Club Car XRT800 2006 Manuals

Manuals and User Guides for Club Car XRT800 2006. We have 1 Club Car XRT800 2006 manual available for free PDF download: Maintenance Service Manual

Club Car XRT800 2006 Maintenance Service Manual (376 pages)

GASOLINE/ELECTRIC

Brand: Club Car | Category: Utility Vehicle | Size: 27 MB

Table of Contents
5
Section 1 - Safety
15
General Warning
15
Section 2 - Vehicle Specifications
19
Section 3 - General Information
21
Serial Number Identification
21
Storage - Gasoline Vehicle
22
Preparing the Gasoline Vehicle for Extended Off-Season Storage
22
Returning the Stored Gasoline Vehicle to Service
23
Storage - Electric Vehicle
24
Preparing the Electric Vehicle for Extended Off-Season Storage
24
Returning the Stored Electric Vehicle to Service
25
Section 4 - Body and Trim
27
Cleaning the Vehicle
27
Seat Cleaning
27
Front and Rear Body Repair
28
Minor Scratches and Surface Blemishes
28
Small Scratches that Cannot be Buffed out
28
Gouges, Punctures, Tears, Large Scratches, and Abrasions
28
Touch-Up Paint Color Chart
29
Front Body
29
Bumper Removal
29
Bumper Installation
29
Brush Guard Removal
30
Brush Guard Installation
30
Front Body Removal
30
Dash Removal
30
Dash Installation
31
Front Body Installation
31
Cargo Bed
32
Cargo Bed Removal
32
Cargo Bed Installation
32
Bed Latch Assembly
32
Bed Latch Assembly Installation
34
Seat Back Support Brackets
34
Seat Back Support Bracket Removal
35
Seat Back Support Bracket Installation
35
Rear Body and Fenders
36
Rear Body Removal
36
Forward/Reverse Switch
37
Rear Fender Removal
39
Rear Fender Installation
39
Rear Body Installation
39
Floor Mat
40
Floor Mat Removal
40
Floor Mat Installation
40
Section 5 - Accelerator and Brake Pedal Group
41
Brake Pedal and Park Brake
41
Brake Pedal Removal
41
Brake Pedal Installation
42
Park Brake Removal
43
Park Brake Installation
44
Accelerator Pedal - Gasoline Vehicles
45
Accelerator Pedal Removal
45
Accelerator Pedal Installation
47
Accelerator Pedal - Electric Vehicles
48
Accelerator Pedal Removal
48
Accelerator Pedal Installation
50
Pedal Group Adjustment - Gasoline Vehicle
51
Bottom View
53
Pedal Group Adjustment - Electric Vehicles
56
Section 6 - Wheel Brake Assemblies
61
Brake Shoe Removal
61
Brake Assembly Cleaning
65
Brake Shoe Installation
66
Brake Adjustment
68
Brake Cluster Removal and Installation
68
Brake Cluster Installation
69
Brake Cable Removal and Installation
69
Section 7 - Steering and Front Suspension
71
General Information
71
Steering Wheel
71
Steering Wheel Removal
71
Steering Wheel Installation
72
Steering Column
72
Steering Column Removal
72
Steering Column Disassembly
74
Steering Column Assembly
74
Steering Column Installation
75
Steering Adjustment
76
Rack and Pinion
77
Rack and Pinion Removal
77
Rack and Pinion Disassembly
77
Pinion Gear
79
Rack and Pinion Assembly
80
Rack and Pinion Installation
82
Tie Rod and Drag Link
82
Tie Rod and Drag Link Removal
82
Tie Rod and Drag Link Installation
82
Front Suspension
83
Lubrication
83
Wheel Alignment
83
Front Suspension Components
85
Tapered Leaf Spring Removal
85
Tapered Leaf Spring Installation
85
Kingpin and Steering Spindle Removal
86
Kingpin and Steering Spindle Installation
86
Delta A-Plate Removal
86
Delta A-Plate Installation
89
Shock Absorber Removal
89
Shock Absorber Installation
89
Front Wheel Bearings and Hubs
89
Front Wheel Free Play Inspection
89
Front Hub Removal
89
Front Hub Installation
90
Section 8 - Wheels and Tires
91
General Information
91
Wheels
91
Wheel Removal
91
Wheel Installation
91
Tires
91
Tire Removal
