park brake in the third tooth of the ratchet. Place a wedge between the park brake pedal and brake pedal to prevent the park brake from disengaging while equalizing the brake cables (Figure 6-19, Page 6-11). Figure 6-19 Set Park Brake and Insert Wedge Equalize the brake cables.

  • Page 72: Test Drive Vehicle

    Brake Cluster Removal and Installation WHEEL BRAKE ASSEMBLIES TEST DRIVE VEHICLE With the vehicle on a level surface, release the park brake and push the vehicle by hand. If brake drag exists, readjust cable tension and brakes. See Brake Cable Equalization on page 6-11. See also Final Brake Cluster Adjustment on page 6-11.

  • Page 73: Front Brake Cluster Removal

    WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation CAUTION • Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to installing the axle shaft. Be sure bolts (20) and new cone lock nuts (19) are used to mount the brake assembly (Figure 6-17, Page 6-9 or Figure 6-18, Page 6-10).

  • Page 74: Front Brake Cluster Installation

    Front Brake Cables WHEEL BRAKE ASSEMBLIES Figure 6-20 Front Spindle Assembly (Four-Wheel Brake Vehicles) Remove hub and bearing assembly from spindle shaft. Remove four bolts (22), cone washers (21), lock washers (20) and hex nuts (19) that mount the brake assembly to the spindle (Figure 6-18, Page 6-10). Remove brake cluster assembly from spindle.

  • Page 75: Front Brake Cable Installation

    WHEEL BRAKE ASSEMBLIES Front Brake Cables Remove cotter pin (9), clevis pin (10), and E-clip (8) from brake cable at equalizer (18) (Figure 6-22, Page 6-16). Remove bolt (4) and nut (6) from brake cable clamp (5) (Figure 6-21, Page 6-15). Remove cable from vehicle.
  • Page 76 Front Brake Cables WHEEL BRAKE ASSEMBLIES Figure 6-22 Brake Equalizer Place brake cable clevis (6) on equalizer (18) and install the clevis pin (10) and new cotter pin (9). Route cable towards the rear of vehicle and over to the driver-side I-beam and secure with wire ties so that the brake cable does not touch the brake equalizer (Figure 6-23, Page 6-17).

  • Page 77: Rear Brake Cables

    WHEEL BRAKE ASSEMBLIES Rear Brake Cables Route cable along I-beam towards front of the vehicle and secure as shown (Figure 6-23, Page 6-17). NOTE: 77.5 in. (196.9 cm) and 78.5 in. (199.4 cm) wheelbase electric vehicles: Route cable through hole in I-beam crossmember.

  • Page 78: Rear Brake Cable Installation

    Rear Brake Cables WHEEL BRAKE ASSEMBLIES Figure 6-24 Loosen Equalizer Nut Figure 6-25 Disconnect Cables at Rear Brakes REAR BRAKE CABLE INSTALLATION Place the cable ends in the equalizer (4) (Figure 6-24, Page 6-18). Route cables through hangers in the same manner as the ones removed.

  • Page 79: Section 7 - Steering And Front Suspension

    SECTION 7 – STEERING AND FRONT SUSPENSION DANGER • See General Warning on page 1-1. WARNING • See General Warning on page 1-1. GENERAL INFORMATION Steering is controlled through a rack and pinion steering assembly that is connected by a steering column to a steering wheel.

  • Page 80: Steering Wheel Installation

    Steering Column STEERING AND FRONT SUSPENSION 1500-18300-10252 1500-18300-10253 Figure 7-1 Steering Wheel Removal Figure 7-2 Steering Wheel Puller STEERING WHEEL INSTALLATION NOTE: To minimize corrosion and to make future removal of the steering wheel easier, apply a small amount of oil or anti-seize compound to steering shaft splines and taper before installing the steering wheel.
  • Page 81 STEERING AND FRONT SUSPENSION Steering Column Figure 7-3 Steering Column Remove the center dash panel. See Key Switch Removal in the Electrical Components Section. Remove the driver-side dash pocket. 4.1. Remove the flange lock screw from the top of the dash pocket. 4.2.

  • Page 82: Steering Column Disassembly

    Steering Column STEERING AND FRONT SUSPENSION Remove the upper bolt (2) and lock washer (3) from the universal joint (Figure 7-3, Page 7-3). Remove the nuts (9), bolts (8 and 10), and washers (7 and 11) from the steering column mount (4 and 5) (Figure 7-3, Page 7-3).

  • Page 83: Steering Adjustment

    STEERING AND FRONT SUSPENSION Steering Adjustment (CCI P/N 1014259) 2-2 1/8 inches (CCI P/N 1014264) (CCI P/N 1014264) (5.1-5.4 cm) 1. Step 1 1. Step 1 2. Step 2 2. Step 2 3. Step 3 3. Step 3 Figure 7-4 Steering Shaft – Bottom End Figure 7-5 Steering Shaft –...

  • Page 84: Rack And Pinion

    Rack and Pinion STEERING AND FRONT SUSPENSION against rack and pinion housing at exactly the same time the spindle stops against the passenger side A-plate (with vehicle wheels turned to the right). If simultaneous contact occurs, steering is in correct adjustment; proceed to step 4.

  • Page 85: Rack And Pinion Disassembly

    STEERING AND FRONT SUSPENSION Rack and Pinion Remove the bolts (30), washers (31), and lock nuts (32) from the steering rack assembly mounting bracket (Figure 7-11, Page 7-9). Remove the bolt (2) and flat washer (3) on the upper universal joint, then remove the rack assembly and universal joint from the vehicle (Figure 7-3, Page 7-3) .
  • Page 86 Rack and Pinion STEERING AND FRONT SUSPENSION 1. Press Ram 2. Pinion Gear 3. Bearing Figure 7-8 Remove Pinion from Housing Figure 7-9 Remove Bearing from Pinion If necessary, remove the dust seal (12). See following NOTE. NOTE: If the dust seal (12) is removed, replace with a new one. Use snap ring pliers to remove the internal snap ring (11) (Figure 7-11, Page 7-9).

  • Page 87: Rack And Pinion Assembly

    STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION ASSEMBLY Install a new tab washer (4) and an inner ball joint (3) (Figure 7-10, Page 7-8). Install the ball joint onto the rack by securing the rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack from damage.
  • Page 88 Rack and Pinion STEERING AND FRONT SUSPENSION CAUTION • In step 4, do not press against the outer race of the bearing. If the bearing (9) was removed, press on a new bearing, exerting all pressure on the inner race (grease the bearing before installing it).

  • Page 89: Rack And Pinion Installation

    STEERING AND FRONT SUSPENSION Rack and Pinion Apply a small amount of grease to the rack guide (13) where it comes into contact with the rack (17) (Figure 7-11, Page 7-9). 10. Place a few drops of Loctite ® 222 to the threads of the screw (16) (Figure 7-11, Page 7-9). 11.

  • Page 90: Tie Rod And Drag Link

    Tie Rod and Drag Link STEERING AND FRONT SUSPENSION TIE ROD AND DRAG LINK See General Warning on page 1-1. TIE ROD AND DRAG LINK REMOVAL Using locking pliers to hold tie rod and drag link, loosen jam nuts (7 and 12) on tie rod ball joints (Figure 7-20, Page 7-17)and loosen jam nuts (27 and 29) on the drag link (Figure 7-11, Page 7-9).

  • Page 91: Front Suspension

    STEERING AND FRONT SUSPENSION Front Suspension FRONT SUSPENSION See General Warning on page 1-1. LUBRICATION Five grease fittings are provided (one in each spindle housing, one in the ball joint on each end of the tie rod, and one in the ball joint of the steering drag link). Lubricate these fittings at the recommended interval with the proper lubricant. See Periodic Lubrication Schedules on page 10-6.
  • Page 92 Front Suspension STEERING AND FRONT SUSPENSION Loosen, but do not remove, the hex nut (8) on the adjustment eccentric (7) (Figure 7-21, Page 7-18) in the center of the spring. See also Figure 7-16, Page 7-13. Use a 7 mm deep well socket to rotate the eccentric (Figure 7-16, Page 7-13). After adjusting camber, tighten the four spring retaining nuts (32) (Figure 7-21, Page 7-18) to 23 ft-lb (31 N·m).

  • Page 93: Front Suspension Components

    STEERING AND FRONT SUSPENSION Front Suspension Components FRONT SUSPENSION COMPONENTS See General Warning on page 1-1. LEAF SPRING REMOVAL Loosen lug nuts on both front wheels and raise front of vehicle with a chain hoist or floor jack. Place jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands.
  • Page 94 Front Suspension Components STEERING AND FRONT SUSPENSION Figure 7-19 Connect Front Brake Cables Remove cotter pins (22) and nuts (20), then remove ball joints from the spindles (Figure 7-20, Page 7-17). Remove drag link ball joint. See also Tie Rod and Drag Link Removal on page 7-12. Remove the nut (17) from the top of the kingpin (26) (Figure 7-21, Page 7-18).
  • Page 95 STEERING AND FRONT SUSPENSION Front Suspension Components Figure 7-20 Four-Wheel Brake Vehicle – Upper Portion 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual Page 7-17...
  • Page 96 Front Suspension Components STEERING AND FRONT SUSPENSION Figure 7-21 Four-Wheel Brake Vehicle – Lower Portion Page 7-18 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual...

  • Page 97: Kingpin And Steering Spindle Installation

    STEERING AND FRONT SUSPENSION Front Suspension Components KINGPIN AND STEERING SPINDLE INSTALLATION Inspect all parts and replace them as necessary. Install the kingpin (26) over the leaf spring eye. Insert the bolt (25) and install the nut (14) (Figure 7-21, Page 7-18).

  • Page 98: Front Wheel Bearings And Hubs - 4-Wheel Brake Vehicles

    Front Wheel Bearings and Hubs – 4-Wheel Brake Vehicles STEERING AND FRONT SUSPENSION Tighten the nuts to 20 ft-lb (27 N·m). FRONT WHEEL BEARINGS AND HUBS – 4-WHEEL BRAKE VEHICLES See General Warning on page 1-1. FRONT WHEEL FREE PLAY INSPECTION Raise the front of the vehicle.

  • Page 99: Front Wheel Bearings And Hub Installation

    STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs – 4-Wheel Brake Vehicles Clean all parts and inspect them for wear. Replace any damaged or worn parts. See following NOTE. NOTE: Do not use compressed air to dry wheel bearings after cleaning. Inspect the surface of the spindle shaft where the seal (6) seats.

  • Page 101: Section 8 - Wheels And Tires

    SECTION 8 – WHEELS AND TIRES DANGER • See General Warning on page 1-1. WARNING • See General Warning on page 1-1. GENERAL INFORMATION Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care. •...

  • Page 102: Tires

    Tires WHEELS AND TIRES TIRES See General Warning on page 1-1. TIRE REMOVAL NOTE: Tire must be removed or installed from the valve stem side of the rim. Remove the tire and wheel assembly from the vehicle as instructed above. See Wheel Removal on page 8-1. Remove the valve cap and valve core and allow air to escape from the tire.

  • Page 103: Tire Installation

    WHEELS AND TIRES Tires Small holes in the casing can be plugged using a standard automotive tubeless tire repair kit available at auto supply stores. When the cause of the air leak has been determined, remove tire from the rim and repair as required. See Tire Removal on page 8-2.
  • Page 104 Tires WHEELS AND TIRES Figure 8-2 Inflate Tire Page 8-4 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual...

  • Page 105: Section 9 - Rear Suspension

    SECTION 9 – REAR SUSPENSION DANGER • See General Warning on page 1-1. WARNING • See General Warning on page 1-1. GENERAL INFORMATION The rear suspension and powertrain of the vehicle move independently from the vehicle frame. The suspension includes two multi-leaf springs controlled by two hydraulic shock absorbers mounted between the spring mounting plate and the frame.

  • Page 106: Multi-Leaf Springs

    Multi-Leaf Springs REAR SUSPENSION Figure 9-1 Shock Absorber Removal MULTI-LEAF SPRINGS See General Warning on page 1-1. MULTI-LEAF SPRING REMOVAL Loosen the lug nuts on the wheel(s) to be removed. Place chocks at the front wheels and lift rear of vehicle with a chain hoist or floor jack (Figure 9-2, Page 9-3). Position jack stands under the frame crossmember between the rear leaf spring front frame mount and the side stringer, just forward of each rear wheel.

  • Page 107: Multi-Leaf Spring Installation

    REAR SUSPENSION Multi-Leaf Springs 1. Position floor jack under hitch bracket or frame. 2. Lifting Position For Standard Turf 1 and Carryall 1 3. Lifting Position For Turf 2 and 252, Carryall 2 and 252, Carryall 2 Plus and XRT 900 4.
  • Page 108 Multi-Leaf Springs REAR SUSPENSION A. Gasoline Vehicles Only B. Electric Vehicles Only C. Rear Brake Cable Figure 9-3 Rear Suspension – All Turf/Carryall 252 and XRT 900 Vehicles Page 9-4 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual...

  • Page 109: Snubber

    REAR SUSPENSION Snubber SNUBBER See General Warning on page 1-1. NOTE: The snubber is installed on the gasoline vehicle only. SNUBBER REMOVAL Support the powertrain with a floor jack under the engine mounting plate so that the snubber (1) is raised slightly and does not rest on the vehicle frame.

  • Page 110: Stabilizer Bar

    Stabilizer Bar REAR SUSPENSION STABILIZER BAR See General Warning on page 1-1. NOTE: A stabilizer bar is installed on gasoline Turf 252, Carryall 252 and XRT 900 vehicles. STABILIZER BAR REMOVAL Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame crossmember between the spring mount and the side stringer, just forward of each rear wheel.
  • Page 111 REAR SUSPENSION Stabilizer Bar Figure 9-5 Stabilizer Bar 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual Page 9-7...

  • Page 113: Section 10 - Periodic Maintenance

    Contact your local authorized distributor/dealer to perform all repairs and semiannual and annual periodic service. PRE-OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new vehicle(s), you should become familiar with its controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery.

  • Page 114: Performance Inspection

    Club Car vehicles operate at reduced speed in reverse. When the pedal is released, it should return to the original position and the motor should rotate freely or go into motor braking mode. See Pedal Up Motor Braking below.

  • Page 115: Periodic Service Schedules

    When the pedal is released it should return to the original position and the engine should stop. Club Car vehicles operate at reduced speed in reverse. • Accelerator for key-start vehicle: After starting the engine with the key switch and placing the Forward/Reverse handle in the FORWARD position, the vehicle should accelerate smoothly to full speed as the accelerator pedal is pressed.
  • Page 116 Periodic Service Schedules PERIODIC MAINTENANCE PERIODIC SERVICE SCHEDULE – ELECTRIC VEHICLES REGULAR INTERVAL SERVICE See Pre-Operation and Daily Safety Pre-Operation and Daily Safety Checklist Checklist on page 10-1. Daily service by owner Performance Inspection See Performance Inspection on page 10-2. Batteries Charge batteries (after each daily use only).
  • Page 117 PERIODIC MAINTENANCE Periodic Service Schedules PERIODIC SERVICE SCHEDULE – GASOLINE VEHICLES REGULAR INTERVAL SERVICE See Pre-Operation and Daily Safety Pre-Operation and Daily Safety Checklist Checklist on page 10-1. Daily service by owner Performance Inspection See Performance Inspection on page 10-2. Check engine oil level;...

  • Page 118: Periodic Lubrication Schedules

    Periodic Lubrication Schedules PERIODIC MAINTENANCE PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE – ELECTRIC VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Brake pedal shaft bearings Dry Moly Lube (CCI P/N 1012151) Brake linkage and pivots Dry Moly Lube (CCI P/N 1012151) Semiannually by owner or Accelerator pivot rod supports Dry Moly Lube (CCI P/N 1012151)

  • Page 119: Engine Oil - Gasoline Vehicle

    PERIODIC MAINTENANCE Engine Oil – Gasoline Vehicle PERIODIC LUBRICATION SCHEDULE – GASOLINE VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Brake pedal shaft bearings Dry Moly Lube (CCI P/N 1012151) Brake linkage and pivots Dry Moly Lube (CCI P/N 1012151) Semiannually by owner or trained technician (or every 50 Accelerator pivot rod supports and...

  • Page 120: Engine Oil Level Check

    Engine Oil – Gasoline Vehicle PERIODIC MAINTENANCE ENGINE OIL LEVEL CHECK Remove the oil level dipstick from the oil filler tube, and wipe oil off dipstick (1) (Figure 10-3). See following CAUTION. CAUTION • Do not remove dipstick while engine is running. Check oil by fully inserting the dipstick into the oil filler tube (2) and immediately removing it.
  • Page 121 PERIODIC MAINTENANCE Engine Oil – Gasoline Vehicle 1. Drain pan 2. Drain plug 3. Oil filter. Figure 10-4 Engine Oil Drain Plug and Pan Use a 14 mm socket or wrench to remove the drain plug, turning it counterclockwise, and allow the engine oil to drain into the pan.
  • Page 122 NOTE: Use only Club Car oil filters (CCI P/N 1016467) designed for this engine. 12. Tighten the oil filter by hand until tight. Do not use a band wrench or channel lock plier to tighten.

  • Page 123: Section 11 - Troubleshooting And Electrical System: Key-Start With Neutral Rev Gas Vehicle

    SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START WITH NEUTRAL REV GAS VEHICLE DANGER • See General Warning on page 1-1. WARNING • See General Warning on page 1-1. GENERAL INFORMATION This section contains the information required to correctly troubleshoot the gasoline vehicle. A troubleshooting guide is provided for general troubleshooting.
  • Page 124 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Troubleshooting Guide KEY-START WITH NEUTRAL REV GAS VEHICLE TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO See Section 15 – S10 FE 350 Engine. See Spark plug is fouled or in poor condition Section 16 – S27 FE 350 Engine. See Section 15 –...
  • Page 125 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START WITH NEUTRAL REV GAS VEHICLE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO See the Engines and Transaxles manual (CCI Exhaust valve is restricted with carbon deposit P/N 102396501) Muffler or exhaust pipe restricted with carbon See Section 19 –...
  • Page 126 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Troubleshooting Guide KEY-START WITH NEUTRAL REV GAS VEHICLE TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Fuse is blown Test Procedure 2 – Fuse Battery is dead Test Procedure 1 – Battery Test Procedure 8 – Starter/Generator (Starter Starter control circuit is not operating Function) Test Procedure 8 –...
  • Page 127 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START WITH NEUTRAL REV GAS VEHICLE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO See Section 15 – S10 FE 350 Engine. See Engine mounting nuts or bolts are loose Section 16 – S27 FE 350 Engine. See Section 15 –...

  • Page 128: Electrical System

    TROUBLESHOOTING AND ELECTRICAL SYSTEM: Electrical System KEY-START WITH NEUTRAL REV GAS VEHICLE ELECTRICAL SYSTEM The electrical system on the gasoline key-start vehicles is 12 volts DC with negative ground to frame. It consists of the following: • Starter Circuit • Generator Circuit •...

