Name: Club Car CARRYALL 252 2007
Brand: Club Car
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2007-2009Turf252,Carryall252

andXRT900Maintenanceand

ServiceManual

GasolineandElectricVehicles

ManualNumber103209112

EditionCode1008C0312B

Table of Contents5
Section 1 - Safety17
General Warning17
Disabling the Vehicle19
Disconnecting the Battery - Gasoline Vehicles19
Connecting the Battery - Gasoline Vehicles19
Disconnecting the Batteries - Electric Vehicles20
Connecting the Batteries - Electric Vehicles20
Section 2 - Vehicle Specifications21
Vehicle Specifications - Gasoline Vehicles21
Vehicle Specifications - Electric Vehicles23
Section 3 - General Information25
Serial Number Identification25
Storage - Gasoline Vehicle26
Preparing the Gasoline Vehicle for Extended Storage27
Returning the Stored Gasoline Vehicle to Service28
Storage - Electric Vehicle29
Preparing the Electric Vehicle for Extended Storage29
Returning the Stored Electric Vehicle to Service30
Section 4 - Body and Trim31
Cleaning the Vehicle31
Front Body Repair32
Stress Lines or Streaks32
Minor Impact Damage/Deformations32
Minor Scratches and Surface Blemishes32
Small Scratches that Cannot be Buffed out33
Touch-Up Paint Color Chart33
Gouges, Punctures, Tears, Large Scratches, and Abrasions33
Front Body33
Front Body Removal33
Front Body Installation34
Tilt Bed35
Tilt Bed Removal35
Tilt Bed Installation35
Rear Fender37
Rear Fender Removal37
Rear Fender Installation38
Trailer Hitch (Optional on some Models)38
Trailer Hitch Removal38
Trailer Hitch Installation39
Receiver Hitch (Optional on some Models)39
Receiver Hitch Removal39
Receiver Hitch Installation39
Tailskirt40
Tailskirt Removal40
Tailskirt Installation40
Floor Mat41
Front Floor Mat Removal41
Front Floor Mat Installation41
Section 5 - Accelerator and Brake Pedal Group43
Brake Pedal and Park Brake43
Brake Pedal Removal43
Brake Pedal Installation45
Park Brake Removal45
Park Brake Installation46
Accelerator Pedal - Gasoline Vehicles47
Accelerator Pedal Removal - Gasoline Vehicles47
Accelerator Pedal Installation - Gasoline Vehicles48
Accelerator Pedal - Electric Vehicles49
Accelerator Pedal Removal - Electric Vehicles49
Accelerator Pedal Installation - Electric Vehicles52
Pedal Group Adjustment - Gasoline Vehicles52
Pedal Group Adjustment - Electric Vehicles57
Section 6 - Wheel Brake Assemblies61
General Information61
Brake Shoe Removal61
Brake Assembly Cleaning (Manually-Adjusted Brakes)63
Brake Shoe Installation (Manually-Adjusted Brakes)65
Brake Adjustment (Manually-Adjusted Brakes)67
Brake Cluster Adjustment67
Brake Cable Equalization71
Final Brake Cluster Adjustment71
Test Drive Vehicle72
Brake Cluster Removal and Installation72
Rear Brake Cluster Removal72
Rear Brake Cluster Installation72
Front Brake Cluster Removal73
Front Brake Cluster Installation74
Front Brake Cables74
Front Brake Cable Removal74
Front Brake Cable Installation75
Rear Brake Cables77
Rear Brake Cable Removal77
Rear Brake Cable Installation78
Section 7 - Steering and Front Suspension79
General Information79
Steering Wheel79
Steering Wheel Removal79
Steering Wheel Installation80
Steering Column80
Steering Column Removal80
Steering Column Disassembly82
Steering Column Assembly82
Steering Column Installation82
Steering Adjustment83
Rack and Pinion84
Rack and Pinion Removal84
Rack and Pinion Disassembly85
Rack and Pinion Assembly87
Rack and Pinion Installation89
Tie Rod and Drag Link90
Tie Rod and Drag Link Removal90
Tie Rod and Drag Link Installation90
Front Suspension91
Lubrication91
Wheel Alignment91
Front Suspension Components93
Leaf Spring Removal93
Leaf Spring Installation93
Kingpin and Steering Spindle Removal93
Kingpin and Steering Spindle Installation97
