Club Car CARRYALL 252 2007 Maintenance And Service Manual Download

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Troubleshooting

ELECTRICAL SYSTEM AND TESTING:

ELECTRIC VEHICLES

TROUBLESHOOTING GUIDE 1

SYMPTOM

POSSIBLE CAUSES

CORRECTIVE ACTION

Speed controller logic malfunction

Failed controller FET (that powers up solenoid

coil)

Disconnect the batteries and allow the speed

controller capacitors to discharge.

See WARNING

“To avoid unintentionally starting...” in See

General Warning on page 1-1.

Reconnect the

batteries and see if the symptom returns.

Loose, broken, or disconnected wire(s) at solenoid

or B+ speed controller terminal

Repair and/or connect the loose or disconnected

wire(s)

Loose or disconnected 24-pin connector at speed

controller or broken wire

Repair and/or connect the 24-pin connector to the

speed controller

Monitor Menu – MAIN CONT (solenoid)

does not indicate ON when the solenoid

should be activated. or Diagnostic

Menu – MAIN CONT DNC (main

contactor (solenoid) did not close) fault

code

Failed solenoid

Replace solenoid.

See Solenoid Removal on

page 24-9.

Loose or disconnected wires at key switch

terminals or broken wire

Repair and/or connect the quick disconnect

terminals to the Forward/Reverse switch

Loose or disconnected 24-pin connector at speed

controller or broken wire

Repair and/or connect the 24-pin connector to the

speed controller

Monitor Menu – KEY INPUT does not

indicate ON when key switch is in the

ON position

Failed key switch

Test Procedure 9 – Key Switch and MCOR Limit

Switch Circuit on page 22-18

Loose or disconnected three-pin connector at the

MCOR or broken wire

Repair and/or connect the three-pin connector to

the MCOR

Loose or disconnected 24-pin connector at speed

controller or broken wire

Repair and/or connect the 24-pin connector to the

speed controller

Diagnostic Menu – THROTTLE FAULT

1 fault code

Failed MCOR

Test Procedure 4 – MCOR Voltage on page 22-13

Armature drive FET’s (field-effect transistors)

inside speed controller have failed

Replace the speed controller.

See Speed

Controller Removal on page 24-12.

Diagnostic Menu – HW FAILSAFE

(Hardware Failsafe) fault code

Speed controller logic malfunction

Disconnect the batteries and allow the speed

controller capacitors to discharge.

See WARNING

“To avoid unintentionally starting...” in See

General Warning on page 1-1.

Reconnect the

batteries and see if the symptom returns.

Diagnostic Menu – MAIN WELDED

(main solenoid contacts welded) fault

code

solenoid contacts have failed closed

Replace solenoid.

See Solenoid Removal on

page 24-9.

Speed controller logic malfunction

Disconnect the batteries and allow the speed

controller capacitors to discharge.

See WARNING

“To avoid unintentionally starting...” in See

General Warning on page 1-1.

Reconnect the

batteries and see if the symptom returns.

Diagnostic Menu – MAIN DRIVER ON

or MAIN DRIVER OFF fault code

Failure of the FET that controls the solenoid coil

Replace the speed controller.

See Speed

Controller Removal on page 24-12.

Diagnostic Menu – MAIN COIL FAULT

fault code or Diagnostic Menu – MAIN

DROPOUT fault code

Solenoid coil has failed in an open condition or

broken wire to solenoid coil

Replace solenoid.

See Solenoid Removal on

page 24-9.

TABLE CONTINUED ON NEXT PAGE

Page 22-6

2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual

Summary of Contents for CARRYALL 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 2: ......

Page 3: ...ans who want to learn more about our products For more information contact your local dealer or Club Car s Technical Services department for a list of upcoming classes This manual covers all aspects of typical vehicle service however unique situations sometimes occur when servicing a vehicle If it appears that a service question is not answered in this manual please contact your nearest authorized...

Page 4: ......

Page 5: ... Front Body Repair 4 2 Stress Lines or Streaks 4 2 Minor Impact Damage Deformations 4 2 Minor Scratches and Surface Blemishes 4 2 Small Scratches That Cannot Be Buffed Out 4 3 Touch Up Paint Color Chart 4 3 Gouges Punctures Tears Large Scratches and Abrasions 4 3 Front Body 4 3 Front Body Removal 4 3 Front Body Installation 4 4 Tilt Bed 4 5 Tilt Bed Removal 4 5 Tilt Bed Installation 4 5 Rear Fende...

Page 6: ...uster Removal 6 13 Front Brake Cluster Installation 6 14 Front Brake Cables 6 14 Front Brake Cable Removal 6 14 Front Brake Cable Installation 6 15 Rear Brake Cables 6 17 Rear Brake Cable Removal 6 17 Rear Brake Cable Installation 6 18 SECTION 7 STEERING AND FRONT SUSPENSION 7 1 General Information 7 1 Steering Wheel 7 1 Steering Wheel Removal 7 1 Steering Wheel Installation 7 2 Steering Column 7 ...

Page 7: ...ber Removal 9 5 Snubber Installation 9 5 Stabilizer Bar 9 6 Stabilizer Bar Removal 9 6 Stabilizer Bar Installation 9 6 SECTION 10 PERIODIC MAINTENANCE 10 1 General Information 10 1 Pre Operation and Daily Safety Checklist 10 1 Performance Inspection 10 2 Periodic Service Schedules 10 3 Periodic Lubrication Schedules 10 6 Engine Oil Gasoline Vehicle 10 7 Engine Oil Level Check 10 8 Engine Oil And F...

Page 8: ...itch Removal 13 17 Key Switch Installation 13 18 Solenoid 13 19 Solenoid Removal 13 19 Solenoid Installation 13 19 Fuse 13 20 Fuse Removal 13 20 Fuse Installation 13 20 Neutral Lockout Limit Switch 13 21 Neutral Lockout Limit Switch Removal 13 21 Neutral Lockout Limit Switch Installation 13 22 Reverse Warning Buzzer 13 23 Reverse Warning Buzzer Removal 13 23 Reverse Warning Buzzer Installation 13 ...

Page 9: ...tion 14 5 Bearing Removal 14 5 Field Coil Removal 14 6 Visual Inspection of Armature 14 6 Commutator Cleaning and Inspection 14 7 Armature Ground Test 14 8 Visual Inspection of Field Coils 14 9 Starter Generator Rework 14 9 Starter Generator Assembly 14 9 Starter Generator Installation 14 10 Belt Tension Adjustment 14 12 Voltage Regulator 14 12 Voltage Regulator Removal 14 12 Voltage Regulator Ins...

Page 10: ...stallation 14 31 Battery 14 32 General Information 14 32 Testing the Battery 14 32 Preventive Maintenance 14 33 Water Level 14 33 Self Discharge 14 33 Vibration Damage 14 34 Mineral Content 14 34 Battery Removal 14 35 Charging the Battery 14 35 Battery Installation 14 35 Battery Storage 14 36 Charging a Dead Battery 14 36 Ground Cables 14 36 SECTION 15 S10 FE 350 ENGINE 15 1 General Information 15...

Page 11: ...17 1 Main Jet Elevation Size Chart 17 2 Changing the Main Jet 17 3 Engine Control Linkage 17 6 General Information 17 6 Accelerator Rod 17 6 Governor Cable 17 8 Accelerator Cable 17 10 Closed Throttle or Idle Adjustment 17 10 Engine RPM Adjustment 17 11 Choke and Air Intake System 17 12 General Information 17 12 Choke Cable Removal 17 12 Choke Cable Installation 17 12 Air Box Removal 17 12 Air Box...

Page 12: ...lter 18 15 Fuel Filters 18 17 General Information 18 17 Fuel Filter Removal 18 17 Fuel Filter Installation 18 17 Fuel Pump 18 19 General Information 18 19 Fuel Pump Removal 18 19 Fuel Pump Disassembly 18 20 Fuel Pump Cleaning and Inspection 18 20 Fuel Pump Assembly 18 21 Fuel Pump Installation 18 21 Fuel Tank 18 23 General Information 18 23 Fuel Tank Removal 18 23 Fuel Tank Disposal 18 24 Fuel Tan...

Page 13: ...lutch Disassembly 21 12 Driven Clutch Inspection 21 13 Driven Clutch Assembly 21 13 Driven Clutch Installation 21 16 SECTION 22 ELECTRICAL SYSTEM AND TESTING ELECTRIC VEHICLES 22 1 General Information 22 1 Wiring Diagrams 22 2 Troubleshooting 22 4 Troubleshooting the Vehicle with the IQDM 22 4 Troubleshooting Guide 1 22 5 Troubleshooting Guide 2 22 8 Test Procedures 22 10 Communication Display Mod...

Page 14: ...u 23 9 System Faults 23 10 Fault Recovery 23 11 Fault Descriptions 23 12 Functions Menu 23 14 Get Settings From Controller 23 14 Write Settings to Controller 23 16 Reset All Settings 23 17 Information 23 18 Model Number 23 18 Serial Number 23 18 MFG Date 23 18 Software Version 23 18 Programmer Setup 23 18 Program 23 18 Faults 23 18 Information 23 19 IQDM and IQDM P Handset Troubleshooting 23 19 Te...

Page 15: ...24 14 Receptacle Fuse Link 24 15 Receptacle Fuse Link Removal 24 15 Receptacle Fuse Link Installation 24 16 Battery Warning Light 24 16 Battery Warning Light Removal 24 16 Battery Warning Light Installation 24 16 SECTION 25 BATTERIES ELECTRIC VEHICLES 25 1 General Information 25 1 Battery Replacement 25 2 Battery Care 25 3 Preventive Maintenance 25 3 Self Discharge 25 3 Electrolyte Level 25 3 Mine...

Page 16: ...Installation 27 13 SECTION 28 TRANSAXLE TYPE G ELECTRIC VEHICLES 28 1 Lubrication 28 1 Axle Bearing and Shaft 28 1 Axle Shaft 28 1 Axle Bearing 28 4 Transaxle 28 5 Transaxle Removal 28 5 Transaxle Disassembly Inspection and Assembly 28 7 Transaxle Disassembly and Inspection 28 7 Transaxle Assembly 28 9 Transaxle Installation 28 11 SECTION 29 IQ DISPLAY MODULE IQDM P SERIES 2 PROGRAMMING 29 1 Plugg...

Page 17: ...thout the safety alert symbol indicates a potentially hazardous situation that could result in property damage GENERAL WARNING The following safety statements must be heeded whenever the vehicle is being operated repaired or serviced Service technicians should become familiar with these general safety statements Also other specific safety statements appear throughout this manual and on the vehicle...

Page 18: ...ame engine or any other metal component Electric vehicles only Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning could result in a battery explosion or severe personal injury To avoid unintentionally starting an electric vehicle disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicle...

Page 19: ...d while bed is raised Do not close bed until all persons are clear of cargo bed area Keep hands clear of all crush areas Do not drop cargo bed lower gently and keep entire body clear Failure to heed this warning could result in severe personal injury or death Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance severe personal injury or death...

Page 20: ...h in the TOW position before disconnecting or connecting the batteries Failure to heed this warning could result in a battery explosion or severe personal injury 3 Disconnect the batteries negative cable first as shown Figure 1 2 Page 1 4 4 After disconnecting the batteries wait 90 seconds for the controller capacitors to discharge CONNECTING THE BATTERIES ELECTRIC VEHICLES CAUTION IQ Plus vehicle...

Page 21: ...able speed dry type STEERING SUSPENSION BRAKES Steering Self adjusting rack and pinion Suspension Front and rear multi leaf springs with dual hydraulic shocks Brakes Mechanical brake cable system to manually adjusted drum brakes on each wheel with automatic release park brake BODY CHASSIS Frame Chassis Twin I Beam welded aluminum Side and rear body All aluminum with a powder coated steel box bed S...

Page 22: ...m Load bed size box bed inside dimensions 48 0 x 49 8 x 10 9 in 121 9 x 126 x 28 cm 15 3 cubic feet 48 8 x 49 8 x 10 9 in 124 x 126 x 28 cm 15 3 cubic feet Floorboard height 16 0 in 40 cm Seat height at seat bottom 28 0 in 71 cm Vehicle rated capacity level surface only 900 lb 408 kg Bed load capacity level surface only 500 lb 227 kg Standard seating capacity 2 LIQUID CAPACITIES Engine crankcase w...

Page 23: ... on all four wheels Park brake is automatically released BODY CHASSIS Frame chassis Twin I Beam welded aluminum Side and rear body All aluminum with a powder coated steel box bed Side and rear body All aluminum Front body ArmorFlex Front body finish Matched paint finish over molded in color Tires Heavy Duty All Terrain tubeless 6 ply rated Turf tubeless 4 ply rated DIMENSIONS WEIGHT Overall length...

Page 24: ... dimensions 48 0 x 49 8 x 10 9 in 121 9 x 126 x 28 cm 15 3 cubic feet 48 8 x 49 8 x 10 9 in 124 x 126 x 28 cm 15 3 cubic feet Floorboard height 16 0 in 40 cm Seat height 28 0 in 71 cm Vehicle rated capacity Level surface only 900 lb 408 kg Bed load capacity level surface only 500 lb 227 kg Standard seating capacity 2 LIQUID CAPACITIES Transaxle 22 oz 0 67 liters TIRE PRESSURE Off road tread 14 18 ...

Page 25: ...ed with the vehicle for information on the following topics Controls and Indicators Pre Operation and Daily Safety Checklist Driving Instructions Bed Latch Prop Rod Loading and Unloading Towing with a Vehicle Transporting on a Trailer Subsequent Owner Registration Warranties SERIAL NUMBER IDENTIFICATION The serial number of the vehicle is printed on a bar code decal mounted on the frame directly a...

Page 26: ...an approved fuel container only Store in a well ventilated area away from sparks open flames heaters or heat sources Keep fuel out of the reach of children Do not siphon fuel from the vehicle WARNING Turn the key switch to the OFF position remove the key and leave the Forward Reverse handle in the NEUTRAL position during storage This is to prevent unintentionally starting the vehicle or a fire haz...

Page 27: ...3 Page 3 3 or Figure 3 4 Page 3 3 and run the engine until fuel remaining in the carburetor and fuel lines is depleted and the engine stalls 1 2 3 1 Fuel Shut off Valve 2 Closed OFF 3 Open ON NOTE When selecting valve position ensure that it is fully opened or fully closed 2 1 3 Viewed from driver side of vehicle 1 Fuel Shut off Valve 2 Closed OFF 3 Open ON NOTE When selecting valve position ensur...

Page 28: ...ck the wheels to prevent the vehicle from rolling RETURNING THE STORED GASOLINE VEHICLE TO SERVICE 1 Restore fuel system to operation 1 1 Remove plug from the fuel tank vent Figure 3 5 Page 3 4 1 2 Connect vent tube to fuel tank vent 2 Connect battery See Connecting the Battery Gasoline Vehicles Section 1 Page 1 3 3 Completely open the fuel shut off valve 1 Figure 3 3 Page 3 3 or Figure 3 4 Page 3...

Page 29: ...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 Rinse solution off batteries Do not allow this solution to enter the batteries Be sure terminals are tight Let the terminals dry and then coat them with Battery Terminal Protector Spray CCI P N 1014305 4 Store vehicle in a cool dry place This will min...

Page 30: ...ect the DC cord stationary charger from the vehicle or the AC cord onboard charger from the power source wait five seconds then reconnect it CAUTION Be sure to check the batteries and charger monthly to maintain correct battery water level and to ensure the charger is operating correctly during storage 9 4 If the charger cannot remain plugged in AC power will not be available during extended stora...

Page 31: ...lly available aluminum cleaner paste and fine grade 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 The seats of the vehicle will last longer with proper cleaning To preserve seat appearance clea...

Page 32: ...edure similar to the one used to remove stress lines To remove deformations resulting from minor impact damage 1 Hold a heat gun 12 inches 30 cm away from the affected area with the gun on its lowest heat setting 2 Periodically remove the heat gun and bend the body using a push block in the opposite direction of the deformation 3 Continue heating and bending the body until the original shape retur...

Page 33: ...ratch Multiple layers of paint may be required to fill the scratch 4 Allow paint to dry completely approximately 10 20 minutes then lightly buff the imperfection 5 Apply wax to the entire body part to restore luster and weather protection TOUCH UP PAINT COLOR CHART COLOR CCI P N Beige 101997201 White 101997202 Red 101997203 Gray 101997204 Dark Gray 101997205 Royal Blue Pacific Blue 101997206 Black...

Page 34: ...ng front body trim against front body 5 Vehicles equipped with headlights Disconnect the light wiring harness from the headlight assemblies 6 Pull front body 12 from under trim 13 and remove from vehicle 1 13 14 11 12 6 17 16 15 18 19 5 3 4 2 3 9 8 10 9 8 B A Detail A Front Bumper Detail B Heavy Duty Front Bumper Figure 4 1 Front Body Assembly FRONT BODY INSTALLATION 1 Install front body 12 under ...

Page 35: ...from top end of prop rod where prop rod attaches to bed Remove prop rod 17 from bed and place prop rod between prop rod track 18 and rear body panel Lower bed onto vehicle frame Figure 4 2 Page 4 6 2 Remove two lock nuts 10 from left and right hinge assemblies 3 and 25 3 Apply slight upward pressure by hand on the rear of the bed to relieve pressure on the hinges and remove the hinge bolts 9 from ...

Page 36: ...4 Tilt Bed BODY AND TRIM TYPICAL 2 PLACES 9 3 10 25 22 23 18 17 2 1 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: ... washers 1 and 1 4 x 1 bolts 2 from front of fender 6 Figure 4 3 Page 4 8 3 Remove two nylon lock nuts 3 flat washers 1 and 1 4 x 1 bolts 2 from the top of fender 6 4 Vehicles with rear reverse buzzer Remove the rear reverse buzzer 4 1 Remove pan head screws connecting reverse buzzer to rear fender 6 and disconnect the two wires from the reverse buzzer 5 All vehicles Remove fender 6 from vehicle F...

Page 38: ...rt Turf Carryall and XRT REAR FENDER INSTALLATION 1 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 TRAILER HITCH REMOVAL 1 Remove the tailskirt See Tailskirt Removal on page 4 10 Page 4 8 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual ...

Page 39: ...MODELS See General Warning on page 1 1 RECEIVER HITCH REMOVAL 1 Remove the tailskirt See Tailskirt Removal on page 4 10 2 Remove two 5 16 18 hex nuts 6 lockwashers 7 flat washers 5 and 5 16 18 x 1 inch bolts 2 from the top of hitch 4 Figure 4 4 Page 4 10 3 Remove two 5 16 18 hex nuts 6 lockwashers 7 flat washers 5 and 5 16 18 x 1 inch bolts 2 where the hitch 4 mounts to the vehicle frame and remov...

Page 40: ... 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 1 Insert upper edge of tailskirt 4 under and in front of back edge of rear body Figure 4 3 Page 4 8 Page 4 10 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual ...

Page 41: ...ve the brake and accelerator pedals See Accelerator and Brake Pedal Group on page 5 1 2 Remove horn switch if so equipped 3 Remove the top edge of the floor mat from the overlapping flange under the dash 4 Lift the mat from the vehicle FRONT FLOOR MAT INSTALLATION 1 Install the floor mat in the reverse order of removal 2 Install the brake and accelerator pedals See Accelerator and Brake Pedal Grou...

Page 42: ......

Page 43: ... 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 Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 3 Remove the brake pedal asse...

Page 44: ... 25 24 21 20 18 19 17 12 31 32 30 33 33 17 22 10 13 23 34 35 STOP 16 15 27 28 27 28 29 5 11 7 3 6 2 26 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: ...ne vehicles see Pedal Group Adjustment Gasoline Vehicles on page 5 10 For electric vehicles see Pedal Group Adjustment Electric Vehicles on page 5 15 S TO P 10 1 30 32 30 22 23 10 21 12 17 18 19 35 Figure 5 2 Brake Pedal Weldment Through Floor Figure 5 3 Park Brake Assembly PARK BRAKE REMOVAL 1 Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire s Se...

Page 46: ...o the park brake pawl shaft 3 Install the spacer 23 and torsion spring 22 on the park brake pedal shaft on the brake pedal assembly 4 Install the two bushings 30 in the park brake pedal and position the park brake pedal on the shaft on the brake pedal assembly weldment 10 Figure 5 3 Page 5 3 Then attach the ends of the torsion spring to the park brake pedal and to the brake pedal weldment as shown...

Page 47: ...h to remove the nut 7 two washers 5 and bolt 4 securing the accelerator pedal 1 to the pivot rod 6 5 Remove the nut 10 and ball stud 8 from the accelerator pivot rod assembly 6 6 Slide the spring retainer 11 off of the accelerator pivot rod 7 Inspect the pivot support bearing 9 for wear and replace if necessary 8 Use a marker to mark the position of the park brake ratchet 23 on the accelerator piv...

Page 48: ... this time Figure 5 5 Page 5 6 2 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 3 Install the plastic spacer 20 on the pivot rod 6 4 Insert the pivot rod through the pivot rod supports on the vehicle frame 5 Tighten the four bolts 22 attaching the pivot rod supports to the frame to 75 in lb 8 5 ...

Page 49: ... and forth slightly to align the splines and slide the ratchet onto the splines 11 Install the nylon lock nut 26 on the pivot rod and tighten the nut to 18 ft lb 24 N m Figure 5 5 Page 5 6 12 Install the accelerator rod assembly 17 25 and 24 Figure 5 5 Page 5 6 13 Adjust the pedal group See Pedal Group Adjustment Gasoline Vehicles on page 5 10 ACCELERATOR PEDAL ELECTRIC VEHICLES See General Warnin...

Page 50: ...ould cause it to be installed improperly resulting in improper adjustment and possible failure of the park brake 9 Remove the lock nut 23 from the accelerator pivot rod 10 Press the brake pedal slightly and slide the park brake ratchet 24 toward the end of the accelerator pivot rod Rotate the ratchet and remove it from the pivot rod 11 Remove the pivot rod 6 and spacer 20 from the accelerator pivo...

Page 51: ...L GROUP Accelerator Pedal Electric Vehicles 5 GO 3 2 11 10 7 5 4 5 1 8 9 6 15 16 21 20 21 22 24 23 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: ... its tip is pointed downward Figure 5 6 Page 5 7 The ratchet should now rotate freely on the rod 9 Rotate the ratchet clockwise until it touches the park brake pawl then slide the ratchet onto the splines of the pivot rod it may be necessary to push the pivot rod toward the driver side of the vehicle to make the splines accessible The ratchet may have to be rotated counterclockwise slightly to ali...

Page 53: ...inches 15 2 cm from floormat to back of brake pedal Figure 5 10 Brake Pedal Height Adjustment Figure 5 11 Brake Pedal Height Measurement 3 Adjust park brake ratchet pawl gap and pawl engagement 3 1 Inspect the park brake pawl and ratchet for excessive wear grooves cracks or chips If either the pawl or ratchet is damaged both must be replaced 3 2 Adjust retaining nut 7 on spring support rod until t...

Page 54: ...engages the pawl Figure 5 14 Page 5 12 Tooth engagement should be between the two lines marked on the pawl 00000 00000 00000 00000 0 PARK STO P GO 1 2 3 4 5 6 7 8 9 10 A B 1 2 3 1 Locked Position 2 Ratchet B Tooth Length 3 Make sure pawl A engages at least 75 of ratchet tooth length B Figure 5 13 Accelerator Pedal Height Measurement Figure 5 14 Ratchet Pawl Tooth Engagement 3 5 With park brake sti...

Page 55: ...5 5 8 inches 14 3 cm Use a rubber strap to hold pedal in position against the floorboard and then tighten nut to 26 ft lb 35 3 N m Figure 5 17 Page 5 13 000 000 000 0 STOP PARK GO 0 GO 0 STOP PARK MICRO BREAK POINT MICRO BREAK POINT 1 2 1 Accelerator Pedal Adjustment Tool CCI P N 101871001 2 Rubber Strap Figure 5 17 Accelerator Pedal Height Adjustment 5 Adjust the accelerator rod See following DAN...

Page 56: ...with one end disconnected hold the disconnected accelerator rod with locking pliers When tightening jam nuts on the accelerator rod hold the disconnected ball joint with locking pliers 5 3 Reconnect the accelerator rod at the accelerator pedal 5 4 Before tightening jam nuts on accelerator rod set park brake to first ratchet and pawl position Press accelerator pedal and make sure the following even...