  • Page 129: Wiring Diagrams

    TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START WITH NEUTRAL REV GAS VEHICLE Wiring Diagrams WIRING DIAGRAMS FUEL GAUGE/ HOUR METER (Through mid-2007) 18_ORG( W23 ) FUE L TANK 18 _BLU(W41) S ENDING UNIT 16_BLK(W36) 18 _BLK(W16 ) DETAIL CEN TER DASH OIL LIGHT PANEL 18_YEL( W 41) ASM.
  • Page 130 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Wiring Diagrams KEY-START WITH NEUTRAL REV GAS VEHICLE FO RWARD LIMI T S WITCH BARE BATTERY 10_NON_INS UL(W37) ENGINE REVERS E LIMI T S WITCH 6_RED (W38) 18_RED_WHT_ST P(W0 3) 6_WHT(W08) 18_ORG (W25) P/N 1014948 WHITE STARTER GENERATOR 18_BLU(W11)

  • Page 131: Test Procedures

    TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START WITH NEUTRAL REV GAS VEHICLE Test Procedures TEST PROCEDURES Index of Test Procedures 1 – Battery 2 – Fuse 3 – Ground Cables 4 – Key Switch (Starter Circuit) 5 – Key Switch (Accessory Terminal) 6 –...
  • Page 132 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures KEY-START WITH NEUTRAL REV GAS VEHICLE DANGER – Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable oil. Call a physician immediately. – Eyes: Flush with water for 15 minutes. Call a physician immediately. NOTE: The battery must be properly maintained and fully charged in order to perform the following test procedures.
  • Page 133 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START WITH NEUTRAL REV GAS VEHICLE Test Procedures 1.250 1.280 1. Level Indicator 2. Cap 3. Plates Electrolyte level at least 1/2 inch (13 MM) above plates or to level View at eye level. indicator. Figure 11-3 Hydrometer Test Figure 11-4 Battery Electrolyte Level Hydrometer Calibration Most hydrometers are calibrated to read correctly at 80 °F (27 °C).
  • Page 134 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures KEY-START WITH NEUTRAL REV GAS VEHICLE Load Test Connect a 160-ampere load tester to the battery posts. Turn the switch on the load tester to the ON position. Read the battery voltage after the load tester has been turned ON for 15 seconds. Compare the battery’s voltage reading with the table below.
  • Page 135 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START WITH NEUTRAL REV GAS VEHICLE Test Procedures If the reading is incorrect, clean and tighten wire connections. If the connections are good and the reading is incorrect, repair or replace the wire. Check the engine ground strap. 4.1.
  • Page 136 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures KEY-START WITH NEUTRAL REV GAS VEHICLE TEST PROCEDURE 4 – Key Switch (Starter Circuit) See General Warning on page 1-1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.
  • Page 137 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START WITH NEUTRAL REV GAS VEHICLE Test Procedures 1. Cover 2. Electrical Component Box 3. 6 Ga. White Wire 4. 16 Ga. White Wire 5. 16 Ga. Red Wire 6. Solenoid Figure 11-10 Remove Solenoid Wires TEST PROCEDURE 6 –...
  • Page 138 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures KEY-START WITH NEUTRAL REV GAS VEHICLE WAVETEK WAVETEK 1000 1000 2000 2000 200k 200k 200nA 200nA 1000 --- FUSED 750V 1000 --- FUSED 750V Figure 11-11 Solenoid Continuity Test Figure 11-12 Solenoid Ground Test 11.
  • Page 139 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START WITH NEUTRAL REV GAS VEHICLE Test Procedures WAVETEK WAVETEK 1000 1000 2000 2000 200k 200k 200nA 200nA 1000 --- 1000 --- FUSED FUSED 750V 750V 1. Lever Up 2. Lever Depressed 3. Tester light is OFF. Meter reads 1. 4. Tester light is ON. Meter reads approx. zero ohms. Figure 11-13 Neutral Lockout Limit Switch Test Connect battery and spark plug wire(s).
  • Page 140 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures KEY-START WITH NEUTRAL REV GAS VEHICLE will need to be removed from the vehicle and disassembled by a qualified technician. See Starter/Generator Removal, Section 13, Page 13-1. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1.
  • Page 141 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START WITH NEUTRAL REV GAS VEHICLE Test Procedures The reading should indicate an overload (no continuity). A diode is designed to conduct current in one direction only. If a diode conducts current (shows continuity) with the meter probes as described, the diode has failed and must be replaced.
  • Page 142 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures KEY-START WITH NEUTRAL REV GAS VEHICLE WAVETEK 1000 WAVETEK 1000 2000 200k 2000 200k 200nA 200nA 1000 --- FUSED 750V 1000 --- FUSED 750V Figure 11-17 Diode Test Figure 11-18 Diode Test – Probes Reversed TEST PROCEDURE 11 –...
  • Page 143 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START WITH NEUTRAL REV GAS VEHICLE Test Procedures Check that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Check the engine RPM setting to ensure that it is adjusted correctly. See Engine RPM Adjustment on page 17-11.
  • Page 144 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures KEY-START WITH NEUTRAL REV GAS VEHICLE WARNING • When the white/black engine kill wire is disconnected, the engine will not stop running after the key switch is turned to the OFF position. It will be necessary to pull and hold the choke handle until the engine stops running.
  • Page 145 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START WITH NEUTRAL REV GAS VEHICLE Test Procedures TEST PROCEDURE 15 – RPM Limiter See General Warning on page 1-1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.
  • Page 146 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures KEY-START WITH NEUTRAL REV GAS VEHICLE WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 200 Ohm Setting Figure 11-23 Primary Coil Resistance – In Vehicle Test WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1.
  • Page 147 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START WITH NEUTRAL REV GAS VEHICLE Test Procedures Figure 11-25 Ignition Coil and Cap Figure 11-26 Spark Plug Cap Removal Ignition Coil – In Vehicle Test Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.
  • Page 148 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures KEY-START WITH NEUTRAL REV GAS VEHICLE WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 20k Ohm Setting 2. Spark Plug Cap Figure 11-27 Spark Plug Cap Test Ignition Coil – Bench Test Remove the coil from the engine.
  • Page 149 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START WITH NEUTRAL REV GAS VEHICLE Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 20k Ohm Setting Figure 11-28 Secondary Coil Test Without Cap WAVETEK 1000 WAVETEK 1000 2000 200k 2000 200k 200nA 1000 --- FUSED...
  • Page 150 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures KEY-START WITH NEUTRAL REV GAS VEHICLE WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 20k Ohm Setting 2. Core 3. Spark Plug Wire Figure 11-31 Secondary Coil Resistance – Bench Test TEST PROCEDURE 17 – Key Switch (Engine Kill Circuit) See General Warning on page 1-1.
  • Page 151 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START WITH NEUTRAL REV GAS VEHICLE Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Reading with key switch in the OFF position. Figure 11-32 Test Key Switch – Engine Kill Circuit TEST PROCEDURE 18 – Engine Kill Wire See General Warning on page 1-1.
  • Page 152 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures KEY-START WITH NEUTRAL REV GAS VEHICLE TEST PROCEDURE 20 – Reverse Buzzer See General Warning on page 1-1. The front reverse buzzer is mounted to the instrument panel under the front body. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.
  • Page 153 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START WITH NEUTRAL REV GAS VEHICLE Test Procedures TEST PROCEDURE 23 – Battery Test (Under Load) See General Warning on page 1-1. NOTE: Keep the battery connected while performing this test procedure. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.
  • Page 154 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures KEY-START WITH NEUTRAL REV GAS VEHICLE If the readings are correct and the fuel gauge does not function correctly, check the continuity of the orange wire from the fuel level sending unit to the fuel gauge/hour meter. Leave the battery disconnected while checking continuity.
  • Page 155 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START WITH NEUTRAL REV GAS VEHICLE Test Procedures TEST PROCEDURE 25 – Fuel Gauge See General Warning on page 1-1. Two fuel gauges were used for model year 2007 (Figure 11-34, Page 11-33 and Figure 11-35, Page 11-33). The terminal configuration on the back of the gauge easily denotes the type.
  • Page 156 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures KEY-START WITH NEUTRAL REV GAS VEHICLE WAVETEK 1000 WAVETEK 1000 2000 200k 2000 200k 200nA 1000 --- FUSED 750V 200nA 1000 --- FUSED 750V 1. 20 VDC Setting 2. Orange 3. Black 4. White 5. Blue 1.
  • Page 157 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START WITH NEUTRAL REV GAS VEHICLE Test Procedures WAVETEK WAVETEK 1000 1000 2000 2000 200k 200k 200nA 200nA 1000 --- FUSED 750V 1000 --- FUSED 750V 1. 20 VDC Setting 2. Orange 3. Black 4. White 5. Blue 1.
  • Page 158 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures KEY-START WITH NEUTRAL REV GAS VEHICLE With the key switch OFF, check the hour meter display. It is powered by an internal battery and should always be on, even with the engine off and the key removed. Start the engine and let it idle.
  • Page 159 TROUBLESHOOTING AND ELECTRICAL SYSTEM: KEY-START WITH NEUTRAL REV GAS VEHICLE Test Procedures TEST PROCEDURE 28 – Headlight Diode See General Warning on page 1-1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.
  • Page 160 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures KEY-START WITH NEUTRAL REV GAS VEHICLE Inspect wires at light bulb socket. Make sure wires are securely fastened to the contacts inside socket. Remove the wire harness from the headlight (Figure 11-42, Page 11-38). Using a multimeter set to 20 volts DC, place the black (–) probe of multimeter into the black wire terminal of the wire harness.

  • Page 161: Section 12 - Troubleshooting And Electrical System: Pedal-Start Gas Vehicle

    SECTION 12 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE DANGER • See General Warning on page 1-1. WARNING • See General Warning on page 1-1. GENERAL INFORMATION This section contains the information required to correctly troubleshoot the vehicle. A troubleshooting guide is provided for general troubleshooting.
  • Page 162 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Troubleshooting Guide PEDAL-START GAS VEHICLE TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION See Section 15 – S10 FE 350 Engine. See Spark plug is fouled or in poor condition Section 16 – S27 FE 350 Engine. See Section 15 –...
  • Page 163 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION See Section 15 – S10 FE 350 Engine. See Exhaust valve is restricted with carbon deposit Section 16 – S27 FE 350 Engine. Muffler or exhaust pipe restricted with carbon See Section 19 –...
  • Page 164 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Troubleshooting Guide PEDAL-START GAS VEHICLE TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION See Section 12 – Troubleshooting and Neutral lockout switch is in the wrong position Electrical System: Pedal-Start Gas Vehicle. Fuse is blown Test Procedure 2 – Fuse Battery is dead Test Procedure 1 –...
  • Page 165 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION See Section 15 – S10 FE 350 Engine. See Engine mounting nuts or bolts are loose Section 16 – S27 FE 350 Engine. Snubber on frame is worn or damaged See Section 15 –...

  • Page 166: Wiring Diagram

    TROUBLESHOOTING AND ELECTRICAL SYSTEM: Wiring Diagram PEDAL-START GAS VEHICLE WIRING DIAGRAM FUEL GAUGE/ HOUR METER (Through mid-2007) 18_ORG( W23 ) 18 _BLU(W41) 18 _BLK(W16 ) DETAIL FUEL/HOUR METER GAUGE WD103197101B5-L Figure 12-1 Wiring Diagram for Pedal-Start Gasoline Vehicle Page 12-6 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual...
  • Page 167 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Wiring Diagram WD103197101B5-R Figure 12-2 Wiring Diagram for Pedal-Start Gasoline Vehicle 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual Page 12-7...
  • Page 168 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Wiring Diagram PEDAL-START GAS VEHICLE HEAD LIGHT RIGHT LIGHT SW ITCH 14 _BLU(W26) 14_YEL(W10 ) 16_BLK(W24 ) HEAD LIGHT LEFT VOLTAGE LIMITER 16_BLK(W17 ) WD103255601A Figure 12-3 Wiring Diagram – Headlights Page 12-8 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual...

  • Page 169: Electrical System

    TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Electrical System ELECTRICAL SYSTEM The electrical system on the gasoline vehicle is 12 volts DC with negative (–) ground to frame, and consists of the following circuits that are easily identified: • Starter Circuit •...
  • Page 170 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE 21 – Low Oil Warning Light 22 – Oil Level Sensor 23 – Neutral Lockout Switch 24 – Battery Test (Under Load) 25 – Fuel Level Sending Unit 26 – Fuel Gauge 27 –...
  • Page 171 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures CAUTION • Do not allow battery acid from battery caps or hydrometer to drip onto the body. Battery acid will cause permanent damage. Wash off immediately. Performing the Hydrometer Test Be sure that the battery has sufficient water to cover the plates by approximately 1/2 inch (12.7 mm) and is fully charged prior to beginning the test.
  • Page 172 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE SPECIFIC GRAVITY (TEMPERATURE CORRECTED) APPROXIMATE STATE OF CHARGE 1.250-1.280 100% 1.220-1.240 1.190-1.210 1.160-1.180 If the difference between the cells is 0.020 or more, the low cell should be suspected. It may require a catch-up charge or it may be a weak cell.
  • Page 173 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures Remove fuse to be tested from the fuse block. See Fuse Removal on page 14-16. The red 10-amp fuse protects the solenoid for the starter (cranking) circuit. The 20-amp fuse at the yellow wire connection protects the headlights and brake lights (if equipped).
  • Page 174 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 200 Ohm Setting 2. Disconnect the 6-gauge black wire from the battery. Place red (+) probe on disconnected end of cable. 3.
  • Page 175 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 5 – Accelerator Pedal Limit Switch See General Warning on page 1-1. The accelerator pedal limit switch is the top switch located in the electrical component box. There is an 18-gauge green wire and an 18-gauge orange wire connected to this limit switch.
  • Page 176 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE TEST PROCEDURE 6 – Solenoid See General Warning on page 1-1. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3. Remove the electrical component box cover. Ensure that the wires are connected correctly and are tight.
  • Page 177 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 7 – Neutral Lockout Limit Switch See General Warning on page 1-1. This switch is located on the Forward/Reverse switch assembly. A black/light blue wire, a gray wire, and a tan wire are connected to this limit switch.
  • Page 178 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE TEST PROCEDURE 8 – Starter/Generator (Starter Function) See General Warning on page 1-1. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3. Ensure that wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Disconnect the wires from all the terminals on the starter/generator.
  • Page 179 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 9 – Wire Continuity See General Warning on page 1-1. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3. To test a wire for continuity, disconnect either end from the electrical component it is attached to. Set the multimeter to 200 ohms and place the red (+) probe on the terminal at one end of the wire.
  • Page 180 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. Voltage Regulator 2. Solenoid 3. Battery 4. 20 VDC Setting Figure 12-16 Voltage Regulator Test TEST PROCEDURE 12 – Disconnected Kill Wire See General Warning on page 1-1.
  • Page 181 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures 1. Ignition Gap Test Tool 2. Chassis 1. Disconnect White/Black Engine Kill Wire 2. RPM Limiter Figure 12-17 Ignition Spark Test Figure 12-18 White/Black Engine Kill Wire TEST PROCEDURE 13 – Ignition Spark See General Warning on page 1-1.
  • Page 182 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE TEST PROCEDURE 14 – RPM Limiter See General Warning on page 1-1. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3. Disconnect both of the bullet terminals (Figure 12-19, Page 12-22). Using a multimeter set to 200 ohms, place the red (+) probe on the brown ground wire and place the black (–) probe on one of the black wire female bullet connectors.
  • Page 183 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 15 – Ignition Coil See General Warning on page 1-1. The following test procedures will properly detect a coil that has failed in most cases; however, in rare cases, some ignition coils can fail to operate at normal (warmer) operating temperatures.
  • Page 184 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 20k Ohm Setting Figure 12-21 Secondary Coil Test – In Vehicle Test Using a multimeter set to 20k ohms, measure the resistance of the secondary coil and spark plug cap together. 3.1.
  • Page 185 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures Figure 12-22 Ignition Coil and Cap Figure 12-23 Spark Plug Cap Removal 4.3. Using a multimeter set to 20k ohms, place the red (+) probe of the multimeter into the end of the spark plug cap that normally connects to the spark plug and place the black (–) probe into the end of the cap with the internal screw (Figure 12-24, Page 12-25).
  • Page 186 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 20k Ohm Setting Figure 12-25 Secondary Coil Test Without Cap Test the secondary coil separately from the spark plug cap. 5.1. Using a multimeter set to 20k ohms, place the red (+) probe of the meter into the end of the spark plug wire and place the black (–) probe on a clean unpainted surface of the engine or frame (Figure 12-25, Page 12-26).
  • Page 187 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures WAVETEK 1000 WAVETEK 1000 2000 200k 2000 200k 200nA 1000 --- FUSED 750V 200nA 1000 --- FUSED 750V 1. 20k Ohm Setting 2. Core 3. Spark Plug Cap 1. Ignition Coil Terminal 2. Core 3. 200 Ohm Setting Figure 12-26 Primary Coil Resistance –...
  • Page 188 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 20k Ohm Setting 2. Core 3. Spark Plug Wire Figure 12-28 Secondary Coil Resistance – Bench Test 3.2. If the resistance is between 12.0k - 14.0k ohms, the secondary coil and spark plug cap are within acceptable limits;...
  • Page 189 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 16 – Kill Limit Switch See General Warning on page 1-1. The kill limit switch is located inside the electrical component box. The accelerator kill switch is the lower of the two limit switches and has a white/black wire and black wire connected to it.
  • Page 190 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE TEST PROCEDURE 17 – Key Switch (Engine Kill Circuit) See General Warning on page 1-1. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3. Remove the center dash assembly.
  • Page 191 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 18 – Engine Kill Wire See General Warning on page 1-1. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3. Disconnect white/black wire bullet connector located at the engine RPM limiter (Figure 12-18, Page 12-21). Connect red (+) probe of multimeter to the male bullet terminal on the white/black wire and connect the black (–) probe to the vehicle frame.
  • Page 192 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE TEST PROCEDURE 21 – Low Oil Warning Light See General Warning on page 1-1. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3. Remove the center dash assembly.
  • Page 193 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 23 – Neutral Lockout Switch See General Warning on page 1-1. Remove the wires from the switch (Figure 12-31, Page 12-33). With switch in position 1: 2.1. Check for no continuity between terminals T1 and T2. 2.2.
  • Page 194 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE TEST PROCEDURE 24 – Battery Test (Under Load) See General Warning on page 1-1. NOTE: Keep the battery connected while performing this test procedure. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position.
  • Page 195 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 2k Ohm Setting 2. Black Wire 3. Ground Figure 12-32 Fuel Level Sending Unit Test If the readings are within the specifications listed above, the fuel level sending unit is working properly. If the readings are incorrect, the fuel level sending unit has failed and the fuel tank must be replaced.
  • Page 196 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE TEST PROCEDURE 26 – Fuel Gauge See General Warning on page 1-1. Two fuel gauges were used for model year 2007 (Figure 12-33, Page 12-36 and Figure 12-34, Page 12-36). The terminal configuration on the back of the gauge easily denotes the type.
  • Page 197 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures WAVETEK 1000 WAVETEK 1000 2000 200k 2000 200k 200nA 1000 --- FUSED 750V 200nA 1000 --- FUSED 750V 1. 20 VDC Setting 2. Orange 3. Black 4. White 5. Blue 1. 20 VDC Setting 2. Orange Figure 12-35 Fuel Gauge Voltage Test - Terminal 2 Figure 12-36 Fuel Gauge Voltage Test - Terminal 1 Fuel Gauge (From mid-2007)
  • Page 198 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE WAVETEK WAVETEK 1000 1000 2000 2000 200k 200k 200nA 200nA 1000 --- FUSED 750V 1000 --- FUSED 750V 1. 20 VDC Setting 2. Orange 3. Black 4. White 5. Blue 1. 20 VDC Setting 2. Orange Figure 12-37 Fuel Gauge Voltage Test - Terminal 2 Figure 12-38 Fuel Gauge Voltage Test - Terminal 4 TEST PROCEDURE 27 –...
  • Page 199 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures With the key switch OFF, check the hour meter display. It is powered by an internal battery and should always be on, even with the engine off and the key removed. Start the engine and let it idle.
  • Page 200 TROUBLESHOOTING AND ELECTRICAL SYSTEM: Test Procedures PEDAL-START GAS VEHICLE TEST PROCEDURE 29 – Voltage Limiter See General Warning on page 1-1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels. Disconnect battery and spark plug wire(s).
  • Page 201 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures Inspect wires at light bulb socket. Make sure wires are securely fastened to the contacts inside socket. Remove the wire harness from the headlight (Figure 12-41, Page 12-41). Using a multimeter set to 20 volts DC, place the black (–) probe of multimeter into the black wire terminal of the wire harness.