Delta A-Plate Removal97
Delta A-Plate Installation97
Shock Absorber Removal97
Shock Absorber Installation97
Front Wheel Bearings and Hubs - 4-Wheel Brake Vehicles98
Front Wheel Free Play Inspection98
Front Wheel Bearings and Hub Removal98
Front Wheel Bearings and Hub Installation99
Section 8 - Wheels and Tires101
General Information101
Wheels101
Wheel Removal101
Wheel Installation101
Tires102
Tire Removal102
Tire Repair102
Tire Installation103
Section 9 - Rear Suspension105
General Information105
Shock Absorbers105
Shock Absorber Inspection and Removal105
Shock Absorber Installation105
Multi-Leaf Springs106
Multi-Leaf Spring Removal106
Multi-Leaf Spring Installation107
Snubber109
Snubber Removal109
Snubber Installation109
Stabilizer Bar110
Stabilizer Bar Removal110
Stabilizer Bar Installation110
Section 10 - Periodic Maintenance113
General Information113
Pre-Operation and Daily Safety Checklist113
Performance Inspection114
Periodic Service Schedules115
Periodic Lubrication Schedules118
Engine Oil - Gasoline Vehicle119
Engine Oil Level Check120
Engine Oil and Filter Change120
Section 11 - Troubleshooting and Electrical System: Key-Start with Neutral Rev Gas Vehicle123
General Information123
Troubleshooting Guide123
Electrical System128
Wiring Diagrams129
Test Procedures131
Section 12 - Troubleshooting and Electrical System: Pedal-Start Gas Vehicle161
General Information161
Troubleshooting Guide161
Wiring Diagram166
Electrical System169
Test Procedures169
Section 13 - Electrical Components: Key-Start with Neutral Rev Gas Vehicle203
Starter/Generator203
Testing the Starter/Generator203
Starter/Generator Removal203
Disassembly of the Starter/Generator to Service the Brushes204
Brush Inspection and Replacement204
Brush Spring Inspection and Replacement205
Starter/Generator Assembly205
Disassembly of the Starter/Generator to Service the Armature/Commutator206
Bearing Cleaning and Inspection206
Bearing Removal207
Field Coil Removal208
Visual Inspection of Armature and Commutator209
Commutator Cleaning and Inspection209
Armature Ground Test210
Visual Inspection of Field Coils210
Starter/Generator Rework211
Starter/Generator Assembly211
Starter/Generator Installation212
Belt Tension Adjustment214
Voltage Regulator215
Voltage Regulator Removal215
Voltage Regulator Installation215
Diode217
Diode Removal217
Diode Installation217
Key Switch219
Key Switch Removal219
Key Switch Installation220
Solenoid221
Solenoid Removal221
Solenoid Installation221
Fuse222
Fuse Removal222
Fuse Installation222
Neutral Lockout Limit Switch223
Neutral Lockout Limit Switch Removal223
Neutral Lockout Limit Switch Installation224
Reverse Warning Buzzer225
Reverse Warning Buzzer Removal225
Reverse Warning Buzzer Installation225
Reverse Buzzer Limit Switch226
Reverse Buzzer Limit Switch Removal226
Reverse Buzzer Limit Switch Installation226
Oil Warning Light227
Oil Warning Light Removal227
Oil Warning Light Installation227
Fuel Gauge/Hour Meter228
Fuel Gauge/Hour Meter Removal228
Fuel Gauge/Hour Meter Installation229
Fuel Level Sending Unit229
RPM Limiter229
RPM Limiter Removal229
RPM Limiter Installation230
Ignition Coil231
Ignition Coil Removal231
Ignition Coil Installation232
Oil Level Sensor234
Oil Level Sensor Removal234
Oil Level Sensor Installation234
Headlights234
Headlight Bulb Removal235
Headlight Bulb Installation235
Voltage Limiter236
Voltage Limiter Removal236
Voltage Limiter Installation236
Light Switch237
Light Switch Removal237
Light Switch Installation237
Battery237
General Information238
Testing the Battery238
Preventive Maintenance238
Self-Discharge239
Water Level239
Vibration Damage240
Mineral Content240
Battery Removal241
Charging the Battery241
Battery Installation241
Battery Storage242