Page 57: ...ing nuts 2 and 3 on the equalizer rod 1 Figure 5 19 Page 5 15 2 3 Four wheel brake vehicles only Loosen the front brake equalizer rod Figure 5 20 Page 5 15 1 3 2 4 2 Figure 5 19 Loosen Rear Brake Equalizer Rod Nuts Figure 5 20 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 Next adjust the brak...

Page 58: ...e of pawl movement If the gap is not consistent loosen the four bolts 6 securing the accelerator pivot rod supports and adjust the supports If the gap becomes smaller as the park brake pedal is pressed move the pivot rod supports slightly rearward until the gap is consistent If the gap becomes larger as the park brake pedal is pressed move the pivot rod supports slightly forward until gap is consi...

Page 59: ...or counterclockwise to decrease engagement Reconnect ball joint Figure 5 26 Page 5 17 3 7 Check for proper brake operation prior to driving the vehicle 4 Adjust accelerator pedal height 4 1 Loosen the nut and bolt Figure 5 27 Page 5 17 securing the accelerator pedal to the pivot plate Clamp the accelerator pedal adjustment tool CCI P N 101871001 to the accelerator pedal with the end marked acceler...

Page 60: ...CRO BREAK POINT MICRO BREAK POINT 1 2 1 Accelerator Pedal Adjustment Tool CCI P N 101871001 2 Rubber Strap Figure 5 28 Accelerator Pedal Height Adjustment 5 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: ...stem or low pressure wet cleaning method per 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 See also WARNING on page 6 1 1 To remove rear brake shoes place chocks at the front wheels loosen the rear wheel lug nuts an...

Page 62: ...ove the axle shaft 4 1 Using 90 snap ring pliers CCI P N 1012560 remove axle retaining ring 1 Figure 6 2 Page 6 2 4 2 Pull the axle shaft 2 from the axle tube Figure 6 2 Page 6 2 0 0 1 2 Figure 6 2 Remove Axle Retaining Ring 5 Using needle nose pliers rotate the clip retainer pin 1 90 to remove the shoe retainer clip 2 on each shoe Figure 6 3 Page 6 3 See following CAUTION Page 6 2 2007 2009 Turf ...

Page 63: ...al components 2 Remove rubber boot from backing plate and wipe with a clean damp cloth 3 Lubricate slide 1 and slide plate 2 with dry moly lubricant CCI P N 1012151 on both sides of the backing plate After lubricating work slide back and forth to ensure it slides smoothly and easily Figure 6 5 Page 6 4 Reinstall rubber boot onto backing plate See following WARNING WARNING Apply grease carefully wh...

Page 64: ...efully apply a light coat of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent to each end of both brake shoes and into the slots in the brake shoe mounting block as shown Figure 6 7 Page 6 4 See preceding WARNING 6 Use a small brush to carefully apply a light coat of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent to the brake actuator assembly as shown Figure 6 8 Page...

Page 65: ...ible 00 J 1 0 1 2 Figure 6 9 Orient and Insert Shoes Figure 6 10 Retainer Clip 2 Install shoe retainer clip 1 using pliers to compress clip while turning clip retainer pin 2 into position Figure 6 10 Page 6 5 3 Attach the springs with hooks pointing outwards onto the shoe already installed Then hold the other shoe next to it correctly oriented and attach the springs to it Figure 6 11 Page 6 6 See ...

Page 66: ...2 into axle tube and install retaining ring 1 Figure 6 2 Page 6 2 See following WARNING WARNING Be sure retaining ring is properly seated in groove If ring is not properly installed axle assembly will separate from transaxle and damage axle assembly and other components Loss of vehicle control could result in severe personal injury or death 7 Install the brake drum and make sure that it is properl...

Page 67: ...ubricated and in good working condition prior to beginning brake adjustment All wheels must be installed on the vehicle and lug nuts properly tightened See Wheel Installation Section 8 Page 8 1 BRAKE CLUSTER ADJUSTMENT 1 Chock wheels 1 1 To provide slack in the brake cables loosen the equalizer retaining nuts 1 and 5 on the equalizer rod 2 Figure 6 13 Page 6 7 2 Four wheel brake vehicles only Loos...

Page 68: ... tightened to 15 ft lb 20 3 N m and continue clockwise rotation to the point at which torque is released Stop tightening the bolt as soon as the torque releases or the brake will not be properly adjusted See following NOTE NOTE If a wheel can still be turned by hand after step 4 inspect the brake clusters and clean and or replace all parts that do not work properly 5 Four wheel brake vehicles only...

Page 69: ...nt Manually Adjusted Brakes 6 13 22 17 11 21 10 11 1 20 16 9 19 10 5 4 3 6 8 7 18 00 00 00 00 00 12 14 2 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: ...es WHEEL BRAKE ASSEMBLIES 20 10 19 21 23 9 22 11 10 11 16 17 14 2 13 0000 0000 00 00 1 3 4 5 6 7 8 18 15 12 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: ...hten the jam nut 1 to 13 ft lb 17 6 N m Figure 6 14 Page 6 7 2 5 Hold the jam nut 5 on the rear equalizer rod 2 in place with a wrench and tighten the lock nut 1 to 13 ft lb 17 6 N m Figure 6 13 Page 6 7 See following CAUTION CAUTION If the brake pedal return spring 6 was disconnected while equalizing the brake cables be sure to reconnect it before proceeding Figure 6 13 Page 6 7 FINAL BRAKE CLUST...

Page 72: ...inal Brake Cluster Adjustment on page 6 11 Brake adjustment must be maintained so the brake pedal cannot be pressed to the floor under any circumstance BRAKE CLUSTER REMOVAL AND INSTALLATION See General Warning on page 1 1 See also WARNING on page 6 1 REAR BRAKE CLUSTER REMOVAL 1 Place chocks at the front wheels loosen the lug nuts on the rear wheels and lift the rear of the vehicle with a chain h...

Page 73: ...described in this section for the appropriate vehicle See Brake Adjustment Manually Adjusted Brakes on page 6 7 FRONT BRAKE CLUSTER REMOVAL 1 Place chocks at rear wheels loosen lug nuts on front wheels and lift the front of the vehicle with a chain hoist or floor jack Place jack stands under the round tube crossmember of the frame to support vehicle 2 Release park brake 3 Loosen the equalizer reta...

Page 74: ...ock washers 20 and hex nuts 19 to mount brake assembly Figure 6 18 Page 6 10 2 Tighten bolts to 30 ft lb 41 N m Adjust brakes as previously described in this section for the appropriate vehicle Use new bow tie pins when reconnecting brake cables FRONT BRAKE CABLES See General Warning on page 1 1 See also WARNING on page 6 1 FRONT BRAKE CABLE REMOVAL 1 Remove bow tie pin 2 and clevis pin 3 from bra...

Page 75: ... nut 6 from brake cable clamp 5 Figure 6 21 Page 6 15 5 Remove cable from vehicle 2 3 1 4 6 8 7 5 Figure 6 21 Front Brake Cables FRONT BRAKE CABLE INSTALLATION 1 Place brake cable through frame mounting hole behind equalizer and install E clip 8 on cable housing Figure 6 22 Page 6 16 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual Page 6 15 ...

Page 76: ... 3 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 NOTE 77 5 in 196 9 cm and 78 5 in 199 4 cm wheelbase vehicles The cable should pass over the inside I beam Figure 6 23 Page 6 17 Page 6 16 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual ...

Page 77: ...s described in this section for the appropriate vehicle 2 7 3 Figure 6 23 Front Brake Cable Routing REAR BRAKE CABLES See General Warning on page 1 1 See also Warning on Page 6 1 REAR BRAKE CABLE REMOVAL 1 Chock wheels to keep vehicle from unintentionally moving 2 Release park brake if latched and loosen equalizer retaining nuts 1 on equalizer rod 2 to slightly loosen brake cables 3 Figure 6 24 Pa...

Page 78: ...18 Route cables through hangers in the same manner as the ones removed 2 At the rear wheel brakes connect the cables to the brake actuator arms using clevis pins 2 and new bow tie pins 1 Figure 6 25 Page 6 18 3 Place cables in cable support bracket 5 and secure with E clips 4 Adjust brakes as described in this section for the appropriate vehicle Page 6 18 2007 2009 Turf 252 Carryall 252 and XRT 90...

Page 79: ...ng wheel 3 and steering column shaft 4 so when the steering wheel is removed it can be placed back in exactly the same position on steering column shaft 4 Loosen the steering wheel nut 5 and back it off approximately 1 4 inch 6 mm Do not remove the nut 5 Use the steering wheel puller CCI P N 102061201 to remove steering wheel 5 1 Place the puller anvil 6 through the top opening of the steering whe...

Page 80: ...lign the match marks placed on the wheel and steering column shaft in step 2 above Figure 7 1 Page 7 2 2 Install the steering wheel nut 5 and tighten to 156 in lb 17 6 N m 3 Install the plate 2 and screws 1 Figure 7 1 Page 7 2 Tighten screws to 16 in lb 1 8 N m 4 Connect the battery cables See Connecting the Battery Gasoline Vehicles Section 1 Page 1 3 See Connecting the Batteries Electric Vehicle...

Page 81: ...Steering Column 3 Remove the center dash panel See Key Switch Removal in the Electrical Components Section 4 Remove the driver side dash pocket 4 1 Remove the flange lock screw from the top of the dash pocket 4 2 Drill out the two pop rivets holding the dash pocket in place 4 3 Slide dash pocket out of vehicle 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual Page 7 3 ...

Page 82: ... the bearing 17 all the way into the bearing seat 18 using a steering column bearing press tool CCI P N 1014264 or a metal tube approximately six inches 15 2 cm long with a maximum outer diameter of 1 3 16 inches 3 3 cm and a minimum inside diameter of 7 8 inch 2 2 cm Be sure the bearing is installed in the bearing seat as shown Figure 7 4 Page 7 5 so the wedge 16 will ride against the inner race ...

Page 83: ...r tighten 6 Tighten the two nuts 9 and bolts 8 to 18 ft lb 24 4 N m Figure 7 3 Page 7 3 7 Tighten the bolt 2 on the upper universal joint to 15 ft lb 20 N m Figure 7 3 Page 7 3 8 Check the other two bolts of the universal joint 1 to ensure that they are properly tightened to 15 ft lb 20 N m Figure 7 3 Page 7 3 9 Reinstall dash pocket and related hardware 10 Reinstall center dash panel in reverse o...

Page 84: ...ave been completed tighten the nuts 27 and 29 on the drag link assembly with an open end wrench Tighten nuts to 21 ft lb 28 4 N m Figure 7 11 Page 7 9 See following CAUTION CAUTION When tightening the nuts 27 and 29 make sure the drag link 28 does not turn Figure 7 11 Page 7 9 4 Straighten wheels and turn steering wheel from lock to lock Wheels should turn smoothly and easily If steering wheel doe...

Page 85: ...left hand threads 1 Remove ball joint from the spindle and inspect it for excessive wear Figure 7 7 Page 7 7 2 Remove the drag link 28 Figure 7 11 Page 7 9 3 Remove both bellows clamps 2 plastic wire ties 4 Remove the hex nut 29 and slide off the dust seal bellows 1 5 Remove the retaining ring 21 then slide off dust seal bellows 20 6 Remove the rack screw lock nut 15 rack guide screw 16 rack guide...

Page 86: ...ed remove the external snap ring 10 Figure 7 11 Page 7 9 and press the bearing off Figure 7 9 Page 7 8 12 Remove retaining ring 19 and stop washer 18 then remove rack 17 from housing 6 Figure 7 11 Page 7 9 13 If the inner ball joint 3 is excessively worn remove the ball joint and tab washer 4 from the rack Figure 7 10 Page 7 8 13 1 Secure the rack in a vise using wood blocks 5 between the rack and...

Page 87: ... joint to 60 ft lb 81 N m 2 Bend the edges of the tab washer 4 up against the ball joint 3 Figure 7 10 Page 7 8 3 Apply a light coating of EP grease to the teeth of the rack 17 then slide the rack through the bushing 5 and housing 6 Install the stop washer 18 and retaining ring 19 to the end of the rack Figure 7 11 Page 7 9 24 23 27 28 26 25 22 29 1 2 3 4 12 11 10 9 7 5 8 13 14 15 16 32 30 31 6 17...

Page 88: ...Page 7 9 Make sure the rack gear teeth will mesh with the gear teeth on the pinion The rack may need to be rotated slightly while lightly tapping on the pinion bearing assembly with a rubber mallet See following CAUTION CAUTION Do not force the pinion bearing assembly into the housing The gear teeth or the small bearing could be damaged 1 2 16 15 Figure 7 12 Press In Dust Seal Figure 7 13 Rack and...

Page 89: ...l the dust seal bellows 1 and hex nut 29 Figure 7 11 Page 7 9 14 Install the universal joint on the pinion Tighten the bolt to 15 ft lb 20 N m 15 Install new bellows clamps wire ties 2 Figure 7 11 Page 7 9 16 Install the drag link 28 by fully threading the ground end into the inner ball joint 3 See following CAUTION CAUTION The ball joint 23 Figure 7 11 Page 7 9 has left hand threads The tie rod a...

Page 90: ...ad ball joints in deep enough may cause a ball joint to separate from the rod during adjustment or while being operated possibly resulting in loss of vehicle control and severe personal injury CAUTION The tie rod and drag link have right hand threads on one end and left hand threads on the other end Right hand threads are identified by a groove in the tie rod or drag link 2 Install ball joint ends...

Page 91: ...g toe in of the front wheels There is also a drag link adjustment to equalize the turning radius in both directions See Steering Adjustment on page 7 5 See following NOTE NOTE Prior to making any front suspension adjustments inspect components for wear and damage and repair or replace as necessary Camber Adjustment 1 Check each front wheel with a framing square At the floor or ground there should ...

Page 92: ...ons until the marks appear on the forward facing surfaces of the tires at about the same height from the floor Figure 7 17 Page 7 14 Figure 7 17 Check Toe In Figure 7 18 Adjust Toe In 4 Measure the distance between the marks on the forward facing surfaces of the tires See following NOTE NOTE The front measurement must be less than the rear measurement 5 Subtract the measurement on the front of the...

Page 93: ...gure 7 21 Page 7 18 2 Install tapered leaf spring 6 bottom spring plate 29 four bolts 30 four lock washers 31 and four nuts 32 Using a crisscross pattern sequence tighten bolts to 23 ft lb 31 N m 3 Install spring in king pins 26 with bolts 25 and nuts 14 Tighten to 23 ft lb 31 N m 4 Install the wheels and finger tighten the lug nuts 5 Lower the vehicle and finish tightening lug nuts using a crissc...

Page 94: ... washer 20 and inspect it If the washer is broken or has a wave bottom to wave crest height dimension of less than 0 040 inch 0 10 cm it must be replaced 9 Remove bolt 25 and nut 14 from bottom of kingpin 26 and remove kingpin 10 Inspect the kingpin and spindle If either is worn or damaged it must be replaced 11 Inspect the bushings 3 and 4 If the bushings are worn or damaged remove them and press...

Page 95: ...pension Components 7 17 20 22 1 2 2 2 2 4 4 15 3 2 2 10 5 14 11 19 5 13 12 10 32 18 7 6 9 16 8 5 23 24 5 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 15 17 19 3 14 1 25 26 14 2 5 7 4 20 27 8 30 31 32 6 29 28 27 16 11 21 22 24 12 10 9 10 23 13 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: ...f the vehicle frame and lower the vehicle onto the jack stands 2 Remove wheel Remove bolts 10 and 24 A Plate straps 14 and nuts 5 Figure 7 20 Page 7 17 3 Remove the lower shock absorber mounting nut 9 then slide the shock absorber free of the Delta A Plate 4 Remove the Delta A Plate 1 5 Inspect the bushings 2 and sleeves 3 and 4 in the Delta A Plate and replace them if necessary DELTA A PLATE INST...

Page 98: ...turn freely loosen spindle nut one more cotter pin position 4 Install a new cotter pin 2 If movement continues replace the wheel bearings 5 as required Figure 7 22 Page 7 20 6 5 7 3 8 5 7 1 2 4 Figure 7 22 Front Wheel Bearings and Hub Four Wheel Brake Vehicles FRONT WHEEL BEARINGS AND HUB REMOVAL 1 Remove the front wheels See Wheel Removal on page 8 1 2 Remove the front wheel hubs 2 1 Remove dust ...

Page 99: ... Install the wheel bearings 5 into the hub and install a new seal 6 with the metal edge toward the hub See following NOTE NOTE Apply grease around dust seal inner lip before installation 4 Install the hub assembly 4 and flat washer 8 on the spindle and start the spindle nut 3 5 Tighten the spindle nut until the hub is hard to turn then back the nut 3 off until the hub turns freely Install a new co...

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Page 101: ...1 Slightly loosen the lug nuts on the wheel to be removed 2 Raise the end of the vehicle from which the wheel is to be removed Make sure the wheels are off the ground See WARNING Lift only one end of the vehicle in General Warning on page 1 1 3 Remove the lug nuts and remove the wheel WHEEL INSTALLATION 1 Install wheel s and tighten the lug nuts using a crisscross pattern until they are snug 2 Low...

Page 102: ...the edge of the rim 3 3 When top bead is free of the rim pull the bead from the bottom side of the rim up into the upper part of the rim well Insert the tire tool under the lower bead as shown Figure 8 1 Page 8 2 Detail C and carefully pry the lower bead over the rim flange 3 4 Once the lower bead is started over the rim flange the tire can be removed from the rim by hand A 1 2 3 5 B 4 6 C 1 Upper...

Page 103: ...ber mallet and tire iron 5 Remove the valve core and position the tire so that both beads are on the rim flange narrow bead seats 6 Place the tire and wheel assembly against a wall in an upright position and push it against the wall while inflating the tire to the recommended pressure See Vehicle Specifications on page 2 1 The three point contact wall floor and hand will help ensure that beads sna...

Page 104: ...8 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: ... and fluid leakage around the lower housing of the shock absorber body Replace damaged or leaking shock absorbers Figure 9 3 Page 9 4 2 To remove a shock absorber 7 remove the nut 5 cup washer 9 and rubber bushing 10 from the upper shock absorber stem 3 Remove lower mounting hardware 5 9 and 10 on shock absorber lower mount Figure 9 3 Page 9 4 See also Figure 9 1 Page 9 2 4 Compress the shock abso...

Page 106: ...embly on the side from which the spring is to be removed Thread one lug nut onto a stud on the rear hub This will keep the brake drum on the hub 5 Remove lower nut 5 cup washer 9 and rubber bushing 10 from shock absorber 7 Figure 9 3 Page 9 4 6 Remove the lock nuts 14 attaching the U bolt 11 to the shock mount bracket 16 Do not disconnect brake cable from bracket Figure 9 3 Page 9 4 7 Raise axle w...

Page 107: ...hten to 15 ft lb 20 3 N m 3 Align the other end of leaf spring with the holes in the spring shackles 1 Insert bolt 15 through leaf spring eye and shackles Install lock nut 2 and tighten to 15 ft lb 20 3 N m Lower transaxle onto leaf spring 12 See following CAUTION CAUTION When placing transaxle on spring be sure to position locating bolt on the spring in the locating hole in the transaxle saddle 2...

Page 108: ...23 12 3 4 25 2 1 2 5 9 10 10 9 11 18 24 18 C C A B B 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: ...me 2 Remove the two bolts 2 and two lock nuts 3 securing the snubber mounting bracket 4 to the engine mounting plate Figure 9 4 Page 9 5 3 Slide snubber and bracket assembly toward battery to remove it from vehicle SNUBBER INSTALLATION 1 Install in the reverse order of removal 2 Tighten snubber bracket mounting lock nuts 3 to 156 in lb 17 6 N m Figure 9 4 Page 9 5 ClubCar 4 1 2 3 Figure 9 4 Snubbe...

Page 110: ...R INSTALLATION 1 Position stabilizer bar at the transaxle mounting brackets Install a bushing 13 onto bar making sure the bushing is located in the center of the four mounting holes in the bracket Figure 9 5 Page 9 7 2 Place the bushing support 12 onto the bushing Install four hex head bolts 14 through the bushing support and transaxle mounting bracket 3 Install four lock nuts 15 and tighten to 75...

Page 111: ...REAR SUSPENSION Stabilizer Bar 9 1 1 13 15 14 12 00 00 6 0 0 0 0 0 00 0 3 4 7 3 2 4 5 Figure 9 5 Stabilizer Bar 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual Page 9 7 ...

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Page 113: ...ained technician General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tight On gasoline vehicles check all hose clamps for tight fit as well as the starter belt for tightness Safety and information decals Check to ensure that all safety and information decals are in place See Safety Decal and Feature Identification section the appropriate Owner...

Page 114: ... for any unusual noises such as squeaks or rattles Check the vehicle ride and performance Have a Club Car distributor dealer or a trained technician investigate anything unusual Electric Vehicles Accelerator With the key switch in the ON position and the Forward Reverse switch in the FORWARD position as the accelerator pedal is pressed the motor should start and the vehicle should accelerate smoot...

Page 115: ...7 km h on a level surface The gasoline XRT 900 should operate at 17 19 mph 27 31 km h on a level surface Turf 252 and Carryall 252 electric vehicles should operate at a standard speed of 15 17 mph 24 27 km h on a level surface They can be adjusted to a maximum speed of 17 19 mph 27 31 km h on a level surface XRT 900 electric vehicles can be set at the factory to operate at either 15 17 mph 24 27 k...

Page 116: ...lace if necessary or adjust as required See Wheel Brake Assemblies Section Lubricate brake slides per Lubrication Schedule See Wheel Brake Assemblies Section Brake system Check brake cables for damage replace if necessary Electrical wiring and connections Check for tightness and damage Forward Reverse switch Check condition of contacts and wire connections make sure connections are tight Front whe...

Page 117: ...nd camber Check and adjust if necessary See Steering and Front Suspension Section Electrical wiring and connections Check for tightness and damage Check brake shoes replace if necessary or adjust as required See Wheel Brake Assemblies Section Lubricate brake slides per Lubrication Schedule See Wheel Brake Assemblies Section Semiannual service by trained technician only or every 50 hours of operati...

Page 118: ...ly Lube CCI P N 1012151 Semiannually by owner or trained technician or every 50 hours of operation whichever comes first Front suspension 5 fittings Chassis Lube EP NLGI Grade 2 Check fill transaxle to plug level 7 22 oz 0 67 liters SAE 30 WT API Class SE SF or SG Oil or higher Annually by trained technician only or every 100 hours of operation whichever comes first Inspect front wheel bearings Re...

Page 119: ...r 80 90 WT AGMA Class EP Gear Lube Annually by trained technician only or every 100 hours of operation whichever comes first Inspect front wheel bearings Repack as necessary 7 Chassis Lube EP NLGI Grade 2 First change 100 hours additional change every 200 hours of operation or annually whichever comes first Change engine oil and oil filter 8 32 oz 95 liters without filter 38 oz 1 12 liters with fi...

Page 120: ...oil in accordance with local state and federal regulations 1 3 2 1 Full level 2 Safe level 3 Low level 23 Figure 10 3 Engine Oil Level Check ENGINE OIL AND FILTER CHANGE Engine oil and oil filter should be changed after the first 100 hours of operation After that they should be changed every 200 hours of operation or annually whichever comes first 1 Turn the key switch to the OFF position then rem...

Page 121: ...kwise and tighten to 18 ft lb 24 4 N m 8 Relocate the oil drain pan to a position under the engine oil filter Figure 10 4 9 Remove the engine oil filter 1 turning it counterclockwise allowing the residual oil in the filter port and filter to drain into the oil drain pan 2 Figure 10 5 See following NOTE NOTE An oil drip guard 3 can be used to prevent excess oil from dripping into the engine base pl...

Page 122: ...ne oil into the dipstick port Use a funnel or pour spout to direct the oil into the dipstick port With filter change the engine requires 38 ounces 1 12 liters of oil per change Refer to oil viscosity guidelines for selection of oil grade Figure 10 7 Replace the dipstick SAE 5 W 30 SAE 10W 30 SAE 10W 40 SAE 30 SAE 40 27 Figure 10 6 Coat Oil Filter Rubber Seal 213 Figure 10 7 Oil Viscosity Chart 14 ...

Page 123: ...d service manual TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Spark plug is partially fouled or in poor condition See Section 15 S10 FE 350 Engine See Section 16 S27 FE 350 Engine Spark plug wire is damaged or loose See Section 15 S10 FE 350 Engine See Section 16 S27 FE 350 Engine Loose wire connection at ignition coil or RPM limiter Test Procedures 14 Ignition Spark 15 RPM Limiter and 1...