  • Page 203: Section 13 - Electrical Components: Key-Start With Neutral Rev Gas Vehicle

    SECTION 13 – ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE DANGER • See General Warning on page 1-1. WARNING • See General Warning on page 1-1. STARTER/GENERATOR See General Warning on page 1-1. TESTING THE STARTER/GENERATOR See Test Procedure 8 – Starter/Generator (Starter Function) on page 11-17. Also see Test Procedure 11 – Starter/Generator (Generator Function) on page 11-20.

  • Page 204: Disassembly Of The Starter/Generator To Service The Brushes

    ELECTRICAL COMPONENTS: KEY-START WITH Starter/Generator NEUTRAL REV GAS VEHICLE A. To Battery Ground Post Figure 13-1 Starter/Generator Removal DISASSEMBLY OF THE STARTER/GENERATOR TO SERVICE THE BRUSHES Remove the two bolts (20) and pull commutator end cover (23) free of starter/generator housing (24) (Figure 13-2, Page 13-2).

  • Page 205: Brush Spring Inspection And Replacement

    ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE Starter/Generator Check the wear line on the side of the brush. If the end of the brush is within 1/16-inch (1.6 mm) of the wear line, replace all four brushes (Figure 13-4, Page 13-3). 1.

  • Page 206: Disassembly Of The Starter/Generator To Service The Armature/Commutator

    ELECTRICAL COMPONENTS: KEY-START WITH Starter/Generator NEUTRAL REV GAS VEHICLE Install the commutator. Lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover to avoid interference. The springs will rest on the sides of the brushes and help prevent them from sliding to the center (Figure 13-6, Page 13-4).

  • Page 207: Bearing Removal

    ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE Starter/Generator Figure 13-7 Armature and Output End Cover Assembly Figure 13-8 Bearing Play Inspection BEARING REMOVAL Place the wedge attachment tool (CCI P/N 1012812) between the bearing and the armature. Make sure the wedge attachment tool is supporting the inner race of the bearing.

  • Page 208: Field Coil Removal

    ELECTRICAL COMPONENTS: KEY-START WITH Starter/Generator NEUTRAL REV GAS VEHICLE FIELD COIL REMOVAL Remove the retaining nut from each field coil terminal and slide the insulator out of the slots in the housing. Remove the four pole piece screws from the housing. Remove the four pole pieces from inside the housing. Remove the field coils from the inside of the housing (Figure 13-10, Page 13-6).

  • Page 209: Visual Inspection Of Armature And Commutator

    ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE Starter/Generator VISUAL INSPECTION OF ARMATURE AND COMMUTATOR Some defects can be seen by examining the armature and commutator. Defects seen during the visual inspection can aid in diagnosing the original cause of the failure. Items to look for are listed below. •...

  • Page 210: Armature Ground Test

    ELECTRICAL COMPONENTS: KEY-START WITH Starter/Generator NEUTRAL REV GAS VEHICLE 1. Measure each position in two places 90° apart. Figure 13-11 Inspect Commutator ARMATURE GROUND TEST CAUTION • Do not submerge armature in solvent. NOTE: Before testing, wipe the armature with a clean cloth and remove carbon dust and metal particles from between commutator bars.

  • Page 211: Starter/Generator Rework

    ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE Starter/Generator WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 200 Ohm Setting 2. Commutator 3. Armature Shaft Figure 13-12 Armature Ground Test STARTER/GENERATOR REWORK Any rework must be performed by a qualified technician. Starter/Generator service specifications are listed in the following table.

  • Page 212: Starter/Generator Installation

    ELECTRICAL COMPONENTS: KEY-START WITH Starter/Generator NEUTRAL REV GAS VEHICLE Slide the bearing retainer onto the output end of the armature shaft (33) so that it will hold the outside of the bearing (35) only (Figure 13-7, Page 13-5). Press a new ball bearing (35) onto the output end of the armature (Figure 13-7, Page 13-5). Press a new ball bearing onto the commutator end of the armature shaft.
  • Page 213 ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE Starter/Generator Figure 13-13 Starter/Generator Installation 1. Belt Tension Gauge 2. End View Figure 13-14 Belt Tension Gauge 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual Page 13-11...

  • Page 214: Belt Tension Adjustment

    ELECTRICAL COMPONENTS: KEY-START WITH Starter/Generator NEUTRAL REV GAS VEHICLE BELT TENSION ADJUSTMENT Belt tension should be checked periodically. If the belt slips when starter/generator motor operates, adjust belt to correct tension. Turn the key switch is OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.

  • Page 215: Voltage Regulator

    ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE Voltage Regulator VOLTAGE REGULATOR See General Warning on page 1-1. TESTING THE VOLTAGE REGULATOR See Test Procedure 12 – Voltage Regulator on page 11-20. VOLTAGE REGULATOR REMOVAL Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.
  • Page 216 ELECTRICAL COMPONENTS: KEY-START WITH Voltage Regulator NEUTRAL REV GAS VEHICLE 1. Red wire to solenoid. 2. To kill limit switch. 3. To frame ground. 4. To bullet connector. Figure 13-15 Voltage Regulator Page 13-14 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual...

  • Page 217: Diode

    ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE Diode DIODE See General Warning on page 1-1. TESTING THE DIODE See Test Procedure 10 – Diode (Generator Circuit) on page 11-18. DIODE REMOVAL Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.
  • Page 218 ELECTRICAL COMPONENTS: KEY-START WITH Diode NEUTRAL REV GAS VEHICLE A. Some wires omitted for clarity. B. Viewed from inside driver side frame rail. Figure 13-16 Electrical Component Box and Diode Orientation Route and connect the red (5) and white (8) diode wires to the solenoid posts in the electrical component box. See following WARNING.

  • Page 219: Key Switch

    ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE Key Switch KEY SWITCH See General Warning on page 1-1. TESTING THE KEY SWITCH See Test Procedure 4 – Key Switch (Starter Circuit) on page 11-14. Also see Test Procedure 17 – Key Switch (Engine Kill Circuit) on page 11-28.

  • Page 220: Key Switch Installation

    ELECTRICAL COMPONENTS: KEY-START WITH Key Switch NEUTRAL REV GAS VEHICLE Figure 13-18 Key Switch Removal KEY SWITCH INSTALLATION Reverse removal procedures to install key switch in the dash. Connect wires to key switch. See Wiring Diagrams on page 11-7. Coat the connectors with Battery Terminal Protector Spray (CCI P/N 1014305) to prevent corrosion. Be sure that key switch terminals cannot touch the frame and that panel is properly seated and snapped in place.

  • Page 221: Solenoid

    ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE Solenoid SOLENOID See General Warning on page 1-1. TESTING THE SOLENOID See Test Procedure 6 – Solenoid on page 11-15. SOLENOID REMOVAL Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.

  • Page 222: Fuse

    ELECTRICAL COMPONENTS: KEY-START WITH Fuse NEUTRAL REV GAS VEHICLE FUSE See General Warning on page 1-1. TESTING THE FUSE See Test Procedure 2 – Fuse on page 11-12. FUSE REMOVAL Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.

  • Page 223: Neutral Lockout Limit Switch

    ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE Neutral Lockout Limit Switch NEUTRAL LOCKOUT LIMIT SWITCH See General Warning on page 1-1. TESTING THE NEUTRAL LOCKOUT LIMIT SWITCH See Test Procedure 7 – Neutral Lockout Limit Switch on page 11-16. NEUTRAL LOCKOUT LIMIT SWITCH REMOVAL Disconnect battery and spark plug wire(s).

  • Page 224: Neutral Lockout Limit Switch Installation

    ELECTRICAL COMPONENTS: KEY-START WITH Neutral Lockout Limit Switch NEUTRAL REV GAS VEHICLE NEUTRAL LOCKOUT LIMIT SWITCH INSTALLATION Install the neutral lockout limit switch with two washers and two nuts (Figure 13-20, Page 13-21). Tighten to 5 in-lb (0.6 N·m). Place the Forward/Reverse handle in REVERSE to make sure that both switches actuate. See following CAUTION.

  • Page 225: Reverse Warning Buzzer

    ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE Reverse Warning Buzzer REVERSE WARNING BUZZER See General Warning on page 1-1. TESTING THE REVERSE WARNING BUZZER See Test Procedure 20 – Reverse Buzzer on page 11-30. REVERSE WARNING BUZZER REMOVAL Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.

  • Page 226: Reverse Buzzer Limit Switch

    ELECTRICAL COMPONENTS: KEY-START WITH Reverse Buzzer Limit Switch NEUTRAL REV GAS VEHICLE REVERSE BUZZER LIMIT SWITCH See General Warning on page 1-1. TESTING THE REVERSE BUZZER LIMIT SWITCH See Test Procedure 19 – Reverse Buzzer Limit Switch on page 11-29. REVERSE BUZZER LIMIT SWITCH REMOVAL Disconnect battery and spark plug wire(s).

  • Page 227: Oil Warning Light

    ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE Oil Warning Light Test drive the vehicle in both forward and reverse to check for proper operation. OIL WARNING LIGHT See General Warning on page 1-1. TESTING THE OIL WARNING LIGHT See Test Procedure 22 – Oil Warning Light on page 11-30. OIL WARNING LIGHT REMOVAL Disconnect battery and spark plug wire(s).

  • Page 228: Fuel Gauge/Hour Meter

    ELECTRICAL COMPONENTS: KEY-START WITH Fuel Gauge/Hour Meter NEUTRAL REV GAS VEHICLE Figure 13-24 Fuel Gauge/Hour Meter Installation – Mid-2007 and Newer Vehicles FUEL GAUGE/HOUR METER See General Warning on page 1-1. TESTING THE FUEL GAUGE/HOUR METER See Test Procedure 25 – Fuel Gauge on page 11-33. Also see Test Procedure 26 – Hour Meter on page 11-35. Early to mid-2007 vehicles: With the key switch in the OFF position, the fuel gauge/hour meter fields are blank.

  • Page 229: Fuel Gauge/Hour Meter Installation

    ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE Fuel Level Sending Unit FUEL GAUGE/HOUR METER INSTALLATION Install a new fuel gauge/hour meter (1) into the hole in the instrument panel until the flange seats against the dash. Secure the fuel gauge/hour meter. 2.1.

  • Page 230: Rpm Limiter Installation

    ELECTRICAL COMPONENTS: KEY-START WITH RPM Limiter NEUTRAL REV GAS VEHICLE Disconnect the black wire (5) at the other bullet connector (6) near the RPM limiter. Remove the flange head bolts (7) from the RPM limiter band (8) and remove the RPM limiter and damper (9) (Figure 13-25, Page 13-28).

  • Page 231: Ignition Coil

    ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE Ignition Coil IGNITION COIL See General Warning on page 1-1. The ignition coil is located under the flywheel shroud of the engine. To replace it requires the removal and installation of the engine and transaxle. It is recommended that the ignition coil be thoroughly tested prior to replacement. TESTING THE IGNITION COIL See Test Procedure 14 –...

  • Page 232: Ignition Coil Installation

    ELECTRICAL COMPONENTS: KEY-START WITH Ignition Coil NEUTRAL REV GAS VEHICLE Figure 13-26 Fan Housing Removal Figure 13-27 Ignition Coil Removal IGNITION COIL INSTALLATION NOTE: If a new ignition coil is being installed, the spark plug cap, gasket, protector tube and grommet must be removed from the old coil and installed on the new coil.
  • Page 233 ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE Ignition Coil 13. When installing fan housing, make sure the top front corner of the housing is above the upper cylinder shroud. The front edge of the fan housing should be behind the lower cylinder shroud. Align the slots in the housing with the flanged bolts (6) loosened earlier (Figure 13-26, Page 13-30).

  • Page 234: Oil Level Sensor

    ELECTRICAL COMPONENTS: KEY-START WITH Oil Level Sensor NEUTRAL REV GAS VEHICLE OIL LEVEL SENSOR See General Warning on page 1-1. TESTING THE OIL LEVEL SENSOR See Test Procedure 21 – Oil Level Sensor on page 11-30. OIL LEVEL SENSOR REMOVAL See Oil Level Sensor Removal on page 15-5.

  • Page 235: Headlight Bulb Removal

    ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE Headlights HEADLIGHT BULB REMOVAL Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels. Disconnect battery. See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3. From the front of vehicle, reach under body and turn the wire harness/halogen bulb assembly (4 and 6) clockwise one-quarter turn (Figure 13-30, Page 13-32).

  • Page 236: Voltage Limiter

    ELECTRICAL COMPONENTS: KEY-START WITH Voltage Limiter NEUTRAL REV GAS VEHICLE VOLTAGE LIMITER See General Warning on page 1-1. TESTING THE VOLTAGE LIMITER See Test Procedure 28 – Headlight Diode on page 11-37. VOLTAGE LIMITER REMOVAL Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.

  • Page 237: Light Switch

    ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE Light Switch LIGHT SWITCH See General Warning on page 1-1. TESTING THE LIGHT SWITCH See Test Procedure 27 – Light Switch on page 11-36. LIGHT SWITCH REMOVAL Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.

  • Page 238: General Information

    ELECTRICAL COMPONENTS: KEY-START WITH Battery NEUTRAL REV GAS VEHICLE DANGER • Tools, wires, and metal objects can cause sparks when shorted across a battery. • Follow all instructions carefully when working with batteries. • Charge battery in a well-ventilated area only. •...

  • Page 239: Self-Discharge

    ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE Battery CAUTION • If battery wire terminals are damaged or corroded, replace or clean them as necessary. Failure to do so may cause them to overheat during operation and could result in a fire, property damage, or personal injury.

  • Page 240: Vibration Damage

    ELECTRICAL COMPONENTS: KEY-START WITH Battery NEUTRAL REV GAS VEHICLE VIBRATION DAMAGE The battery hold-down clamp should always be tight enough to keep the battery from bouncing. Battery life may be severely shortened if the clamp is too loose. Excessive vibration shortens the life of the battery. It may also cause acid to leak out of the vent caps and corrosion to build up on surrounding metal parts.

  • Page 241: Battery Removal

    ELECTRICAL COMPONENTS: KEY-START WITH NEUTRAL REV GAS VEHICLE Battery BATTERY REMOVAL See General Warning on page 1-1. Also see DANGER at beginning of Battery topic. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.

  • Page 242: Battery Storage

    ELECTRICAL COMPONENTS: KEY-START WITH Ground Cables NEUTRAL REV GAS VEHICLE BATTERY STORAGE See General Warning on page 1-1. Also see DANGER at beginning of Battery topic. Keep the battery clean and free of corrosion. See Preventive Maintenance on page 13-36. The battery cables should be disconnected from the battery so the battery can be connected to the charger.

  • Page 243: Section 14 - Electrical Components: Pedal-Start Gas Vehicle

    SECTION 14 – ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE DANGER • See General Warning on page 1-1. WARNING • See General Warning on page 1-1. STARTER/GENERATOR See General Warning on page 1-1. TESTING THE STARTER/GENERATOR See Test Procedure 8 – Starter/Generator (Starter Function) on page 12-18. See Test Procedure 10 –...

  • Page 244: Disassembly Of The Starter/Generator To Service The Brushes

    ELECTRICAL COMPONENTS: PEDAL- Starter/Generator START GAS VEHICLE Figure 14-1 Starter/Generator Removal DISASSEMBLY OF THE STARTER/GENERATOR TO SERVICE THE BRUSHES Remove the two bolts (20) and pull commutator end cover (23) free of starter/generator housing (24) (Figure 14-2, Page 14-2). See following NOTE. NOTE: If the brushes are not removed, contact between the brushes and commutator as the commutator end cover is being removed or installed could damage the brushes.

  • Page 245: Brush Spring Inspection And Replacement

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator Check the wear line on the side of the brush. If the end of the brush is within 1/16 inch (1.6 mm) of the wear line, replace all four brushes (Figure 14-4, Page 14-3). Figure 14-4 Inspect Brushes BRUSH SPRING INSPECTION AND REPLACEMENT Visually inspect springs.

  • Page 246: Disassembly Of The Starter/Generator To Service The Armature/Commutator

    ELECTRICAL COMPONENTS: PEDAL- Starter/Generator START GAS VEHICLE To prevent contact between the brushes and commutator as the commutator is installed, and possible damage to the brushes, lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover.

  • Page 247: Bearing Cleaning And Inspection

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator Figure 14-7 Armature and Output End Cover Assembly BEARING CLEANING AND INSPECTION Using a clean cloth, wipe the carbon dust from the two bearings. Inspect bearings by spinning them by hand and checking for both axial (A) and radial (B) play (Figure 14-8, Page 14-5). Replace the bearing if it is noisy, does not spin smoothly, or has excessive play.

  • Page 248: Field Coil Removal

    ELECTRICAL COMPONENTS: PEDAL- Starter/Generator START GAS VEHICLE Discard the bearings. Slide the bearing retainer (32) off of the output end of the shaft (Figure 14-7, Page 14-5). Figure 14-9 Bearing Removal FIELD COIL REMOVAL Remove the retaining nut from each field coil terminal and slide the insulator out of the slots in the housing. Remove the four pole piece screws from the housing.

  • Page 249: Commutator Cleaning And Inspection

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator Figure 14-10 Field Coil Assembly COMMUTATOR CLEANING AND INSPECTION Clean the carbon dust, dirt and oil from the commutator. Visually inspect the commutator for worn, burned or glazed areas. Check for loose or raised commutator bars. Slight roughness of the commutator can be polished away with 400 grit (or finer) sandpaper.

  • Page 250: Armature Ground Test

    ELECTRICAL COMPONENTS: PEDAL- Starter/Generator START GAS VEHICLE Figure 14-11 Inspect Commutator ARMATURE GROUND TEST CAUTION • Do not submerge armature in solvent. NOTE: Before testing, wipe the armature with a clean cloth and remove carbon dust and metal particles from between commutator bars.

  • Page 251: Visual Inspection Of Field Coils

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator VISUAL INSPECTION OF FIELD COILS If the insulation on the field coils appears blackened or charred, the serviceability of the coils is questionable. Burned or scorched coil insulation indicates the starter/generator has overheated due to overloads or grounded or shorted coil windings.

  • Page 252: Starter/Generator Installation

    ELECTRICAL COMPONENTS: PEDAL- Starter/Generator START GAS VEHICLE Install the output end cover (36) onto the armature. Secure the bearing retainer (32) to the cover and tighten the screws (43) to 39 in-lb (4.4 N·m) (Figure 14-7, Page 14-5). Slide the housing with field coils over the armature. Use the locating pin to align housing to the cover. NOTE: The terminal insulators should be on the commutator end of the housing.
  • Page 253 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator Figure 14-13 Starter/Generator Installation Belt Tension Gauge 2. End View Figure 14-14 Belt Tension Gauge 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual Page 14-11...

  • Page 254: Belt Tension Adjustment

    ELECTRICAL COMPONENTS: PEDAL- Voltage Regulator START GAS VEHICLE BELT TENSION ADJUSTMENT Belt tension should be checked periodically. If the belt slips when starter/generator motor operates, adjust belt to correct tension. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3.

  • Page 255: Voltage Regulator Installation

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Key Switch 1. Red wire to solenoid. 2. To kill limit switch. 3. To frame ground. 4. To bullet connector. Figure 14-15 Voltage Regulator VOLTAGE REGULATOR INSTALLATION Position the voltage regulator (9) in the electrical component box and install the mounting screw (8) (Figure 14-15, Page 14-13).
  • Page 256 ELECTRICAL COMPONENTS: PEDAL- Key Switch START GAS VEHICLE Remove the center dash panel. 2.1. Remove the plastic cap (1) covering the mounting screw (2) on each side of the center dash panel (3) (Figure 14-16, Page 14-14). 2.2. Loosen, but do not remove, the screw (2) on each side of the center dash panel (3). 2.3.

  • Page 257: Key Switch Installation

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Solenoid KEY SWITCH INSTALLATION Reverse removal procedures to install key switch in the dash. Connect wires to key switch. See Wiring Diagram on page 12-6. Coat the connectors with Battery Terminal Protector Spray (CCI P/N 1014305) to prevent corrosion. Be sure that key switch terminals cannot touch the frame and that panel is properly seated and snapped in place.