Charging a Dead Battery242
Ground Cables242
Section 14 - Electrical Components: Pedal-Start Gas Vehicle243
Starter/Generator243
Starter/Generator Removal243
Disassembly of the Starter/Generator to Service the Brushes244
Brush Inspection and Replacement244
Brush Spring Inspection and Replacement245
Starter/Generator Assembly245
Disassembly of the Starter/Generator to Service the Armature/Commutator246
Bearing Cleaning and Inspection247
Bearing Removal247
Field Coil Removal248
Visual Inspection of Armature248
Commutator Cleaning and Inspection249
Armature Ground Test250
Visual Inspection of Field Coils251
Starter/Generator Rework251
Starter/Generator Assembly251
Starter/Generator Installation252
Belt Tension Adjustment254
Voltage Regulator254
Voltage Regulator Removal254
Voltage Regulator Installation255
Key Switch255
Key Switch Removal255
Key Switch Installation257
Solenoid257
Solenoid Removal257
Solenoid Installation257
Fuse258
Fuse Removal258
Fuse Installation258
Kill Limit Switch258
Kill Limit Switch Removal258
Kill Limit Switch Installation259
Neutral Lockout Limit Switch260
Neutral Lockout Limit Switch Removal260
Neutral Lockout Limit Switch Installation261
Reverse Warning Buzzer261
Reverse Warning Buzzer Removal261
Reverse Warning Buzzer Installation261
Reverse Buzzer Limit Switch263
Reverse Buzzer Limit Switch Removal263
Reverse Buzzer Limit Switch Installation263
Low Oil Warning Light264
Low Oil Warning Light Removal264
Low Oil Warning Light Installation264
Fuel Gauge/Hour Meter265
General Information265
Fuel Gauge/Hour Meter Removal265
Fuel Gauge/Hour Meter Installation266
Fuel Level Sending Unit266
RPM Limiter266
RPM Limiter Removal266
RPM Limiter Installation267
Ignition Coil268
Ignition Coil Removal268
Ignition Coil Installation269
Oil Level Sensor270
Oil Level Sensor Removal271
Oil Level Sensor Installation271
Headlights271
Headlight Bulb Removal271
Headlight Bulb Installation272
Voltage Limiter272
Voltage Limiter Removal272
Voltage Limiter Installation272
Headlight Switch273
Headlight Switch Removal273
Headlight Switch Installation273
Battery274
General Information274
Testing the Battery274
Preventive Maintenance275
Water Level275
Self-Discharge275
Vibration Damage276
Mineral Content276
Battery Removal277
Charging the Battery277
Battery Installation277
Battery Storage278
Charging a Dead Battery278
Ground Cables278
Section 15 - S10 Fe 350 Engine279
General Information279
Before Servicing279
Engine Rotation279
Spark Plug279
Cylinder Head281
General Information281
Breather Valve (Reed Valve)281
Crankcase281
Engine Removal281
Crankcase Cover Removal282
Oil Level Sensor283
Crankcase Cover Installation284
Ignition Coil and Flywheel285
Ignition Coil and Flywheel Removal285
Flywheel Installation286
Ignition Coil Inspection and Repair287
Ignition Coil Installation287
Crankcase Cover Installation287
Engine Installation287
Torque Specifications288
Adjustments and Settings289
Section 16 - S27 Fe 350 Engine291
General Information291
Before Servicing291
Engine Rotation291
Spark Plug291
Cylinder Head293
General Information293
Breather Valve (Reed Valve)293
Valve Clearance Check and Adjustment293
Crankcase294
Engine Removal294
Crankcase Cover Removal294
Oil Level Sensor296
Crankcase Cover Installation297
Ignition Coil and Flywheel298
Ignition Coil and Flywheel Removal298
Flywheel Installation299
Ignition Coil Inspection and Repair300
Ignition Coil Installation300
Crankcase Cover Installation300
Engine Installation300
Torque Specifications301
Adjustments and Settings302
Section 17 - S10 Fe 350 Fuel System303
General Information303
Carburetor303
Main Jet Elevation/Size Chart304
Changing the Main Jet305
Engine Control Linkage308
General Information308
Accelerator Rod308