Page 124: ...ine Loose wire connection at ignition coil or RPM limiter Test Procedures 14 Ignition Spark 15 RPM Limiter and 16 Ignition Coil Engine flooded with fuel as result of excess choking See Owner s Manual Controls and Indicators See Choke Fuel pump malfunction or failure See Section 17 S10 FE 350 Fuel System See Section 18 S27 FE 350 Fuel System Ignition coil or RPM limiter failed Test Procedures 14 Ig...

Page 125: ...ter is not backshifting properly See Section 21 Torque Converter Gasoline Vehicles Incorrect plug See Section 15 S10 FE 350 Engine See Section 16 S27 FE 350 Engine Unsuitable fuel or incorrect rich fuel mixture See Section 15 S10 FE 350 Engine See Section 16 S27 FE 350 Engine Spark plug wire is damaged See Section 15 S10 FE 350 Engine See Section 16 S27 FE 350 Engine Dirt entering combustion chamb...

Page 126: ...ircuit Test Procedure 11 Starter Generator Generator Function Generator field coil is shorted Test Procedure 11 Starter Generator Generator Function Brushes are worn or commutator is dirty Starter Generator on page 13 1 Starter generator belt is loose or slipping Belt Tension Adjustment on page 13 12 Voltage regulator failed Test Procedure 12 Voltage Regulator Starter Generator does not charge bat...

Page 127: ...e vehicle vibration RPM setting is incorrect Engine RPM Adjustment on page 17 11 Drive belt is worn cracked glazed or frayed Drive Belt on page 21 2 Drive clutch malfunction Driven Clutch Inspection on page 21 13 Driven clutch malfunction Driven Clutch Inspection on page 21 13 Torque converter does not shift smoothly Governor is sticking See the Engines and Transaxles manual CCI P N 102396501 Kill...

Page 128: ...nition Circuit Engine Kill Circuit Reverse Buzzer Circuit Low Oil Warning Circuit Fuel Gauge and Sending Unit Circuit Hour Meter Circuit Lighting Circuit A key start with neutral rev vehicle uses the ignition key to activate the electrical system and start the engine It allows the engine to run at idle or advanced RPM using the accelerator pedal when the Forward Reverse handle is in the NEUTRAL po...

Page 129: ...UNIT IGN KILL P N 1017721 POWE R P OINT ELECTRICAL COMPONENT BOX 6 7 1 4 2 18_ORG W25 14_YEL W10 18_BLU W11 18_WHT_BLK W12 16_BLU W15 14_BLU W26 16_BLK W16 16_BLK_WHT_S TP W27 16_BLK W17 16_BLK W28 18_YEL W18 16_BLK W36 16_BLK W30 16_ORG W31 18_YEL W41 18_ORG W01 16_BLU W23 16_BLK W24 18_BLK W06 18_BLK W05 18_BLK W13 18_RED W04 18_BLU W20 18_YEL W21 18_WHT W19 18_YEL W22 18_YEL W29 18_RED_WHT_ STP...

Page 130: ...CTRICAL COMPONENT BOX BATTERY WHITE RED 10_NON_INSUL W37 18_BLK W14 18_BLK W40 16_BLK W42 18_BLK W43 18_GRN W07 6_RED W38 6_BLK W35 6_WHT W08 18_YEL W09 10_RED W39 6_BLK W02 6_GREEN_HIGH_TEMP W34 18_RED W44 18_YEL W45 16_ORG W31 14_YEL W10 18_RED W04 18_ORG W25 18_ORG W25 18_RED_WHT_STP W0 3 18_BLU W11 WD103198101B5 R Figure 11 2 Wiring Diagram for Key Start Neutral Rev Gasoline Vehicles Page 11 8...

Page 131: ...24 Fuel Level Sending Unit 25 Fuel Gauge 26 Hour Meter 27 Light Switch 28 Headlight Diode 29 Voltage at Headlight Socket TEST PROCEDURE 1 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 around a battery Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ve...

Page 132: ...ot 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 1 Be sure that the battery has sufficient water to cover the plates by approximately 1 2 inch 13 mm and is fully charged prior to beginning the test If water must be added recharge the battery before performing the hydrometer test ...

Page 133: ... more the low cell should be suspected It may require a catch up charge or it may be a weak cell When the variations between cells reach 0 050 or more the battery should be replaced Voltage Test Place the red probe of a multimeter set at Volts DC 20 volt range on the positive cable and place the black probe on the negative post of the battery and take a voltage reading If it shows less than 12 4 v...

Page 134: ...component box 4 Check that wires are connected correctly and are tight If they are not rewire or tighten as necessary 5 Remove fuse to be tested from the fuse block See Fuse Removal Section 13 Page 13 20 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 6 Connect the probes of a multimeter set to 200 ohm...

Page 135: ...nd cable 6 1 A 6 gauge black wire connects the negative battery post to the frame The frame connection should be clean and tight Visual inspection of the connection on the frame is very difficult The best check for tightness is to pull on the black wire If the wire moves at the connection end disassemble the frame connection and clean the bolt ring terminal and nut Install the frame connection 6 2...

Page 136: ...With the red probe of the multimeter on the B terminal and the black probe on the L terminal of the key switch the reading should be continuity If either reading is incorrect replace the key switch See Key Switch Removal Section 13 Page 13 17 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED M B L G S Reading with key switch ...

Page 137: ...Page 11 15 7 Set the multimeter to 200 ohms Connect the red probe to one of the large posts of the solenoid and connect the black probe to the other large post Figure 11 11 Page 11 16 8 With the key switch in the OFF position connect the battery positive cable first 9 Place the Forward Reverse handle in the NEUTRAL position With the key in the OFF position the reading on the multimeter should be n...

Page 138: ... Page 1 3 TEST PROCEDURE 7 Neutral Lockout Limit Switch See General Warning on page 1 1 This switch is located on the Forward Reverse control assembly A black light blue wire a gray wire and a tan wire are connected to this limit switch 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 1 Page 1 3 2 Check for proper wiring and tight connections 3 Set...

Page 139: ...n 13 Page 13 1 An incorrect reading from the A1 or A2 terminal indicates three possible problems 1 a grounded A1 or A2 terminal 2 a grounded wire in the brush area or 3 a grounded armature commutator If the F1 or F2 reading is incorrect it indicates a possible grounded F1 or F2 terminal or a grounded field coil If the DF reading is incorrect it indicates a possible grounded DF terminal or a ground...

Page 140: ...Place the black probe on the other terminal end of the wire The reading should be continuity If the reading is incorrect repair or replace the wire TEST PROCEDURE 10 Diode Generator Circuit See General Warning on page 1 1 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in the NEUTRAL position Chock the wheels 2 Disconnect battery and spark plug wire s See Disconnectin...

Page 141: ...inals of the diode The multimeter should indicate an overload no continuity If continuity reading does occur it indicates that one or both of the diode leads are grounded to the diode body case and the diode must be replaced See Diode Removal Section 13 Page 13 15 7 If the diode tests good reconnect the diode leads See Diode Installation Section 13 Page 13 15 See also following WARNING WARNING Inc...

Page 142: ...e yellow wire will not short to ground Then using a jumper wire ground the DF terminal to the A2 terminal Figure 11 15 Page 11 18 4 Using a multimeter set to 20 volts DC place the red probe on the positive cable of the battery and place the black probe on the negative post Start the engine and run it at full governed speed The reading should show the voltage rising on the meter If the voltage rise...

Page 143: ...n See Hydrometer Test on page 12 11 If the reading is lower than 14 7 volts and not rising and the starter generator is good or if the reading is over 15 3 volts and continues to rise replace voltage regulator See Voltage Regulator Removal Section 13 Page 13 13 R ED 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 4 2 1 3 1 ...

Page 144: ...nt check for correct spark Figure 11 20 Page 11 22 2 1 Adjust the tester probes to approximately to 18 000 volts 18 Kv setting SE Small Engine Setting on the Thexton 404 tool Connect the tester to the spark plug wire and connect the alligator clip to a solid engine ground 2 2 Start the engine There should be a strong blue spark between the probes of the spark gap tester If there is no spark or if ...

Page 145: ...load due to heat while operating Another method of testing is to replace the RPM limiter and then run the engine If the engine runs properly keep the new RPM limiter in the circuit TEST PROCEDURE 16 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 no...

Page 146: ... COM 200nA MAX 1000 750V FUSED 1 1 200 Ohm Setting 467 Figure 11 23 Primary Coil Resistance In Vehicle Test 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 1 1 20k Ohm Setting 468 Figure 11 24 Secondary Coil Test In Vehicle Test Page 11 24 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual ...

Page 147: ...tance is not between 12 0k 14 0k ohms the spark plug cap and secondary coil must be tested independently from each other 5 Test the spark plug cap separately from the secondary coil 5 1 Remove the rubber gasket 1 on the plug cap 2 by rolling back the gasket onto the spark plug wire 3 Figure 11 25 Page 11 25 5 2 Remove the cap from the wire by turning the cap counterclockwise three or four revoluti...

Page 148: ... previously tested test the spark plug cap separately from the secondary coil 4 1 Remove the rubber gasket 1 on the plug cap 2 by rolling back the gasket onto the spark plug wire 3 Figure 11 25 Page 11 25 4 2 Remove the cap from the wire by turning the cap counterclockwise three or four revolutions while gently pulling it off the wire Figure 11 26 Page 11 25 4 3 Using a multimeter set to 20k ohms ...

Page 149: ...00 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2 1 3 1 Ignition Coil Terminal 2 Core 3 200 Ohm Setting 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2 3 1 1 20k Ohm Setting 2 Core 3 Spark Plug Cap 473 Figure 11 29 Primary Coil Resistance Bench Test 474 Figure 11 30 Secondary C...

Page 150: ...t battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 1 Page 1 3 3 Remove the instrument panel See Key Switch Removal Section 13 Page 13 17 4 Remove the connector from the key switch 5 Place the red probe on the M terminal and the black probe on the G terminal With the key switch OFF the reading should be continuity With the key switch turned ON the reading should...

Page 151: ...e noting the multimeter reading There should be no continuity when the key switch is in the ON or START position If there is continuity check for worn insulation on the white black wire that is allowing the wire to ground to the frame TEST PROCEDURE 19 Reverse Buzzer Limit Switch See General Warning on page 1 1 NOTE Keep the battery connected while performing this test procedure The reverse buzzer...

Page 152: ...ht should illuminate If the low oil warning light does not illuminate the oil level sensor may need to be replaced Refer to Test Procedure 22 before replacing sensor See Oil Level Sensor Removal Section 15 Page 15 5 6 Fill the engine with new oil and install a new oil filter before returning the vehicle to service See Engine Oil Gasoline Vehicle Section 10 Page 10 7 TEST PROCEDURE 22 Oil Warning L...

Page 153: ...7 TEST PROCEDURE 24 Fuel Level Sending Unit See General Warning on page 1 1 WARNING To avoid the possibility of fire or explosion make sure the fuel tank cap is securely in place while performing this test procedure 1 Turn the key switch to OFF and remove the key Place the Forward Reverse handle in the NEUTRAL position Chock the wheels 2 Disconnect battery See Disconnecting the Battery Gasoline Ve...

Page 154: ... the black ground wires at the fuel level sending unit and at the fuel gauge hour meter See Fuel Gauge Hour Meter Removal Section 13 Page 13 26 8 If the readings are correct according to the position of the float but give an incorrect reading on the fuel gauge hour meter test the fuel gauge hour meter See Fuel Gauge on page 11 33 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000...

Page 155: ...f the fuel gauge hour meter See Key Switch Removal Section 13 Page 13 17 3 Place a sheet of insulating material between the front frame and the electrical connections on the rear of the instrument panel to prevent contact between the two 4 Disconnect the orange wire from the fuel gauge hour meter 5 Set a multimeter to 20 volts DC and place the red probe of the multimeter on the positive post of th...

Page 156: ...e wire from the fuel gauge hour meter 5 Set a multimeter to 20 volts DC and place the red probe of the multimeter on the positive post of the battery Place the black probe on the negative post of the battery Record the voltage reading 6 Set a multimeter to 20 volts DC and place the red probe on the 2 terminal of the fuel gauge hour meter with the blue wire is connected Place the black probe on the...

Page 157: ...dition the meter used through mid 2007 has one terminal 3 to ground it whereas the meter used from mid 2007 has two ground terminals 1 and 6 with a black jumper wire connecting them See following NOTE NOTE Keep the battery connected while performing this test procedure Hour Meter Through mid 2007 1 Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Turn the key switch ON to verify the ...

Page 158: ...ock the wheels 2 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 1 Page 1 3 3 Remove the instrument panel See Key Switch Removal Section 13 Page 13 17 4 Using a multimeter set on 20 volts DC place alligator clips on the multimeter probes Connect the red probe to the light switch terminal with the blue wire connected to it Figure 11 40 Page 11 36 5 C...

Page 159: ...k wire from the headlight to the headlight diode Check continuity of the 16 gauge black wire from headlight diode to the vehicle frame If the wires show continuity and the readings are still incorrect replace the headlight diode See Voltage Limiter Removal Section 13 Page 13 34 8 With the Forward Reverse handle in the NEUTRAL position and the wheels chocked start the engine and press the accelerat...

Page 160: ...er set to 20 volts DC attach using an alligator clip the black probe of multimeter onto the negative battery terminal and place the red probe into the blue wire terminal of the wire harness If multimeter reading is approximately 12 volts the blue wire has continuity 7 Check continuity of the 16 gauge black wire from the headlight to the ground terminal Using a multimeter set to 20 volts DC place t...

Page 161: ...RRECTIVE ACTION Spark plug is partially fouled or in poor condition See Section 15 S10 FE 350 Engine See Section 16 S27 FE 350 Engine Spark plug wire is damaged or loose See Section 15 S10 FE 350 Engine See Section 16 S27 FE 350 Engine Loose wire connection at ignition coil or RPM limiter Test Procedures 13 Ignition Spark 14 RPM Limiter and 15 Ignition Coil Intermittent ignition coil failure Test ...

Page 162: ...n at ignition coil or RPM limiter Test Procedures 13 Ignition Spark 14 RPM Limiter and 15 Ignition Coil Ignition coil or RPM limiter failed Test Procedures 13 Ignition Spark 14 RPM Limiter and 15 Ignition Coil Engine flooded with fuel as result of excess choking See Owner s Manual Controls and Indicators See Choke Kill circuit grounded Test Procedures 16 Kill Limit Switch 17 Key Switch Engine Kill...

Page 163: ...ng properly See Section 21 Torque Converter Gasoline Vehicles Incorrect plug See Section 15 S10 FE 350 Engine See Section 16 S27 FE 350 Engine Spark plug wire is damaged See Section 15 S10 FE 350 Engine See Section 16 S27 FE 350 Engine Unsuitable fuel or incorrect rich fuel mixture See Section 17 S10 FE 350 Fuel System See Section 18 S27 FE 350 Fuel System Ignition coil failed Test Procedures 13 I...

Page 164: ...ystem See Section 18 S27 FE 350 Fuel System Loose or broken wire in the starter generator circuit Test Procedure 10 Starter Generator Generator Function Generator field coil is shorted Test Procedure 10 Starter Generator Generator Function Brushes are worn or commutator is dirty See Section 14 Electrical Components Pedal Start Gas Vehicle Starter Generator on page 14 1 Starter generator belt is lo...

Page 165: ...ection 18 S27 FE 350 Fuel System Engine RPM Adjustment on page 17 11 Drive belt is worn cracked glazed or frayed See Section 21 Torque Converter Gasoline Vehicles Drive clutch malfunction See Section 21 Torque Converter Gasoline Vehicles Torque converter does not shift smoothly Governor is sticking See Section 20 Unitized Transaxle Dash Mounted Shifter Kill circuit wire is disconnected from the ig...

Page 166: ... 18_BLK W16 18_ORG W23 18_WHT W40 18_BLU W41 1 2 3 4 5 6 FUEL GAUGE HOUR METER Through mid 2007 DETAIL 6 7 1 4 2 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: ... ELECTRICAL SYSTEM PEDAL START GAS VEHICLE Wiring Diagram 12 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: ...T HEAD LIGHT RIGHT LIGHT SWITCH VOLTAGE LIMITER 16 _BLU W15 14_BLU W26 16 _BLK W16 16 _BLK_WHT_ST P W2 7 16_BLK W17 16_BLU W23 16_BLK W24 16 _BLU W32 14_YEL W10 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: ...kly isolate the source of an electrical problem Use the appropriate test procedure to correct the electrical problem See Test Procedures on page 12 9 For a complete wiring diagram see page 12 6 TEST PROCEDURES Index of Test Procedures 1 Battery 2 Fuse 3 Ground Cables 4 Key Switch Starter Circuit 5 Accelerator Pedal Limit Switch 6 Solenoid 7 Neutral Lockout Limit Switch 8 Starter Generator Starter ...

Page 170: ... 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 Battery maintenance procedures including watering information and allowable mineral content can be found in section Electrical Components Pedal Start Gas Vehicle ...

Page 171: ...rom the cell and release the pressure from the bulb 6 Hold the hydrometer vertically ensuring that the float is not contacting the sides of the glass tube Hold the hydrometer at eye level and read the scale at the level of electrolyte Figure 12 4 Page 12 11 7 Record the reading 8 Return the electrolyte to the cell from which it was taken Replace vent cap 9 Repeat steps 2 through 8 on all cells 4 0...

Page 172: ...have a specific gravity of at least 1 225 in all cells and the difference in the specific gravity of any two cells should be less than 50 points Open circuit voltage should be at least 12 4 volts Load Test 1 Connect a 160 ampere load tester to the battery posts 2 Turn the switch on the load tester to the ON position 3 Read the battery voltage after the load tester has been turned ON for 15 seconds...

Page 173: ...d cable terminal end located on the oil filler bracket on the engine Figure 12 7 Page 12 13 Place the black probe on the vehicle frame The reading should be continuity If the reading is incorrect clean and tighten cable connections If the connections are good and the reading is incorrect repair or replace the cable F2 1 2 1 Ground to Chassis 2 A2 Terminal 00 00 Place test probes at each end of gro...

Page 174: ... the center dash assembly See Key Switch Removal on page 13 17 3 Ensure that the wires are connected correctly and are tight If they are not rewire or tighten as necessary 4 Insert the key and turn the key to ON Place the red probe of the multimeter on the 2 terminal and the black probe on the 1 terminal of the key switch The reading should be continuity If the reading is incorrect replace the key...

Page 175: ...timeter to 200 ohms Place the red probe on the common COM terminal green wire of the limit switch and place the black probe on the normally closed NC terminal orange wire of the limit switch 4 Make sure the battery is disconnected With the key switch in the OFF position the Forward Reverse handle in NEUTRAL and the accelerator pedal in the UP position the reading should be no continuity With the a...

Page 176: ... in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position Turn the key switch to the ON position With the accelerator in the UP position the reading on the multimeter should be no continuity Press the accelerator pedal and listen for the solenoid click There should be continuity If either reading is incorrect replace the solenoid 9 With the Forward Reverse handle still in...

Page 177: ...the lever and the reading should be continuity If either reading is incorrect replace the limit switch Figure 12 13 Page 12 17 4 Check to be sure the lobe on the cam is pressing the neutral lockout limit switch as the Forward Reverse shifter is being shifted The limit switch should make an audible click as it is pressed If it does not check for wear on the cam lobe and replace cam if necessary 2m ...

Page 178: ...200 ohms place the red probe on the A1 terminal and the black probe on the A2 terminal The reading should be continuity If the reading is incorrect a possible open or poor contact in a brush assembly and or open armature windings may be the cause The starter generator will need to be removed from the vehicle and disassembled by a qualified technician See Starter Generator Removal on page 14 1 6 Wi...

Page 179: ... the voltage regulator See Voltage Regulator on page 12 19 If the voltage does not rise a tear down inspection of the starter generator will be necessary See Starter Generator Removal on page 14 1 5 Connect the yellow wire to the DF terminal on the starter generator TEST PROCEDURE 11 Voltage Regulator See General Warning on page 1 1 NOTE Keep the battery connected while performing this test proced...

Page 180: ...hite black wire at the bullet connector located next to the RPM limiter Figure 12 18 Page 12 21 3 Start the engine in a well ventilated area Turn the key switch to the ON position Press the accelerator pedal to start the engine 4 If the engine begins to run test the engine kill circuit for a shorted wire or other failed components in the engine kill circuit See Key Switch Engine Kill Circuit on pa...

Page 181: ...e 12 17 Page 12 21 2 1 Adjust the tester probes to approximately 18 000 volts 18 Kv setting SE Small Engine Setting on the Thexton 404 tool Connect the tester to the spark plug wire and connect the alligator clip to a solid engine ground 2 2 Start the engine There should be a strong blue spark between the probes of the spark gap tester If there is no spark or if the spark is a faint yellow or red ...

Page 182: ...ack wire female bullet connectors The reading should be no continuity If the reading is not correct replace the RPM Limiter 4 This test will find most bad RPM Limiters Some of them may bench test okay but fail under a load due to heat while operating Another method of testing is to replace the RPM Limiter and then run the engine If the engine runs properly keep the new RPM Limiter in the circuit 0...

Page 183: ...icle Test 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 1 Page 1 3 2 Using a multimeter set to 200 ohms measure the primary coil resistance 2 1 Disconnect both of the bullet terminals at the RPM limiter Figure 12 19 Page 12 22 Place the red probe of the meter on the male bullet terminal of the wire connecting to the ignition coil under the fan h...

Page 184: ...f the engine or frame Figure 12 21 Page 12 24 3 2 If the resistance is between 12 0k 14 0k ohms the secondary coil and spark plug cap are within acceptable limits proceed to step 6 on page 12 25 If the resistance is not between 12 0k 14 0k ohms the spark plug cap and secondary coil must be tested independently from each other 4 Test the spark plug cap separately from the secondary coil 4 1 Remove ...

Page 185: ...nd place the black probe into the end of the cap with the internal screw Figure 12 24 Page 12 25 If the resistance is not between 4 5k 6 0k ohms the cap has failed and must be replaced Proceed to the next step with the spark plug cap still removed 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2 1 1 20k Ohm Setting 2 Spark...

Page 186: ...resistance is between 6 0k 11 0k ohms the secondary coil is within acceptable limits If the resistance is not between 6 0k 11 0k ohms bench test the ignition coil 6 If the preceding tests indicate that the ignition coil resistance readings are within acceptable ranges but the coil fails to function properly proceed to the following bench test procedures Ignition Coil Bench Test 1 Remove the coil f...

Page 187: ...m Setting 2 Core 3 Spark Plug Cap 473 Figure 12 26 Primary Coil Resistance Bench Test 474 Figure 12 27 Secondary Coil and Cap Resistance Bench Test 2 2 If the resistance is not between 0 6 1 7 ohms replace the ignition coil 3 Using a multimeter set to 20k ohms measure the resistance of the secondary coil and spark plug cap together 3 1 Place the red probe of the meter into the end of the spark plu...

Page 188: ...the wire Figure 12 23 Page 12 25 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 If the resistance is not between 4 5k 6 0k ohms the cap has failed and must be replaced Proceed to the next step wit...

Page 189: ...imit switch for continuity Place the red probe of the multimeter on the common COM terminal white black wire of the limit switch Place the black probe on the normally open NO terminal black wire of the limit switch Without the lever pressed the reading should be no continuity Press the lever and the reading should be continuity If either reading is incorrect replace the limit switch Figure 12 29 P...

Page 190: ...should be continuity With the key switch ON the reading should be no continuity If either reading is incorrect replace the key switch Figure 12 30 Page 12 30 5 Connect wires to the key switch Make sure wires are connected correctly and are tight If they are not rewire or tighten as necessary 6 Install dash panel in reverse order of removal 1 M 2 M 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20...

Page 191: ...s 2 Move the Forward Reverse handle to REVERSE and listen for an audible click from the limit switch If there is no click check the switch for proper alignment and switch arm movement 3 If the switch is being activated but the buzzer does not function place the red probe of the multimeter on one terminal and the black probe on the other terminal of the limit switch Without the lever pressed the re...

Page 192: ...the wire replace the wire Then test the key switch See Key Switch Starter Circuit on page 12 14 If the yellow wire and the key switch test okay then replace the low oil warning light TEST PROCEDURE 22 Oil Level Sensor See General Warning on page 1 1 NOTE Keep the battery connected while performing this test procedure 1 Place the Forward Reverse handle in the NEUTRAL position the neutral lockout sw...