  • Page 258: Fuse

    ELECTRICAL COMPONENTS: PEDAL- Fuse START GAS VEHICLE FUSE See General Warning on page 1-1. TESTING THE FUSE See Test Procedure 2 – Fuse on page 12-12. FUSE REMOVAL Disconnect battery. See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3. Remove electrical component box cover.

  • Page 259: Kill Limit Switch Installation

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Kill Limit Switch Disconnect the two white/black wires and the black wire from the kill limit switch (12). Remove the kill limit switch (12). A. To Voltage Regulator Figure 14-18 Accelerator Starter and Kill Limit Switches KILL LIMIT SWITCH INSTALLATION Install the kill limit switch (12) onto the two screws (16) (Figure 14-18, Page 14-17).

  • Page 260: Neutral Lockout Limit Switch

    ELECTRICAL COMPONENTS: PEDAL- Neutral Lockout Limit Switch START GAS VEHICLE NEUTRAL LOCKOUT LIMIT SWITCH See General Warning on page 1-1. TESTING THE NEUTRAL LOCKOUT LIMIT SWITCH See Test Procedure 7 – Neutral Lockout Limit Switch on page 12-17. NEUTRAL LOCKOUT LIMIT SWITCH REMOVAL Disconnect battery and spark plug wire(s).

  • Page 261: Neutral Lockout Limit Switch Installation

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Reverse Warning Buzzer NEUTRAL LOCKOUT LIMIT SWITCH INSTALLATION Install the neutral lockout limit switch with two washers and two nuts (Figure 14-20, Page 14-18). Tighten to 5 in-lb (0.6 N·m). Place the Forward/Reverse handle in REVERSE to make sure that both switches actuate. See following CAUTION.
  • Page 262 ELECTRICAL COMPONENTS: PEDAL- Reverse Warning Buzzer START GAS VEHICLE Reverse removal procedures to install the center dash in the vehicle. Be sure that the key switch terminals cannot touch the frame and that the panel is properly seated and snapped in place. Connect battery and spark plug wire(s).

  • Page 263: Reverse Buzzer Limit Switch

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Reverse Buzzer Limit Switch REVERSE BUZZER LIMIT SWITCH See General Warning on page 1-1. TESTING THE REVERSE BUZZER LIMIT SWITCH See Test Procedure 19 – Reverse Buzzer Limit Switch on page 12-31. REVERSE BUZZER LIMIT SWITCH REMOVAL Disconnect battery and spark plug wire(s).

  • Page 264: Low Oil Warning Light

    ELECTRICAL COMPONENTS: PEDAL- Low Oil Warning Light START GAS VEHICLE Test drive the vehicle in both forward and reverse to check for proper operation. LOW OIL WARNING LIGHT See General Warning on page 1-1. TESTING THE LOW OIL WARNING LIGHT See Test Procedure 21 –...

  • Page 265: Fuel Gauge/Hour Meter

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Fuel Gauge/Hour Meter Figure 14-24 Fuel Gauge/Hour Meter Installation – Mid-2007 and Newer Vehicles FUEL GAUGE/HOUR METER See General Warning on page 1-1. TESTING THE FUEL GAUGE/HOUR METER See Test Procedure 26 – Fuel Gauge on page 12-36. Also see Test Procedure 27 – Hour Meter on page 12-38. GENERAL INFORMATION Early to mid-2007 vehicles: With the key switch in the OFF position, the fuel gauge/hour meter fields are blank.

  • Page 266: Fuel Gauge/Hour Meter Installation

    ELECTRICAL COMPONENTS: PEDAL- Fuel Level Sending Unit START GAS VEHICLE FUEL GAUGE/HOUR METER INSTALLATION Install a new fuel gauge/hour meter (1) into the hole in the instrument panel until the flange seats against the dash. Secure the fuel gauge/hour meter. 2.1.

  • Page 267: Rpm Limiter Installation

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE RPM Limiter Remove the flange head bolts (7) from the RPM limiter band (8) and remove the RPM limiter and damper (9) (Figure 14-25, Page 14-25). Figure 14-25 RPM Limiter Assembly RPM LIMITER INSTALLATION Place the RPM limiter (4) on the damper (9) squarely so that RPM limiter fits tightly against the damper. Place the RPM limiter with damper on the front of the RPM limiter mounting bracket (10) (Figure 14-25, Page 14-25).

  • Page 268: Ignition Coil

    ELECTRICAL COMPONENTS: PEDAL- Ignition Coil START GAS VEHICLE IGNITION COIL See General Warning on page 1-1. TESTING THE IGNITION COIL See Test Procedure 13 – Ignition Spark on page 12-21 and Test Procedure 15 – Ignition Coil on page 12-23. IGNITION COIL REMOVAL Disconnect battery and spark plug wire(s).

  • Page 269: Ignition Coil Installation

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Ignition Coil Figure 14-27 Fan Housing Removal Figure 14-28 Ignition Coil Removal IGNITION COIL INSTALLATION NOTE: If a new ignition coil is being installed, the spark plug cap, gasket, protector tube and grommet must be removed from the old coil and installed on the new coil.

  • Page 270: Oil Level Sensor

    ELECTRICAL COMPONENTS: PEDAL- Oil Level Sensor START GAS VEHICLE Remove the gasket (1) and protector tube (3) from the old coil. See following NOTE. NOTE: Moisten the spark plug wire with water to make gasket removal and installation easier. Remove the grommet (4) from the old spark plug wire. Clean the grommet and place it on the new spark plug wire (5).

  • Page 271: Oil Level Sensor Removal

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Headlights OIL LEVEL SENSOR REMOVAL See Oil Level Sensor Removal on page 15-5. OIL LEVEL SENSOR INSTALLATION See Oil Level Sensor Installation on page 15-5. HEADLIGHTS See General Warning on page 1-1. TESTING THE HEADLIGHT SOCKET See Test Procedure 30 –...

  • Page 272: Headlight Bulb Installation

    ELECTRICAL COMPONENTS: PEDAL- Voltage Limiter START GAS VEHICLE HEADLIGHT BULB INSTALLATION NOTE: When handling halogen bulbs, do not touch glass portion of bulb. Oil from finger tips can cause premature failure of bulb. Connect wire harness (4) to the halogen bulb assembly (6). The retaining tab should lock onto the halogen bulb assembly (Figure 14-31, Page 14-29).

  • Page 273: Headlight Switch

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Headlight Switch Figure 14-32 Voltage Limiter Figure 14-33 Light Switch HEADLIGHT SWITCH See General Warning on page 1-1. TESTING THE LIGHT SWITCH See Test Procedure 28 – Light Switch on page 12-39. HEADLIGHT SWITCH REMOVAL Disconnect battery and spark plug wire(s).

  • Page 274: Battery

    ELECTRICAL COMPONENTS: PEDAL- Battery START GAS VEHICLE BATTERY See General Warning on page 1-1. DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working on or near batteries. • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area.

  • Page 275: Preventive Maintenance

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Battery PREVENTIVE MAINTENANCE To keep the battery in good operating condition, remove any corrosion immediately. Post connections should be clean and tight. Any frayed or worn wires should be replaced. After all cables have been connected and properly tightened to 144 in-lb (16 N·m), coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to prevent future corrosion.

  • Page 276: Vibration Damage

    ELECTRICAL COMPONENTS: PEDAL- Battery START GAS VEHICLE Hot weather also has an effect on a battery’s self-discharge rate. The higher the temperature, the quicker a battery will discharge. In hotter climates, therefore, the battery should be checked more often. When storing the battery, keep in a cool place.

  • Page 277: Battery Removal

    ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Battery BATTERY REMOVAL See General Warning on page 1-1. Also see DANGER at beginning of Battery topic. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels. Disconnect battery and spark plug wire(s).

  • Page 278: Battery Storage

    ELECTRICAL COMPONENTS: PEDAL- Ground Cables START GAS VEHICLE BATTERY STORAGE See General Warning on page 1-1. Also see DANGER at beginning of Battery topic. Keep the battery clean and free of corrosion. See Preventive Maintenance on page 14-33. The battery cables should be disconnected from the battery so the battery can be connected to the charger. The battery can be left in the vehicle.

  • Page 279: Section 15 - S10 Fe 350 Engine

    SECTION 15 – S10 FE 350 ENGINE DANGER • See General Warning on page 1-1. WARNING • See General Warning on page 1-1. GENERAL INFORMATION See General Warning on page 1-1. This gasoline vehicle is powered by a 4-cycle, overhead valve, single cylinder, air-cooled engine. The 4-cycle engine has an oil reservoir (crankcase) similar to automobiles, trucks, aircraft, heavy equipment, machinery and other applications designed for reliable heavy-duty service.
  • Page 280 General Information S10 FE 350 ENGINE CAUTION • Before removal and disassembly, clean the engine. Remove all dirt from plug base in the cylinder head before removing plug. Use a 13/16-inch deep well socket wrench or 13/16-inch spark plug wrench to loosen the plug. Spark Plug Cleaning, Inspection and Repair Examine the plug (Figure 15-1, Page 15-2).

  • Page 281: Cylinder Head

    S10 FE 350 ENGINE Cylinder Head CYLINDER HEAD See General Warning on page 1-1. GENERAL INFORMATION Test cylinder compression using a standard compression tester. Low compression would normally indicate a problem in the cylinder assembly such as defective rings, gaskets, etc. At a cranking speed of 550-600 RPM, the compression should be 156-185 psi.

  • Page 282: Crankcase Cover Removal

    Crankcase S10 FE 350 ENGINE Remove crankcase oil drain plug and filler tube. Tip the engine slightly to allow all of the oil to drain from the crankcase. Dispose of engine oil properly. CRANKCASE COVER REMOVAL Remove yellow jumper wire (11) from cord connector (12) (Figure 15-2, Page 15-4). Remove nuts and clamps at two-ended bolts (1 and 2) (Figure 15-3, Page 15-4).

  • Page 283: Oil Level Sensor

    S10 FE 350 ENGINE Crankcase Figure 15-4 Engine Mounting Plate OIL LEVEL SENSOR Testing the Oil Level Sensor See Oil Level Sensor on page 11-30. Oil Level Sensor Removal If not already removed, remove crankcase cover. See Crankcase Cover Removal on page 15-4. Disconnect the oil level sensor wire (2) from the cord connection (1) (Figure 15-2, Page 15-4).

  • Page 284: Crankcase Cover Installation

    Crankcase S10 FE 350 ENGINE Position the sensor and bracket on inside of crankcase and install two mounting screws. Connect sensor wire (2) to cord connector (1) (Figure 15-5, Page 15-6). Install screw (3) through wire clamp and into crankcase cover. Tighten to 30 in-lb (3.4 N·m). Figure 15-5 Oil Level Sensor CRANKCASE COVER INSTALLATION CAUTION...

  • Page 285: Ignition Coil And Flywheel

    S10 FE 350 ENGINE Ignition Coil and Flywheel Figure 15-6 Crankcase Cover Installation IGNITION COIL AND FLYWHEEL See General Warning on page 1-1. IGNITION COIL AND FLYWHEEL REMOVAL Loosen three screws (2) and remove the remaining four screws (1) attaching the flywheel housing as shown, then remove the housing (Figure 15-7, Page 15-7).

  • Page 286: Flywheel Installation

    Ignition Coil and Flywheel S10 FE 350 ENGINE CAUTION • The flywheel nut has right-hand threads. Turn it clockwise to tighten, or counterclockwise to loosen. • Do not damage the fan blades with the strap wrench. Do not place screwdriver or pry bar in the fan blades.

  • Page 287: Ignition Coil Inspection And Repair

    S10 FE 350 ENGINE Engine Installation Figure 15-11 Fan and Flywheel Installation IGNITION COIL INSPECTION AND REPAIR See Ignition Coil, Section 11, Page 11-23. IGNITION COIL INSTALLATION Installation is the reverse of removal. While tightening the two bolts (6), use a bronze feeler gauge to adjust the ignition coil air gap to 0.012 inch (0.304 mm) (Figure 15-10, Page 15-8).

  • Page 288: Torque Specifications

    Engine Installation S10 FE 350 ENGINE type of oil. This engine should be regarded as a new engine for next scheduled oil change. See Periodic Maintenance on page 10-1. Check all hardware for proper torque/tightness. Check engine oil level (Figure 15-12, Page 15-10). 9.1.

  • Page 289: Adjustments And Settings

    S10 FE 350 ENGINE Engine Installation ADJUSTMENTS AND SETTINGS ITEM LIMITS Spark plug gap (standard) 0.027 to 0.031 in. (0.69 to 0.79 mm) Ignition coil air gap (standard) 0.012 in. (0.304 mm) Compression pressure (min.) 156 psi (1076 kPa) 3050 (±30) RPM for XRT 900 Engine RPM 2900 (±30) RPM for Turf/CA 252 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual...

  • Page 291: Section 16 - S27 Fe 350 Engine

    SECTION 16 – S27 FE 350 ENGINE DANGER • See General Warning on page 1-1. WARNING • See General Warning on page 1-1. GENERAL INFORMATION See General Warning on page 1-1. This vehicle is powered by a 4-cycle, overhead valve, single cylinder, air-cooled engine. The S27 engine is identified by labelling on the blower housing and has mechanical lifters as opposed to a hydraulically-lifted valve train.
  • Page 292 General Information S27 FE 350 ENGINE CAUTION • Before removal and disassembly, clean the engine. Remove all dirt from plug base in the cylinder head before removing plug. Use a 13/16-inch deep well socket wrench or 13/16-inch spark plug wrench to loosen the plug. Spark Plug Cleaning, Inspection and Repair Examine the plug (Figure 16-1, Page 16-2).

  • Page 293: Cylinder Head

    S27 FE 350 ENGINE Cylinder Head CYLINDER HEAD See General Warning on page 1-1. GENERAL INFORMATION Test cylinder compression using a standard compression tester. Low compression would normally indicate a problem in the cylinder assembly such as defective rings, gaskets, etc. Compression should be: •...

  • Page 294: Crankcase

    Crankcase S27 FE 350 ENGINE CRANKCASE See General Warning on page 1-1. ENGINE REMOVAL To perform repairs on crankcase components, remove engine from the vehicle. See following CAUTION. CAUTION • Before removal and disassembly, clean the engine. Remove the powertrain. See Unitized Transaxle Removal on page 20-7. See following NOTE. NOTE: The crankshaft has left-hand threads at the clutch mounting hole.
  • Page 295 S27 FE 350 ENGINE Crankcase Figure 16-4 Oil Level Sensor Wire Figure 16-5 Crankcase Cover 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual Page 16-5...

  • Page 296: Oil Level Sensor

    Crankcase S27 FE 350 ENGINE Figure 16-6 Engine Mounting Plate OIL LEVEL SENSOR Testing the Oil Level Sensor See Oil Level Sensor on page 11-30. Oil Level Sensor Removal If not already removed, remove crankcase cover. See Crankcase Cover Removal on page 16-4. Disconnect the oil level sensor wire (2) from the cord connection (1) (Figure 16-7, Page 16-7).

  • Page 297: Crankcase Cover Installation

    S27 FE 350 ENGINE Crankcase Position the sensor and bracket on inside of crankcase and install two mounting screws. Connect sensor wire (2) to cord connector (1). Install screw (3) through wire clamp and into crankcase cover. Tighten to 30 in-lb (3.4 N·m). Figure 16-7 Oil Level Sensor CRANKCASE COVER INSTALLATION CAUTION...

  • Page 298: Ignition Coil And Flywheel

    Ignition Coil and Flywheel S27 FE 350 ENGINE Figure 16-8 Crankcase Cover Installation IGNITION COIL AND FLYWHEEL See General Warning on page 1-1. IGNITION COIL AND FLYWHEEL REMOVAL Loosen three screws (2) and remove the remaining four screws (1) attaching the flywheel housing as shown, then remove the housing (Figure 16-9, Page 16-8).

  • Page 299: Flywheel Installation

    S27 FE 350 ENGINE Ignition Coil and Flywheel CAUTION • The flywheel nut has right-hand threads. Turn it clockwise to tighten, or counterclockwise to loosen. • Do not damage the fan blades with the strap wrench. Do not place screwdriver or pry bar in the fan blades.

  • Page 300: Ignition Coil Inspection And Repair

    Engine Installation S27 FE 350 ENGINE Figure 16-13 Fan and Flywheel Installation IGNITION COIL INSPECTION AND REPAIR See Ignition Coil, Section 11, Page 11-23. IGNITION COIL INSTALLATION Installation is the reverse of removal. While tightening the two bolts (6), use a bronze feeler gauge to adjust the ignition coil air gap to 0.012 inch (0.304 mm) (Figure 16-12, Page 16-9).

  • Page 301: Torque Specifications

    S27 FE 350 ENGINE Engine Installation type of oil. This engine should be regarded as a new engine for next scheduled oil change. See Periodic Maintenance on page 10-1. Check all hardware for proper torque/tightness. Check engine oil level. 9.1. With vehicle on level surface, remove dip stick and clean with cloth (Figure 16-14, Page 16-11). 9.2.

  • Page 302: Adjustments And Settings

    Engine Installation S27 FE 350 ENGINE ADJUSTMENTS AND SETTINGS ITEM LIMITS Spark plug gap (standard) 0.027 to 0.031 in. (0.69 to 0.79 mm) Ignition coil air gap (standard) 0.012 in. (0.304 mm) Compression pressure (min.) 128 psi (883 kPa) 3050 (±30) RPM for Key-Start Vehicles Engine RPM 2900 (±30) RPM for Pedal-Start Vehicles Page 16-12...

  • Page 303: Section 17 - S10 Fe 350 Fuel System

    SECTION 17 – S10 FE 350 FUEL SYSTEM DANGER • See General Warning on page 1-1. WARNING • See General Warning on page 1-1. GENERAL INFORMATION The engine is equipped with a float bowl type carburetor with fixed jets that require no adjustment. The carburetor atomizes the fuel, mixes it with air, and feeds the combustible mixture into the cylinder.

  • Page 304: Main Jet Elevation/Size Chart

    Carburetor S10 FE 350 FUEL SYSTEM Figure 17-1 Carburetor Mounting MAIN JET ELEVATION/SIZE CHART ALTITUDE FE290 ENGINE MAIN JET SIZE FE350 ENGINE MAIN JET SIZE 0-3000 ft. (0-914.4 m) 3000-5000 ft. (914.4-1524 m) 5000-8000 ft. (1524-2438.4 m) TABLE CONTINUED ON NEXT PAGE Page 17-2 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual...

  • Page 305: Changing The Main Jet

    S10 FE 350 FUEL SYSTEM Carburetor ALTITUDE FE290 ENGINE MAIN JET SIZE FE350 ENGINE MAIN JET SIZE 8000-10,000 ft. (2438.4-3048 m) 10,000 ft. and over (3048 m and over) CHANGING THE MAIN JET See General Warning on page 1-1. Remove the carburetor. 1.1.
  • Page 306 Carburetor S10 FE 350 FUEL SYSTEM NOTE: Make sure the fuel bowl gasket (9) remains properly seated in the carburetor body when the fuel bowl is removed (Figure 17-4, Page 17-4). During normal operation, the fuel bowl retains the float pivot pin (6). Make sure that the float pivot pin does not fall out of the carburetor body after the fuel bowl is removed.
  • Page 307 S10 FE 350 FUEL SYSTEM Carburetor CAUTION • Make sure the fuel bowl is properly seated against the carburetor fuel bowl gasket, and the gasket is not pinched. 1. If spring looks like this... 2. then adjust spring to look like this by... 3. holding float firmly and rotating valve counterclockwise to seat spring in seat of float bowl 4.