91
Tire Repair
92
Tire Installation
93
Section 9 - Rear Suspension
95
General Information
95
Shock Absorbers
95
Shock Absorber Removal and Inspection
95
Shock Absorber Installation
95
Leaf Springs
95
Leaf Spring Removal
95
Leaf Spring Installation
98
Section 10 - Periodic Maintenance
99
General Information
99
Periodic Service Schedules
99
Regular Interval
100
Periodic Lubrication Schedules
102
Lubrication Points
103
Recommended Lubricant
103
Batteries - Electric Vehicles
104
Battery Care
104
Battery Charger - Electric Vehicles
104
Charging Batteries
105
Plug and Receptacle
106
Receptacle Fuse Link
107
Battery - Gasoline Vehicles
107
Engine Oil - Gasoline Vehicles
108
Engine Oil Level Check
108
Engine Oil and Filter Change
109
Drain Plug
110
Drain Pan
111
Oil Viscosity
111
Fueling Instructions - Gasoline Vehicles
112
Section 11 - Troubleshooting and Electrical System: Gasoline Vehicle
113
Troubleshooting Guide
113
Electrical System
117
Lockout Cam
117
Wiring Diagrams
118
Circuit Testing
120
Test Procedures
120
Index of Test Procedures
120
Black Wire
149
Section 12 - Electrical Components: Gasoline Vehicles
151
Starter/Generator
151
Service Limit
158
Voltage Regulator
161
Diode
162
Key Switch
164
Solenoid
165
Fuse
166
Lockout Cam Limit Switch
167
Lockout Cam
167
Reverse Warning Buzzer
168
Reverse Buzzer Limit Switch
169
Oil Warning Light
170
Fuel Gauge/Hour Meter
171
Fuel Level Sending Unit
172
RPM Limiter
172
Ignition Coil
173
Oil Level Sensor
176
Headlights
177
Headlight Diode
178
Light Switch
178
Battery
179
Ground Cables
182
Section 13 - Fe290 and Fe350 Engines
183
General Information
183
Before Servicing
183
Engine Rotation
183
Spark Plug
183
Cylinder Head
185
General Information
185
Breather Valve (Reed Valve)
185
Crankcase
185
Engine Removal
185
Crankcase Cover Removal
185
Oil Level Sensor
187
Crankcase Cover Installation
187
Ignition Coil and Flywheel
188
Flywheel Installation
190
Engine Installation
191
Torque Specifications
192
Adjustments and Settings
192
Section 14 - Fuel System: Gasoline Vehicle
193
General Information
193
Carburetor
193
Main Jet Elevation/Size Chart
194
Changing the Main Jet
194
Engine Control Linkage
197
General Information
197
Accelerator Rod
198
Governor Cable
200
Accelerator Cable
201
Closed Throttle or Idle Adjustment
203
Engine RPM Adjustment
203
Choke and Air Intake System
204
Choke Button Removal
204
Choke Button Installation
204
Air Box Removal
204
Air Box Installation
204
Intake Duct Removal
205
Intake Duct Installation
205
Air Filter
207
Fuel Filters
207
Fuel Filter Removal
207
Fuel Filter Installation
209
Fuel Pump
209
General Information
209
Fuel Pump Removal
209
Fuel Pump Disassembly
210
Fuel Pump Cleaning and Inspection
210
Fuel Pump Assembly
211
Fuel Pump Installation
211
Fuel Tank
212
General Information
212
Fuel Tank Removal
212
Fuel Tank Disposal
213
Tank Connection
213
Fuel Tank Storage
214
Fuel Tank Installation
214
Fuel Lines
215
Fuel Shut-Off Valve
216
Section 15 - Exhaust System: Gasoline Vehicles
217
Muffler
217
Muffler Removal
217
Muffler Installation
217
Section 16 - Unitized Transaxle: Gasoline Vehicle
219
General Information
219
Lubrication
220
Axle Shaft
220
Axle Shaft and Oil Seal Removal
220
Axle Bearing
221
Driver Side
222
Passenger Side
222
Axle Shaft Installation
223
Unitized Transaxle Removal
224
Unitized Transaxle Installation
232
Ground Wire
234
Top View
235
Forward/Reverse Shifter Cable
237
Forward/Reverse Shifter Cable Removal
237
Forward/Reverse Shifter Cable Installation
237
Forward/Reverse Shifter Cable Adjustment
238