Page 193: ...minals T2 and T3 3 2 Check for continuity between terminals T1 and T2 T1 T3 T2 3 2 1 T1 Black Light Blue Stripe T2 Black T3 Black Yellow Stripe 1 Position 1 2 Position 2 478 Figure 12 31 Neutral Lockout Switch Test for Pedal Start Vehicles Toggle Position Operates Position 1 Position 2 ON ON T2 T3 T1 T2 4 If switch 4 1 does not work as stated in previous steps replace switch 4 2 does work as state...

Page 194: ...the test results are good and the voltage reading is zero there may be a broken or damaged 6 gauge white wire from the solenoid to the starter generator See Starter Generator Starter Function on page 12 18 TEST PROCEDURE 25 Fuel Level Sending Unit See General Warning on page 1 1 WARNING To avoid the possibility of fire or explosion make sure the fuel tank cap is securely in place while performing ...

Page 195: ...22 6 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 Also check the continuity of the blue wire from the fuel gauge hour meter to the key switch and the black ground wires at the fuel level sending unit and at the ...

Page 196: ... hour meter See Key Switch Removal Section 13 Page 13 17 3 Place a sheet of insulating material between the front frame and the electrical connections on the rear of the instrument panel to prevent contact between the two 4 Disconnect the orange wire from the fuel gauge hour meter 5 Set a multimeter to 20 volts DC and place the red probe of the multimeter on the positive post of the battery Place ...

Page 197: ...from the fuel gauge hour meter 5 Set a multimeter to 20 volts DC and place the red probe of the multimeter on the positive post of the battery Place the black probe on the negative post of the battery Record the voltage reading 6 Set a multimeter to 20 volts DC and place the red probe on the 2 terminal of the fuel gauge hour meter with the blue wire is connected Place the black probe on the 1 term...

Page 198: ...he meter used through mid 2007 has one terminal 3 to ground it whereas the meter used from mid 2007 has two ground terminals 1 and 6 with a black jumper wire connecting them See following NOTE NOTE Keep the battery connected while performing this test procedure Hour Meter Through mid 2007 1 Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Turn the key switch ON to verify the display ...

Page 199: ...els 2 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 1 Page 1 3 3 Remove the instrument panel See Key Switch Removal Section 14 Page 14 13 4 Using a multimeter set on 20 volts DC place alligator clips on the multimeter probes Connect the red probe to the light switch terminal with the blue wire connected to it Figure 12 39 Page 12 39 5 Connect batt...

Page 200: ...the headlight to the voltage limiter Check continuity of the 16 gauge black wire from voltage limiter to the vehicle frame If the wires show continuity and the readings are still incorrect replace the voltage limiter See Voltage Limiter Removal Section 13 Page 13 34 8 With the Forward Reverse handle in the NEUTRAL position and the wheels chocked start the engine and press the accelerator pedal to ...

Page 201: ...o 20 volts DC attach using an alligator clip the black probe of multimeter onto the negative battery terminal and place the red probe into the blue wire terminal of the wire harness If multimeter reading is approximately 12 volts the blue wire has continuity 7 Check continuity of the 16 gauge black wire from the headlight to the ground terminal Using a multimeter set to 20 volts DC place the black...

Page 202: ......

Page 203: ... Chock the wheels 2 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 1 Page 1 3 3 Disconnect the wires from the starter generator 1 Mark wires before disconnecting Loosen the pivot nuts 7 and bolts 5 Figure 13 1 Page 13 2 4 Remove the mounting adjustment nut 12 washer 9 and bolt 11 Lower the starter generator and slip the belt 4 off the pulley 10 5 S...

Page 204: ...s back from the center of the commutator end cover The springs will help prevent them from sliding back towards the center Figure 13 6 Page 13 4 2 Remove brush covers 29 and 30 screws 25 lockwashers 26 brush springs 28 and brushes 27 Figure 13 3 Page 13 2 See following NOTE NOTE To clean and inspect the armature commutator and the bearings see Disassembly of the Starter Generator to Service the Ar...

Page 205: ... 13 2 Using a spring scale test brush spring tension If any spring has a tension less than 24 ounces 6 67 N replace all four springs Figure 13 5 Page 13 3 See following CAUTION CAUTION When checking brush spring tension do not push springs beyond the point they would normally be if there were new brushes installed Exerting excessive force or pushing brush springs beyond their normal maximum extens...

Page 206: ...rator housing 24 Figure 13 2 Page 13 2 See following NOTE NOTE Brushes must be removed to avoid damaged from commutator removal Lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator and cover The springs will help prevent them from sliding back towards the center Figure 13 6 Page 13 4 2 Remove nut 41 lockwasher 40 pulley 39 shaft key 3...

Page 207: ...ure the wedge attachment tool is supporting the inner race of the bearing If a press is not available secure a bearing puller CCI P N 1012811 to the wedge attachment tool and pull the bearing off of the end of the armature shaft Support the armature so that it will not drop when the bearing is removed Figure 13 9 Page 13 6 2 Discard the bearings 3 Slide the bearing retainer 32 off of the output en...

Page 208: ...the field coils unless an electrical test indicates that it is necessary Figure 13 10 Page 13 6 See Test Procedure 8 Starter Generator Starter Function on page 11 17 1 2 4 3 5 6 2 5 7 1 Press Ram 2 Wedge Attachment Tool 3 Bearing is sectioned for clarity 4 Support inner race of bearing 5 Use a 1 2 inch 12mm socket or pipe 6 Press against armature shaft 7 Bearing Puller Tool 494 Figure 13 9 Bearing...

Page 209: ...D INSPECTION 1 Clean the carbon dust dirt and oil from the commutator Slight roughness of the commutator can be polished away with 400 grit or finer sandpaper See following CAUTION CAUTION Never use emery cloth on the commutator Particles of emery are conductive and may short circuit the commutator bars Never use oil or lubricants on the commutator or brushes 2 Use a micrometer and measure the out...

Page 210: ...multimeter set on 200 ohms and place the positive probe on the commutator bars and the negative probe on the armature core The reading should be no continuity If the reading is incorrect replace the armature and the two bearings Figure 13 12 Page 13 9 VISUAL INSPECTION OF FIELD COILS Burned blackened charred or scorched coil insulation indicates the starter generator has overheated due to overload...

Page 211: ... Starter field coil resistance 0 006 0 01 ohms Generator field coil resistance 4 5 5 5 ohms STARTER GENERATOR ASSEMBLY 1 Place the field coil into the housing The two insulators that look alike fit into the slots next to the F1 and F2 markings on the outside of the housing The insulator that looks different slides into the slot next to the DF marking 2 After the insulators are seated in the slots ...

Page 212: ... the commutator end cover 23 Figure 13 3 Page 13 2 11 Slide the spacer 37 onto the end of the shaft Insert the shaft key 34 into the shaft Install the belt pulley 39 onto the shaft and install the lockwasher 40 and M14 nut 41 and tighten the nut to 28 ft lb 38 N m Figure 13 7 Page 13 5 STARTER GENERATOR INSTALLATION 1 Install the green wire from the F1 terminal to the A1 terminal on the starter ge...

Page 213: ...ICLE Starter Generator 13 13 7 5 2 3 10 4 11 1 9 12 498 Figure 13 13 Starter Generator Installation 1 2 1 Belt Tension Gauge 2 End View 499 Figure 13 14 Belt Tension Gauge 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual Page 13 11 ...

Page 214: ...und the drive clutch pulley install the starter generator belt 3 5 Place a pry bar 13 between the top of the starter generator mounting bracket 2 and the underside of the starter generator by passing the pry bar under the exhaust header 6 Hold the pry bar and measure the belt tension using a Krikit gauge 1 available at NAPA Auto Parts stores or equivalent Proper tension for a new starter generator...

Page 215: ...d remove the voltage regulator 9 VOLTAGE REGULATOR INSTALLATION 1 Position the voltage regulator 9 in the electrical component box and install the mounting screw 8 and tighten screw to 23 in lb 2 6 N m Figure 13 15 Page 13 14 2 Connect the voltage regulator red wire 1 at the large post on the solenoid with the other red wires the yellow wire 4 at the bullet connector and the black wire 7 to the wi...

Page 216: ...RT WITH NEUTRAL REV GAS VEHICLE 7 8 4 1 2 3 9 1 Red wire to solenoid 2 To kill limit switch 3 To frame ground 4 To bullet connector 500 Figure 13 15 Voltage Regulator Page 13 14 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual ...

Page 217: ...uge white wire 8 should be attached to the other large solenoid post along with the red wire 9 from the voltage regulator and the white wire 10 from the starter generator 6 Remove the nut 11 and remove the diode 12 and thermal transfer pad 13 from the vehicle frame I beam 14 Figure 13 16 Page 13 16 DIODE INSTALLATION 1 Thoroughly clean and dry the area of the I beam 14 where the new diode 12 is to...

Page 218: ... 4 1 Connect the 12 gauge red wire 5 from the diode to the solenoid post with the fuse block and battery red wires 6 and 7 and tighten locknut 3 to 55 in lb 6 2 N m Figure 13 16 Page 13 16 4 2 Connect the 12 gauge white wire 8 to the other large solenoid post along with the red wire 9 from the voltage regulator and white wire 10 from the starter generator and tighten nut 3 to 55 in lb 6 2 N m 5 Re...

Page 219: ...h 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 Do not allow wires to touch See following NOTE NOTE Take care to prevent key switch terminals and wires from touching the metal frame around the dash 2 5 Slide center dash panel up t...

Page 220: ... 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 2 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 1 Page 1 3 Page 13 18 2007 2009 Turf 252 Carryall 252 and XRT 900 ...

Page 221: ...n making final connections 2 Connect all wires as indicated 2 1 Connect the 6 gauge white wire from the starter generator 18 gauge red wire from the voltage regulator and the 12 gauge white wire from the diode to the large post on the solenoid See Wiring Diagrams on page 11 7 2 2 Connect the 6 gauge red wire from the battery the 10 gauge red wire from the fuse block and the 12 gauge red wire from ...

Page 222: ...om the fuse block FUSE INSTALLATION 1 Install the fuse See following WARNING WARNING If a fuse is blown determine the cause of the failure and make necessary repairs before installing a new fuse Use the appropriately rated fuse if a fuse with a higher amp rating is used damage to the vehicle electrical system may occur 2 Install the snap on electrical box cover by firmly pressing down on all corne...

Page 223: ...owl brace 2 4 Untwist and remove forward reverse shifter knob and pull center dash out from the frame 2 5 Rotate center dash panel counter clockwise around the steering column to gain access to the limit switches Figure 13 19 Page 13 21 See following NOTE NOTE Take care to manipulate under dash wires to prevent damage to wires It may be nessesary to remove key switch from the dash panel to allow d...

Page 224: ...out limit switch See Wiring Diagrams on page 11 7 3 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 1 Page 1 3 4 Check limit switch operation Place the Forward Reverse handle in the NEUTRAL position Make sure everyone is clear of the vehicle Turn the key switch to the START position and hold until the engine is running smoothly Release the key and it will...

Page 225: ...ockwasher 5 and flat washer 6 securing the buzzer to the vertical frame support REVERSE WARNING BUZZER INSTALLATION 1 Install the screw 3 through the buzzer 2 bracket tab and frame secure with hardware and tighten to 14 in lb 1 6 N m Figure 13 21 Page 13 23 See following NOTE NOTE The reverse warning buzzer is secured at one hole only 2 Connect the black wire from the wire harness to the negative ...

Page 226: ...verse buzzer limit switch located on the top of the Forward Reverse control 4 Use a wrench and a pair of needle nosed pliers to remove the two nuts and washers securing the limit switches Figure 13 20 Page 13 21 5 Slide the neutral lockout limit switch off of the screws Do not disconnect the wires 6 Slide the reverse buzzer limit switch off the screws REVERSE BUZZER LIMIT SWITCH INSTALLATION 1 Pla...

Page 227: ...ouch 4 Press the retaining tabs and remove the low oil warning light from the center dash OIL WARNING LIGHT INSTALLATION 1 Push a new unit into hole in dash until plastic tabs engage dash Figure 13 22 Page 13 25 2 Connect yellow wire from the key switch and yellow wire from the oil level sensor to the low oil warning light 3 Install the center dash in reverse order of removal Be sure that key swit...

Page 228: ...tenth hour but does not record additional time unless the key switch is in the ON position and the engine is on When recording the hourglass icon on the left blinks slowly on Early 2007 vehicles FUEL GAUGE HOUR METER REMOVAL 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 1 Page 1 3 2 Remove the center dash panel See Key Switch Removal on page 13 ...

Page 229: ...305 5 Install the center dash in reverse order of removal Be sure that key switch terminals cannot touch the frame and that panel is properly seated and snapped in place 6 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 1 Page 1 3 FUEL LEVEL SENDING UNIT See General Warning on page 1 1 The fuel level sending unit is an integral part of the fuel tank and s...

Page 230: ...imiter mounting bracket 10 Figure 13 25 Page 13 28 3 Place the band 8 over the RPM limiter and align the holes Place the brown wire ring connector 11 onto the flange head bolt 7 and secure the left side of the band Use another flange head bolt to secure the other side of the band Make sure the band holds the RPM limiter securely in place Tighten fasteners to 7 ft lb 9 5 N m 4 Connect the black wir...

Page 231: ... The crankshaft has left hand threads at the clutch mounting hole 2 Remove the muffler See Muffler Removal on page 19 1 3 Remove the engine mounting hardware items 1 2 and 5 Figure 15 4 Page 15 5 4 Remove the two nuts 6 and washers 3 from the stud bolts on the engine body 5 Slide the engine away from the transaxle housing and lift the engine from the mounting plate 6 Place the engine on a solid fl...

Page 232: ...4 Remove the grommet 4 from the old spark plug wire Clean the grommet and place it on the new spark plug wire 5 5 Install the protector tube 3 onto the new wire Figure 13 28 Page 13 31 6 Slide the gasket 1 onto the end of the new spark plug wire 7 Install the cap 2 on the new coil spark plug wire by rotating it clockwise three or four revolutions while applying light pressure on the cap 8 Install ...

Page 233: ...nsaxle housing Loosely attach the two nuts 6 finger tight Figure 15 4 Page 15 5 17 Attach the engine to the bottom of the engine mounting plate using the bolts 1 washers 2 and nuts 5 Tighten hardware to 21 ft lb 28 4 N m Figure 15 4 Page 15 5 18 Tighten the two engine body bolt nuts 6 to 17 ft lb 23 1 N m 19 Install the engine and transaxle assembly See Unitized Transaxle Installation on page 20 1...

Page 234: ...30 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 29 Voltage at Headlight Socket on page 11 37 7 6 4 513 Figure 13 30 Headlight Assembly Page 13 32 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Serv...

Page 235: ...halogen bulb assembly 6 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 1 Connect wire harness 4 to the halogen bulb assembly 6 The retaining tab should lock onto the halogen bulb assembly Figure 13 30 Page 13 32 2 From the front of vehicle reach under body and insert wire harness halogen bulb ...

Page 236: ...re 13 31 Page 13 33 NOTE Identify terminal for solid black wire and terminal for black white wire 5 Remove the mounting hardware 2 from the voltage limiter and remove it from the vehicle VOLTAGE LIMITER INSTALLATION 1 Mount the voltage limiter to the frame using the mounting hardware and tighten to 25 in lb 2 8 N m Figure 13 31 Page 13 33 2 Connect the black white wire from harness to the negative...

Page 237: ...e instrument panel with nut 2 on the outside of the dash and tighten the nut to 14 in lb 1 6 N m Figure 13 32 Page 13 33 3 Push the light switch shaft in Screw the knob 2 onto the end of the shaft until the knob touches the outer nut Then turn the knob in the opposite direction until the headlight beams on the knob are horizontal to the ground Tighten the set screw 5 to lock the knob to the shaft ...

Page 238: ...ed vehicle the same size battery with adequate amperage ratings should be used as a replacement A group 70 side post battery CCI P N 1012328 with a 650 cranking amp rating at 32 F 0 C 500 CCA at 0 F 17 8 C and a reserve capacity of at least 105 minutes is recommended The group 70 classification indicates battery size 8 1 4 inches W x 6 1 2 inches D x 7 1 4 inches H 21 0 cm W x 16 5 cm D x 18 4 cm ...

Page 239: ...e on page 13 38 SELF DISCHARGE Dirt and battery acid can provide a path for a small current draw that slowly discharges the battery To prevent self discharge the battery should always be kept clean 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 Wh...

Page 240: ...LLOWABLE CONTENT PARTS PER MILLION EFFECTS OF IMPURITY Suspended matter Trace Total solids 100 0 Calcium 40 0 Increase of positive shedding Magnesium 40 0 Reduced life Iron 3 0 Increased self discharge at both plates lower on charge voltage Ammonia 8 0 Slight self discharge of both plates Organic matter 50 0 Corrosion of positive plate Nitrates 10 0 Increased sulfation at negative Nitrites 5 0 Cor...

Page 241: ...ive charger cable to the negative battery post 4 The battery may be charged with a slow charge 3 10 amps or a fast charge 20 30 amps Charge until the specific gravity reaches 1 250 See following WARNING WARNING If the battery case feels hot approximately 125 F 52 C or more emits gases or fluid boils from vents stop charging immediately Failure to stop charging battery when any of these conditions ...

Page 242: ...d be recharged See following WARNING WARNING If the battery is frozen or the container is bulged discard battery A frozen battery can explode 6 The frequency of recharging required depends on the temperature of the storage area but it is recommended that the battery be monitored for state of charge every month Also if the storage area is unheated in a cold climate and recharging is required it is ...

Page 243: ... 1 3 2 Place the neutral lockout switch in the MAINTENANCE position Access the engine compartment by removing the seat 3 Disconnect the wires from the starter generator 1 Mark wires before disconnecting Loosen the pivot nuts 7 and bolts 5 Figure 14 1 Page 14 2 4 Remove the mounting adjustment nut 12 washer 9 and bolt 11 Lower the starter generator and remove the belt 4 from the pulley 10 5 Support...

Page 244: ...hes back from the center of the commutator end cover The springs will rest on the sides of the brushes and help prevent them from sliding towards the center of the cover Figure 14 6 Page 14 4 2 Remove brush covers 29 and 30 screws 25 and lock washers 26 brush springs 28 and brushes 27 Figure 14 3 Page 14 2 See following NOTE NOTE To clean and inspect the armature commutator and the bearings see Di...

Page 245: ... spring tension If any spring has a tension less than 24 ounces 6 67 N replace all four springs Figure 14 5 Page 14 3 See following CAUTION CAUTION When checking brush spring tension do not push springs beyond the point they would normally be if there were new brushes installed Exerting excessive force or pushing brush springs beyond their normal maximum extension point will damage springs 0 5 10 ...

Page 246: ...aining three brush covers 29 in the openings in the commutator end cover 23 Figure 14 3 Page 14 2 1 491 Figure 14 6 Pull Brushes Away From Center of the Commutator End Cover DISASSEMBLY OF THE STARTER GENERATOR TO SERVICE THE ARMATURE COMMUTATOR 1 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 bru...

Page 247: ...etal of the bearing Bearings should be replaced if there is extensive wear or pitting on the balls or on the rolling surfaces Do not remove the bearings unless they are to be replaced A B 493 Figure 14 8 Bearing Play Inspection BEARING REMOVAL 1 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 t...

Page 248: ...electrical test indicates that it is necessary Figure 14 10 Page 14 7 See Starter Generator Starter Function on page 12 18 VISUAL INSPECTION OF ARMATURE Obvious defects can be seen by examining the armature If an armature has frayed or charred insulation broken wires or thrown solder it is obvious without testing that it should be replaced Faults seen during the visual inspection can aid in diagno...

Page 249: ...r can be polished away with 400 grit or finer sandpaper See following CAUTION CAUTION Do not use emery cloth on the commutator Particles of emery are conductive and may short circuit the commutator bars Do not use oil or lubricants on the commutator or brushes 2 Using a micrometer measure the outside diameter at two points along the commutator If the commutator outside diameter is less than 1 535 ...

Page 250: ... bars 1 Using a multimeter set on 200 ohms place the positive probe on the commutator bars and the negative probe on the armature core The reading should be no continuity If the reading is incorrect replace the armature and the two bearings Figure 14 12 Page 14 8 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 1 3 2 497 Fig...

Page 251: ... alike fit into the slots next to the F1 and F2 markings on the outside of the housing The insulator that looks different slides into the slot next to the DF marking 2 After the insulators are seated in the slots install the threaded terminals through the wire connectors and then through the insulators Install a flat washer lock washer and nut onto each threaded terminal on the outside of the hous...

Page 252: ... M14 nut 41 Tighten the nut to 28 ft lb 38 0 N m Figure 14 7 Page 14 5 STARTER GENERATOR INSTALLATION 1 Install the green wire from the F1 terminal to the A1 terminal on the starter generator Figure 14 1 Page 14 2 Install a flat washer lock washer and nut onto each terminal and tighten to 48 in lb 5 4 N m 2 Install two 3 8 inch hex head pivot bolts 5 into the mounting bracket with the heads of the...

Page 253: ...tarter Generator 14 13 7 5 2 3 10 4 11 1 9 12 498 Figure 14 13 Starter Generator Installation 1 2 Belt Tension Gauge 2 End View 499 Figure 14 14 Belt Tension Gauge 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual Page 14 11 ...

Page 254: ...it gauge 1 available at NAPA Auto Parts stores or equivalent Proper tension for a new starter generator belt should be 75 lb 101 7 N or 45 lb 61 N for an existing belt Figure 14 14 Page 14 11 7 While maintaining the tension tighten the adjustment nut 12 to 144 in lb 16 3 N m Tighten the two pivot bolts 5 and hex nuts 7 to 23 ft lb 31 2 N m Figure 14 13 Page 14 11 See following CAUTION CAUTION Remo...

Page 255: ...mly press down all corners Install screw and tighten to 18 in lb 2 N m 4 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 1 Page 1 3 5 Place Forward Reverse handle in NEUTRAL and place the neutral lockout switch in the MAINTENANCE position Start the engine and check regulator for proper functioning as described in the voltage regulator test procedure See V...

Page 256: ...mounted on the dash panel Do not allow wires to touch See following NOTE NOTE Take care to prevent key switch terminals and wires from touching the metal frame around the dash 2 5 Slide center dash panel up the steering column 1 2 3 516 Figure 14 16 Center Dash Panel Removal 3 Disconnect the wires from the key switch 4 Remove the key switch 4 1 Remove the key switch cap with a small flat blade scr...

Page 257: ... the electrical component box Use two screws to secure the solenoid to the box and tighten to 14 in lb 1 6 N m 2 Connect all wires as indicated See Wiring Diagram on page 12 6 2 1 Connect the 6 gauge white wire from the starter generator the 18 gauge white wire from the fuel gauge hour meter and the 16 gauge red wire from the voltage regulator to the large post on the solenoid 2 2 Connect the 6 ga...

Page 258: ... system may occur 2 Install the snap on electrical box cover by pressing down firmly on all corners and install the screw tightening to 18 in lb 2 N m 3 Connect battery See Connecting the Battery Gasoline Vehicles Section 1 Page 1 3 KILL LIMIT SWITCH See General Warning on page 1 1 TESTING THE KILL LIMIT SWITCH See Test Procedure 16 Kill Limit Switch on page 12 29 KILL LIMIT SWITCH REMOVAL 1 Disco...

Page 259: ... located in the electrical component box Place the accelerator limit switch 11 on the mounting screws located in the electrical component box 3 Secure the switches using two washers 10 and two nuts 9 Tighten to 5 in lb 0 6 N m See following CAUTION CAUTION Do not overtighten the retaining nuts If the nuts are overtightened limit switches could be damaged 4 Press and release the accelerator pedal t...

Page 260: ...e of cowl brace 2 4 Untwist and remove forward reverse shifter knob and pull center dash out from the frame 2 5 Rotate center dash panel counter clockwise around the steering column to gain access to the limit switches Figure 14 19 Page 14 18 See following NOTE NOTE Take care to manipulate under dash wires to prevent damage to wires It may be nessesary to remove key switch from the dash panel to a...

Page 261: ...the vehicle Turn the key switch to the ON position The engine should not crank when pressing the accelerator If the engine does crank turn the key switch OFF and readjust the shift linkage 5 Test drive the vehicle in both forward and reverse to check for proper operation REVERSE WARNING BUZZER See General Warning on page 1 1 TESTING THE REVERSE WARNING BUZZER See Test Procedure 20 Reverse Buzzer o...

Page 262: ...not touch the frame and that the panel is properly seated and snapped in place 5 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 1 Page 1 3 1 M 2 M 3 2 As seen from front driver side of vehicle with body removed 520 Figure 14 21 Front Reverse Warning Buzzer Page 14 20 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual ...