  • Page 308: Engine Control Linkage

    Engine Control Linkage S10 FE 350 FUEL SYSTEM ENGINE CONTROL LINKAGE See General Warning on page 1-1. DANGER • To ensure the vehicle does not run over you while you disconnect or adjust the accelerator push rod, do the following: –...
  • Page 309 S10 FE 350 FUEL SYSTEM Engine Control Linkage Figure 17-6 Accelerator Rod Accelerator Rod Installation and Adjustment Before installing the accelerator rod, adjust accelerator pedal position. See Pedal Group Adjustment – Gasoline Vehicles on page 5-10. Install the ball joint on the ball stud at the accelerator pedal (Figure 17-6, Page 17-7). Access the engine compartment.

  • Page 310: Governor Cable

    Engine Control Linkage S10 FE 350 FUEL SYSTEM Figure 17-7 Cam Position – Parallel with Box (Top View) Figure 17-8 Accelerator Rod – Pull Spring Release to Attach (Bottom View) Before tightening the jam nuts, set the park brake to the first latch and pawl position and check for proper activation of switches.
  • Page 311 S10 FE 350 FUEL SYSTEM Engine Control Linkage Governor Cable Installation and Adjustment Install the cable onto the governor cable support bracket (10) and the engine bracket (11) (Figure 17-9, Page 17-9). Push the cable dust shields onto the ends of the cable conduit. Connect the governor cable to the carburetor throttle at the carburetor.

  • Page 312: Accelerator Cable

    Engine Control Linkage S10 FE 350 FUEL SYSTEM ACCELERATOR CABLE Accelerator Cable Removal Access the engine compartment. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3. Remove the electrical box screw and cover and loosen the cable housing retaining nuts (Figure 17-7, Page 17-8). Disconnect cable (1) from cam (17) in the electrical box (Figure 17-9, Page 17-9).

  • Page 313: Engine Rpm Adjustment

    S10 FE 350 FUEL SYSTEM Engine Control Linkage Figure 17-10 Idle Screw ENGINE RPM ADJUSTMENT DANGER • Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. If the governor is adjusted, proceed to step 2;...

  • Page 314: Choke And Air Intake System

    Choke and Air Intake System S10 FE 350 FUEL SYSTEM CHOKE AND AIR INTAKE SYSTEM See General Warning on page 1-1. GENERAL INFORMATION The choke system is a simple mechanism requiring very little or no maintenance. The system consists of a choke assembly that is attached to the driver side of the front body, an air filter housing with a hose that is attached to the carburetor, and an air duct that provides the engine with air from outside the engine compartment.

  • Page 315: Air Box Installation

    S10 FE 350 FUEL SYSTEM Choke and Air Intake System Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3. Remove the air intake box from the vehicle by removing intake hose (16) and three screws (23) and washers (22) that mount the intake box to the vehicle (Figure 17-12, Page 17-15).

  • Page 316: Intake Duct Installation

    Choke and Air Intake System S10 FE 350 FUEL SYSTEM Lift air box assembly off the intake duct. Be careful that the intake seal on the bottom of the air box assembly is not dislodged in the process. Pull the intake duct forward and out of the vehicle. INTAKE DUCT INSTALLATION The intake duct assembly is installed from the front of the vehicle.
  • Page 317 S10 FE 350 FUEL SYSTEM Choke and Air Intake System Figure 17-12 Air Intake and Choke Assemblies 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual Page 17-15...

  • Page 318: Intake Duct Repair

    • If air box is extremely dirty, remove air box from vehicle and clean thoroughly. • Use only Club Car replacement air filters (CCI P/N 1015426). The use of other air filters could result in engine damage. If the air filter is too thin, the cover will seat before the filter can seal, leaving space for dirt to pass into the engine on all sides of the element.

  • Page 319: Fuel Filter Installation

    S10 FE 350 FUEL SYSTEM Fuel Filters Remove the primary fuel filter (17) (Figure 17-13, Page 17-18). 4.1. Remove the clamps (16) and fuel lines (1 and 2) from the filter and plug the fuel lines. Remove the secondary filter (22), if equipped. 5.1.
  • Page 320 Fuel Filters S10 FE 350 FUEL SYSTEM Figure 17-13 Fuel and Vent Lines LENGTH FUEL LINE NO. ROUTING SOLID COLOR CLEAR Fuel tank to primary fuel filter 14.0 in. (35.6 cm) Primary fuel filter to fuel pump 6.0 in. (15.0 cm) Fuel pump to secondary fuel filter 11.5 in.

  • Page 321: Fuel Pump

    S10 FE 350 FUEL SYSTEM Fuel Pump FUEL PUMP See General Warning on page 1-1. GENERAL INFORMATION The gasoline vehicle is equipped with an impulse fuel pump. If the fuel pump is not operating properly, perform the following tests: • Make sure all hose clamps are tight. •...

  • Page 322: Fuel Pump Cleaning And Inspection

    Fuel Pump S10 FE 350 FUEL SYSTEM Remove four screws (24) and lock washers (25) from front of the fuel pump (Figure 17-14, Page 17-20). Remove the front cover (37) of the fuel pump while holding the rest of the pump intact. Note the orientations of the impulse gasket (27), the diaphragm (28), and the gasket (29), then remove them from the pump.

  • Page 323: Fuel Pump Installation

    S10 FE 350 FUEL SYSTEM Fuel Pump CAUTION • If the valve assembly is not installed exactly as shown (Figure 17-14, Page 17-20), the impulse fuel pump will not operate properly. Install the pumping chamber (30) on top of the fuel diaphragm (34). Be sure the fuel inlet (38) and the fuel outlet (39) align with the arrows on the front of the front cover (Figure 17-14, Page 17-20).

  • Page 324: Fuel Tank

    Fuel Tank S10 FE 350 FUEL SYSTEM FUEL TANK See General Warning on page 1-1. GENERAL INFORMATION The vehicle is equipped with a high impact plastic, seven gallon (26.5 liter) fuel tank. WARNING • If the fuel tank is damaged, replace it. Do not attempt to repair it. See the following tank removal and disposal procedure.

  • Page 325: Fuel Tank Disposal

    S10 FE 350 FUEL SYSTEM Fuel Tank WARNING • Make sure the key switch is off before disconnecting wiring. Remove the vent tube (6) and fuel line (1) from the fuel tank (Figure 17-13, Page 17-18). 10. Loosen the strap (13) by removing the screw (12) from the speed nut (11). 11.

  • Page 326: Fuel Tank Installation

    Fuel Tank S10 FE 350 FUEL SYSTEM FUEL TANK INSTALLATION With the retaining strap correctly positioned, install the fuel tank in the vehicle. Insert the filler neck into the polyurethane filler bezel. Secure the tank with the retaining strap (13) (Figure 17-13, Page 17-18). 2.1.

  • Page 327: Fuel Lines

    S10 FE 350 FUEL SYSTEM Fuel Lines 1. Vent 2. Fuel Shut-off Valve 3. Fuel Vent Line 4. Fuel Tank Figure 17-17 Fuel Tank FUEL LINES See General Warning on page 1-1. The fuel lines must be properly routed, and all hose clamps must be tight. The fuel lines should be kept clean. See following WARNING.

  • Page 328: Fuel Shut-Off Valve

    Fuel Shut-Off Valve S10 FE 350 FUEL SYSTEM FUEL SHUT-OFF VALVE See General Warning on page 1-1. The fuel shut-off valve is located on top of the fuel tank (Figure 17-18, Page 17-26 or Figure 17-19, Page 17-26). The fuel shut-off valve should always be turned to the closed (OFF) position during vehicle storage, towing or trailering. Unless the engine will be run as part of a procedure, the fuel shut-off valve should also be closed (OFF) before performing maintenance or service procedures.
  • Page 329 S10 FE 350 FUEL SYSTEM Fueling Instructions CAUTION • To allow for expansion, do not fill higher than 2.54 cm (one inch) from the top of the fuel tank. Avoid spilling fuel. NOTE: Whenever possible, avoid using oxygenated fuels and fuels that are blended with alcohol. Vehicles to be stored for extended periods should be prepared for storage as instructed.

  • Page 331: Section 18 - S27 Fe 350 Fuel System

    SECTION 18 – S27 FE 350 FUEL SYSTEM DANGER • See General Warning on page 1-1. WARNING • See General Warning on page 1-1. GENERAL INFORMATION The engine is equipped with a float bowl type carburetor with fixed jets that require no adjustment. The carburetor atomizes the fuel, mixes it with air, and feeds the combustible mixture into the cylinder.

  • Page 332: Main Jet Elevation/Size Chart

    Carburetor S27 FE 350 FUEL SYSTEM Figure 18-1 Carburetor Mounting MAIN JET ELEVATION/SIZE CHART ALTITUDE S27 FE350 ENGINE MAIN JET SIZE 0-3200 ft. (0-975 m) 3200-6500 ft. (975-1981 m) 6500-9800 ft. (1981-2987 m) 9800 ft. and above (2987 m and above) Page 18-2 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual...

  • Page 333: Changing The Main Jet

    S27 FE 350 FUEL SYSTEM Carburetor CHANGING THE MAIN JET See General Warning on page 1-1. Remove the carburetor. 1.1. Turn fuel shut-off valve on fuel tank to the closed (OFF) position (Figure 18-18, Page 18-26 or Figure 18-19, Page 18-26). 1.2.
  • Page 334 Carburetor S27 FE 350 FUEL SYSTEM Remove the main jet (8) from the carburetor body and discard it (Figure 18-4, Page 18-4). See following NOTE. NOTE: Make sure the fuel nozzle (7) does not fall out of the carburetor body after removal of the main jet. This is best accomplished by positioning the carburetor upside down during main jet removal .

  • Page 335: Engine Control Linkage

    S27 FE 350 FUEL SYSTEM Engine Control Linkage 1. If spring looks like this... 2. then adjust spring to look like this by... 3. holding float firmly and rotating valve counterclockwise to seat spring in seat of float bowl 4. Check for coil located in groove above both ears. 5. Check for spring seated in recess of float. Figure 18-5 Inspect Float Valve/Spring Assembly –...

  • Page 336: General Information

    Engine Control Linkage S27 FE 350 FUEL SYSTEM DANGER • To ensure the vehicle does not run over you while you disconnect or adjust the accelerator push rod, do the following: – Turn key switch OFF and remove key, place Forward/Reverse handle in the NEUTRAL position, and chock the wheels prior to servicing the vehicle.
  • Page 337 S27 FE 350 FUEL SYSTEM Engine Control Linkage Accelerator Rod Installation and Adjustment Before installing the accelerator rod, adjust accelerator pedal position. See Accelerator and Brake Pedal Group Section in the appropriate maintenance and service manual. Install the ball joint on the ball stud at the accelerator pedal (Figure 18-6, Page 18-6). Access the engine compartment.

  • Page 338: Governor Cable

    Engine Control Linkage S27 FE 350 FUEL SYSTEM While holding the accelerator ball joint with pliers, tighten the jam nuts against the ball joints, accelerator ball joint first, at each end of the accelerator rod. 10. Check rod adjustment for proper switch activation. 11.

  • Page 339: Accelerator Cable

    S27 FE 350 FUEL SYSTEM Engine Control Linkage Figure 18-9 Governor and Accelerator Cables ACCELERATOR CABLE Accelerator Cable Removal Access the engine compartment. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3. Remove the electrical box screw and cover and loosen the cable housing retaining nuts (Figure 18-7, Page 18-7).

  • Page 340: Closed Throttle Or Idle Adjustment

    Engine Control Linkage S27 FE 350 FUEL SYSTEM Accelerator Cable Installation Connect the cable to the cam (17) in the electrical box (Figure 18-9, Page 18-9). Insert the cable housing into the mounting slot in the wall of the electrical box, with approximately the same number of threads visible between the jam nuts as are visible from the nut inside the box to the end of the cable housing (Figure 18-7, Page 18-7).

  • Page 341: Engine Rpm Adjustment

    S27 FE 350 FUEL SYSTEM Choke and Air Intake System ENGINE RPM ADJUSTMENT DANGER • Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. If the governor is adjusted, proceed to step 2; otherwise, adjust the governor. See Governor Cable Installation and Adjustment on page 18-8.

  • Page 342: Choke Cable Removal

    Choke and Air Intake System S27 FE 350 FUEL SYSTEM CHOKE CABLE REMOVAL Turn the key switch to the OFF position and remove the key, place the Forward/Reverse handle in the NEUTRAL position, and chock the wheels. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3.
  • Page 343 S27 FE 350 FUEL SYSTEM Choke and Air Intake System Figure 18-11 Air Intake and Choke Assemblies 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual Page 18-13...

  • Page 344: Air Box Removal

    Choke and Air Intake System S27 FE 350 FUEL SYSTEM AIR BOX REMOVAL Turn the key switch to the OFF position and remove the key, place the Forward/Reverse handle in the NEUTRAL position, and chock the wheels. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3.

  • Page 345: Intake Duct Installation

    S27 FE 350 FUEL SYSTEM Choke and Air Intake System Separate the double-sided tape that secures the top of the air duct shield to the frame and remove air duct shield from vehicle. Drill out the two pop rivets (25) securing the intake duct to the floorboard. Remove three screws (23) and flat washers (22) from the bottom of the air box assembly.
  • Page 346 • If air box is extremely dirty, remove air box from vehicle and clean thoroughly. • Use only Club Car replacement air filters (CCI P/N 1015426). The use of other air filters could result in engine damage. If the air filter is too thin, the cover will seat before the filter can seal, leaving space for dirt to pass into the engine on all sides of the element.

  • Page 347: Fuel Filters

    S27 FE 350 FUEL SYSTEM Fuel Filters FUEL FILTERS See General Warning on page 1-1. GENERAL INFORMATION Fuel is supplied to the fuel pump and carburetor through flexible lines. An in-line filter is installed between the fuel tank and the carburetor (Figure 18-13, Page 18-18). Fuel filter, fuel lines, and the fuel tank vent should be inspected periodically for leaks.
  • Page 348 Fuel Filters S27 FE 350 FUEL SYSTEM 1310 Figure 18-13 Fuel and Vent Lines – Side Fill Tank Page 18-18 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual...

  • Page 349: Fuel Pump

    S27 FE 350 FUEL SYSTEM Fuel Pump LENGTH FUEL LINE NO. ROUTING SOLID COLOR CLEAR Fuel tank to fuel filter 6.0 in. (15.0 cm) Fuel filter to fuel pump 6.0 in. (15.0 cm) 17.0 in. (44.0 cm) * Fuel pump to carburetor 24.0 in.

  • Page 350: Fuel Pump Disassembly

    If leaking occurs, all new gaskets and diaphragms must be installed. NOTE: A fuel pump rebuild kit is available from Club Car (CCI P/N 1014524). This kit includes all gaskets, diaphragms, and valves.

  • Page 351: Fuel Pump Assembly

    S27 FE 350 FUEL SYSTEM Fuel Pump 1. Fuel Outlet 2. Vent 3. Fuel Inlet 4. Impulse Line 5. Direction of Fuel Flow Figure 18-14 Fuel Pump Figure 18-15 Fuel Pump Orientation FUEL PUMP ASSEMBLY Install the fuel gasket (35) and diaphragm (34) on the back cover (36) (Figure 18-14, Page 18-21). Install the valve assembly in the pumping chamber (30).
  • Page 352 Fuel Pump S27 FE 350 FUEL SYSTEM Connect to the output side of the fuel pump, the fuel line (3) that goes to the carburetor (Figure 18-13, Page 18-18). Connect the impulse line (5) to the bottom nipple on the fuel pump. Use a new clamp (20). Install the fuel pump onto the mounting bracket with two thread-rolling screws (25) and tighten to 40 in-lb (4.5 N·m).

  • Page 353: Fuel Tank

    S27 FE 350 FUEL SYSTEM Fuel Tank FUEL TANK See General Warning on page 1-1. GENERAL INFORMATION The vehicle is equipped with a high impact plastic, seven gallon (26.5 liter) fuel tank. WARNING • If the fuel tank is damaged, replace it. Do not attempt to repair it. See the following tank removal and disposal procedure.

  • Page 354: Fuel Tank Disposal

    Fuel Tank S27 FE 350 FUEL SYSTEM WARNING • Make sure the key switch is off before disconnecting wiring. 10. Remove the vent tube (6) and fuel line (1) from the fuel tank (Figure 18-13, Page 18-18). 11. Loosen the strap (13) by removing the screw (12) from the speed nut (11) (Figure 18-13, Page 18-18). 12.
  • Page 355 S27 FE 350 FUEL SYSTEM Fuel Tank 2.1. Position the strap in the indention on the tank. 2.2. Install the screw(s) (12) into the speed nut(s) (11). Tighten screw(s) to 25 in-lb (2.8 N·m). Install cargo bed on the vehicle if removed. Install seat back support if removed. See Section 4 – Body and Trim. Connect the vent tube (6) to the fuel tank vent.

  • Page 356: Fuel Lines

    Fuel Lines S27 FE 350 FUEL SYSTEM FUEL LINES See General Warning on page 1-1. The fuel lines must be properly routed, and all hose clamps must be tight. The fuel lines should be kept clean. See following WARNING. WARNING •...

  • Page 357: Section 19 - Exhaust System: Gasoline Vehicles

    SECTION 19 – EXHAUST SYSTEM: GASOLINE VEHICLES DANGER • See General Warning on page 1-1. WARNING • See General Warning on page 1-1. MUFFLER MUFFLER REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3.
  • Page 358 Muffler EXHAUST SYSTEM: GASOLINE VEHICLES DANGER • Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. Figure 19-1 Exhaust System Page 19-2 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual...

  • Page 359: Section 20 - Unitized Transaxle: Dash-Mounted Shifter

    SECTION 20 – UNITIZED TRANSAXLE: DASH-MOUNTED SHIFTER DANGER • See General Warning on page 1-1. WARNING • See General Warning on page 1-1. GENERAL INFORMATION The vehicles addressed in this manual are equipped with heavy-duty, fully-synchronized Unitized Transaxles. The unitized transaxle utilizes fully-synchronized internal gearing to change vehicle direction. Because the unitized transaxle is used to reverse vehicle direction, the engine, drive clutch, belt, and driven clutch rotate in the same direction;...

  • Page 360: Governor System

    UNITIZED TRANSAXLE: DASH-MOUNTED General Information SHIFTER Figure 20-1 Neutral Lockout Switch – Turf/Carryall 252 GOVERNOR SYSTEM The governor system regulates vehicle ground speed. It is mounted inside the unitized transaxle and is driven by transaxle gears. If any of the governor linkages are removed in order to service other components, readjustment of the governor linkage is required.

  • Page 361: Tools Required For This Section

    UNITIZED TRANSAXLE: DASH-MOUNTED SHIFTER Axle Shaft TOOLS REQUIRED FOR THIS SECTION Hydraulic floor jack (or chain hoist) Torque wrench, 3/8-in. drive 1/2-in. combination wrench Jack stands (2) (one ton capacity) 3/8-in. socket, 3/8-in. drive 9/16-in. combination wrench Standard slip joint pliers 7/16-in.

  • Page 362: Axle Bearing

    UNITIZED TRANSAXLE: DASH-MOUNTED Axle Shaft SHIFTER Figure 20-4 Retaining Ring Position a 16-inch (40 cm) rolling head prybar (Figure 20-5, Page 20-4) under the inside lip of the seal and pull the oil seal out (Figure 20-6, Page 20-4). See following CAUTION. CAUTION •...
  • Page 363 UNITIZED TRANSAXLE: DASH-MOUNTED SHIFTER Axle Shaft CAUTION • Do not tighten the bearing puller wedge attachment against the axle shaft. This could damage the axle shaft when pressing the bearing and collar off. Press the bearing (71) and collar (73) off together (Figure 20-7, Page 20-5). See also Figure 20-8, Page 20-7. See following NOTE.

  • Page 364: Axle Shaft Installation

    UNITIZED TRANSAXLE: DASH-MOUNTED Axle Shaft SHIFTER Install a new axle bearing (71) on axle (67 or 68). Push bearing onto axle until bearing is flush against axle shoulder (Figure 20-7, Page 20-5). Apply two drops of Loctite 271 ® to inside of the collar. See following CAUTION. CAUTION •...