Governor Cable310
Accelerator Cable312
Closed Throttle or Idle Adjustment312
Engine RPM Adjustment313
Choke and Air Intake System314
General Information314
Choke Cable Removal314
Choke Cable Installation314
Air Box Removal314
Air Box Installation315
Intake Duct Removal315
Intake Duct Installation316
Intake Duct Repair318
Air Filter318
Fuel Filters318
Fuel Filter Removal318
Fuel Filter Installation319
Fuel Pump321
General Information321
Fuel Pump Removal321
Fuel Pump Disassembly321
Fuel Pump Cleaning and Inspection322
Fuel Pump Assembly322
Fuel Pump Installation323
Fuel Tank324
General Information324
Fuel Tank Removal324
Fuel Tank Disposal325
Fuel Tank Storage325
Fuel Tank Installation326
Fuel Lines327
Fuel Shut-Off Valve328
Fueling Instructions328
Section 18 - S27 Fe 350 Fuel System331
General Information331
Carburetor331
Main Jet Elevation/Size Chart332
Changing the Main Jet333
Engine Control Linkage335
General Information336
Accelerator Rod336
Governor Cable338
Accelerator Cable339
Closed Throttle or Idle Adjustment340
Engine RPM Adjustment341
Choke and Air Intake System341
General Information341
Choke Cable Removal342
Choke Cable Installation342
Air Box Removal344
Air Box Installation344
Intake Duct Removal344
Intake Duct Installation345
Intake Duct Repair345
Air Filter345
Fuel Filters347
General Information347
Fuel Filter Removal347
Fuel Filter Installation347
Fuel Pump349
General Information349
Fuel Pump Removal349
Fuel Pump Disassembly350
Fuel Pump Cleaning and Inspection350
Fuel Pump Assembly351
Fuel Pump Installation351
Fuel Tank353
General Information353
Fuel Tank Removal353
Fuel Tank Disposal354
Fuel Tank Storage354
Fuel Tank Installation354
Fuel Lines356
Fuel Shut-Off Valve356
Section 19 - Exhaust System: Gasoline Vehicles357
Muffler357
Muffler Removal357
Muffler Installation357
Section 20 - Unitized Transaxle: Dash-Mounted Shifter359
General Information359
Shifter Lever359
Neutral Lockout359
Governor System360
Unitized Transaxle Service360
Tools Required for this Section361
Lubrication361
Axle Shaft361
Axle Shaft and Oil Seal Removal361
Axle Bearing362
Axle Shaft Installation364
Unitized Transaxle Removal365
Unitized Transaxle Installation372
Forward/Reverse Shifter Cable378
Forward/Reverse Shifter Cable Removal378
Forward/Reverse Shifter Cable Installation378
Forward/Reverse Shifter Cable Adjustment380
Section 21 - Torque Converter: Gasoline Vehicles381
General Information381
Troubleshooting381
Drive Belt382
Drive Belt Removal383
Drive Belt Installation383
Drive Clutch384
Drive Clutch Removal384
Drive Clutch Cleaning and Inspection385
Drive Clutch Disassembly387
Inspection of Drive Clutch Parts389
Drive Clutch Assembly390
Drive Clutch Installation391
Driven Clutch392
Driven Clutch Removal392
Driven Clutch Disassembly392
Driven Clutch Inspection393
Driven Clutch Assembly393
Driven Clutch Installation396
Section 22 - Electrical System and Testing: Electric Vehicles397
General Information397
Wiring Diagrams398
Troubleshooting400
Troubleshooting the Vehicle with the IQDM400
Troubleshooting Guide 1401
Troubleshooting Guide 2404
Test Procedures406
Communication Display Module (CDM)432
Using the CDM to Retrieve Data from the Onboard Computer433
CDM Troubleshooting Guide434
Section 23 - Iq Display Module (Iqdm) Series 2 and Iqdm-P Diagnostics435
Plugging the Handset into the Vehicle435
Introductory Display436
Menu Navigation436
Program (IQDM-P Only)437
Monitor Menu438
Speed in438
Throttle438
Batt Voltage438
Heatsink Temp438
Mode439
Arm Current439
Field Current439
Arm PWM439
Field PWM439
Foot Input439
Key Input439
Forward Input439
Reverse Input440
Mode Switch440
WK Away Relay440
Main Cont440
Password Tries (IQDM-P Only)440
Cir BRKR Open440
THRTL Fault440