Page 263: ...uzzer limit switch located on the top of the Forward Reverse control 4 Use a wrench and a pair of needle nosed pliers to remove the two nuts and washers securing the limit switches Figure 14 20 Page 14 18 5 Slide the neutral lockout limit switch off of the screws Do not disconnect the wires 6 Slide the reverse buzzer limit switch off the screws REVERSE BUZZER LIMIT SWITCH INSTALLATION 1 Place the ...

Page 264: ...ouch 4 Press the retaining tabs and remove the low oil warning light from the center dash LOW OIL WARNING LIGHT INSTALLATION 1 Push a new unit into hole in dash until plastic tabs engage dash Figure 14 22 Page 14 22 2 Connect yellow wire from the key switch and yellow wire from the oil level sensor to the low oil warning light 3 Install the center dash in reverse order of removal Be sure that key ...

Page 265: ...ne tenth hour but does not record additional time unless the key switch is in the ON position and the engine is on When recording the hourglass icon on the left blinks slowly on Early 2007 vehicles FUEL GAUGE HOUR METER REMOVAL 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 1 Page 1 3 2 Remove the center dash panel See Key Switch Removal on page ...

Page 266: ...witch terminals cannot touch the frame and that panel is properly seated and snapped in place 6 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 1 Page 1 3 FUEL LEVEL SENDING UNIT See General Warning on page 1 1 The fuel level sending unit is an integral part of the fuel tank and should never be removed Thoroughly test the fuel level sending unit before re...

Page 267: ...5 3 Place the band 8 over the RPM limiter and align the holes Place the brown wire ring connector 11 onto the flange head bolt 7 and secure the left side of the band Use another flange head bolt to secure the other side of the band Make sure the band holds the RPM limiter securely in place Tighten fasteners to 7 ft lb 9 5 N m 4 Connect the black wire 2 to the white black kill circuit wire 1 at the...

Page 268: ...e bolts 2 and nuts 3 securing the stiffener to the mounting plate 4 Figure 14 26 Page 14 26 5 Remove the pan head bolts 5 securing the fan shroud 8 to the fan housing 9 Figure 14 27 Page 14 27 6 Loosen but do not remove the three bolts 6 attaching the fan housing as shown 7 Remove the remaining four bolts 10 attaching the fan housing as shown Figure 14 27 Page 14 27 then while opening the housing ...

Page 269: ...edures to remove and install these existing parts If the existing ignition coil will be remounted proceed to step 9 1 Remove the rubber gasket 1 on the plug cap 2 by rolling back the gasket onto the spark plug wire Figure 14 29 Page 14 27 2 Remove the cap 2 from the wire by turning the cap counterclockwise three or four revolutions while gently pulling it off the wire CAP 8 6 7 4 3 1 2 5 0 012 Inc...

Page 270: ...housing close to the engine crankcase and slide the plug wire grommet into the notch on the housing 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 loosened earlier 14 Install the four remaining flange bol...

Page 271: ...IGHT BULB REMOVAL 1 Disconnect battery See Disconnecting the Battery Gasoline Vehicles Section 1 Page 1 3 2 From the front of vehicle reach under cowl and turn the wire harness halogen bulb assembly 4 and 6 clockwise one quarter turn Figure 14 31 Page 14 29 3 Remove the wire harness halogen bulb assembly 4 and 6 from the headlight lens 7 4 Lift the retaining tabs on the connector 4 and remove halo...

Page 272: ... NEUTRAL position Chock the wheels 2 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 1 Page 1 3 3 Remove the instrument panel See Key Switch Removal on page 14 13 4 Disconnect wires from the voltage limiter 1 Do not allow wires to touch Figure 14 32 Page 14 31 NOTE Identify terminal for solid black wire and terminal for black white wire 5 Remove the...

Page 273: ...ION 1 Connect the wires to the light switch See Wiring Diagram on page 12 6 2 Thread the check nut 4 onto the switch until an equal number of threads show on both sides Insert the switch through the center dash and install the nut on the outside of the dash Tighten the nut to 14 in lb 1 6 N m Figure 14 33 Page 14 31 3 Push the light switch shaft in Screw the knob onto the end of the shaft until th...

Page 274: ...l Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately WARNING Do not jump start a dead battery using another battery and jumper cables GENERAL INFORMATION See preceding DANGER and WARNING statements Gasoline vehicles are equipped with 12 volt low maintenance batteries that requires infrequent watering When changing a 12 volt battery in any gasoline powere...

Page 275: ...e with water Do not allow solution to enter battery through the vent cap holes See Self Discharge on page 14 33 3 Maintain proper water level See Water Level on page 14 33 4 Check battery periodically to see that it is in a full state of charge See Charging the Battery on page 14 35 5 Keep battery hold down clamp tight See Vibration Damage on page 14 34 WATER LEVEL The water level should be checke...

Page 276: ...els listed in the following table See following NOTE NOTE Contact your local water department for mineral content analysis IMPURITY ALLOWABLE CONTENT PARTS PER MILLION EFFECTS OF IMPURITY Suspended matter Trace Total solids 100 0 Calcium 40 0 Increase of positive shedding Magnesium 40 0 Reduced life Iron 3 0 Increased self discharge at both plates lower on charge voltage Ammonia 8 0 Slight self di...

Page 277: ...rger cable to the negative battery post 4 The battery may be charged with a slow charge 3 10 amps or a fast charge 20 30 amps Charge until the specific gravity reaches 1 250 See following WARNING WARNING If the battery case feels hot approximately 125 F 52 C or more emits gases or fluid boils from vents stop charging immediately Failure to stop charging battery when any of these conditions are pre...

Page 278: ...harged See following WARNING WARNING If the battery is frozen or the container is bulged discard battery A frozen battery can explode 6 The frequency of recharging required depends on the temperature of the storage area but it is recommended that the battery be monitored for state of charge every month Also if the storage area is unheated in a cold climate and recharging is required it is recommen...

Page 279: ...ly repair rebuilding and reassembly see your authorized dealer BEFORE SERVICING Carefully read the applicable information and instructions before beginning engine service Diagrams DANGER WARNING CAUTION and NOTE statements and detailed descriptions have been included wherever necessary Anyone attempting engine service should have knowledge and experience in small engine service and repair ENGINE R...

Page 280: ...g wire to avoid accidental start up of the engine when servicing vehicle To avoid ignition of fuel and serious personal injury or death never try to start the engine with plug removed from engine A 524 Figure 15 1 Spark Plug Testing the Spark Plug Check the sparking ability of a cleaned and properly gapped plug on a sparking comparator if possible Spark should be blue and strong and able to jump a...

Page 281: ... laden air in the crankcase passes through the reed valve and expands into the rocker chamber In the rocker chamber most oil separates from the air and drains back to the crankcase The air passes through a tube and vents to the intake manifold See Engines and Transaxles Manual for inspection and repair CRANKCASE See General Warning on page 1 1 ENGINE REMOVAL To perform repairs on crankcase compone...

Page 282: ...ended bolts 1 and 2 Figure 15 3 Page 15 4 3 Remove eight bolts 3 and remove the crankcase cover 4 See following NOTE NOTE If the crankcase cover sticks tap lightly with a plastic mallet on alternate sides near the dowel pins 5 Figure 15 3 Page 15 4 4 Remove the crankcase cover gasket completely It may stick to the flanged surface of the crankcase 11 12 3 4 1 2 5 5 526 Figure 15 2 Oil Level Sensor ...

Page 283: ...nection 1 Figure 15 2 Page 15 4 3 Remove the screw 3 from the wire clamp 4 4 Remove the two mounting screws from the inside of the crankcase cover and remove the oil level sensor and bracket 5 If necessary remove the three screws 7 that hold the sensor to the bracket 5 Oil Level Sensor Installation 1 If the oil level sensor was removed from the bracket install sensor 6 into bracket 5 and secure wi...

Page 284: ...Clean the gasket surfaces on the crankcase cover to fit a new gasket during installation and inspect the oil seal for wear and damage 2 Install crankcase cover Using HANDS ONLY seat cover completely against the crankcase If the cover will not seat the camshaft is not installed correctly 3 Install and finger tighten evenly the eight cover mounting bolts Figure 15 6 Page 15 7 4 Tighten the cover mou...

Page 285: ... 15 7 Page 15 7 2 Disconnect the ignition coil 11 from its primary lead wire at the connector 12 Remove the two bolts 10 and take out the ignition coil Figure 15 8 Page 15 7 2 1 1 12 11 13 10 531 Figure 15 7 Flywheel Housing 510 Figure 15 8 Ignition Coil 3 Hold the flywheel 4 not the fan 7 with a strap wrench 5 and using a 25 mm socket remove the flywheel nut and flat washer by turning it counterc...

Page 286: ...crankshaft Then align the keyway in the flywheel to the key and push the flywheel and fan assembly onto the crankshaft until it seats Install flat washer and nut finger tight 2 Use a strap wrench 3 to keep the flywheel and fan assembly 1 from turning while tightening the flywheel nut to 63 ft lb 85 4 N m Figure 15 11 Page 15 9 See following CAUTION CAUTION The flywheel nut has right hand threads T...

Page 287: ...ine mounting plate and tighten the mounting hardware 1 2 and 5 to 13 ft lb 17 7 N m Tighten nuts 6 to 17 ft lb 23 1 N m Figure 15 4 Page 15 5 2 Install drive clutch See Drive Clutch Installation on page 21 11 3 Install drive belt See Drive Belt Installation on page 21 3 4 Install muffler See Muffler Installation on page 19 1 5 Install starter generator and belt See Starter Generator Installation o...

Page 288: ...ug gapped to 0 027 0 031 inch 0 69 0 79 mm 11 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 1 Page 1 3 12 Adjust the engine RPM setting See Engine RPM Adjustment on page 17 11 13 Test drive vehicle to ensure all systems are functional and correctly adjusted TORQUE SPECIFICATIONS ITEM SIZE LIMITS Flywheel retaining nut M16 63 ft lb 86 N m Crankcase cover...

Page 289: ...g 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 Engine RPM 3050 30 RPM for XRT 900 2900 30 RPM for Turf CA 252 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual Page 15 11 ...

Page 290: ......

Page 291: ...lacing the engine For complete instruction on engine disassembly repair rebuilding and reassembly see your authorized dealer BEFORE SERVICING Carefully read the applicable information and instructions before beginning engine service Diagrams DANGER WARNING CAUTION and NOTE statements and detailed descriptions have been included wherever necessary Anyone attempting engine service should have knowle...

Page 292: ...g wire to avoid accidental start up of the engine when servicing vehicle To avoid ignition of fuel and serious personal injury or death never try to start the engine with plug removed from engine A 524 Figure 16 1 Spark Plug Testing the Spark Plug Check the sparking ability of a cleaned and properly gapped plug on a sparking comparator if possible Spark should be blue and strong and able to jump a...

Page 293: ...through the piston rings oil seals or gaskets The breather has a reed valve which limits the direction of air flow caused by the piston moving up and down Air can flow out of the crankcase but the one way reed valve blocks return flow and therefore maintains a vacuum in the crankcase Oil laden air in the crankcase passes through the reed valve and expands into the rocker chamber In the rocker cham...

Page 294: ...unting hardware items 1 2 5 and 6 Figure 16 6 Page 16 6 6 Lift engine from the mounting plate 7 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 1 Remove yellow jumper wire 11 from cord connector 12 Figure 16 4 Page 16 5 2 Remove nuts and clamps at two ended bolts 1 and...

Page 295: ...27 FE 350 ENGINE Crankcase 16 11 12 3 4 1 2 5 5 526 Figure 16 4 Oil Level Sensor Wire 527 Figure 16 5 Crankcase Cover 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual Page 16 5 ...

Page 296: ...nection 1 Figure 16 7 Page 16 7 3 Remove the screw 3 from the wire clamp 4 4 Remove the two mounting screws from the inside of the crankcase cover and remove the oil level sensor and bracket 5 If necessary remove the three screws 7 that hold the sensor to the bracket 5 Oil Level Sensor Installation 1 If the oil level sensor was removed from the bracket install sensor 6 into bracket 5 and secure wi...

Page 297: ...Clean the gasket surfaces on the crankcase cover to fit a new gasket during installation and inspect the oil seal for wear and damage 2 Install crankcase cover Using HANDS ONLY seat cover completely against the crankcase If the cover will not seat the camshaft is not installed correctly 3 Install and finger tighten evenly the eight cover mounting bolts 4 Tighten the cover mounting bolts in two ste...

Page 298: ...16 9 Page 16 8 2 Disconnect the ignition coil 11 from its primary lead wire at the connector 12 Remove the two bolts 10 and take out the ignition coil Figure 16 10 Page 16 8 2 1 1 12 11 13 10 531 Figure 16 9 Flywheel Housing 510 Figure 16 10 Ignition Coil 3 Hold the flywheel 4 not the fan 7 with a strap wrench 5 and using a 25 mm socket remove the flywheel nut and flat washer by turning it counter...

Page 299: ...crankshaft Then align the keyway in the flywheel to the key and push the flywheel and fan assembly onto the crankshaft until it seats Install flat washer and nut finger tight 2 Use a strap wrench 3 to keep the flywheel and fan assembly 1 from turning while tightening the flywheel nut to 63 ft lb 85 4 N m Figure 16 13 Page 16 10 See following CAUTION CAUTION The flywheel nut has right hand threads ...

Page 300: ...ne mounting plate and tighten the mounting hardware 1 2 and 5 to 13 ft lb 17 7 N m Tighten nuts 6 to 17 ft lb 23 1 N m Figure 16 6 Page 16 6 2 Install drive clutch See Drive Clutch Installation on page 21 11 3 Install drive belt See Drive Belt Installation on page 21 3 4 Install muffler See Muffler Installation on page 19 1 5 Install starter generator and belt See Starter Generator Installation on...

Page 301: ... 0 027 0 031 inch 0 69 0 79 mm 11 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 1 Page 1 3 12 Adjust the engine RPM setting See Engine RPM Adjustment on page 18 11 13 Test drive vehicle to ensure all systems are functional and correctly adjusted TORQUE SPECIFICATIONS ITEM SIZE LIMITS Flywheel retaining nut M16 63 ft lb 86 N m Crankcase cover to block bo...

Page 302: ...ndard 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 Engine RPM 3050 30 RPM for Key Start Vehicles 2900 30 RPM for Pedal Start Vehicles Page 16 12 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual ...

Page 303: ...e 17 16 Choke and air intake system for restriction of air flow See Choke and Air Intake System on page 17 12 Fuel pump Fuel lines from fuel tank to filter to pump to filter to carburetor See Fuel Lines on page 17 25 Exhaust system for restrictions See Exhaust System Gasoline Vehicles on page 19 1 If the carburetor floods or leaks fuel at the float bowl gasket or carburetor vent tube the fuel inle...

Page 304: ... 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 82 85 3000 5000 ft 914 4 1524 m 80 82 5000 8000 ft 1524 2438 4 m 78 80 TABLE CONTINUED ON NEXT PAGE Page 17 2 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual ...

Page 305: ...y 12 so that it can be replaced in the same orientation Figure 17 1 Page 17 2 When removing the carburetor body the throttle return spring 11 must be disconnected Note its proper orientation so that it can be replaced in the same orientation The carburetor must be kept upright during removal 2 Position the carburetor with the drain screw 11 over a catch basin Figure 17 4 Page 17 4 3 Turn the carbu...

Page 306: ...Components 7 Select the proper size main jet See Main Jet Elevation Size Chart on page 17 2 Check the size designation on the jet to make sure it is the correct part 8 Install the new main jet and tighten it to 12 in lb 1 4 N m See following CAUTION and NOTE CAUTION Do not remove the valve spring assembly from the float assembly Doing so will damage the spring NOTE Inspect the main jet nozzle 7 an...

Page 307: ...ure 17 1 Page 17 2 12 1 Attach the throttle return spring 11 to the carburetor and then to the throttle bracket 4 just before positioning the carburetor and securing it to the engine Figure 17 1 Page 17 2 12 2 Install the intake pipe gasket 16 check for proper orientation and intake pipe 17 12 3 Install the carburetor retaining nuts 19 and tighten them to 50 in lb 5 7 N m 13 Connect fuel supply li...

Page 308: ...age and throttle adjustments are done correctly and in the proper sequence See following CAUTION CAUTION Improper adjustment can result in poor vehicle performance and or damage to the engine components ACCELERATOR ROD Accelerator Rod Removal 1 Raise the front of the vehicle Place chocks at the rear wheels and lift the front of the vehicle with a chain hoist or floor jack Place jack stands under t...

Page 309: ... 6 Page 17 7 adjust the length of the accelerator rod so the indicated cam edge is parallel with the electrical component box as shown Figure 17 7 Page 17 8 See following CAUTION CAUTION Be sure that approximately an equal number of threads are exposed at each end of the accelerator rod 6 Install the accelerator rod on the bell crank ball joint on the electrical component box Figure 17 8 Page 17 8...

Page 310: ...roperly adjusted adjust the engine RPM setting See Engine RPM Adjustment on page 17 11 12 Install the electrical box cover and tighten retaining screw to 18 in lb 2 0 N m 13 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 1 Page 1 3 GOVERNOR CABLE Governor Cable Removal 1 Turn the key switch to the OFF position and remove the key place the Forward Reverse...

Page 311: ...e governor lever arm loose on the governor shaft use a 1 8 inch punch or scratch awl to turn the governor arm shaft counterclockwise until it stops Then pull the governor lever arm rearward until the carburetor throttle is in the wide open throttle WOT position 6 While holding the arm and shaft in the fully counterclockwise position tighten the governor arm lever nut to 36 in lb 4 0 N m 7 Check en...

Page 312: ...able in accelerator cable bracket 5 Figure 17 9 Page 17 9 5 Push the cable dust shield onto the spring end of the cable conduit 6 Before tightening the cable housing retaining nuts make sure the engine RPM adjustment is correct See Engine RPM Adjustment on page 17 11 7 Install the electrical box cover and tighten the retaining screw to 18 in lb 2 0 N m 8 Connect battery and spark plug wire s See C...

Page 313: ...ng temperature check high speed RPM With the accelerator pedal pressed to the floor the tachometer should read 3050 30 RPM XRT 900 or 2900 30 RPM Turf Carryall 252 7 To reduce RPM loosen the accelerator cable retaining nut on the outside of the electrical box wall and tighten the retaining nut on the inside of the wall until the specified RPM is reached Figure 17 7 Page 17 8 To increase RPM loosen...

Page 314: ...CABLE REMOVAL 1 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 2 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 1 Page 1 3 3 Remove the screw 17 securing cable to air box and detach cable end from choke lever 6 Figure 17 12 Page 17 15 4 Remove three screws 19 ...

Page 315: ...hose onto air box and secure with wire clamp 4 Attach the choke cable to the air box top See Choke Cable Installation on page 17 12 5 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 1 Page 1 3 6 Test choke for proper operation INTAKE DUCT REMOVAL 1 Remove the front body See Front Body Removal Section 4 Page 4 3 2 Remove the front left wheel See Wheel Remo...

Page 316: ...he air duct shield Do not remove backing from exposed side of tape 3 3 Secure the bottom of the air duct shield to the floorboard with a rivet 31 3 4 Remove the backing from the tape and secure top of air duct shield to frame 4 Install air box See Air Box Installation on page 17 13 5 Install steering joint assembly See following NOTE NOTE Make sure steering wheel and front wheels are properly alig...

Page 317: ...Intake System 17 25 31 26 30 25 26 26 24 16 15 15 13 12 18 4 17 5 6 11 10 9 8 3 2 1 7 22 23 14 21 20 19 833 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: ...r box Close the lid 6 Fasten wire latches 3 Make sure latches securely engage the bottom half of the box See following CAUTION CAUTION Engine damage will occur if the air box cover is not properly secured 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...

Page 319: ...ps 16 Figure 17 13 Page 17 18 2 If equipped install the secondary fuel filter 22 in the fuel line Use new clamps 16 3 Turn the fuel shut off valve to the ON position Figure 17 18 Page 17 26 or Figure 17 19 Page 17 26 4 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 1 Page 1 3 5 XRT 900 Place the Forward Reverse handle in the NEUTRAL position and chock th...

Page 320: ... in 35 6 cm 2 Primary fuel filter to fuel pump 6 0 in 15 0 cm 3 Fuel pump to secondary fuel filter 11 5 in 29 2 cm 4 Secondary fuel filter to carburetor Some vehicles do not have a secondary fuel filter 2 5 in 6 4 cm 5 Vent tube Carburetor 22 0 in 55 9 cm 6 Vent tube Fuel Tank 17 0 in 43 2 cm 7 Impulse line 14 0 in 35 6 cm Total 45 0 in 114 5 cm 39 0 in 99 1 cm Page 17 18 2007 2009 Turf 252 Carrya...

Page 321: ...ion Figure 17 18 Page 17 26 or Figure 17 19 Page 17 26 4 Remove hardware attaching the fuel pump 24 and lift the fuel pump out of the engine compartment Figure 17 13 Page 17 18 5 Remove the clamp and impulse line 7 from fuel pump 6 Disconnect the fuel lines 2 and 3 from the pump and plug them to prevent fuel leakage See following WARNING WARNING Carefully drain any fuel remaining in the pump into ...

Page 322: ...1 Using a nonflammable solvent clean the front cover pumping chamber and back cover Be sure the vent 40 on the front cover is clean both inside and out 2 Inspect the valve assemblies 31 32 and 33 and all gaskets and diaphragms for damage Figure 17 14 Page 17 20 3 If a valve assembly is damaged the rubber retaining plug 33 and valve assembly must be replaced 24 32 31 30 35 38 34 36 33 39 40 25 37 2...

Page 323: ...he pump Direction of fuel flow is indicated by the arrows on the fuel pump Figure 17 13 Page 17 18 See also Figure 17 15 Page 17 20 2 Connect to the output side of the fuel pump the fuel line 3 that goes to the secondary fuel filter 3 Connect the impulse line 7 to the bottom nipple on the fuel pump Use a new clamp 16 4 Install the fuel pump onto the mounting bracket with two thread rolling screws ...

Page 324: ... 17 26 or Figure 17 19 Page 17 26 5 Disconnect battery See Disconnecting the Battery Gasoline Vehicles Section 1 Page 1 3 6 Loosen but do not remove the carburetor drain screw 11 and drain fuel remaining in the carburetor bowl into an approved container Figure 17 4 Page 17 4 Retighten carburetor drain screw 7 Using a siphon with a suction device siphon all fuel out of the tank and into an approved...

Page 325: ...ng fuel 3 In a well ventilated area set the tank upside down so that the water can drain out of it To make sure that the tank dries completely allow the tank to sit for 24 hours See following CAUTION CAUTION Dispose of wastewater and fuel tank in accordance with local state and federal laws and ordinances FUEL TANK STORAGE 1 Remove the cap from the tank and thoroughly rinse it with water 2 In a we...

Page 326: ...0 Check to be sure the fuel shut off valve on top of the fuel tank is in the open ON position Figure 17 18 Page 17 26 or Figure 17 19 Page 17 26 11 XRT 900 Place the Forward Reverse handle in the NEUTRAL position and chock the wheels See following DANGER 12 Turf Carryall 252 Place the Forward Reverse handle in the NEUTRAL position chock the wheels and the neutral lockout switch in the MAINTENANCE ...

Page 327: ...irection Figure 17 13 Page 17 18 Fuel line no 2 runs directly from the primary fuel filter to the fuel inlet of the fuel pump Fuel line no 3 runs directly from the fuel outlet of the fuel pump to the secondary fuel filter Figure 17 13 Page 17 18 The secondary fuel filter has an arrow indicating fuel flow direction and is identical to the primary fuel filter See following NOTE NOTE Some vehicles do...

Page 328: ...g valve position ensure that it is fully opened or fully closed 449 Figure 17 18 Fuel Shut off Valve 49 State Fuel Tank 450 Figure 17 19 Fuel Shut off Valve California Fuel Tank FUELING INSTRUCTIONS See General Warning on page 1 1 DANGER Turn the key switch to the OFF position before fueling Do not pour fuel into the fuel tank when the engine is hot or while it is running To avoid electric arc cau...

Page 329: ...tored for extended periods should be prepared for storage as instructed See Preparing the Gasoline Vehicle for Extended Storage on page 3 3 1 Turn the key switch to the OFF position 2 The fuel tank is located on passenger side of vehicle Remove fuel cap and fill the fuel tank with fresh unleaded gasoline only See preceding CAUTION 3 Replace fuel cap on tank Ensure cap is tightened securely 2007 20...