  • Page 365: Unitized Transaxle Removal

    UNITIZED TRANSAXLE: DASH-MOUNTED SHIFTER Unitized Transaxle Removal WARNING • Be sure bearing retaining ring is properly seated in its groove. If ring is not properly installed, the axle assembly will separate from the transaxle and damage the axle assembly and other components. Loss of vehicle control could result in severe personal injury or death.
  • Page 366 UNITIZED TRANSAXLE: DASH-MOUNTED Unitized Transaxle Removal SHIFTER Figure 20-10 Carburetor Vent Tube Figure 20-11 Air Intake Hose 4.3. Disconnect impulse line from fuel pump (Figure 20-12, Page 20-8). 4.4. Loosen the hose clamp and then disconnect the fuel line from the carburetor. To prevent spilling fuel, the disconnected end of the line can be plugged with a 1/4-inch bolt (Figure 20-13, Page 20-8).
  • Page 367 UNITIZED TRANSAXLE: DASH-MOUNTED SHIFTER Unitized Transaxle Removal Figure 20-14 Throttle Cable and Retaining Nuts (Top View) Figure 20-15 Engine Ground Wire and Retaining Nut 4.7. Loosen nuts securing shifter cable to shifter cable mounting bracket. Then disconnect the shifter cable rod end from the shifter arm on the unitized transaxle and remove the cable from the cable mounting bracket (Figure 20-16, Page 20-9).
  • Page 368 UNITIZED TRANSAXLE: DASH-MOUNTED Unitized Transaxle Removal SHIFTER Figure 20-18 Oil Level Sensor Jumper Wire Figure 20-19 Ignition Kill Wire Disconnect the brake cables. 5.1. Remove bow tie pins (1), brake cable clevis pins (2), and E-clips (3) (Figure 20-20, Page 20-10). 5.2.
  • Page 369 UNITIZED TRANSAXLE: DASH-MOUNTED SHIFTER Unitized Transaxle Removal 1. Position floor jack under hitch bracket or frame. 2. Lifting Position For Standard Turf 1 and Carryall 1 3. Lifting Position For Turf 2 and 252, Carryall 2 and 252, Carryall 2 Plus and XRT 900 4.
  • Page 370 UNITIZED TRANSAXLE: DASH-MOUNTED Unitized Transaxle Removal SHIFTER 11. Continue raising vehicle until frame or trailer hitch is higher than the top of the unitized transmission (enough to allow transaxle and engine to be rolled under and out of vehicle) (Figure 20-25, Page 20-12). 12.
  • Page 371 UNITIZED TRANSAXLE: DASH-MOUNTED SHIFTER Unitized Transaxle Removal 17. Remove the drive belt. 17.1.Grasp belt midway between drive and driven clutch and pull up on belt to force the driven clutch sheaves apart. Roll the belt counterclockwise while pulling it off driven clutch (Figure 20-30, Page 20-13). 6 in.

  • Page 372: Unitized Transaxle Installation

    UNITIZED TRANSAXLE: DASH-MOUNTED Unitized Transaxle Installation SHIFTER Figure 20-33 Governor Cable Bracket Figure 20-34 Accelerator Cable Bracket 22. Remove the six bolts mounting the unitized transaxle to the engine. 22.1.Remove four transaxle mounting bolts (one at each corner of the transaxle mounting plate) (Figure 20-35, Page 20-14).
  • Page 373 UNITIZED TRANSAXLE: DASH-MOUNTED SHIFTER Unitized Transaxle Installation Position the transaxle mounting plate on the two mounting studs at the rear of the engine, and then install the two mounting nuts finger tight (Figure 20-36, Page 20-15). Install the remaining four mounting bolts and four nuts (one bolt and nut at each corner of the mounting plate) finger tight.
  • Page 374 UNITIZED TRANSAXLE: DASH-MOUNTED Unitized Transaxle Installation SHIFTER Figure 20-38 Driven Clutch and Key Figure 20-39 Snubber and Bracket 14. Position the floor jack under the rear frame crossmember and raise the jack high enough to support the vehicle (Figure 20-40, Page 20-16). Make sure the vehicle is stable on the jack, then remove the jack stands. 15.
  • Page 375 UNITIZED TRANSAXLE: DASH-MOUNTED SHIFTER Unitized Transaxle Installation 20. Install three wire ties to secure the engine kill wire to the accelerator cable where they both route together on the passenger side of the engine. Figure 20-42 Shock Absorber Figure 20-43 Ignition Kill Wire 21.
  • Page 376 UNITIZED TRANSAXLE: DASH-MOUNTED Unitized Transaxle Installation SHIFTER 1. Nuts. 2. Pull spring release back to connect shifter cable to lever. Figure 20-46 Shifter Cable (Top View) Figure 20-47 Engine Ground and Retaining Nut 25. Connect accelerator cable to actuator cam in the electrical box. Position the accelerator cable in the mounting slot in the wall of the electrical box and tighten mounting nuts to 18 in-lb (2.0 N·m) (Figure 20-48, Page 20-18).
  • Page 377 UNITIZED TRANSAXLE: DASH-MOUNTED SHIFTER Unitized Transaxle Installation Figure 20-50 Impulse Line Figure 20-51 Air Intake Hose 29. Connect carburetor vent tube to carburetor and secure with hose clamp (Figure 20-52, Page 20-19). Figure 20-52 Carburetor Vent Tube 30. Install transaxle drain plug and tighten to 21 ft-lb (28.5 N·m). 31.

  • Page 378: Forward/Reverse Shifter Cable

    UNITIZED TRANSAXLE: DASH-MOUNTED Forward/Reverse Shifter Cable SHIFTER FORWARD/REVERSE SHIFTER CABLE See General Warning on page 1-1. If the Forward/Reverse shifter cable is damaged in any way, it must be replaced. FORWARD/REVERSE SHIFTER CABLE REMOVAL NOTE: Before removing cable, note cable routing and positions of wire ties or other devices securing the cable to the vehicle.
  • Page 379 UNITIZED TRANSAXLE: DASH-MOUNTED SHIFTER Forward/Reverse Shifter Cable Figure 20-53 Forward/Reverse Shifter Cable 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual Page 20-21...

  • Page 380: Forward/Reverse Shifter Cable Adjustment

    UNITIZED TRANSAXLE: DASH-MOUNTED Forward/Reverse Shifter Cable SHIFTER FORWARD/REVERSE SHIFTER CABLE ADJUSTMENT With the shifter lever of the unitized transaxle in the NEUTRAL position (Figure 20-54, Page 20-22), the Forward/Reverse handle (9) (Figure 20-53, Page 20-21) should align with the N position on the dash. For minor adjustments, the nut (10) may be loosened and the ball joint socket (4) rotated to get the proper adjustment (Figure 20-53, Page 20-21).

  • Page 381: Section 21 - Torque Converter: Gasoline Vehicles

    SECTION 21 – TORQUE CONVERTER: GASOLINE VEHICLES DANGER • See General Warning on page 1-1. WARNING • See General Warning on page 1-1. GENERAL INFORMATION The torque converter consists of a drive clutch, a driven clutch, and a drive belt. The drive clutch, which is mounted to the engine, is in the open position when the engine is at idle.

  • Page 382: Drive Belt

    Drive Belt TORQUE CONVERTER: GASOLINE VEHICLES Check the governor and throttle settings. See Governor Cable on page 17-8. Inspect the driven clutch for dirt and dust buildup on its component parts. Clean the driven clutch with water to remove any dust or dirt, then drive the vehicle and check for proper operation. If cleaning the driven clutch does not solve the problem, disassemble and thoroughly clean all parts of the drive clutch.

  • Page 383: Drive Belt Removal

    TORQUE CONVERTER: GASOLINE VEHICLES Drive Belt DRIVE BELT REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3. Grasp the belt midway between the drive (2) and driven (1) clutches. Lift upward on the belt to force the sheaves of the DRIVEN clutch apart, then roll the belt off the DRIVEN clutch by rotating the clutch counterclockwise (Figure 21-2, Page 21-3).

  • Page 384: Drive Clutch

    Drive Clutch TORQUE CONVERTER: GASOLINE VEHICLES DRIVE CLUTCH See General Warning on page 1-1. CAUTION • Be very careful when handling the clutches. A clutch that has been dropped will not be properly balanced. If either clutch is dropped, assume that it is damaged and replace it. DRIVE CLUTCH REMOVAL Remove the drive belt as instructed.

  • Page 385: Drive Clutch Cleaning And Inspection

    TORQUE CONVERTER: GASOLINE VEHICLES Drive Clutch WARNING • Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold vehicle in raised position.
  • Page 386 Drive Clutch TORQUE CONVERTER: GASOLINE VEHICLES Figure 21-5 Drive Clutch Assembly Page 21-6 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual...

  • Page 387: Drive Clutch Disassembly

    TORQUE CONVERTER: GASOLINE VEHICLES Drive Clutch DRIVE CLUTCH DISASSEMBLY CAUTION • The drive clutch is balanced as an assembly. Before disassembly, make match marks on the drive clutch hub and on the moveable face assembly so they can be reassembled in the same positions (Figure 21-6, Page 21-7).
  • Page 388 Drive Clutch TORQUE CONVERTER: GASOLINE VEHICLES Figure 21-8 Drive Button Mounting Figure 21-9 Weight Position Remove the clutch weights: 5.1. Remove the screws (1) and flat washers (2) attaching the weights (3) as shown (Figure 21-9, Page 21-8). 5.2. Pull the weight assemblies (3), with pins, from slots (4) in the clutch. See following NOTE. NOTE: Before removing, note the orientation of the wave washer (1) and secondary weight (2) on the primary weight (3) (Figure 21-10, Page 21-8).

  • Page 389: Inspection Of Drive Clutch Parts

    TORQUE CONVERTER: GASOLINE VEHICLES Drive Clutch Remove the retaining ring (3) from the shaft of the fixed face assembly (7) and slide the moveable face (14) off the shaft (Figure 21-5, Page 21-6). See following NOTE. NOTE: If the moveable face is removed from the hub of the fixed face, the spiral back-up rings (12) must be replaced with new ones (Figure 21-5, Page 21-6).

  • Page 390: Drive Clutch Assembly

    Drive Clutch TORQUE CONVERTER: GASOLINE VEHICLES DRIVE CLUTCH ASSEMBLY Press idler bearing (6) onto the shaft of the fixed face assembly (7). Press on the inner race of the bearing only. Make sure that the cup side of bearing is facing away from the fixed face (Figure 21-5, Page 21-6). Using needle nose pliers, install the spring retainer (5) onto the spring (4).

  • Page 391: Drive Clutch Installation

    TORQUE CONVERTER: GASOLINE VEHICLES Drive Clutch 14. Compress each take-up spring and install the drive button over the rib and take-up spring (Figure 21-8, Page 21-8). 15. Install a no. 10-24 button retaining screw with flat washer through each button and into the rib. Tighten the screws to 34 in-lb (3.8 N·m) (Figure 21-9, Page 21-8).

  • Page 392: Driven Clutch

    Driven Clutch TORQUE CONVERTER: GASOLINE VEHICLES DRIVEN CLUTCH See General Warning on page 1-1. DRIVEN CLUTCH REMOVAL Remove the drive belt as instructed. See Drive Belt Removal on page 21-3. Remove the bolt (11) and mounting washer (12) from the clutch shaft (Figure 21-17, Page 21-14). Grasp the driven clutch assembly and slide it off the shaft.

  • Page 393: Driven Clutch Inspection

    TORQUE CONVERTER: GASOLINE VEHICLES Driven Clutch Figure 21-15 Remove Retaining Ring Figure 21-16 Driven Clutch Disassembly DRIVEN CLUTCH INSPECTION Inspect the cam (4) for excessive wear. Replace it if necessary (Figure 21-17, Page 21-14). Inspect the drive buttons (6) for excessive wear. Replace if necessary. To remove the drive buttons, remove the socket-head cap screws and then the buttons.
  • Page 394 Driven Clutch TORQUE CONVERTER: GASOLINE VEHICLES Figure 21-17 Driven Clutch Assembly Holding the cam (4) in position for assembly on the shaft, install the other end of the spring (5) into the center spring hole of the cam. Rotate the cam until the keyway is aligned with the key (3) on the fixed face assembly, and then start the cam onto the shaft approximately 1/4 to 3/8 inch (6.3 to 9.5 mm).
  • Page 395 TORQUE CONVERTER: GASOLINE VEHICLES Driven Clutch 5.1.1. Place the clutch assembly in a press and position the cam press tool (CCI P/N 101809101) on the cam as shown (Figure 21-18, Page 21-15). 5.1.2. Hold the fixed face assembly (3) and rotate the moveable face assembly (1) one-third turn clockwise, then press the cam (2) onto the fixed face assembly (Figure 21-18, Page 21-15).

  • Page 396: Driven Clutch Installation

    Driven Clutch TORQUE CONVERTER: GASOLINE VEHICLES 5.2.6. Hold the fixed face assembly of the clutch (5) and rotate the moveable face of the clutch one-third turn clockwise. 5.2.7. Use two wrenches, and hold the bolt head while tightening the cam press hub (6) pressing the cam onto the keyed shaft.

  • Page 397: Section 22 - Electrical System And Testing: Electric Vehicles

    Contact your Club Car dealer/distributor to inquire about this programmable feature. • Regenerative Braking: When motor braking is activated, the vehicle motor acts as a generator, slowing the vehicle as it creates energy that is used to charge the batteries.

  • Page 398: Wiring Diagrams

    ELECTRICAL SYSTEM AND TESTING: Wiring Diagrams ELECTRIC VEHICLES WIRING DIAGRAMS WD103221901A5-L WD103221901A5-L Figure 22-1 Wiring Diagram Page 22-2 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual...
  • Page 399 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLES Wiring Diagrams WD103221901A5-R Figure 22-2 Wiring Diagram (Continued) 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual Page 22-3...

  • Page 400: Troubleshooting

    TROUBLESHOOTING THE VEHICLE WITH THE IQDM Club Car recommends the use of the IQDM handset for troubleshooting vehicles equipped with the IQ Plus electrical system. Troubleshooting Guide 1 is to be used in conjunction with the IQDM handset. Refer to the IQDM Owner’s Manual for operating instructions.

  • Page 401: Troubleshooting Guide 1

    ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLES Troubleshooting TROUBLESHOOTING GUIDE 1 The following troubleshooting guide is intended for use with an IQDM handset. For IQDM operating instructions, refer to the IQDM Owner’s Manual. See following NOTE. NOTE: Before troubleshooting the vehicle, check the diagnostic history from the Special Diagnostics Menu. Note any fault codes.
  • Page 402 ELECTRICAL SYSTEM AND TESTING: Troubleshooting ELECTRIC VEHICLES TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Speed controller logic malfunction Disconnect the batteries and allow the speed controller capacitors to discharge. See WARNING “To avoid unintentionally starting...” in See Failed controller FET (that powers up solenoid General Warning on page 1-1.
  • Page 403 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLES Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected motor field coil wires at Repair and/or connect the field coil wires motor or speed controller or broken wire Diagnostic Menu – FIELD MISSING See Section 27 –...

  • Page 404: Troubleshooting Guide 2

    ELECTRICAL SYSTEM AND TESTING: Troubleshooting ELECTRIC VEHICLES TROUBLESHOOTING GUIDE 2 TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Batteries discharged Charge batteries Check vehicle wiring. See Wiring Diagrams Improper or poor battery connections beginning on page 22-2 Battery charger is connected to the vehicle – Disconnect the battery charger from the vehicle Solenoid lockout feature has disabled the vehicle Test Procedure 2 –...
  • Page 405 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLES Troubleshooting TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Procedure 24 – Motor Speed Sensor on page Speed sensor disconnected or failed 22-30 To change the programmed top speed of the Incorrect speed setting vehicle, an IQDM-P handset must be used Check vehicle wiring.