Section 17 - Torque Converter: Gasoline Vehicle
241
General Information
241
Troubleshooting
241
Drive Belt
242
Drive Belt Removal
242
Drive Belt Installation
243
Drive Clutch
244
Drive Clutch Removal
244
Drive Clutch Cleaning and Inspection
245
Drive Clutch Disassembly
247
Inspection of Drive Clutch Parts
249
Drive Clutch Assembly
250
Drive Clutch Installation
252
Driven Clutch
252
Driven Clutch Removal
252
Driven Clutch Disassembly
252
Driven Clutch Inspection
253
Driven Clutch Assembly
253
Driven Clutch Installation
256
Section 18 - Electrical System and Testing: Electric Vehicle
257
General Information
257
Wiring Diagram
258
Troubleshooting
260
Troubleshooting the Vehicle with the Diagnostic Handset
260
Troubleshooting Guide 1
261
Troubleshooting Guide 2
264
Test Procedures
266
Index of Test Procedures
266
Test Procedure
275
Speed Controller
278
Communication Display Module (CDM)
291
Using the CDM to Retrieve Data from the Onboard Computer
292
CDM Troubleshooting Guide
293
Section 19 - Electrical Components: Electric Vehicle
295
Key Switch
295
Forward/Reverse Rocker Switch
296
Tow/Run Switch
297
Motor Controller Output Regulator (MCOR)
298
Reverse Buzzer
299
Solenoid
300
Onboard Computer (OBC)
301
Solid State Speed Controller
303
Charger Receptacle
304
Receptacle Fuse Link
306
Battery Warning Light
306
Pin 9 Diode
307
Section 20 - Batteries: Electric Vehicles
309
General Information
309
Battery Replacement
309
Battery Care
310
Preventive Maintenance
310
Self-Discharge
311
Electrolyte Level
311
Mineral Content
312
Vibration Damage
312
Battery Charger
312
Charger Shuts off after 16 Hours
313
Deep-Discharge
313
Early Excessive Discharging
313
Incoming AC Service
313
Fleet Rotation
313
Numbering Vehicles and Chargers
313
Battery Troubleshooting Chart
314
Battery Testing
315
Battery Charger Test
315
On-Charge Voltage Test
315
Hydrometer Test
315
Discharge Test
317
Battery Troubleshooting Examples
319
Battery Storage
320
Charging a Battery Pack that Has Low Voltage
320
Section 21 - Battery Charger: Electric Vehicle
321
Section 22A - Motor (Model 5Bc59Jbs6365)
323
General Information
323
Motor Identification
323
External Motor Testing
323
Motor
324
Motor Component Testing and Inspection
327
Armature
327
Field Windings Inspection
328
Motor Components
328
Bearing Inspection
329
Bearing Removal
329
Bearing Installation
329
Speed Sensor Magnet Inspection
331
Speed Sensor Magnet Removal
331
Speed Sensor Magnet Installation
331
Reconditioning the Motor
331
Motor Assembly
332
Bearing Puller
332
Motor Installation
334
Shaft End
335
Motor Speed Sensor
337
Section 22B - Motor (Model Ej4-4001)
339
General Information
339
Motor Identification
339
External Motor Testing
339
Motor
340
Motor Removal
340
Motor Disassembly
342
Motor Component Testing and Inspection
344
Armature Inspection and Testing
344
Motor Frame and Field Windings Inspection
346
Motor Brush, Spring, and Terminal Insulator Inspection
346
Reconditioning the Motor
349
Motor Assembly
349
Motor Installation
351
Section 23 - Transaxle (Type G): Electric Vehicle
355
Transaxle Identification
355
Lubrication
355
Axle Bearing and Shaft
355
Axle Shaft
355
Axle Bearing
358
Transaxle
358
Transaxle Removal
358
Intermediate Gear Assembly
360
Differential Gear Case
360
Transaxle Disassembly, Inspection, and Assembly
361
Transaxle Disassembly and Inspection
361
Transaxle Assembly
364
Transaxle Installation
365

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Club Car XRT800 2006 Maintenance Service Manual (376 pages)

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