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Page 331: ...8 17 Choke and air intake system for restriction of air flow See Choke and Air Intake System on page 18 11 Fuel pump See Fuel Pump on page 18 19 Fuel lines from fuel tank to filter to pump to carburetor See Fuel Lines on page 18 26 Exhaust system for restrictions See Exhaust System Gasoline Vehicles on page 19 1 If the carburetor floods or leaks fuel at the float bowl gasket or carburetor vent tub...

Page 332: ...3 14 16 17 534 Figure 18 1 Carburetor Mounting MAIN JET ELEVATION SIZE CHART ALTITUDE S27 FE350 ENGINE MAIN JET SIZE 0 3200 ft 0 975 m 82 3200 6500 ft 975 1981 m 80 6500 9800 ft 1981 2987 m 78 9800 ft and above 2987 m and above 76 Page 18 2 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual ...

Page 333: ...an be replaced in the same orientation The carburetor must be kept upright during removal 2 Position the carburetor with the drain screw 11 over a catch basin Figure 18 2 Page 18 3 3 Turn the carburetor bowl drain screw counterclockwise two or three turns and drain all the fuel from the bowl into the catch basin Tighten the drain screw to 10 in lb 1 1 N m Return fuel to the fuel tank or dispose of...

Page 334: ... See following CAUTION and NOTE CAUTION Do not remove the valve spring assembly from the float assembly Doing so will damage the spring NOTE Inspect the main jet nozzle 7 and pilot jet 4 to ensure they are free from contamination Figure 18 4 Page 18 4 Replace any part that is clogged with contamination Replace the float if it is damaged or if the float valve is damaged or worn Examine the float va...

Page 335: ... to the carburetor and then to the throttle bracket 4 just before positioning the carburetor and securing it to the engine 12 2 Install the intake pipe gasket 16 check for proper orientation and intake pipe 17 12 3 Install the carburetor retaining nuts 19 and tighten them to 50 in lb 5 7 N m 13 Connect fuel supply line 26 and tighten screw clamp to 9 in lb 1 0 N m Figure 18 1 Page 18 2 14 Install ...

Page 336: ...y and in the proper sequence See following CAUTION CAUTION Improper adjustment can result in poor vehicle performance and or damage to the engine components ACCELERATOR ROD Accelerator Rod Removal 1 Raise the front of the vehicle Place chocks at the rear wheels and lift the front of the vehicle with a chain hoist or floor jack Place jack stands under the round frame cross tube to support the vehic...

Page 337: ...s are exposed at each end of the accelerator rod 6 Install the accelerator rod on the bell crank ball joint on the electrical component box Figure 18 8 Page 18 7 See following CAUTION and NOTE CAUTION Inspect the limit switch inside the electrical box If the limit switch lever is bent replace the switch NOTE Use the inside hole location or hole closest to the bell crank shaft as shown Figure 18 8 ...

Page 338: ...rburetor throttle Figure 18 9 Page 18 9 5 Disconnect the governor cable 2 from the governor lever arm 15 6 Remove the governor cable 2 from the governor cable engine bracket 11 and governor cable support bracket 10 Remove the cable 2 from the vehicle Governor Cable Installation and Adjustment 1 Install the cable onto the governor cable support bracket 10 and the engine bracket 11 Figure 18 9 Page ...

Page 339: ...ttery Gasoline Vehicles Section 1 Page 1 3 3 Remove the electrical box screw and cover and loosen the cable housing retaining nuts Figure 18 7 Page 18 7 4 Disconnect cable 1 from cam 17 in the electrical box Figure 18 9 Page 18 9 5 Disconnect the spring 16 from the engine governor arm 6 Remove the accelerator cable from the accelerator cable bracket 5 Remove the cable assembly from the vehicle 200...

Page 340: ...x cover and tighten the retaining screw to 18 in lb 2 0 N m 8 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles Section 1 Page 1 3 CLOSED THROTTLE OR IDLE ADJUSTMENT Pedal Start vehicles When the accelerator pedal is released the engine will stop Therefore it is not possible to measure or set idling speed under normal vehicle operating conditions Set throttle valve...

Page 341: ...t the electrical box and then check the RPM again If the RPM needs to be adjusted repeat step 7 9 If more adjustment is required than the cable housing will allow make sure the spring on the other end of the accelerator cable is properly positioned Excessive belt and torque converter wear can also prevent proper RPM adjustment Check them for excessive wear See See Section 21 Torque Converter Gasol...

Page 342: ...e 18 11 Page 18 13 CHOKE CABLE INSTALLATION 1 Insert choke cable through hole in body until choke lever assembly seats against body 2 Install three screws 19 washers 20 and lock nuts 21 as shown and tighten to 18 in lb 2 0 N m Figure 18 11 Page 18 13 3 Check the hex nut on the cable at the back of the choke lever assembly If it is loose tighten it until the lock washer beside it collapses complete...

Page 343: ...Intake System 18 25 31 26 30 25 26 26 24 16 15 15 13 12 18 4 17 5 6 11 10 9 8 3 2 1 7 22 23 14 21 20 19 833 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: ...x assembly into vehicle and install three flat washers 22 and screws 23 from underside of air box mounting plate into air box Figure 18 11 Page 18 13 Tighten to 33 in lb 3 7 N m 3 Place hose onto air box and secure with wire clamp 4 Attach the choke cable to the air box top See Choke Cable Installation on page 18 12 5 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicl...

Page 345: ...e air duct shield to the floorboard with a rivet 31 3 4 Remove the backing from the tape and secure top of air duct shield to frame 4 Install air box See Air Box Installation on page 18 14 5 Install steering joint assembly See following NOTE NOTE Make sure steering wheel and front wheels are properly aligned before installing steering joint 5 1 Position steering joint assembly 1 on vehicle as show...

Page 346: ...latches are not caught between lid and air box Close the lid 6 Fasten wire latches 3 Make sure latches securely engage the bottom half of the box See following CAUTION CAUTION Engine damage will occur if the air box cover is not properly secured 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 ...

Page 347: ... filter 17 Figure 18 13 Page 18 18 4 1 Remove the clamps 16 and fuel lines 1 and 2 from the filter and plug the fuel lines FUEL FILTER INSTALLATION CAUTION Fuel filters are marked with flow direction arrows Make sure that filters are installed with arrows pointing in the direction of fuel flow from tank to carburetor 1 Install the fuel filter 17 in the fuel line Use new clamps 16 Figure 18 13 Page...

Page 348: ...EM 16 20 5 20 17 23 14 6 23 1 16 16 2 21 7 14 13 19 9 28 4 10 27 15 26 8 16 25 24 22 18 29 3 12 11 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: ...el pump is not operating properly perform the following tests Make sure all hose clamps are tight Inspect the impulse line and fuel lines for damage or clogging Make sure the air vent on the fuel pump is not clogged with dirt Make sure the fuel filters are not clogged To clean the air vent the fuel pump must be disassembled FUEL PUMP REMOVAL 1 Turn the key switch to the OFF position and remove the...

Page 350: ...shers 25 from front of the fuel pump Figure 18 14 Page 18 21 3 Remove the front cover 37 of the fuel pump while holding the rest of the pump intact 4 Note the orientations of the impulse gasket 27 the diaphragm 28 and the gasket 29 then remove them from the pump 5 If the impulse gasket 27 and the diaphragm 28 come off with the front cover note their orientations and remove them 6 Remove the pumpin...

Page 351: ...he arrows on the front of the front cover 4 Install the gasket 29 clear impulse diaphragm 28 and the paper impulse gasket 27 to the pumping chamber 30 5 Install the front cover 37 and then the lock washers 25 and four screws 24 on the assembly Be sure the arrows on the front cover point from the fuel inlet to the fuel outlet Figure 18 15 Page 18 21 Tighten the screws to 26 in lb 3 0 N m FUEL PUMP ...

Page 352: ... position Figure 18 18 Page 18 26 or Figure 18 19 Page 18 26 7 XRT 900 Place the Forward Reverse handle in the NEUTRAL position and chock the wheels See following DANGER 8 Turf Carryall 252 Place the Forward Reverse handle in the NEUTRAL position chock the wheels and the neutral lockout switch in the MAINTENANCE position 9 Start the engine and check for fuel leaks If the fuel pump leaks a rebuild ...

Page 353: ... to the OFF position and remove the key place the Forward Reverse handle in the NEUTRAL position and chock the wheels 6 Disconnect battery See Disconnecting the Battery Gasoline Vehicles Section 1 Page 1 3 7 Loosen but do not remove the carburetor drain screw 11 and drain fuel remaining in the carburetor bowl into an approved container Figure 18 2 Page 18 3 Retighten carburetor drain screw 8 Using...

Page 354: ...ake sure that the tank dries completely allow the tank to sit for 24 hours See following CAUTION CAUTION Dispose of wastewater and fuel tank in accordance with local state and federal laws and ordinances FUEL TANK STORAGE 1 Remove the cap from the tank and thoroughly rinse it with water 2 In a well ventilated area flush the fuel tank with water to remove any remaining fuel 3 In a well ventilated a...

Page 355: ...1 XRT 900 Place the Forward Reverse handle in the NEUTRAL position and chock the wheels See following DANGER 12 Turf Carryall 252 Place the Forward Reverse handle in the NEUTRAL position chock the wheels and the neutral lockout switch in the MAINTENANCE position See following DANGER 13 Start the engine See following DANGER DANGER Do not operate gasoline vehicle in an enclosed area without proper v...

Page 356: ...carburetor A screw band clamp 21 should be used at the carburetor 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 18 18 Page 18 26 or Figure 18 19 Page 18 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 ...

Page 357: ...he cylinder block exhaust stud bolts 3 Attach muffler manifold with lock washers 11 and hex nuts 10 and finger tighten 4 Loosely secure muffler 1 mounting bracket and governor cable bracket 13 using hex head cap screw 7 lock washer 8 and flat washer 9 5 Tighten manifold hex nuts 10 to 11 ft lb 14 9 N m 6 Tighten the hex cap screw 7 to 14 ft lb 18 9 N m 7 Tighten the muffler clamp 6 to 40 in lb 4 5...

Page 358: ...ehicle in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison 1 2 3 4 5 7 11 8 12 000 000 6 10 9 13 835 Figure 19 1 Exhaust System Page 19 2 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual ...

Page 359: ...s a neutral lockout circuit that prevents a driver from starting the vehicle in NEUTRAL If the vehicle is started in FORWARD or REVERSE and then shifted to NEUTRAL the engine will stop running For the convenience of the trained technician there is a neutral lockout switch located on the seat support panel under the seat Figure 20 1 Page 20 2 The neutral lockout switch has two positions MAINTENANCE...

Page 360: ...le Installation and Adjustment on page 17 9 UNITIZED TRANSAXLE SERVICE The unitized transaxle is extremely durable and should require very little service under normal operating conditions The only service required is to maintain proper lubricant level See Periodic Lubrication Schedules on page 10 6 Under normal operating conditions adjustment to the system should not be required F N R C l u bC a r...

Page 361: ...e lubricant level indicator hole Fill with 27 oz 0 8 liter 80 90 WT API class GL or 80 90 WT AGMA class 5 EP gear lubricant or until lubricant begins to run out of the level indicator hole Tighten the plug to 20 ft lb 27 1 N m AXLE SHAFT See General Warning on page 1 1 Removal of the unitized transaxle is not required for servicing or replacing axle shafts axle bearings or axle shaft oil seals If ...

Page 362: ...eal Lip 9 Inspect the axle shaft assembly to be sure the bearing 71 and collar 73 have not slipped and are still seated against the shoulder on the axle shaft Figure 20 7 Page 20 5 10 Inspect the bearing If the bearing is damaged or worn replace it AXLE BEARING Axle Bearing Removal 1 Use external retaining ring pliers 0 047 inch tip to remove the retaining ring 74 Place a bearing puller wedge atta...

Page 363: ...e it Do not remove the large axle retaining ring 70 from the axle Figure 20 7 Page 20 5 Since the inner diameter of the retaining ring 70 is smaller than the outer diameter of the bearing 71 the ring must be in place on the axle before a new bearing and collar are pressed on 74 73 70 71 74 73 70 68 76 75 67 70 71 73 74 72 71 72 557 Figure 20 7 Differential Gear Case and Axle Tubes Axle Bearing Ins...

Page 364: ...Use external snap ring pliers 0 047 in tip to install collar retaining ring 74 Figure 20 7 Page 20 5 AXLE SHAFT INSTALLATION 1 Clean bearing and seal seats in axle tube 75 or 76 Figure 20 7 Page 20 5 2 Place a new oil seal 72 in axle tube with seal lip facing inside of the axle tube Figure 20 7 Page 20 5 Use an axle seal tool CCI P N 1012811 to press it in until it seats firmly in position Figure ...

Page 365: ...ANSAXLE REMOVAL See General Warning on page 1 1 1 Turn the key switch to the OFF position and remove the key and place the Forward Reverse handle in the NEUTRAL position 2 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles Section 1 Page 1 3 3 Close the fuel shut off valve on fuel tank Figure 17 18 Page 17 26 or Figure 17 19 Page 17 26 4 Detach all wires hoses...

Page 366: ...e can be plugged with a 1 4 inch bolt Figure 20 13 Page 20 8 562 Figure 20 12 Impulse Line 846 Figure 20 13 Fuel Line 4 5 Remove the cover from the electrical component box Then loosen the hardware securing the accelerator cable to the box Disconnect the cable from the actuator cam and remove it from the box Figure 20 14 Page 20 9 4 6 Remove retaining nut and disconnect the engine ground wire from...

Page 367: ...oosen nuts 2 Pull spring release back to remove shifter cable from lever DF F2 1 2 3 1 Yellow Wire 2 White Wire 3 Ground Wire at A2 Terminal 566 Figure 20 16 Shifter Cable Top View 836 Figure 20 17 Generator Wires 4 9 Disconnect the engine oil level sensor wire 18 gauge yellow at the connector just to the rear of the starter generator Figure 20 18 Page 20 10 4 10 Disconnect the engine kill switch ...

Page 368: ...support bracket Figure 20 20 Page 20 10 1 4 3 2 570 Figure 20 20 Brake Cable Rear View 6 Remove the lower shock mounting hardware from both rear shocks Figure 20 21 Page 20 11 7 If equipped with a stabilizer bar remove the two bolts securing the stabilizer bar to the stabilizer bar links See Rear Suspension Section 8 Position a floor jack under the vehicle frame crossmember or trailer hitch mount ...

Page 369: ... Turf 6 And Carryall 6 837 Figure 20 21 Shock Absorbers Figure 20 22 Floor Jack Positioned Under Hitch Bracket 9 Raise vehicle just enough to relieve tension from leaf springs then remove the bolts securing the leaf springs to the shackles Figure 20 23 Page 20 11 10 Remove the bolts securing the leaf springs to their front mounts Figure 20 24 Page 20 11 838 Figure 20 23 Rear Shackles 839 Figure 20...

Page 370: ...Pull the floor jack from beneath the vehicle and move it away 14 Carefully lift the snubber out of the snubber bracket in the vehicle frame and lower it to the floor Figure 20 27 Page 20 12 The powertrain should be completely disconnected from the vehicle and resting on the floor 15 Grasp the ends of the leaf springs at the rear of the vehicle and roll the powertrain out from under the vehicle Fig...

Page 371: ...Remove the driven clutch retaining bolt and remove the driven clutch from the unitized transaxle Figure 20 31 Page 20 13 19 Loosen but do not remove the governor arm retaining bolt 1 Figure 20 32 Page 20 13 Remove the governor arm from the shaft Do not disconnect cables 1 581 Figure 20 31 Driven Clutch 582 Figure 20 32 Governor Arm 20 Remove screws 1 securing the governor cable bracket to transaxl...

Page 372: ...move two middle transaxle mounting nuts from the engine block studs 23 Remove leaf springs stabilizer bar wheels and brake assemblies from the transaxle 585 Figure 20 35 Transaxle Mounting UNITIZED TRANSAXLE INSTALLATION See General Warning on page 1 1 1 Install the wheels See Wheel Installation on page 8 1 2 Install the leaf springs See Multi Leaf Spring Installation on page 9 3 3 Install the sta...

Page 373: ...rnor shaft Figure 20 37 Page 20 15 9 1 With the governor lever arm loose on the governor shaft turn the governor arm shaft counterclockwise until it stops Then pull the governor lever arm rearward until the carburetor throttle is in the wide open throttle WOT position Figure 20 37 Page 20 15 9 2 While holding the arm and shaft in the fully counterclockwise position tighten the governor arm lever n...

Page 374: ... 16 Adjust the vehicle height with the floor jack to position the leaf springs for mounting in the shackles Install the mounting bolts and lock nuts Figure 20 41 Page 20 16 Clu bCar Clu bCar Clu bCar Club Car 844 Figure 20 40 Leaf Springs 845 Figure 20 41 Leaf Springs and Shackles 17 Position shocks in the shock mounts and install cushions mounting washers and nuts Figure 20 42 Page 20 17 Tighten ...

Page 375: ... 4 N m Connect the 16 gauge yellow wire to the DF post on the starter generator and tighten to 30 in lb 3 4 N m Figure 20 45 Page 20 17 DF F2 1 2 3 1 Yellow Wire 2 White Wire 3 Ground Wire at A2 Terminal 568 Figure 20 44 Oil Level Sensor Jumper wire 836 Figure 20 45 Starter Generator 23 Position the shifter cable in the shifter cable mounting bracket on the engine and tighten the mounting nuts to ...

Page 376: ...18 in lb 2 0 N m Figure 20 48 Page 20 18 Install electrical box cover and tighten mounting screw 26 Remove the 1 4 inch bolt from the fuel line and connect the fuel line to the carburetor and secure with a hose clamp Figure 20 49 Page 20 18 564 Figure 20 48 Connect Cable to Cam and Secure with Retaining Nuts 846 Figure 20 49 Connect Fuel Line 27 Connect the impulse line to the fuel pump and secure...

Page 377: ...stall and tighten the level indicator hole plug to 21 ft lb 28 5 N m 32 Ensure that all wiring is secured properly See following WARNING WARNING If wires are removed or replaced make sure wiring and wiring harness is properly routed and secured to vehicle frame Failure to properly route and secure wiring could result in vehicle malfunction property damage or personal injury 33 Connect battery and ...

Page 378: ...all stud 5 on the transaxle 6 Loosen the retaining nuts 6 anchoring rear of cable jacket to bracket 7 at starter generator 7 If equipped remove wire tie s securing cable jacket to frame rail 8 Remove cable 8 from the vehicle FORWARD REVERSE SHIFTER CABLE INSTALLATION 1 Begin at the Forward Reverse shifter and route the cable 8 exactly as it was originally to the transaxle shifter lever 2 Secure re...

Page 379: ...NSAXLE DASH MOUNTED SHIFTER Forward Reverse Shifter Cable 20 8 2 3 9 1 6 4 7 5 10 591 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: ... Be sure threads of cable are engaged in ball joint socket at least 1 4 inch 6 35 mm If ball joint socket comes loose from the cable the Forward Reverse shifter will not operate properly F N R 592 Figure 20 54 Forward Reverse Shifter Positions For major adjustments the cable jacket retaining nuts 6 must be loosened and adjusted When the cable is properly adjusted with the Forward Reverse handle 9 ...

Page 381: ...driven clutch is 0 92 to 1 On steep grades or when the vehicle is heavily loaded higher torques are achieved through the use of a torque sensing ramp device on the driven clutch This device overcomes the force of the centrifugal weights to close the driven clutch and open the drive clutch thus increasing axle torque with little or no change in engine RPM The engine and torque converter rotate cloc...

Page 382: ...497 CC P N 1015524 CC P N 101808401 CC P N 1014508 WARNING 1 2 3 7 5 4 6 1 Drive Clutch Hub Puller 2 Driven Clutch Cam Puller 3 Driven Clutch Cam Press Tool 4 Drive Clutch Holder Tool 5 Driven Clutch Puller Plug 6 Cam Installation Tool 7 Drive Clutch Puller 593 Figure 21 1 Torque Converter Tool Kit DRIVE BELT See General Warning on page 1 1 The drive belt should be inspected semiannually for wear ...

Page 383: ...AUTION Make sure fingers are not underneath the belt when rolling the belt off the driven clutch 3 Remove the belt from the drive clutch 1 2 594 Figure 21 2 Drive Belt Removal DRIVE BELT INSTALLATION 1 Position the new belt on the drive clutch then start the belt over the top of the driven clutch 2 With the belt started onto the driven clutch rotate the driven clutch counterclockwise and roll the ...

Page 384: ...ardware and then remove the starter belt See WARNING Moving parts Do not in General Warning on page 1 1 WAR NING 1 2 3 CCI P N 1014496 2 1 595 Figure 21 3 Loosen Retaining Bolt 596 Figure 21 4 Drive Clutch Removal 3 Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to support the vehicle This will allow the wei...

Page 385: ...threaded portion of the clutch puller tool 1 with a light oil and thread the clutch puller tool into the clutch retaining bolt hole Figure 21 4 Page 21 4 6 Use a 1 2 inch drive air wrench to tighten the clutch puller tool The drive clutch 2 will pull free of the crankshaft 7 Support the drive clutch assembly in your hand and back the clutch puller tool out of the crankshaft CAUTION Do not hit or t...

Page 386: ...tch TORQUE CONVERTER GASOLINE VEHICLES 2 1 3 13 4 5 6 7 11 12 12 16 15 14 22 20 21 17 19 10 597 Figure 21 5 Drive Clutch Assembly Page 21 6 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual ...

Page 387: ...N 1014497 into clutch until the stop nut touches the clutch then back the bolt out one half turn Figure 21 7 Page 21 7 2 3 Thread the three small bolts of the puller 1 into corresponding holes in the clutch Tighten bolts evenly making sure the face of the puller plate is parallel to the face of the clutch Figure 21 7 Page 21 7 2 4 Unscrew the puller center bolt out of the clutch to pull drive clut...

Page 388: ...l 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 5 3 Remove the plastic washers weights 2 and 3 and wave washer 1 from the pin 4 Retain all parts 2 3 4 1 602 Figure 21 10 Primary and Secondary Weights Wave Washer and Pin Page 21 8 200...

Page 389: ...DRIVE CLUTCH PARTS 1 Inspect the idler bearing 6 for smooth rotation or seal damage Figure 21 5 Page 21 6 See following NOTE NOTE It is normal for a small amount of grease to be present at the edge of seal 2 Inspect the bore of the moveable face assembly 14 for scarring or wear The moveable face assembly must be replaced if the bore is worn to a diameter of 0 883 inch 22 4 mm or larger Figure 21 5...

Page 390: ...rotruding from it Figure 21 10 Page 21 8 9 Install the secondary weights 2 onto the mounting pins 4 with the weight pins on the secondary weights pointing away from the primary weights 3 The wave washers should be between the primary and secondary weights Figure 21 10 Page 21 8 10 Install white plastic flat washers on each end of the mounting pin and push them against the outside surfaces of the w...

Page 391: ...lt 17 and start the bolt into the crankshaft Figure 21 5 Page 21 6 See following NOTE NOTE The drive clutch retaining bolt has left hand threads The manufacturer recommends replacing the drive clutch retaining bolt CCI PN 103345701 when installing the drive clutch If a new bolt is not available clean the threads of the original bolt and apply Loctite 242 to the threaded end prior to installation 2...

Page 392: ...etaining ring 4 Figure 21 15 Page 21 13 See following WARNING WARNING Do not place fingers under the cam when removing the cam The moveable face may spin when the cam buttons release from the cam ramps resulting in severe personal injury 2 Insert a puller plug 2 CCI P N 1014507 Figure 21 16 Page 21 13 into the shaft bore and use a driven clutch cam puller 1 CCI P N 1014508 to remove the cam 3 from...

Page 393: ...ng in the moveable face If the bearing bore diameter is more than 1 384 inch 35 15 mm the entire moveable face assembly must be replaced 5 Inspect the shaft of the fixed face assembly There should be no noticeable wear Replace the shaft if it is worn scratched or damaged DRIVEN CLUTCH ASSEMBLY 1 Place the three drive buttons 6 in position Apply one drop of Loctite 222 to each of the socket head ca...

Page 394: ... 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 5 1 Press Assembly Process Page 21 14 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual ...

Page 395: ... 19 Cam Installation Tool 5 2 Field Assembly Process NOTE This process is for field assembly requirements where hydraulic and pneumatic press equipment is not available Use the cam installation tool CCI P N 101808401 for this process 5 2 1 With the clutch loosely assembled set the edge of the clutch body 5 on a clean flat surface Figure 21 19 Page 21 15 5 2 2 Assemble the threaded bolt 1 through t...