  • Page 406: Test Procedures

    ELECTRICAL SYSTEM AND TESTING: Test Procedures ELECTRIC VEHICLES TEST PROCEDURES Using the following procedures, the entire IQ Plus electrical system can be tested without major disassembly of the vehicle. See following WARNING. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
  • Page 407 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLES Test Procedures Batteries / Voltage Check with the IQDM Handset Connect the IQDM to the vehicle. See Plugging the Handset into the Vehicle, Section 23, Page 23-1. Access the Test menu and select BATT VOLTAGE by using the SCROLL DISPLAY buttons. The IQDM should indicate at least 48 volts with the batteries fully charged.
  • Page 408 ELECTRICAL SYSTEM AND TESTING: Test Procedures ELECTRIC VEHICLES connector. Make sure pins are properly aligned inside housing. Make sure wire colors match and are connected to the correct terminals. Place insulation-piercing probe on the light blue 18-gauge wire (2) at a point between speed controller 24-pin connector and main wire harness (Figure 22-5, Page 22-12).
  • Page 409 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLES Test Procedures Connect the batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 2k Ohm Setting Figure 22-6 Activating Coil Test TEST PROCEDURE 4 –...
  • Page 410 ELECTRICAL SYSTEM AND TESTING: Test Procedures ELECTRIC VEHICLES 1. Purple/White Wire 2. White Wire 3. Yellow Wire 4. MCOR — Located On Passenger Side Frame Rail 5. Blue Wire 6. Green Wire Figure 22-7 Test MCOR Voltage If reading is zero volts, check the purple/white wire continuity from the three-pin connector at the MCOR to the 24-pin connector at the speed controller.
  • Page 411 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLES Test Procedures 8.6. Using a multimeter set for 20k ohms, connect the red (+) probe of the multimeter to the yellow wire at the MCOR three-pin connector with an insulation piercing probe. Connect black (–) probe to the white wire with an insulation-piercing probe.
  • Page 412 ELECTRICAL SYSTEM AND TESTING: Test Procedures ELECTRIC VEHICLES TEST PROCEDURE 6 – Tow/Run Switch See General Warning on page 1-1. Tow/Run Switch Test with the IQDM Handset With the Tow/Run switch in the RUN position, connect the IQDM to the vehicle. See Plugging the Handset into the Vehicle on page 23-1.
  • Page 413 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLES Test Procedures Figure 22-10 Test Continuity: Pink Wire on Solenoid Post Figure 22-11 Test Continuity: Two-pin Connector TEST PROCEDURE 7 – Circuit Breaker See General Warning on page 1-1. Place the key switch on the OFF position, the Tow/Run switch in the TOW position, and the Forward/Reverse switch in the NEUTRAL position.
  • Page 414 ELECTRICAL SYSTEM AND TESTING: Test Procedures ELECTRIC VEHICLES TEST PROCEDURE 9 – Key Switch and MCOR Limit Switch Circuit See General Warning on page 1-1. Key Switch and MCOR Limit Switch Circuit Test with the IQDM Handset Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame crossmember between the spring mount and side stringer, just forward of each rear wheel.
  • Page 415 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLES Test Procedures 4.6. If the key switch operates as described in the previous steps, install the dash panel in the reverse order of removal and proceed to test the MCOR limit switch. 4.7. Connect the batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Test the MCOR limit switch.
  • Page 416 ELECTRICAL SYSTEM AND TESTING: Test Procedures ELECTRIC VEHICLES If the results of any of the referenced procedures are different from those described in the procedure, check the continuity of the wires in the wire harness and test the connected components with the appropriate test procedures. (See Index of Test Procedures on page 22-10).
  • Page 417 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLES Test Procedures Set a multimeter to 20k ohms. Insert the red (+) probe of the multimeter into pin 15 (yellow wire) of the 24-pin connector. See following CAUTION. Insert the black (–) probe into pin 14 (purple/white wire) of the 24-pin connector (Figure 22-12, Page 22-21).
  • Page 418 ELECTRICAL SYSTEM AND TESTING: Test Procedures ELECTRIC VEHICLES Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame crossmember between the spring mount and side stringer, just forward of each rear wheel. See WARNING “Lift only one end...”...
  • Page 419 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLES Test Procedures TEST PROCEDURE 13 – Pin 8 See General Warning on page 1-1. Pin 8 in the 24-pin connector provides a connection point for the MCOR limit switch to the speed controller. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4.
  • Page 420 ELECTRICAL SYSTEM AND TESTING: Test Procedures ELECTRIC VEHICLES 12. The multimeter should indicate zero volts when the accelerator pedal is not pressed. 13. If any other reading is obtained, check the following items: – Continuity of the wires in the wire harness. –...
  • Page 421 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLES Test Procedures Detail A: Front of 24-Pin Connector Figure 22-15 Test: Pin 19 (Orange/White Wire) TEST PROCEDURE 15 – Pins 10 and 11 See General Warning on page 1-1. Pins 10 and 11 in the 24-pin connector provide a connection point for the Forward/Reverse rocker switch to the speed controller.
  • Page 422 ELECTRICAL SYSTEM AND TESTING: Test Procedures ELECTRIC VEHICLES Place the Forward/Reverse switch in the FORWARD position. The multimeter should indicate full battery voltage (approximately 48 volts). Insert the red (+) probe of the multimeter into pin 11 (blue wire) of the 24-pin connector. Leave the black (–) probe (alligator clip) connected to the B–...
  • Page 423 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLES Test Procedures With a multimeter set for 200 volts DC, insert the red (+) probe of the multimeter into pin 1 (tan wire) of the 24-pin connector. See following CAUTION. With an alligator clip, connect the black (–) probe to the B– terminal of the speed controller (Figure 22-17, Page 22-27).
  • Page 424 ELECTRICAL SYSTEM AND TESTING: Test Procedures ELECTRIC VEHICLES Set a multimeter to 200 volts DC. Use an alligator clip to connect the red (+) probe to the positive terminal on battery no. 1. With an insulation-piercing probe, connect the black (–) probe to the blue/white wire attached to pin 17 of the 24-pin connector.
  • Page 425 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLES Test Procedures If the reading is zero volts, check the continuity of the green/white wire. if the continuity is good, replace the speed controller. TEST PROCEDURE 21 – Onboard Computer Silicon-Controlled Rectifier (SCR) Circuit See General Warning on page 1-1.
  • Page 426 ELECTRICAL SYSTEM AND TESTING: Test Procedures ELECTRIC VEHICLES Figure 22-18 Charger Receptacle Tests TEST PROCEDURE 23 – Voltage at Charger Receptacle Red Wire Socket See General Warning on page 1-1. (This procedure will determine if the 10-guage red wire used to charge the batteries has continuity.) With batteries connected and a multimeter set to 200 volts DC, place the black (–) probe on the negative post of battery no.
  • Page 427 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLES Test Procedures Check voltage at black/white wire: 3.1. Set a multimeter to 200 volts DC. Place the red (+) probe on the battery no. 1 positive post and place the black (–) probe on the black/white wire terminal socket in the three-pin connector. The voltage reading should be 48 to 50 volts (full battery voltage).
  • Page 428 ELECTRICAL SYSTEM AND TESTING: Test Procedures ELECTRIC VEHICLES 5.1. Set a multimeter to 20 volts DC. Place the black (–) probe on the battery no. 8 negative post and place the red (+) probe on the light green wire female terminal in the three-pin connector at the motor speed sensor. The voltage reading should be from 4.60 to 5.00 volts.
  • Page 429 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLES Test Procedures – there is no voltage reading. – the voltage reading is not above 3.50. – the voltage reading does not fluctuate as the motor is turned. TEST PROCEDURE 25 – Solenoid Contacts See General Warning on page 1-1.
  • Page 430 ELECTRICAL SYSTEM AND TESTING: Test Procedures ELECTRIC VEHICLES 2.3. Insert screwdriver at the top center of the dash between dash and cowl brace. Gently pry center dash out slightly from under edge of cowl brace. 2.4. Pull center dash out from the frame and disconnect the wires from the electrical components mounted on the dash panel.
  • Page 431 ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLES Test Procedures 6.2. If reading is zero volts, check orange/white wire continuity and connection at Pin 19 in 24-Pin connector. 6.3. If there is no continuity in the orange/white wire, or the Pin 19 terminal in the 24-Pin connector is not properly seated, repair or replace as required.

  • Page 432: Communication Display Module (Cdm)

    Total accumulated energy units removed. Func4 - Last charge termination type (1 = Incomplete, 2 = DVDT, 4 = Normal, 8 = Max. timer). POWER Club Car PART #17075 1. Low Battery Indicator 2. Display Window 3. Function Button Figure 22-23 CDM The CDM can be used to retrieve from the onboard computer four important items of information that can be useful in troubleshooting the IQ Plus vehicle.

  • Page 433: Using The Cdm To Retrieve Data From The Onboard Computer

    ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLES Communication Display Module (CDM) A 0, 1, 2, 4, or 8 will be displayed. 0 -- Indicates that no charge history has been recorded by the OBC. 1 – Indicates the last charge cycle was incomplete and the batteries were not fully charged. Batteries should be charged again at the earliest opportunity.

  • Page 434: Cdm Troubleshooting Guide

    ELECTRIC VEHICLES CDM TROUBLESHOOTING GUIDE Use the following chart as a starting point for troubleshooting problems with communication between the CDM and onboard computer. Contact your Club Car representative for more comprehensive information. OBC Will Not Communicate With The CDM...

  • Page 435: Section 23 - Iq Display Module (Iqdm) Series 2 And Iqdm-P Diagnostics

    SECTION 23 – IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS DANGER • See General Warning on page 1-1. WARNING • See General Warning on page 1-1. NOTE: For information secific to the IQDM-P handset programming features, see See Section 29 – IQ Display Module (IQDM-P) Series 2 Programming.

  • Page 436: Introductory Display

    IQ DISPLAY MODULE (IQDM) SERIES 2 Introductory Display AND IQDM-P DIAGNOSTICS INTRODUCTORY DISPLAY Immediately after the handset is connected to the vehicle, it begins loading the vehicle speed controller information. After a few seconds, the screen displays the following menu items: •...

  • Page 437: Program (Iqdm-P Only)

    IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Menu Navigation 1. Display Screen 2. Navigation Button 3. Change Value Button 4. Bookmark Buttons Figure 23-2 Handset Controls The following menus are accessible on the IQDM Series 2 handset: PROGRAM (IQDM-P ONLY) The program menu allows the user to view and change custom speed controller settings.

  • Page 438: Monitor Menu

    IQ DISPLAY MODULE (IQDM) SERIES 2 Monitor Menu AND IQDM-P DIAGNOSTICS Information The information menu displays the model number, serial number, manufacturer date and software version of the speed controller. See Information on page 23-18. Programmer Setup The programmer setup menu allows the user to set the LCD contrast, display the fault history of the programmer as well as various other information pertaining to the handset such as model number, serial number, OEM information, etc.

  • Page 439: Mode

    IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Monitor Menu NOTE: Improper brake adjustment can sometimes cause the operating current to be higher than normal. This higher current increases the temperature of the speed controller heatsink. MODE Indicates what mode the vehicle is being operated in (Mode 1 or Mode 2). ARM CURRENT Displays the motor armature current (in amperes).

  • Page 440: Reverse Input

    Mode 2. If repeated attempts are unsuccessful, the speed controller will permanently lock out access to Mode 2. In the event that Mode 2 is locked out, the controller must be removed and shipped to Club Car before Mode 2 can be activated.

  • Page 441: Overvoltage

    IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Monitor Menu OVERVOLTAGE # Displays the number of times the OVERVOLTAGE fault has been detected. See Fault Descriptions on page 23-12. TEMP CUTBACK # Displays the number of times the TEMP CUTBACK fault has been detected. See Fault Descriptions on page 23-12. HPD # Displays the number of times the HPD fault has been detected.

  • Page 442: Motor Stall

    IQ DISPLAY MODULE (IQDM) SERIES 2 Monitor Menu AND IQDM-P DIAGNOSTICS MOTOR STALL # Displays the number of times the MOTOR STALL fault has been detected. See Fault Descriptions on page 23-12. MAIN DRVR OFF# Displays the number of times the MAIN DRVR OFF fault has been detected. See Fault Descriptions on page 23-12. RELAY DNC # Displays the number of times the RELAY DNC fault has been detected (Did not close).

  • Page 443: Drvr Overcur

    IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Faults Menu DRVR OVERCUR # Displays the number of times the DRVR OVERCUR fault has been detected. See Fault Descriptions on page 23-12. RLY DRVR ON # Displays the number of times the RLY DRVR ON fault has been detected. See Fault Descriptions on page 23-12. RLY DRVR OFF # Displays the number of times the RLY DRVR OFF fault has been detected.

  • Page 444: System Faults

    IQ DISPLAY MODULE (IQDM) SERIES 2 Faults Menu AND IQDM-P DIAGNOSTICS Faults displayed in the faults menu will aid the trained technician in troubleshooting the vehicle. Faults displayed often indicate which components in the electrical system need to be tested. Since the faults menu is updated while the vehicle is in operation, the trained technician has the ability to monitor the occurrence of faults in conditions or locations where a problem with vehicle performance has been reported.

  • Page 445: Fault Recovery

    IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Faults Menu 5. Gradually reduce the armature current limit 6. Quickly reduce the armature current until speed sensor pulses occur 7. Gradually reduce Regen Current Limit 8. SmartKey functions NOT enabled 9.

  • Page 446: Fault Descriptions

    IQ DISPLAY MODULE (IQDM) SERIES 2 Faults Menu AND IQDM-P DIAGNOSTICS CONTROLLER FAULT TEST WHEN CONTROLLER RESPONSE RECOVER WHEN 20 DRIVER OVERCURRENT Continuous 1,2,3,11 Throttle Reapplied 21 PRECHARGE FAULT Throttle Applied 1,2,3,11 Cycle KSI or Throttle reapplied 22 FIELD MISSING Throttle Applied 2,10,11 Cycle KSI...
  • Page 447 The max password tries fault is declared when the incorrect password fault has been declared several times. In the event that the max password tries fault is indicated, the speed controller must be removed and shipped to Club Car before it can ever be placed in Mode 2. See also Password Tries (IQDM-P only) on page 23-6.

  • Page 448: Functions Menu

    IQ DISPLAY MODULE (IQDM) SERIES 2 Functions Menu AND IQDM-P DIAGNOSTICS 30 Relay Coil Fault If the Walk Away relay develops an open circuit or is disconnected from the controller, a relay coil fault is detected. Main CONT DNC The main cont dnc (main contactor (solenoid) did not close) fault is detected when the speed controller has sent voltage to the solenoid activating coil but the solenoid contacts are not closed.
  • Page 449 IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Functions Menu Turn the key switch to the OFF position, place the Forward/Reverse handle in the NEUTRAL position, and lock the park brake. Plug the handset into the vehicle. 3.1. Connect one end of the cable to the jack located on the bottom of the handset. 3.2.

  • Page 450: Write Settings To Controller

    IQ DISPLAY MODULE (IQDM) SERIES 2 Functions Menu AND IQDM-P DIAGNOSTICS WRITE SETTINGS TO CONTROLLER This function transfers all of the speed controller settings (except for “private speed mode”) from the handset to the vehicle speed controller. This enables the trained technician to “clone” a speed controller. Once the speed controller settings have been transferred to the handset, the technician can then connect the handset to another vehicle and transfer the stored settings into the speed controller.

  • Page 451: Reset All Settings

    IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Functions Menu All Controller Settings All Controller Settings Set from Programmer. Reset to Original Values. OK (+) OK (+) Figure 23-5 Confirmation Message Figure 23-6 Confirmation Message RESET ALL SETTINGS In the event that a mistake was made and one or more changes should not have been made with the handset, the speed controller settings can be reverted to the original settings from the beginning of the session (when the handset was plugged into the vehicle).

  • Page 452: Information

    IQ DISPLAY MODULE (IQDM) SERIES 2 Information AND IQDM-P DIAGNOSTICS INFORMATION The information menu is accessed by using the up or down arrow to scroll to information and pressing the right arrow key to activate the menu. This menu selection displays information pertaining to the speed controller. The information provided from this menu selection includes the following items: MODEL NUMBER Displays the model number of the speed controller.

  • Page 453: Information

    IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS IQDM and IQDM-P Handset Troubleshooting The following faults can be detected within the handset: CODE NUMBER TEXT DISPLAYED Time Out error detect - no response from controller Communication error with controller Error in handset Handset does not support this function Serial port overrun error...

  • Page 454: Test Procedures

    IQ DISPLAY MODULE (IQDM) SERIES 2 Test Procedures AND IQDM-P DIAGNOSTICS TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION See Section 22 – Electrical System and Onboard computer malfunction Testing: Electric Vehicles. Loose vehicle wire harness connections Test Procedure 3 – IQDM Jacks on page 23-21 See Section 22 –...
  • Page 455 IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Test Procedures 2 – Handset Cord Adaptor 3 – IQDM Jacks 4 – IQDM Jack (Located Under the Instrument Panel) 5 – IQDM Jack (Speed Controller) TEST PROCEDURE 1 – Handset Cord See General Warning on page 1-1.
  • Page 456 IQ DISPLAY MODULE (IQDM) SERIES 2 Test Procedures AND IQDM-P DIAGNOSTICS 3.1.1. Remove the plastic cap (1) covering the mounting screw (2) on each side of the center dash panel (3) (Figure 23-7, Page 23-22). 3.1.2. Loosen, but do not remove, the screw (2) on each side of the center dash panel (3). 3.1.3.
  • Page 457 IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Test Procedures If the handset does not function during Test Procedure 3A, but does function when connected directly to the speed controller, the handset cord adapter and vehicle wire harness should be thoroughly tested. See Test Procedure 2 –...

  • Page 459: Section 24 - Electrical Components: Electric Vehicles

    SECTION 24 – ELECTRICAL COMPONENTS: ELECTRIC VEHICLES DANGER • See General Warning on page 1-1. WARNING • See General Warning on page 1-1. KEY SWITCH See General Warning on page 1-1. TESTING THE KEY SWITCH See Test Procedure 9 – Key Switch and MCOR Limit Switch Circuit on page 22-18. KEY SWITCH REMOVAL Disconnect the batteries and discharge the controller.

  • Page 460: Key Switch Installation

    ELECTRICAL COMPONENTS: ELEC- Key Switch TRIC VEHICLES Figure 24-1 Dash Removal Slide center dash panel up steering column by snapping top out and then rotating the panel out and up. Disconnect the wires from the key switch. Do not allow wires to touch. From the back of the dash panel, push down on the retaining tabs surrounding the key switch (4) and remove the key switch cap (8).

  • Page 461: Forward/Reverse Rocker Switch

    ELECTRICAL COMPONENTS: ELECTRIC VEHICLES Forward/Reverse Rocker Switch Refer to the wiring diagram to connect the wires to the key switch terminals and tighten the terminal screws to 7 in-lb (0.8 N·m). See Wiring Diagrams, Section 22, Page 22-2. Coat the terminals with Battery Terminal Protector Spray (CCI P/N 1014305).

  • Page 462: Tow/Run Switch

    ELECTRICAL COMPONENTS: ELEC- Tow/Run Switch TRIC VEHICLES Figure 24-3 Tow/Run Switch and Forward/Reverse Rocker Switch TOW/RUN SWITCH See General Warning on page 1-1. TESTING THE TOW/RUN SWITCH See Test Procedure 6 – Tow/Run Switch on page 22-16. TOW/RUN SWITCH REMOVAL Disconnect the batteries and discharge the controller.

  • Page 463: Circuit Breaker

    ELECTRICAL COMPONENTS: ELECTRIC VEHICLES Circuit Breaker CIRCUIT BREAKER See General Warning on page 1-1. TESTING THE CIRCUIT BREAKER See Test Procedure 7 – Circuit Breaker on page 22-17 CIRCUIT BREAKER REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4.

  • Page 464: Motor Controller Output Regulator (Mcor)

    ELECTRICAL COMPONENTS: ELEC- Motor Controller Output Regulator (MCOR) TRIC VEHICLES MOTOR CONTROLLER OUTPUT REGULATOR (MCOR) See General Warning on page 1-1. TESTING THE MCOR See Test Procedure 4 – MCOR Voltage on page 22-13 and Test Procedure 9 – Key Switch and MCOR Limit Switch Circuit on page 22-18.

  • Page 465: Reverse Buzzer

    ELECTRICAL COMPONENTS: ELECTRIC VEHICLES Reverse Buzzer Figure 24-5 Motor Controller Output Regulator (MCOR) Mounting REVERSE BUZZER See General Warning on page 1-1. TESTING THE REVERSE BUZZER See Test Procedure 27 – Reverse Buzzer on page 22-34. REVERSE BUZZER REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4.

  • Page 466: Reverse Buzzer Installation

    ELECTRICAL COMPONENTS: ELEC- Speed controller cover TRIC VEHICLES Remove the two screws from the reverse buzzer. Remove the reverse buzzer from the center dash panel. REVERSE BUZZER INSTALLATION Install the reverse buzzer in the reverse order of removal. Tighten screws to 4 in-lb (0.45 N·m). Connect the batteries.

  • Page 467: Solenoid

    ELECTRICAL COMPONENTS: ELECTRIC VEHICLES Solenoid Figure 24-6 Speed Controller Cover SOLENOID See General Warning on page 1-1. The solenoid is located on the passenger side of the electrical component mounting plate. TESTING THE SOLENOID See Test Procedure 3 – Solenoid Activating Coil on page 22-12 and Test Procedure 25 – Solenoid Contacts on page 22-33.

  • Page 468: Solenoid Installation

    ELECTRICAL COMPONENTS: ELEC- Onboard Computer (OBC) TRIC VEHICLES Figure 24-7 Solenoid SOLENOID INSTALLATION Mount solenoid (2) onto component mounting plate with screws (1) (Figure 24-7, Page 24-10). Tighten screws (1) to 60 in-lb (6.8 N·m). Using the wiring diagram, install the wires, washers, and nuts onto the large mounting posts. Tighten nuts to 77 in-lb (8.7 N·m).

  • Page 469: Onboard Computer Installation

    ELECTRICAL COMPONENTS: ELECTRIC VEHICLES Onboard Computer (OBC) Figure 24-8 Onboard Computer Remove the wire tie securing the speed controller wires to the mounting plate. Remove black 6-gauge wire and black 10-gauge wire from the speed controller B– terminal . Disconnect the 24-pin connector from the speed controller. Disconnect the 6-pin connector from the OBC to the main wiring harness.

  • Page 470: Solid State Speed Controller

    ELECTRICAL COMPONENTS: ELEC- Solid State Speed Controller TRIC VEHICLES SOLID STATE SPEED CONTROLLER See General Warning on page 1-1. TESTING THE SOLID STATE SPEED CONTROLLER See Test Procedure 5 – A1 and A2 Motor Voltage on page 22-15. SPEED CONTROLLER REMOVAL Disconnect the batteries and discharge the controller.

  • Page 471: Charger Receptacle

    ELECTRICAL COMPONENTS: ELECTRIC VEHICLES Charger Receptacle – Make sure that the vehicle operates in the reverse direction when the Forward/Reverse switch is in the REVERSE position. The reverse buzzer will sound as a warning when the Forward/Reverse switch is in REVERSE.

  • Page 472: Charger Receptacle Removal

    ELECTRICAL COMPONENTS: ELEC- Charger Receptacle TRIC VEHICLES NOTE: Disassembly of the charger receptacle, for the purpose of removal or installation, is not recommended. CHARGER RECEPTACLE REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4.

  • Page 473: Receptacle Fuse Link

    RECEPTACLE FUSE LINK The fuse link on the 48-volt Club Car electric vehicle should not blow under normal operating conditions; however, if the fuse link has blown, the vehicle will not charge and the fuse must be replaced. The fuse link (6) is mounted on top of the charger receptacle in the battery compartment (Figure 24-11, Page 24-15).