Undervoltage440
Overvoltage441
Temp Cutback441
Hpd441
Main Welded441
Relay Welded441
SPD Sensor441
Main DRV on441
Main Coil OPN441
Main Dropout441
Motor Stall442
Main DRVR off442
Relay DNC442
Current Sense442
M-Shorted442
Relay Coil442
Precharge442
FLD Missing442
HW Failsafe442
DRVR Overcur443
RLY DRVR on443
RLY DRVR off443
Miles X 1000443
Miles X 1443
Faults Menu443
System Faults444
Fault Recovery445
Fault Descriptions446
Functions Menu448
Get Settings from Controller448
Write Settings to Controller450
Reset All Settings451
Information452
Model Number452
Serial Number452
MFG Date452
Software Version452
Programmer Setup452
Program452
Faults452
Information453
IQDM and IQDM-P Handset Troubleshooting453
Test Procedures454
Section 24 - Electrical Components: Electric Vehicles459
Key Switch459
Key Switch Removal459
Key Switch Installation460
Forward/Reverse Rocker Switch461
Forward/Reverse Rocker Switch Removal461
Forward/Reverse Rocker Switch Installation461
Tow/Run Switch462
Tow/Run Switch Removal462
Tow/Run Switch Installation462
Circuit Breaker463
Circuit Breaker Removal463
Circuit Breaker Installation463
Motor Controller Output Regulator (MCOR)464
MCOR Removal464
MCOR Installation464
Reverse Buzzer465
Reverse Buzzer Removal465
Reverse Buzzer Installation466
Speed Controller Cover466
Removing the Speed Controller Cover466
Installing the Speed Controller Cover466
Solenoid467
Solenoid Removal467
Solenoid Installation468
Onboard Computer (OBC)468
Onboard Computer Removal468
Onboard Computer Installation469
Solid State Speed Controller470
Speed Controller Removal470
Speed Controller Installation470
Charger Receptacle471
Charger Receptacle Inspection471
Charger Receptacle Removal472
Charger Receptacle Installation472
Receptacle Fuse Link473
Receptacle Fuse Link Removal473
Receptacle Fuse Link Installation474
Battery Warning Light474
Battery Warning Light Removal474
Battery Warning Light Installation474
Section 25 - Batteries: Electric Vehicles477
General Information477
Battery Replacement478
Battery Care479
Preventive Maintenance479
Self-Discharge479
Electrolyte Level479
Mineral Content480
Vibration Damage481
Battery Charging481
Charger Shuts off after 16 Hours481
Deep-Discharge482
Early Excessive Discharging482
Incoming AC Service482
Fleet Rotation482
Numbering Vehicles and Chargers482
Battery Troubleshooting Chart483
Battery Testing484
Battery Charger Test484
On-Charge Voltage Test484
Hydrometer Test484
Discharge Test486
Battery Troubleshooting Examples487
Battery Storage488
Charging a Battery Pack that Has Low Voltage488
Section 26 - Battery Charger489
Section 27 - Motor (Model Da5-4006): Electric Vehicles491
General Information491
External Motor Testing491
Motor492
Motor Removal492
Motor Disassembly494
Motor Component Testing and Inspection497
Armature Inspection and Testing497
Motor Frame and Field Windings Inspection498
Motor Brush, Spring, and Terminal Insulator Inspection498
Reconditioning the Motor501
Motor Specifications501
Motor Assembly501
Motor Installation503
Section 28 - Transaxle (Type G): Electric Vehicles507
Lubrication507
Axle Bearing and Shaft507
Axle Shaft507
Axle Bearing510
Transaxle511
Transaxle Removal511
Transaxle Disassembly, Inspection, and Assembly513
Transaxle Disassembly and Inspection513
Transaxle Assembly515
Transaxle Installation517
Section 29 - Iq Display Module (Iqdm-P) Series 2 Programming519
Plugging the Handset into the Vehicle519
Program Menu520
M1/M2 Speed520
M1/M2 Fast Accel520
M1/M2 Pedal up520
M1/M2 Speed Cal521
Code A, Code B, and Code C522

Club Car CARRYALL 252 2007 Maintenance And Service Manual

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Brand	Club Car
Model	CARRYALL 252 2007
Category	Utility Vehicle
Language	English