Page 396: ...07 inches 40 82 mm otherwise it must be replaced with a new ring CCI P N 1014080 DRIVEN CLUTCH INSTALLATION 1 To install the driven clutch reverse the removal procedure Make sure that the washer 12 is mounted with the flat portion of the washer against the driven clutch Figure 21 17 Page 21 14 Secure with a new bolt 11 See following NOTE NOTE The bolt 11 must be replaced with a new bolt CCI P N 10...

Page 397: ...lling away too fast to be overtaken on foot If the walk away braking function remains engaged for two seconds or more a warning buzzer will sound to alert the driver that motor braking has been activated WARNING Walk away braking will not limit vehicle speed to 1 mph 1 6 km h on very steep grades Do not operate vehicle on slopes exceeding 20 grades Pedal Down Motor Braking This feature helps to co...

Page 398: ...agrams ELECTRICAL SYSTEM AND TESTING 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: ...LECTRICAL SYSTEM AND TESTING ELECTRIC VEHICLES Wiring Diagrams 22 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: ...OBC The OBC 1 monitors battery condition 2 monitors the number of energy units used by the vehicle 3 determines the number of energy units required to recharge the batteries and shuts the charger off when this number is reached 4 determines when to activate regenerative motor braking 5 locks out vehicle movement while the charger is plugged into the vehicle charger receptacle 6 stores operating da...

Page 401: ...sor Loose or disconnected 24 pin connector at speed controller or broken wire Repair and or connect the 24 pin connector to the speed controller Monitor Menu SPEED PULSES menu item indicates that speed pulses are OFF when the vehicle is in motion or Diagnostic Menu SPEED SENSOR fault code Failed motor speed sensor or failed magnet Test Procedure 24 Motor Speed Sensor on page 22 30 Loose or disconn...

Page 402: ... Repair and or connect the three pin connector to the MCOR Loose or disconnected 24 pin connector at speed controller or broken wire Repair and or connect the 24 pin connector to the speed controller Diagnostic Menu THROTTLE FAULT 1 fault code Failed MCOR Test Procedure 4 MCOR Voltage on page 22 13 Armature drive FET s field effect transistors inside speed controller have failed Replace the speed ...

Page 403: ...ion with the Forward Reverse switch Batteries require charging Place batteries on battery charger and allow them to fully charge Diagnostic Menu LOW BATTERY fault code Improperly maintained or failed batteries See Section 25 Batteries Electric Vehicles Diagnostic Menu MOTOR STALL fault code Operator error Train operators to use the brake to hold the vehicle on a hill rather than holding the vehicl...

Page 404: ...Forward Reverse rocker switch Test Procedure 26 Forward Reverse Rocker Switch on page 22 33 Solenoid loose wires Test Procedure 3 Solenoid Activating Coil on page 22 12 Solenoid failed coil Test Procedure 3 Solenoid Activating Coil on page 22 12 Solenoid failed solenoid diode Test Procedure 3 Solenoid Activating Coil on page 22 12 Speed controller thermal cutback Allow controller to cool and ensur...

Page 405: ...hicle wiring See Wiring Diagrams beginning on page 22 2 Vehicle operates but motor braking function does not Speed sensor disconnected or failed Test Procedure 24 Motor Speed Sensor on page 22 30 Forward Reverse rocker switch improperly wired Test Procedure 26 Forward Reverse Rocker Switch on page 22 33 Motor improperly wired Check motor wiring See Wiring Diagrams beginning on page 22 2 Vehicle wi...

Page 406: ...n 17 18 Pin 3 19 Pin 20 Smart Key Switch Only 20 Pin 23 21 Onboard Computer Silicon Controlled Rectifier SCR Circuit 22 Onboard Computer Gray Wire and Fuse 23 Voltage at Charger Receptacle Red Wire Socket 24 Motor Speed Sensor 25 Solenoid Contacts 26 Forward Reverse Rocker Switch 27 Reverse Buzzer 28 Rebooting the Onboard Computer 29 Battery Warning Light 30 Walk Away Braking Relay TEST PROCEDURE ...

Page 407: ...ting battery cables 2 Remove negative battery cable 3 Remove positive battery cable Connect battery cables in reverse order 73 Figure 22 3 Battery Configuration TEST PROCEDURE 2 Onboard Computer Solenoid Lockout Circuit See General Warning on page 1 1 The solenoid lockout circuit disables the vehicle when the battery charger is plugged into the vehicle Use the following procedure to test the solen...

Page 408: ...o 200 volts DC Place the black probe on the battery no 8 negative post and place the red probe with insulation piercing probe on the red 18 gauge wire located on the OBC side of the six pin connector The reading should be approximately 48 volts If the reading is incorrect test the continuity from the pink wire on the solenoid to the red pin on the OBC harness 7 2 Set a multimeter to 200 volts DC P...

Page 409: ...age 23 1 3 Access the Monitor menu and select THROTTLE by using the SCROLL DISPLAY buttons 4 The IQDM should indicate 0 with the pedal not pressed While monitoring the IQDM display screen slowly press the accelerator pedal As the pedal is pressed the IQDM should indicate a rise from 0 pedal not pressed to 100 pedal fully pressed 5 If the MCOR does not operate as described in previous step proceed ...

Page 410: ... no 6 negative post and the red probe with insulation piercing probe on the yellow wire 3 at a point close to three pin connector at the MCOR Figure 22 7 Page 22 14 The reading should be approximately 0 32 volts with the pedal up Slowly press the accelerator pedal and note the readings on the multimeter As the pedal is pressed the reading should increase until it reaches 4 65 volts when the pedal ...

Page 411: ...es connected and using a multimeter set to 200 volts DC place the black probe on the A2 1 motor terminal white wire and connect the red probe to the A1 2 motor terminal green wire Figure 22 8 Page 22 15 3 With Tow Run switch in the RUN position place the Forward Reverse switch in the FORWARD position turn key switch to the ON position and slowly press accelerator pedal 4 As the accelerator pedal i...

Page 412: ... switch See Key Switch Removal on page 24 1 Tow Run Switch Test without the IQDM Handset 1 Set a multimeter to 200 volts DC With the batteries connected and the Tow Run switch in either the TOW or RUN position connect the black probe to the negative post of battery no 8 and connect red probe with insulation piercing probe on the pink wire close to the two pin connector on the Tow Run switch Figure...

Page 413: ... connect the negative lead to battery no 8 negative post Record the voltage reading from discharge machine 2 Turn the discharge machine on and record the voltage reading of battery pack while under load 3 A fully charged set of batteries in good condition should read between 47 49 volts while under load 4 A reading of 32 46 volts indicates discharged or failed batteries Each battery should be chec...

Page 414: ...ey switch position 5 3 With the key switch in the ON position press the accelerator pedal The IQDM should indicate that FOOT INPUT is ON when the accelerator pedal is pressed 6 If any reading is obtained that is not described in steps 4 and 5 perform the following steps 6 1 Check the pedal group for proper adjustment See Accelerator and Brake Pedal Group Section 6 2 Check the wiring of the key swi...

Page 415: ...ts proceed to the following step 5 4 4 Set a multimeter to 200 volts DC Place the black probe on the battery no 8 negative post and place the red probe with insulation piercing probe on the green wire where it connects to the MCOR With the Tow Run switch in the RUN position the key switch ON the Forward Reverse rocker switch in NEUTRAL and the accelerator pedal pressed the reading should be approx...

Page 416: ...hite 18 gauge Pin 14 Purple White 18 gauge Pin 15 Yellow 18 gauge Test continuity of each wire and perform Test Procedure 11 Pins 13 14 and 15 on page 22 20 Pin 16 Open no wire Pin 17 Blue White 18 gauge Test Procedure 17 Pin 17 on page 22 27 Pin 18 Open no wire Pin 19 Orange White 18 gauge Test Procedure 14 Pin 19 on page 22 24 Pin 20 Purple 18 gauge Test Procedure 19 Pin 20 Smart Key Switch Only...

Page 417: ...probe into pin 13 white wire See previous CAUTION 8 With the accelerator pedal fully up not pressed the multimeter should indicate between 5 67k ohms and 7 43k ohms 9 Slowly press the accelerator pedal while monitoring the multimeter The resistance should drop as the pedal is pressed When the pedal is all the way to the floor the multimeter should indicate approximately 1k ohms 10 If any other rea...

Page 418: ...e 1 4 6 Place the Tow Run switch in the RUN position 7 The multimeter should indicate zero volts DC at this time 8 While monitoring the multimeter plug the battery charger into the vehicle charger receptacle 9 After a short delay the onboard computer should power up come out of sleep mode charger relay should click and the ammeter on the charger should indicate that the vehicle batteries are being...

Page 419: ...lack probe to the B terminal of the speed controller Figure 22 14 Page 22 23 CAUTION Do not fully insert probes into the 24 pin plug Doing so can result in a poor connection A Detail A Front of 24 Pin Connector Figure 22 14 Test Pin 8 Green Wire 5 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first See Connecting the Batteries Electric Vehicles Section ...

Page 420: ...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 in General Warning on page 1 1 3 Disconnect the 24 pin connector at the speed controller 4 Place a jumper wire with an alligator clip between the B terminal of the speed controller use alligator clip for this connection and pin 19 o...

Page 421: ...t and side stringer just forward of each rear wheel See WARNING Lift only one end in General Warning on page 1 1 3 Disconnect the 24 pin connector at the speed controller 4 Set a multimeter to 200 volts DC insert the red probe of the multimeter into pin 10 brown wire of the 24 pin connector See following CAUTION Using an alligator clip connect the black probe to the B terminal of the speed control...

Page 422: ...re harness Forward Reverse switch for proper operation See Forward Reverse Rocker Switch on page 22 33 Tow Run switch for proper operation See Tow Run Switch on page 22 16 A Detail A Front of 24 Pin Connector Figure 22 16 Test Pin 10 Black Wires TEST PROCEDURE 16 Pin 1 See General Warning on page 1 1 Pin 1 in the 24 pin connector provides a connection point for the key switch to the speed controll...

Page 423: ...ition the multimeter should indicate full battery voltage approximately 48 volts With the key switch in the OFF position the reading should be zero volts 9 If any other reading is obtained check the following items Continuity of the wires in the wire harness Tow Run switch for proper operation See Tow Run Switch on page 22 16 Key switch for proper operation See Key Switch and MCOR Limit Switch Cir...

Page 424: ...robe of the multimeter into pin 3 orange wire of the 24 pin connector See following CAUTION With an alligator clip connect the black probe to the negative terminal of battery 8 CAUTION Do not fully insert probes into the 24 pin plug Doing so can result in a poor connection 3 The reading should be 48 volts If the reading is zero volts replace the circuit breaker TEST PROCEDURE 19 Pin 20 Smart Key S...

Page 425: ... If the reading does not rise from approximately 40 volts to full battery voltage when the DC cord is plugged in and the relay clicks on check the following items Charger receptacle fuse and black wire terminal socket in the charger receptacle Onboard computer gray wire and fuse See Onboard Computer Gray Wire and Fuse on page 22 29 Red wire at the charger receptacle See Voltage at Charger Receptac...

Page 426: ... on a level surface To avoid injury or property damage ensure that the path of the vehicle is clear before pushing vehicle 1 Turn the key switch to the OFF position and place the Forward Reverse switch in the NEUTRAL position 2 Connect the IQDM to the vehicle See Plugging the Handset into the Vehicle Section 23 Page 23 1 3 Access the Monitor menu and select SPEED PULSES by using the SCROLL DISPLAY...

Page 427: ...tage at the red motor speed sensor wire 4 1 With Tow Run switch in the RUN position and using a multimeter set to 20 volts DC place the black probe on the battery no 8 negative post and place red probe on red wire terminal socket in three pin connector The voltage reading should be approximately 15 16 volts 4 2 If the voltage reading is zero volts check the continuity of the red wire from the 24 p...

Page 428: ...ensor Light Green Wire 6 Reconnect the three pin connector at the motor speed sensor Using a multimeter set to 20 volts DC place the black probe on the battery no 8 negative post and place the red probe with insulation piercing probe on the green wire between the three pin connector and the motor speed sensor Figure 22 22 Test 13 Speed Sensor Green Wire 6 1 Raise one rear wheel off ground Slowly t...

Page 429: ...t into the Vehicle Section 23 Page 23 1 3 Test FORWARD INPUT 3 1 Access the Monitor menu and select FORWARD INPUT by using the SCROLL DISPLAY buttons The IQDM should indicate OFF when the Forward Reverse switch is in the NEUTRAL or REVERSE position 3 2 Place the Forward Reverse switch in the FORWARD position The IQDM should indicate that FORWARD INPUT is ON If the IQDM indicates any other reading ...

Page 430: ...nter 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 Do not allow wires to touch See following NOTE NOTE Take care to prevent key switch terminals and wires from touching the metal frame around the dash 2 5 Slide the das...

Page 431: ...ven the battery warning light should illuminate for 2 3 seconds See Rebooting the Onboard Computer on page 22 35 If the battery warning light does not illuminate when rebooting the OBC proceed to step 2 2 Turn key switch OFF place Tow Run switch in TOW and place Forward Reverse rocker switch in NEUTRAL 3 Disconnect the six pin connector at the OBC 4 Remove the wedge lock from the six pin connector...

Page 432: ...ng the IQ Plus vehicle To access one of these items the item s corresponding Function Code must be selected on the CDM This is done by pressing the Function Button until the desired function code is displayed in the window See Figure 22 23 Page 22 36 for CDM features Releasing the button when the desired code is displayed will display the data Function codes and corresponding data are as follows F...

Page 433: ...e data stream from the onboard computer hold CDM approximately 6 inches 15 2 cm from battery warning light 3 Wait approximately 30 seconds for a value to appear in the display window 4 If a value does not appear in the display window after 30 seconds try adjusting the aim of the CDM and repeating step 3 until a value appears If there is still no reading check for weak batteries in the CDM 4 1 Adju...

Page 434: ...iled OBC Replace OBC Remove battery lead and discharge the speed controller See the instructions in the WARNING on page 11 1 After a short time replace the lead and restart the OBC OBC program is locked up Restart OBC by driving vehicle or by connecting charger DC plug OBC is in a powerdown mode Batteries discharged Recharge Batteries OBC Will Not Communicate With The CDM Failed Dash Light Replace...

Page 435: ...gramming PLUGGING THE HANDSET INTO THE VEHICLE 1 Connect one end of the cable to the jack located on the bottom of the handset 2 Connect the cable adaptor to the IQDM cable 3 Find the IQDM jack located on the vehicle 4 Remove the dust cap from the IQDM jack 5 Align the keyed portion of the plug with the IQDM jack and connect the plug to the jack Figure 23 1 IQDM Jack Under Instrument Panel 2007 20...

Page 436: ...menu is blinking pressing the right arrow selects that menu item Pressing the left arrow allows the user to go back one screen The CHANGE VALUE BUTTON is the button located on the right side of the handset Figure 23 2 Page 23 3 This button allows the user to change values by pressing or The three yellow buttons labeled 1 2 and 3 are BOOKMARK BUTTONS Figure 23 2 Page 23 3 These buttons allow the us...

Page 437: ...oller troubleshooting See Monitor Menu on page 23 4 Faults The faults menu displays all faults recorded by the speed controller since the history was last cleared Each fault is listed only once in the fault history menu even if the fault has occurred multiple times See Faults Menu on page 23 9 The number of fault occurrences can be viewed in the fault counter located in the lower section of the mo...

Page 438: ...technician has the ability to monitor the status of several components in conditions or locations where a problem with vehicle performance has been reported See following WARNING WARNING The vehicle operator should not monitor the handset while the vehicle is in motion A technician can monitor the handset while traveling as a passenger in the vehicle Failure to heed this warning could result in se...

Page 439: ...f pulse width modulation is 0 to 100 When the vehicle is in operation the pulse width modulation will fluctuate in response to the terrain and throttle input FOOT INPUT Indicates the status of the MCOR motor controller output regulator internal limit switch on or off When the accelerator pedal is unpressed the handset should indicate that the limit switch is off When the accelerator pedal is press...

Page 440: ...ndicates that the solenoid is off PASSWORD TRIES IQDM P ONLY A password is required to activate Mode 2 The speed controller will log unsuccessful and unauthorized attempts to activate 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...

Page 441: ...scriptions on page 23 12 RELAY WELDED Displays the number of times the RELAY WELDED fault has been detected See Fault Descriptions on page 23 12 SPD SENSOR Displays the number of times the SPD SENSOR fault has been detected See Fault Descriptions on page 23 12 MAIN DRV ON Displays the number of times the MAIN DRV ON fault has been detected See Fault Descriptions on page 23 12 MAIN COIL OPN Display...

Page 442: ...en detected See Fault Descriptions on page 23 12 M SHORTED Displays the number of times the M SHORTED fault has been detected See Fault Descriptions on page 23 12 RELAY COIL Displays the number of times the RELAY COIL fault has been detected See Fault Descriptions on page 23 12 PRECHARGE Displays the number of times the PRECHARGE fault has been detected See Fault Descriptions on page 23 12 FLD MIS...

Page 443: ...r of miles the vehicle has been driven in units of 1000 miles MILES X 100 Displays the number of miles the vehicle has been driven in units of 100 miles MILES X 10 Displays the number of miles the vehicle has been driven in units of 10 miles MILES X 1 Displays the number of miles the vehicle has been driven in units of single miles MILES X 0 1 Displays the number of miles the vehicle has been driv...

Page 444: ...ose broken or disconnected wires or connectors Failed components Improper adjustment or installation of electrical or mechanical components examples brake adjustment improper MCOR installation Improper wiring of electrical components As shown above there are many possible causes for faults to occur and the speed controller has a programmed reaction to each fault that is based on the fault currentl...

Page 445: ...d pressed again CONTROLLER FAULT TEST WHEN CONTROLLER RESPONSE RECOVER WHEN 01 THROTTLE FAULT 1 Continuous 10 Condition clears 02 UNDER VOLTAGE Continuous 5 Condition clears 03 OVERVOLTAGE Continuous 7 Condition clears 04 THERMAL CUTBACK Continuous 5 Condition clears 06 HPD KSI Off On F or R on 10 Throttle 25 07 MAIN WELDED Contactor commanded open 4 Main or relay successfully opened 08 RELAY WELD...

Page 446: ...oltage is too high 72 volts 5 the overvoltage fault is detected 04 Thermal Cutback If the controller heatsink temperature is found to be in excess of 85 C 5 C 185 F 9 F or below 25 C 5 C 13 F 9 F the thermal cutback fault is detected 06 HPD The HPD High Pedal Detect fault is detected if the accelerator pedal is already depressed when the key switch is turned to the ON position This fault when not ...

Page 447: ...n the solenoid driver exceeds 6A a driver overcurrent fault is detected 21 Precharge Fault If the internal precharge circuit fails or there is a short between the B and B controller terminals a precharge fault is detected 22 Field Missing If the speed controller is operating at a duty cycle of greater than 90 almost full speed and the field current is less than 3 amps a field missing fault is dete...

Page 448: ...a fault appears in the fault history menu the trained technician should attempt to determine when and where the fault has occurred For example if the motor stall fault is present in the fault history the trained technician may be able to determine the location on the course where an operator has held the vehicle on a hill by using the accelerator pedal Clearing Fault History After a repair has bee...

Page 449: ... button to confirm the operation 8 The handset will display an executing message for the next few seconds while the controller settings are being stored in the handset s memory Figure 23 3 Page 23 15 9 When the handset is finished recording the speed controller settings a confirmation message is displayed Figure 23 4 Page 23 15 10 With the controller settings stored in the memory of the handset th...

Page 450: ... OFF position place the Forward Reverse handle in the NEUTRAL position and lock the park brake 4 Plug the handset into the vehicle 4 1 Connect one end of the cable to the jack located on the bottom of the handset 4 2 Connect the cable adaptor to the IQDM cable 4 3 Remove the dust cap from the IQDM jack 4 4 Align the keyed portion of the plug with the IQDM jack and connect the plug to the jack Figu...

Page 451: ...only when the handset has not been unplugged and power to the speed controller has not been interrupted Resetting All Settings 1 During an active session when the settings need to be returned to the original values the values that were active at the beginning of the session scroll to the functions menu and select 2 Select settings 3 Select reset all settings 4 Press on the change value button to c...

Page 452: ... speed controller was manufactured SOFTWARE VERSION Displays the speed controller software version PROGRAMMER SETUP The programmer setup menu selection allows the user to set the LCD display contrast records the fault history of the handset and displays information pertaining to the handset PROGRAM This menu allows the user to adjust the contrast on the display screen After selecting the LCD Contr...

Page 453: ...leshooting guide should be studied and the referenced test procedures should be performed to troubleshoot the IQDM and IQDM P Series 2 handsets TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Handset cord and or adaptor is disconnected See Plugging the Handset into the Vehicle on page 23 1 Vehicle batteries loose terminals or corrosion See Section 25 Batteries Electric Vehicles Veh...

Page 454: ...icle Wait a few seconds and reconnect the handset to the vehicle Vehicle batteries loose terminals or corrosion See Section 25 Batteries Electric Vehicles Vehicle batteries improperly wired See Section 25 Batteries Electric Vehicles Vehicle batteries batteries failed See Section 25 Batteries Electric Vehicles Vehicle batteries batteries not fully charged See Section 25 Batteries Electric Vehicles ...

Page 455: ...ins one at a time on the other plug of the adaptor 3 The multimeter should indicate continuity on only one pin If any other reading is obtained the adaptor must be replaced 4 Repeat the procedure three more times each time with the red probe inserted into a different terminal on the end of the adaptor with the square plug TEST PROCEDURE 3 IQDM Jacks See General Warning on page 1 1 NOTE The locatio...

Page 456: ...y 3 3 If no problem is found connect the multi pin connectors and install the center dash panel 3 4 Install the three self tapping screws that hold the F R rocker switch case 2 to the body Tighten to 20 in lb 2 2 N m 3 5 Connect the batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 3 6 Align the keyed portion of the plug with the IQDM jack and connect the plug to the jack...

Page 457: ...r the handset cord adapter and vehicle wire harness should be thoroughly tested See Test Procedure 2 Handset Cord Adaptor on page 23 21 The IQDM jacks and connections should also be thoroughly checked See See Section 22 Electrical System and Testing Electric Vehicles 1 Figure 23 8 Disconnect Four pin Connector 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual Page 23 23 ...

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Page 459: ...lastic cap 1 covering the mounting screw 2 on each side of the center dash panel 3 Figure 24 1 Page 24 2 2 2 Loosen but do not remove the screw 2 on each side of the center dash panel 3 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 fr...

Page 460: ...g tabs surrounding the key switch 4 and remove the key switch cap 8 Hold the key switch and remove the switch retaining nut 6 from the outside of the dash panel Figure 24 2 Page 24 2 4 6 8 9 7 Figure 24 2 Key Switch KEY SWITCH INSTALLATION 1 Position the key switch and flat washer 9 in the center dash then install and tighten the switch retaining nut 6 to 40 in lb 4 5 N m Install key switch cap 8 ...

Page 461: ... 4 Press the locking tabs on each end of switch 11 and push switch out of dash panel FORWARD REVERSE ROCKER SWITCH INSTALLATION 1 Press the locking tabs on each end of the rocker switch 11 and push switch into dash panel Figure 24 3 Page 24 4 2 Connect the 18 gauge brown orange and blue wires to the rocker switch exactly as shown in the wiring diagram See Wiring Diagrams Section 22 Page 22 2 3 Ins...

Page 462: ...ric Vehicles Section 1 Page 1 4 2 Remove Tow Run switch boot hex nut 6 Figure 24 3 Page 24 4 3 Remove Tow Run switch 10 and nut 9 from bracket 5 4 Disconnect the two pin connector 7 and remove switch TOW RUN SWITCH INSTALLATION 1 Installation is reverse of removal Make sure groove on switch is aligned with tang on bracket Tighten Tow Run switch boot hex nut 6 to 16 in lb 1 8 N m Figure 24 3 Page 2...

Page 463: ...ires from the spade connectors 4 on the back of the circuit breaker CIRCUIT BREAKER INSTALLATION 1 Installation is reverse of removal Connect tan and green wires to the spade connectors 4 on the back of the circuit breaker See following NOTE NOTE The spade connectors are not polarity sensitive It does not matter what color wire goes to either of the spade connectors 2 Insert the circuit breaker an...