  • Page 474: Receptacle Fuse Link Installation

    ELECTRICAL COMPONENTS: ELEC- Battery Warning Light TRIC VEHICLES RECEPTACLE FUSE LINK INSTALLATION Insert the two fuse link mounting posts into the mounting holes in the charger receptacle. Place the two 10-gauge black wires in their original positions on the fuse link mounting posts. Install nuts (7) on fuse link mounting posts and tighten to 23 in-lb (2.6 N·m) (Figure 24-11, Page 24-15).
  • Page 475 ELECTRICAL COMPONENTS: ELECTRIC VEHICLES Battery Warning Light Figure 24-12 Battery Warning Light 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual Page 24-17...

  • Page 477: Section 25 - Batteries: Electric Vehicles

    GENERAL INFORMATION The batteries supplied with an electric Club Car vehicle are different from those supplied with an automobile. The outward appearance of these two batteries is similar, but the operating characteristics are very different. The Club Car electric vehicle battery is a deep-cycle battery, and the automotive battery is a “starting, lighting and ignition” (SLI) battery.

  • Page 478: Battery Replacement

    Battery Replacement BATTERIES: ELECTRIC VEHICLES BATTERY REPLACEMENT See General Warning on page 1-1. WARNING • To prevent electrolyte leakage from the battery vents, batteries must be kept in an upright position. Tipping a battery beyond a 45° angle in any direction can allow a small amount of electrolyte to leak out the vent hole.

  • Page 479: Battery Care

    BATTERIES: ELECTRIC VEHICLES Battery Care BATTERY CARE See General Warning on page 1-1. WARNING • Ensure battery connections are clean and properly tightened. • Use only 4-gauge (AWG) wires with low-resistance terminals to replace battery wires on IQ Plus models. •...

  • Page 480: Mineral Content

    Battery Care BATTERIES: ELECTRIC VEHICLES 1. Level Indicator 2. Cap 3. Plates Electrolyte level at least 1/2 inch (13 mm) above plates or to level indicator. Figure 25-2 Battery Electrolyte Level Add water only after charging unless the electrolyte is below the level of the plates. If the electrolyte level is below the level of the plates, add just enough water to cover the plates and then charge the batteries.

  • Page 481: Vibration Damage

    IQ Plus vehicles will damage the batteries. The charger supplied with the Club Car electric vehicle resolves the most common problems associated with battery charging. Undercharging and overcharging are prevented provided the charger is allowed to shut off by itself. Also, all cells are automatically given an equalization charge at low current, which prolongs battery life.

  • Page 482: Deep-Discharge

    The deeper the discharge, the harder it is on the batteries. For this reason, it is recommended that Club Car electric vehicle batteries be charged after each use (provided the charge cycle will not be interrupted and the charger will be allowed to shut off automatically). Placing the batteries on charge after each use reduces the depth of discharge and prolongs battery life.

  • Page 483: Battery Troubleshooting Chart

    BATTERIES: ELECTRIC VEHICLES Battery Troubleshooting Chart BATTERY TROUBLESHOOTING CHART V ehicle not operating to expectation. Fully Charge Batteries. Battery Charger T Reading of 6 amps or more. Reading below 6 amps and on-charge voltage above 56 volts. Check electrical system and charger for problems.

  • Page 484: Battery Testing

    Battery Testing BATTERIES: ELECTRIC VEHICLES BATTERY TESTING See General Warning on page 1-1. Four tests have been developed to help diagnose problems with batteries that have not performed as expected. Because each test becomes progressively more detailed and time-consuming, begin with the first test and follow through with the other tests until the problem has been identified as outlined in the Battery Troubleshooting Chart (Figure 25-3, Page 25-7).
  • Page 485 BATTERIES: ELECTRIC VEHICLES Battery Testing When the float rises off the bottom, adjust the electrolyte level so that the float rides free of the bottom but does not strike the top of the glass tube. Remove the hydrometer from the cell and release the pressure from the bulb. Hold the hydrometer vertically, ensuring that the float is not touching the sides of the barrel.

  • Page 486: Discharge Test

    Battery Testing BATTERIES: ELECTRIC VEHICLES CORRECTED SPECIFIC GRAVITY VEHICLE BATTERY ELECTROLYTE CORRECTION REQUIRED TEMPERATURE FACTOR ACTION CELL 1 CELL 2 CELL 3 1.275 –0.024 1.280 – 0.024 1.280 – 0.024 Sound Battery – 20 °F (-6.6 °C) – 0.024 = 1.251 = 1.256 = 1.256 Fully Charged...

  • Page 487: Battery Troubleshooting Examples

    BATTERIES: ELECTRIC VEHICLES Battery Testing BATTERY VOLTAGES BATTERY CONDITION 5.25 5.25 5.25 5.25 5.25 5.25 5.25 5.25 Excellent 5.30 5.30 5.45 4.70 5.30 5.30 5.30 5.30 Battery no. 4 is near end of useful life 5.40 5.40 5.00 5.40 4.60 5.40 5.40 5.40...

  • Page 488: Battery Storage

    (26.7 °C) will have to be recharged every few weeks. 48-volt Club Car electric vehicles and compatible battery chargers are designed to be left connected, with AC power to the charger ON, during off-season storage. The storage charge feature will automatically charge the batteries as needed throughout the storage period.

  • Page 489: Section 26 - Battery Charger

    SECTION 26 – BATTERY CHARGER Refer to the appropriate battery charger maintenance and service manual. 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual Page 26-1...

  • Page 491: Section 27 - Motor (Model Da5-4006): Electric Vehicles

    The IQ Plus vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. This 3.7 horsepower motor is designed for use on IQ Plus vehicles only. Club Car recommends that motors requiring major repair be sent to a qualified motor repair shop; however, there are many relatively simple tasks that can be performed by a technician with general knowledge and experience in electric motor repair.

  • Page 492: Motor

    MOTOR (MODEL DA5-4006): ELECTRIC Motor VEHICLES TEST PROCEDURE 2 – Armature Circuit Open See General Warning on page 1-1. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Disconnect wires from the A1 and A2 terminals on the motor using two wrenches to prevent posts from turning. Set a multimeter to 200 ohms and place the red (+) probe on the A1 terminal and black (–) probe on the A2 terminal.
  • Page 493 MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor 1. Position floor jack under hitch bracket or frame. 2. Lifting Position For Standard Turf 1 and Carryall 1 3. Lifting Position For Turf 2 and 252, Carryall 2 and 252, Carryall 2 Plus and XRT 900 4.

  • Page 494: Motor Disassembly

    MOTOR (MODEL DA5-4006): ELECTRIC Motor VEHICLES Remove the four bolts that mount the motor to the transaxle (Figure 27-20, Page 27-15). See following CAUTION. CAUTION • Do not position fingers under motor when sliding motor off of the input shaft in step 9. Fingers may get pinched when motor disengages.
  • Page 495 MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor Figure 27-6 Brush Springs Positioning Figure 27-7 Armature Removal Orient the motor so that the splined end of the armature is facing down. Remove the four end cap bolts. The weight of the motor housing will cause it to drop when the bolts are removed. See following Caution.
  • Page 496 MOTOR (MODEL DA5-4006): ELECTRIC Motor VEHICLES 11.2. Remove the two nuts securing the brush terminals (A1 and A2) to the end cap. 11.3. Remove the four bolts and the brush rigging from the end cap (Figure 27-8, Page 27-6). 12. Inspect the terminal insulators. See Terminal Insulator Inspection on page 27-9. 13.

  • Page 497: Motor Component Testing And Inspection

    MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor Component Testing and Inspection MOTOR COMPONENT TESTING AND INSPECTION See General Warning on page 1-1. ARMATURE INSPECTION AND TESTING Remove the motor from the vehicle. See Motor Removal, Section 27, Page 27-2. Remove the end cap and armature by performing steps 1 through 6 of Motor Disassembly on page 27-4. Visual Inspection •...

  • Page 498: Motor Frame And Field Windings Inspection

    MOTOR (MODEL DA5-4006): ELECTRIC Motor Component Testing and Inspection VEHICLES Figure 27-10 Armature Test MOTOR FRAME AND FIELD WINDINGS INSPECTION Remove the motor from the vehicle. See Motor Removal, Section 27, Page 27-2. Remove the end cap and armature by performing steps 1 through 6 of Motor Disassembly on page 27-4. Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings.
  • Page 499 MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor Component Testing and Inspection Install the brushes in the same rigging 180° apart from each other. Brush Inspection Remove the motor from the vehicle. See Motor Removal, Section 27, Page 27-2. Release the clasp and remove the headband from the motor. Inspect the brushes (16) for damage or excessive wear (Figure 27-13, Page 27-10).
  • Page 500 MOTOR (MODEL DA5-4006): ELECTRIC Motor Component Testing and Inspection VEHICLES Figure 27-13 Motor Page 27-10 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual...

  • Page 501: Reconditioning The Motor

    MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Reconditioning the Motor RECONDITIONING THE MOTOR See General Warning on page 1-1. Motor reconditioning must be performed by a qualified motor repair technician. The use of proper tools and procedures is absolutely essential for successful motor reconditioning. MOTOR SPECIFICATIONS Any rework must be performed by a qualified technician.
  • Page 502 MOTOR (MODEL DA5-4006): ELECTRIC Motor Assembly VEHICLES Figure 27-14 Retracted Brushes Figure 27-15 Armature Installation With the brushes retracted, use an arbor press to press the armature shaft into the end cap bearing (Figure 27-15, Page 27-12). See following CAUTION. CAUTION •...

  • Page 503: Motor Installation

    MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor Installation MOTOR INSTALLATION See General Warning on page 1-1. Clean the transaxle input shaft. 1.1. Spray the input shaft thoroughly with CRC ® Brakleen™ or equivalent brake cleaner degreaser. 1.2. Wipe input shaft with a clean cloth. 1.3.
  • Page 504 MOTOR (MODEL DA5-4006): ELECTRIC Motor Installation VEHICLES CAUTION • Make sure the motor is properly seated in the transaxle housing. NOTE: Failure to install and tighten the motor mounting bolts in the proper sequence and to the proper tightness may result in motor noise during operation.
  • Page 505 MOTOR (MODEL DA5-4006): ELECTRIC VEHICLES Motor Installation Connect the batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. 10. Place the Tow/Run switch in the RUN position. 11. Inspect the vehicle for proper operation. See following WARNING. WARNING •...

  • Page 507: Section 28 - Transaxle (Type G): Electric Vehicles

    SECTION 28 – TRANSAXLE (TYPE G): ELECTRIC VEHICLES DANGER • See General Warning on page 1-1. WARNING • See General Warning on page 1-1. LUBRICATION See General Warning on page 1-1. There are two plugs located on the lower half of the transaxle housing. The upper plug (21) (as viewed when the vehicle is on a level surface) is used as a lubricant level indicator (Figure 28-5, Page 28-3).
  • Page 508 Axle Bearing and Shaft TRANSAXLE (TYPE G): ELECTRIC VEHICLES CAUTION • Do not scar or damage the inside surfaces of the tube when removing the oil seal and adapter ring. A damaged tube might have to be replaced. NOTE: Do not discard the adapter ring. If the adapter ring is lost or damaged, the axle tube will have to be replaced. 6.2.
  • Page 509 TRANSAXLE (TYPE G): ELECTRIC VEHICLES Axle Bearing and Shaft Figure 28-5 Transaxle – Type G 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual Page 28-3...

  • Page 510: Axle Bearing

    Axle Bearing and Shaft TRANSAXLE (TYPE G): ELECTRIC VEHICLES Axle Shaft and Oil Seal Installation If previously removed, install a new oil seal. 1.1. Clean seal seat in the adapter ring (39) (Figure 28-3, Page 28-2). 1.2. Place a new seal (15) in the adapter ring with the seal lip facing toward the adapter ring lip (Figure 28-3, Page 28-2).

  • Page 511: Transaxle

    TRANSAXLE (TYPE G): ELECTRIC VEHICLES Transaxle TRANSAXLE See General Warning on page 1-1. TRANSAXLE REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Place chocks at the front wheels and slightly loosen lug nuts on both rear wheels. Place a floor jack under the transaxle and raise the rear of the vehicle.
  • Page 512 Transaxle TRANSAXLE (TYPE G): ELECTRIC VEHICLES Figure 28-8 Disconnect Shocks Figure 28-9 Detach Spring From Shackles Disconnect the shock absorbers from their lower mounts (Figure 28-8, Page 28-6). Disconnect the four motor wires. Use two wrenches to prevent the post from turning. With a floor jack supporting the transaxle, remove lower spring shackle nuts and bolts.

  • Page 513: Transaxle Disassembly, Inspection, And Assembly

    TRANSAXLE (TYPE G): ELECTRIC VEHICLES Transaxle Disassembly, Inspection, and Assembly 12. If a floor jack was used, pull floor jack from beneath the transaxle and allow the springs to rest on the floor. 13. Remove the U-bolts attaching the transaxle to the leaf springs (Figure 28-10, Page 28-6). 14.
  • Page 514 Transaxle Disassembly, Inspection, and Assembly TRANSAXLE (TYPE G): ELECTRIC VEHICLES CAUTION • Do not damage gears. Use extreme care when handling them. Use a bearing puller or arbor press to remove bearings (16) from the input pinion gear. If the oil seal (10) is damaged, replace it (Figure 28-5, Page 28-3).

  • Page 515: Transaxle Assembly

    TRANSAXLE (TYPE G): ELECTRIC VEHICLES Transaxle Disassembly, Inspection, and Assembly 8.5. Remove the idler gears (1 and 2) and thrust plates (3 and 4) (Figure 28-16, Page 28-9). Figure 28-15 Differential Pin Figure 28-16 Left Differential 8.6. Remove the differential gears (5 and 6) and thrust plates (7 and 8). 8.7.
  • Page 516 Transaxle Disassembly, Inspection, and Assembly TRANSAXLE (TYPE G): ELECTRIC VEHICLES Install both dowel pins (25) in the transaxle housing (20) (Figure 28-5, Page 28-3). Install left half of transaxle housing: 8.1. Place a 1/8-inch (3 mm) bead of Three Bond liquid gasket on mating surface of housing. 8.2.

  • Page 517: Transaxle Installation

    TRANSAXLE (TYPE G): ELECTRIC VEHICLES Transaxle Installation TRANSAXLE INSTALLATION See General Warning on page 1-1. If using a chain hoist, raise the vehicle and place transaxle in position on the jack stands. If using a floor jack, lower the jack stands to their lowest settings and place the transaxle in position on the jack stands. Align the center hole in the saddle of the transaxle with the pilot bolt in the leaf spring assembly.

  • Page 519: Section 29 - Iq Display Module (Iqdm-P) Series 2 Programming

    SECTION 29 – IQ DISPLAY MODULE (IQDM-P) SERIES 2 PROGRAMMING DANGER • See General Warning on page 1-1. WARNING • See General Warning on page 1-1. NOTE: For information pertaining to the introductory display, menu navigation, and monitor, faults and funtion menus, see See Section 23 –...

  • Page 520: Program Menu

    A vehicle programmed for speed setting 4 does not conform to ANSI Z130.1 – American National Standard for Golf Cars – Safety and Performance Specifications because it is capable of speeds in excess of 15 mph (24.1 km/h). For more information on this feature, contact your local Club Car distributor or dealer. M1/M2 FAST ACCEL M1/M2 fast accel (fast acceleration) is an option that can be enabled or disabled.

  • Page 521: M1/M2 Speed Cal

    IQ DISPLAY MODULE (IQDM-P) SERIES 2 PROGRAMMING Program Menu Program Monitor Faults Functions Information Programmer Setup Figure 29-2 Access Program Menu M1/M2 SPEED CAL The M1/M2 speed cal (speed calibration) menu item allows the user to fine tune the vehicle speed. This feature cannot be used to increase the vehicle speed.

  • Page 522: Code A, Code B, And Code C

    IQ DISPLAY MODULE (IQDM-P) SERIES Program Menu 2 PROGRAMMING Speed Setting M1/M2 Speed Cal 8.0 mph (12.9 km/h) 12.0 mph (19.3 km/h) 15.0 mph (24.1 km/h) 17.0 mph (27.4 km/h) 7.9 mph (12.7 km/h) 11.9 mph (19.2 km/h) 14.9 mph (24.0) 16.9 mph (27.2) 7.8 mph (12.6 km/h) 11.8 mph (19.0 km/h)
  • Page 523 Once activated, Mode 2 settings can be programmed using the same procedures as Mode 1 settings. This allows the vehicle to be customized to perform according to which mode it is operated in. For more information on this feature, contact your local Club Car distributor or dealer. To activate Mode 2: Enter Code A, Code B, and Code C.
  • Page 525 INDEX hydrometer test, interpreting results ....25-9 on-charge voltage test ........25-8 accelerator voltage test..........22-10 cable voltage test (under load) ....... 22-17 installation ......... 17-10, 18-10 troubleshooting examples .........25-11 removal ..........17-10, 18-9 vibration damage..........25-5 pedal (electric) battery height adjustment...........
  • Page 526 INDEX pedal see test procedures ......... 22-19 height adjustment (electric)......5-15 crankcase cover height adjustment (gas) ........5-10 installation ..........15-6, 16-7 installation ............5-3 removal ............15-4, 16-4 removal ............5-1 cylinder head..........15-3, 16-3 shoe installation (manually-adjusted brakes) ............6-5 removal ............6-1 braking, motor DANGER see regenerative braking ........
  • Page 527 INDEX generator fender, rear diode ...............11-18 installation ............4-8 generator circuit removal .............. 4-7 troubleshooting ..........11-20 floor mat, front governor installation ............4-11 governor system..........20-2 removal ............4-11 governor cable flywheel installation and adjustment......17-9, 18-8 removal ............15-7, 16-8 removal ............17-8, 18-8 forward/reverse ground cable cable...
  • Page 528 INDEX spark plug..........15-2, 16-2 lubrication starter/generator front suspension..........7-13 armature ............14-6 transaxle, type g..........28-1 bearing............14-5 brush spring ..........14-3 brushes ............14-2 commutator ........... 14-7 magnet, motor speed sensor field coils ..........13-9, 14-9 see motor, speed sensor magnet......27-9 transaxle, type g..........
  • Page 529 INDEX limit switch RPM adjustment ........17-11, 18-11 installation ......... 13-22, 14-19 RPM limiter removal ..........13-21, 14-18 testing ..........11-23, 12-22 testing ..........11-16, 12-17 neutral lockout switch testing ............12-33 safety..............1-1 schematic diagram key-start (neutral rev) gasoline vehicle ....11-7 pedal-start gasoline vehicle........
  • Page 530 INDEX belt tension adjustment ......13-12, 14-12 shock absorber brush spring inspection............9-1 inspection............14-3 installation ............9-1 replacement ..........14-3 removal ............9-1 brushes ............14-2 snubber inspection............14-2 installation ............9-5 replacement ..........14-2 removal ............9-5 commutator............14-4 stabilizer bar armature replacement ........
  • Page 531 INDEX engine kill circuit ...........11-28 installation ............4-5 starter circuit..........11-14 removal .............. 4-5 light switch ............11-36 tire low oil warning light ..........11-30 installation ............8-3 neutral lockout limit switch ........11-16 pressure ............. 8-1 oil level sensor ..........11-30 removal .............. 8-2 reverse buzzer ..........11-30 repair..............
  • Page 532 INDEX removal ............14-12 testing ..........11-20, 12-19 walk away braking ..........22-1 walk away braking relay testing ............22-35 WARNING definition of ............1-1 water level see batteries, electrolyte level ......25-3 wheel installation ............8-1 removal .............. 8-1 see also tire ............
  • Page 534 Yes / No Your Comments and Suggestions: Please send a copy of this page to: Fax: (706) 228-2662 or Thank You! E-mail: Tech_Pubs@clubcar.com Club Car’s Technical Publications Department 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual...

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