Page 464: ...he MCOR to the frame I beam 5 Remove the MCOR from vehicle 6 Push the drive bar 4 into the hole in the I beam to disengage it from the accelerator pivot rod 5 MCOR INSTALLATION 1 Insert the splined end of the drive bar 4 through the hole in the passenger side frame I beam as shown Figure 24 5 Page 24 7 2 Position the opposite end of the drive bar so that the accelerator pedal sits between the two ...

Page 465: ...ZER See Test Procedure 27 Reverse Buzzer on page 22 34 REVERSE BUZZER REMOVAL 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles Section 1 Page 1 4 2 Remove center dash See Key Switch Removal on page 24 1 3 Disconnect the 18 gauge red and orange white wires from reverse buzzer 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service...

Page 466: ...ter pieces of the 3 push rivets 1 and remove the rivets Figure 24 6 Page 24 9 2 Pull the speed controller cover 2 down and away from the component mounting plate 3 Lift the curved edges of the speed controller cover out of the slots in the component mounting plate INSTALLING THE SPEED CONTROLLER COVER 1 Place the curved edges on the bottom of the speed controller cover 2 into the slots on the comp...

Page 467: ...22 33 SOLENOID REMOVAL 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles Section 1 Page 1 4 2 Remove the speed controller cover See Removing the Speed Controller Cover on page 24 8 3 Disconnect all wires from the solenoid Figure 24 7 Page 24 10 4 Loosen but do not remove the two screws 1 that hold the solenoid 2 to the component mounting plat...

Page 468: ...4 8 6 Connect the batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 ONBOARD COMPUTER OBC See General Warning on page 1 1 TESTING THE ONBOARD COMPUTER See Test Procedure 2 Onboard Computer Solenoid Lockout Circuit on page 22 11 Test Procedure 21 Onboard Computer Silicon Controlled Rectifier SCR Circuit on page 22 29 and Test Procedure 22 Onboard Computer Gray Wire and Fuse...

Page 469: ... the OBC 3 onto the component mounting plate by aligning the three holes on the OBC face plate with three holes on component mounting plate Slide OBC 3 towards inside of vehicle and align heads of self tapping screws 2 with smaller part of three holes in OBC face plate Figure 24 8 Page 24 11 Tighten screws to 60 in lb 6 7 N m See following NOTE NOTE The aluminum plate on the OBC should face toward...

Page 470: ...le 1 2 Figure 24 9 Speed Controller SPEED CONTROLLER INSTALLATION 1 Install the four bolts 1 that hold the speed controller 2 to the component mounting plate and tighten to 60 in lb 6 8 N m Figure 24 9 Page 24 12 2 Using the wiring diagram install the multi pin connectors and all wires as illustrated See Wiring Diagrams Section 22 Page 22 2 Tighten bolts 3 to 9 ft lb 12 2 N m Figure 24 9 Page 24 1...

Page 471: ...lly inspect them for cracks loose connections and frayed wiring they must be replaced when worn or damaged If charger plug or receptacle show signs of corrosion or the plug is difficult to insert or remove the receptacle contacts and plug terminals should be cleaned with a good electrical contact cleaner or lightly sprayed with WD 40 brand spray lubricant The plug should then be inserted and remov...

Page 472: ...ehicle and tilt receptacle upwards in order for the receptacle to pass through the hole in the vehicle body CHARGER RECEPTACLE INSTALLATION 1 Insert the 10 gauge red wire and the 18 gauge gray wire through the hole in the vehicle body and the receptacle backing plate Figure 24 11 Page 24 15 2 Insert receptacle into vehicle body 3 Install the four screws 2 that secure the receptacle to the vehicle ...

Page 473: ...arger receptacle in the battery compartment Figure 24 11 Page 24 15 RECEPTACLE FUSE LINK REMOVAL 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles Section 1 Page 1 4 2 Remove the fuse link 6 from the charger receptacle 5 by removing the two nuts and washers used to secure the 10 gauge black wire 11 from the computer and the 10 gauge black wir...

Page 474: ...TERY WARNING LIGHT See Test Procedure 29 Battery Warning Light on page 22 35 BATTERY WARNING LIGHT REMOVAL 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles Section 1 Page 1 4 2 Remove center dash See Key Switch Removal on page 24 1 3 Disconnect the brown wire at the quick disconnect terminal and remove the orange white wire from the key swit...

Page 475: ...ELECTRICAL COMPONENTS ELECTRIC VEHICLES Battery Warning Light 24 11 Figure 24 12 Battery Warning Light 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual Page 24 17 ...

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Page 477: ...G See General Warning on page 1 1 Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubber gloves when working on or near batteries Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Ensure battery connections are clean and properly tightened S...

Page 478: ...ter does an excellent job of neutralizing and removing the corrosion Be careful not to allow the baking soda solution to enter the battery 1 3 5 7 8 2 4 6 3 2 1 1 Place Tow Run Switch in TOW before disconnecting or connecting battery cables 2 Remove negative battery cable 3 Remove positive battery cable Connect battery cables in reverse order 73 Figure 25 1 Battery Configuration 4 Check and clean ...

Page 479: ...ff batteries Do not allow this solution to enter the batteries Be sure terminals are tight Let the terminals dry and then coat them with Battery Terminal Protector Spray CCI P N 1014305 See Self Discharge on page 25 3 3 Maintain proper electrolyte level See Electrolyte Level on page 25 3 4 Batteries should be properly charged every day they are used Check the batteries periodically to see that the...

Page 480: ...re electrolyte is at its proper level Figure 25 2 Page 25 4 Never allow the electrolyte level to fall below the tops of the plates because this will cause the exposed part of the plate to become permanently inactive For best results use a battery watering gun to add water to batteries Check the electrolyte level more frequently in hot weather or when batteries are old MINERAL CONTENT For the longe...

Page 481: ...s the capacity of the battery and cannot be replaced Battery hold downs should NOT be so tight as to crack or buckle the battery case This may cause leaks which would dry out a cell or cause internal short circuits See Battery Replacement on page 25 2 BATTERY CHARGING See General Warning on page 1 1 CAUTION Only IQ Plus chargers should be used with IQ Plus vehicles Long term use of a PowerDrive ba...

Page 482: ...akers are tripping fuses blow during the night or the charger does not give the required starting rate when sound batteries are put on charge an AC line problem exists The electrical service to the vehicle storage facility should be sufficient to deliver adequate voltage and current to each charger with all the chargers turned on If not consult your local power company or electrical contractor See...

Page 483: ... problems SeeTroubleshooting Guide If problem is not found go to on charge voltage test Any reading below 5 25 V and not within 0 5 V of those batteries above 5 25 V replace battery Replace any battery with a variation of more than 50 points of specific gravity between cells or has a cell with no reading at all Entire battery set with specific gravity readings below 1 250 is being consistently und...

Page 484: ...lack probe on the negative post of battery no 8 Record reading Then set multimeter to 20 volts DC and place the red probe on the positive post and the black probe at the negative post of each battery Record the readings The on charge voltage for the set should be between 56 0 volts and 63 0 volts depending on the age and state of charge of the batteries being tested If individual batteries read ab...

Page 485: ...tly at 80 F 26 7 C The readings obtained as described above must be corrected for temperature For each 10 F 5 6 C above 80 F 26 7 C add 0 004 to the reading For each 10 F 5 6 C below 80 F 26 7 C subtract 0 004 from the reading 4 0 2 0 6 0 8 0 13 00 1 250 1 280 View at eye level 717 Figure 25 4 Hydrometer Interpreting the Results of the Hydrometer Test The approximate state of charge can be determi...

Page 486: ...eries and the most time consuming to perform Use the battery discharge tester CCI P N 101831901 Performing the Discharge Test 1 Be sure the batteries are fully charged and that the electrolyte level is correct in all cells 2 Connect the tester leads to the positive post of battery no 1 and negative post of battery no 8 3 Check and record the electrolyte temperature of the battery packs Check cell ...

Page 487: ... C 70 Minutes 70 74 F 21 23 C 57 Minutes 120 129 F 49 54 C 72 Minutes 75 79 F 24 26 C 60 Minutes 130 150 F 54 66 C 74 Minutes 80 84 F 27 29 C 62 Minutes BATTERY TROUBLESHOOTING EXAMPLES The following information represents a few examples of troubleshooting battery problems Example 1 Vehicle no 68 was suspected of having a bad battery due to its performance As a result the battery charger test was ...

Page 488: ...age and usage as the other batteries in the set BATTERY STORAGE See General Warning on page 1 1 When storing batteries during the off season or when maintaining a replacement stock follow these guidelines 1 Keep the batteries clean and free of corrosion See Battery Care on page 25 3 2 Batteries that are in vehicles for winter storage should be left disconnected in the vehicles if the batteries are...

Page 489: ...SECTION 26 BATTERY CHARGER 26 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 ...

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Page 491: ...cuits See General Warning on page 1 1 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles Section 1 Page 1 4 2 Disconnect wires from terminals on motor using two wrenches to prevent posts from turning 3 With a multimeter set to 200 ohms place black probe on motor housing Scratch through paint to ensure a good connection Place red probe on A1 A2...

Page 492: ...correct a possible open field coil or bad connections at the terminals may be the cause The motor will need to be removed from the vehicle and repaired by a qualified technician See Motor Removal on page 27 2 3 Connect the batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 MOTOR See General Warning on page 1 1 MOTOR REMOVAL 1 Disconnect the batteries and discharge the cont...

Page 493: ...ds 5 Remove both rear wheels 6 Remove the nut cup washer and bushing from the bottom side of the shock absorber Compress the shock absorber pushing upwards to move it out of the way Figure 27 3 Page 27 3 7 Remove the nuts and bolts mounting the rear leaf springs to the shackles 8 To gain easier access to the motor lower the transaxle as low as it will go If more room is needed remove the jack from...

Page 494: ...emoval MOTOR DISASSEMBLY 1 Release the clasp and remove the headband assembly 21 from the motor Visually inspect brushes and springs Figure 27 13 Page 27 10 2 Before continuing disassembly place match marks on the motor end cap 20 and motor frame 14 3 Remove speed sensor 10 and magnet 12 3 1 Remove the two screws 11 that secure the speed sensor 10 to the end cap 20 3 2 Remove the bolt 13 securing ...

Page 495: ...he armature Failure to heed this CAUTION could result in personal injury and or damage to the armature resulting from an unsupported armature falling after it becomes disengaged from the end cap bearing NOTE Replacement of the end cap bearing is recommended if the armature is removed 8 1 Position the brush springs to reduce tension during removal of the armature Figure 27 6 Page 27 5 8 2 Place the...

Page 496: ...l Insulator Inspection on page 27 9 13 Remove the bearing from the end cap 13 1 Remove the retaining ring that secures the bearing in the end cap Figure 27 9 Page 27 6 13 2 Use an arbor press to remove the bearing from the end cap 14 Inspect the bearing for wear and damage See Bearing Inspection on page 27 9 Figure 27 8 Brush Rigging Removal Figure 27 9 Retaining Ring Removal Page 27 6 2007 2009 T...

Page 497: ...ermine original cause of failure Slight roughness of the commutator can be polished smooth with 400 grit or finer sandpaper See following CAUTION and NOTE CAUTION Do not use emery cloth to polish the commutator Particles of emery are conductive and may short circuit the commutator bars Do not use oil or lubricants on the commutator or brushes NOTE Oil on the commutator may indicate a faulty transa...

Page 498: ...the brush springs 18 Figure 27 13 Page 27 10 Replace springs that are discolored from heat light gold or blue tinted 4 Test the brush springs for proper tension 4 1 Place a C shaped steel plate 1 on a scale 2 4 2 Place the end of the C shaped plate 1 so that it is between the spring and the brush 4 3 Gently pull the scale 2 to obtain the spring tension reading See following CAUTION CAUTION When ch...

Page 499: ...as required Bearing Inspection NOTE Replacement of the end cap bearing is highly recommended if the end cap is removed from the motor The following procedure is provided as a guideline for determining general bearing failure 1 Remove the motor from the vehicle See Motor Removal Section 27 Page 27 2 2 Remove the bearing by performing steps 1 through 13 of Motor Disassembly on page 27 4 3 Use a clea...

Page 500: ...Testing and Inspection MOTOR MODEL DA5 4006 ELECTRIC VEHICLES 22 2 4 1 23 13 10 11 9 12 18 16 21 14 15 17 7 6 19 20 Figure 27 13 Motor Page 27 10 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual ...

Page 501: ...g the bearing apply pressure only to the outer race when installing the bearing 1 2 Install the retaining ring to secure the bearing 2 Install the brushes and brush rigging See following NOTE NOTE When installing new brushes remove and replace brushes one at a time This method ensures the terminals and brushes will be properly positioned in the rigging When replacing brushes replace all eight brus...

Page 502: ... this weight 4 Move the springs back to their original position Ensure that the spring rests on the end of each brush 5 Align the match marks on the end cap 20 and the motor frame 14 and secure with four bolts Figure 27 13 Page 27 10 Tighten bolts to 130 in lb 14 7 N m 6 Install the speed sensor magnet 12 with bolt 13 Tighten to 65 in lb 7 3 N m 7 Install the speed sensor 10 with two screws 11 Tig...

Page 503: ...one of the grooves and allow air to escape when the motor is pushed onto the input shaft 1 2 1 2 mm inch 1 2 1 1 2 mm inch 1 8 INCH 3 1 MM 3 8 INCH 9 5 MM Figure 27 16 Grease on Putty Knife Figure 27 17 Application of grease to Input Shaft Grooves 2 6 Check the chamfer 1 and end 2 of the input shaft to ensure these areas are completely clean of grease as shown Figure 27 18 Page 27 14 3 Install mot...

Page 504: ... blue wires with a wire tie so that none of the motor wires will scrub the motor or transaxle when the vehicle is in operation 3 10 Connect the three pin speed sensor plug to the vehicle wire harness 1 2 1 16 INCH 1 6 MM Figure 27 18 Clean Chamfer and Input Shaft End Figure 27 19 Gap at Motor and Transaxle 4 If using a chain hoist lower the vehicle and guide the leaf springs into the shackles If u...

Page 505: ...ion when the Forward Reverse switch is in the FORWARD position 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 Make sure that the vehicle does not operate when the Forward Reverse switch is in the NEUTRAL position 2 3 1 4 Viewed From Drive...

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Page 507: ...ge 1 1 AXLE SHAFT Axle Shaft and Oil Seal Removal 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles Section 1 Page 1 4 2 Place chocks at the front wheels Loosen lug nuts on rear wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to support the vehicle See WARNING Lift only one end i...

Page 508: ...apter ring and discard the oil seal 7 Inspect the axle shaft assembly to be sure the bearing and collar have not slipped and are still seated against the shoulder on the axle shaft 8 Inspect bearing 5 Figure 28 5 Page 28 3 If the bearing in a Type G transaxle is worn or damaged the entire axle shaft assembly 1 or 2 must be replaced 0 0 1 2 Figure 28 1 Remove Internal Retaining Ring Figure 28 2 Axl...

Page 509: ...g and Shaft 28 1 3 6 5 14 15 24 26 13 33 36 32 8 10 11 12 20 18 19 16 16 16 17 23 21 25 36 22 35 13 27 30 31 29 2 5 3 8 36 15 27 30 28 Figure 28 5 Transaxle Type G 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual Page 28 3 ...

Page 510: ...te it to align the shaft splines with the splined bore of the differential side gear 27 Figure 28 5 Page 28 3 Continue advancing the shaft until the bearing on the axle is firmly seated within the axle tube hub seat 2 2 Use a pair of snap ring pliers to install the retaining ring 6 inside axle tube hub so that it seats against the axle bearing assembly and into the machined slot in the inside wall...

Page 511: ...the spring mount and the side stringer just forward of each rear wheel Lower the vehicle to let the jack stands support the vehicle Figure 28 6 Page 28 5 See WARNING Lift only one end of the vehicle in General Warning on page 1 1 4 Remove the rear wheels then thread one lug nut onto a stud on each rear hub This will keep the brake drums on the hubs 5 Remove the bow tie pins 1 brake cable clevis pi...

Page 512: ... enough to permit easy access and clearance for removal of the motor 10 Remove the three motor mounting bolts Figure 28 11 Page 28 6 and the motor positioning bolt Figure 28 12 Page 28 7 mounting the motor to the transaxle See following CAUTION CAUTION Do not position fingers under motor when sliding motor off of the input shaft Fingers may get pinched when motor disengages 1 2 3 4 1 Motor Mountin...

Page 513: ...l Brake Assemblies Section Appearance of motor may be different from the motor shown above Figure 28 12 Motor Positioning Bolt TRANSAXLE DISASSEMBLY INSPECTION AND ASSEMBLY See General Warning on page 1 1 TRANSAXLE DISASSEMBLY AND INSPECTION 1 To detach axle tubes 14 and 35 from the transaxle housing remove the bolts 8 Figure 28 5 Page 28 3 2 Remove 11 bolts 24 that hold housing together 3 Pull th...

Page 514: ...ntermediate gear assembly Figure 28 5 Page 28 3 2 1 1 Press Ram 2 Arbor Figure 28 13 Intermediate Gear Assembly 8 Disassemble the differential gear case 8 1 Remove the hex bolts 33 and the ring gear 32 from the differential case Figure 28 5 Page 28 3 8 2 Remove the ring gear 8 3 Separate the differential gear case housing If necessary install two of the hex bolts removed previously in step 8 1 int...

Page 515: ...ssembly 1 If bearings 13 were removed during disassembly install new bearings using an arbor press Figure 28 5 Page 28 3 2 Assemble the differential gear case 2 1 Install the pin 31 Figure 28 5 Page 28 3 Apply a small amount of oil to all thrust plates and to both ends of the pin 2 2 Install the hex bolts 33 and output gear 32 Tighten bolts to 58 ft lb 78 6 N m 3 Press a new bearing 18 onto the in...

Page 516: ...dvance the shaft through to the bearing on the shaft and rotate it to align the shaft splines with the splined bore of the differential gear Continue advancing the shaft until the bearing on the axle is firmly seated within the axle tube hub seat 11 2 Using 90 internal snap ring pliers 0 090 tip CCI P N 1012560 attach the internal retaining ring into the axle tube hub so that it seats against the ...

Page 517: ...were not tagged when disconnected refer to the wiring diagram for proper connection See Wiring Diagrams Section 22 Page 22 2 7 Insert bolts through the spring shackles and bushings in the leaf spring eyes Secure bolts with locknuts Tighten to 15 ft lb 20 3 N m 8 Connect the brake cables using new bow tie pins 1 Figure 28 7 Page 28 5 9 Install the shock absorbers Tighten shock absorber retaining nu...

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Page 519: ...ries 2 And IQDM P Diagnostics PLUGGING THE HANDSET INTO THE VEHICLE 1 Connect one end of the cable to the jack located on the bottom of the handset 2 Connect the cable adaptor to the IQDM cable 3 Find the IQDM jack mounted under the dash panel 4 Remove the dust cap from the IQDM jack 5 Align the keyed portion of the plug with the IQDM jack and connect the plug to the jack Figure 29 1 IQDM Jack Und...

Page 520: ...act 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 With fast accel turned on the vehicle will accelerate at a noticeably faster rate With this feature turned off the vehicle speed will gradually increase even if the accelerator is quickly pressed to the floor Turn the feature on or off by pressing or on the...

Page 521: ...time the number is increased the top speed will be decreased by approximately 0 1 mph 0 2 km h The top vehicle speed will be determined by the M1 M2 speed menu item and the speed calibration setting For example if the speed setting is set for a value of 3 15 0 mph 24 1 km h and the speed calibration is set for 5 the total top speed of the vehicle should be approximately 14 5 mph 23 3 km h See the ...

Page 522: ...km h 15 4 mph 24 8 km h 17 6 3 mph 10 1 km h 10 3 mph 16 6 km h 13 3 mph 21 4 km h 15 3 mph 24 6 km h 18 6 2 mph 10 0 km h 10 2 mph 16 4 km h 13 2 mph 21 2 km h 15 2 mph 24 5 km h 19 6 1 mph 9 8 km h 10 1 mph 16 3 km h 13 1 mph 21 0 km h 15 1 mph 24 3 km h 20 6 0 mph 9 7 km h 10 0 mph 16 1 km h 13 0 mph 20 9 km h 15 0 mph 24 1 km h 21 5 9 mph 9 5 km h 9 9 mph 15 9 km h 12 9 mph 20 8 km h 14 9 mph ...

Page 523: ... 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 1 Enter Code A Code B and Code C 2 Turn the Tow Run switch to Tow 3 Wait 30 seconds 4 Turn the Tow Run switch to Run 5 M2 options will now appear in the Program Menu See Program Menu on page 29 2 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Servi...

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Page 525: ...r test interpreting results 25 9 on charge voltage test 25 8 voltage test 22 10 voltage test under load 22 17 troubleshooting examples 25 11 vibration damage 25 5 battery hydrometer test 11 10 12 10 installation 13 39 14 35 load test 11 12 storage 13 40 14 36 testing 11 9 12 10 under load 11 31 testing under load 12 12 12 34 voltage test 11 11 12 12 battery charger 16 hour shut off 25 5 AC service...

Page 526: ...odule CDM function codes 22 36 retrieving data from 22 37 troubleshooting 22 38 commutator see starter generator 14 1 connector 24 pin see test procedures 22 19 crankcase cover installation 15 6 16 7 removal 15 4 16 4 cylinder head 15 3 16 3 D DANGER definition of 1 1 diagram wiring key start neutral rev gasoline vehicle 11 7 pedal start gasoline vehicle 12 6 differential see unitized transaxle 20...

Page 527: ...ion 17 24 18 24 removal 17 22 18 23 storage 17 23 18 24 fuse installation 14 16 removal 14 16 testing 11 12 12 12 fuse sense lead testing 22 29 G generator diode 11 18 generator circuit troubleshooting 11 20 governor governor system 20 2 governor cable installation and adjustment 17 9 18 8 removal 17 8 18 8 ground cable testing 12 13 ground cables testing 11 12 H headlight bulb installation 14 30 ...

Page 528: ... 39 low oil warning light installation 13 25 14 22 removal 13 25 14 22 testing 11 30 12 32 lubrication front suspension 7 13 transaxle type g 28 1 M magnet motor speed sensor see motor speed sensor magnet 27 9 maintenance batteries 25 3 motor 22 1 armature ground test 27 7 inspection 27 7 assembly 27 11 bearing inspection 27 9 braking pedal down motor braking 22 1 pedal up motor braking 22 1 brush...

Page 529: ...tment 17 11 18 11 RPM limiter testing 11 23 12 22 S safety 1 1 schematic diagram key start neutral rev gasoline vehicle 11 7 pedal start gasoline vehicle 12 6 serial number vehicle 3 1 service tools torque converter kit 21 1 unitized transaxle 20 3 shock absorber front installation 7 19 removal 7 19 shock absorber rear inspection 9 1 installation 9 1 removal 9 1 snubber installation 9 5 removal 9 ...

Page 530: ...ng installation 9 3 removal 9 2 shock absorber inspection 9 1 installation 9 1 removal 9 1 snubber installation 9 5 removal 9 5 stabilizer bar installation 9 6 removal 9 6 T tailskirt installation 4 10 removal 4 10 test procedures electric vehicle 24 pin connector 22 19 batteries voltage check 22 10 battery pack voltage under load 22 17 battery warning light 22 35 charger receptacle 22 30 circuit ...

Page 531: ...rter generator 12 18 12 19 voltage limiter 12 40 voltage regulator 12 19 wire continuity 12 19 testing armature ground test starter genera tor 14 8 spark plug 15 2 16 2 starter generator armature ground test 13 8 tie rod and drag link installation 7 12 removal 7 12 tilt bed installation 4 5 removal 4 5 tire installation 8 3 pressure 8 1 removal 8 2 repair 8 2 tools see service tools 20 3 torque co...

Page 532: ...ter level see batteries electrolyte level 25 3 wheel installation 8 1 removal 8 1 see also tire 8 3 wire continuity testing 11 18 12 19 wiring diagram key start neutral rev gasoline vehicle 11 7 pedal start gasoline vehicle 12 6 wiring diagrams 22 2 Page i 8 2007 2009 Turf 252 Carryall 252 and XRT 900 Maintenance and Service Manual ...

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Page 534: ...der to help us better serve you please rate this publication in the following categories Poor Fair Average Good Excellent 5 If you are reviewing a Kit Instruction were all indicated parts included in your kit Yes No I am Distributor Dealer Individual Owner Club Car Associate Representative Technician Golf Course Superintendent Other Contact Information Optional Name Title Company Address City Stat...

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