2007 Club Car Ds Gasoline And Electric Golf Cart Repair Pdf
FILE DETAILS:
2007 Club Car Ds Gasoline And Electric Golf Cart Repair Pdf
FILE TYPE:PDF
MANUAL LANGUAGE:ENGLISH
PAGES:404
DOWNLOADABLE:YES
DESCRIPTION:
2007 Club Car Ds Gasoline And Electric Golf Cart Repair Pdf
- This Downloadable PDF Manual Covers The Following Machines:
2007 Club Car DS Gasoline Golf Cart
2007 Club Car DS Electric Golf Cart - Club Car vehicles are designed and built to provide the ultimate in performance efficiency; however, proper maintenance and repair are essential for achieving maximum service life and continued safe and reliable operation. This manual provides detailed information for the maintenance and repair of the Club Car DS Golf Cars and should be thoroughly reviewed prior to servicing the vehicle.
- The procedures provided must be properly implemented, and the DANGER, WARNING, and CAUTION statements must be heeded. This manual was written for the trained technician who already possesses knowledge and skills in electrical and mechanical repair. If the technician does not have such knowledge and skills, attempted service or repairs to the vehicle may render the vehicle unsafe.
- For this reason, Club Car advises that all repairs and/or service be performed by an authorized Club Car distributor/dealer representative or by a Club Car factorytrained technician. It is the policy of Club Car to assist its distributors and dealers in continually updating their service knowledge and facilities so they can provide prompt and efficient service for vehicle owners.
- Regional technical representatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and other service publications also represent Club Car’s continuing commitment to customer support. 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, you may write to us at: Club Car, Inc., P.O. Box 204658; Augusta, GA 30917-4658 USA, Attention: Technical Services, or contact a Club Car Technical Service Representative at (706) 863-3000, ext. 3580.
TABLE OF CONTENTS:
2007 Club Car Ds Gasoline And Electric Golf Cart Repair Pdf
SECTION i – INDEX
SECTION 1 – SAFETY
General Warning 1-1
SECTION 2 – VEHICLE SPECIFICATIONS
SECTION 3 – GENERAL INFORMATION
Serial Number Identification 3-1
Safety Committee 3-2
Storage – Gasoline Vehicle 3-2
Preparing the Gasoline Vehicle for Extended Off-Season Storage 3-3
Returning the Stored Gasoline Vehicle to Service 3-4
Storage – Electric Vehicle 3-5
Preparing the Electric Vehicle for Extended Off-Season Storage 3-5
Returning the Stored Electric Vehicle to Service 3-5
SECTION 4 – PERIODIC MAINTENANCE
General Information 4-1
Periodic Service Schedules 4-1
Periodic Lubrication Schedules 4-4
Engine Oil – Gasoline Vehicles 4-6
Engine Oil Level Check 4-6
Engine Oil And Filter Change 4-6
Oil Viscosity 4-8
SECTION 5 – BODY AND TRIM
Cleaning the Vehicle 5-1
Seat Cleaning 5-1
Page 4 2007 DS Golf Car Maintenance and Service Manual
Front and Rear Body Repair 5-2
Stress Lines or Streaks 5-2
Minor Impact Damage/Deformations 5-2
Minor Scratches and Surface Blemishes 5-2
Small Scratches That Cannot Be Buffed Out 5-2
Gouges, Punctures, Tears, Large Scratches, and Abrasions 5-3
Touch-up Paint Color Chart 5-3
Canopy 5-3
Canopy Removal 5-3
Canopy Installation 5-5
Front Body 5-5
Front Body Removal 5-5
Front Body Installation 5-5
Rear Body 5-7
Rear Body Removal 5-7
Rear Body Installation 5-9
Floor Mat 5-10
Floor Mat Removal 5-10
Floor Mat Installation 5-10
SECTION 6 – WHEEL BRAKE ASSEMBLIES
Brake Shoe Removal 6-1
Brake Assembly Cleaning 6-5
Brake Shoe Installation 6-6
Brake Adjustment 6-8
Brake Cluster Removal and Installation 6-8
Brake Cluster Installation 6-9
Brake Cable Removal and Installation 6-9
SECTION 7 – STEERING AND FRONT SUSPENSION
General Information 7-1
Steering Wheel 7-1
Steering Wheel Removal 7-1
Steering Wheel Installation 7-2
Steering Column 7-2
Steering Column Removal 7-2
Steering Column Disassembly 7-5
Steering Column Assembly 7-5
Steering Column Installation 7-6
Steering Adjustment 7-6
2007 DS Golf Car Maintenance and Service Manual Page 5
Rack and Pinion 7-8
Rack and Pinion Removal 7-8
Rack and Pinion Disassembly 7-8
Rack and Pinion Assembly 7-11
Rack and Pinion Installation 7-13
Tie Rod and Drag Link 7-13
Tie Rod and Drag Link Removal 7-13
Tie Rod and Drag Link Installation 7-13
Front Suspension 7-14
Lubrication 7-14
Wheel Alignment 7-14
Front Suspension Components 7-16
Tapered Leaf Spring Removal 7-16
Tapered Leaf Spring Installation 7-16
Kingpin and Steering Spindle Removal 7-17
Kingpin and Steering Spindle Installation 7-17
Delta A-Plate Removal 7-17
Delta A-Plate Installation 7-20
Shock Absorber Removal 7-20
Shock Absorber Installation 7-20
Front Wheel Bearings and Hubs 7-20
Front Wheel Free Play Inspection 7-20
Front Hub Removal 7-20
Front Hub Installation 7-21
SECTION 8 – WHEELS AND TIRES
General Information 8-1
Wheels 8-1
Wheel Removal 8-1
Wheel Installation 8-1
Tires 8-1
Tire Removal 8-1
Tire Repair 8-2
Tire Installation 8-3
SECTION 9 – REAR SUSPENSION
General Information 9-1
Shock Absorbers 9-1
Shock Absorber Removal and Inspection 9-1
Shock Absorber Installation 9-1
Page 6 2007 DS Golf Car Maintenance and Service Manual
Leaf Springs 9-1
Leaf Spring Removal 9-1
Leaf Spring Installation 9-4
SECTION 10 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES
General Information 10-1
Troubleshooting Guide 10-1
Electrical System 10-8
Test Procedures 10-8
Index of Test Procedures 10-8
SECTION 11 – ELECTRICAL COMPONENTS: GASOLINE VEHICLES
Starter/Generator (MODEL G425419) 11-1
Starter/Generator (MODEL 114-01-4005) 11-12
Voltage Regulator 11-22
Key Switch 11-23
Solenoid 11-24
Fuse 11-25
Accelerator Pedal Limit Switch 11-25
Kill Limit Switch 11-26
Neutral Lockout Limit Switch 11-27
Neutral Lockout Cam 11-28
Reverse Warning Buzzer 11-29
Reverse Buzzer Limit Switch 11-30
Low Oil Warning Light 11-31
Fuel Gauge/Hour Meter 11-32
Fuel Level Sending Unit 11-33
RPM Limiter 11-33
Ignition Coil 11-34
Oil Level Sensor 11-37
Battery 11-38
Ground Cables 11-42
SECTION 12 – FE290 ENGINE
General Information 12-1
Before Servicing 12-1
Engine Rotation 12-1
Spark Plug 12-1
2007 DS Golf Car Maintenance and Service Manual Page 7
Cylinder Head 12-3
General Information 12-3
Breather Valve (Reed Valve) 12-3
Crankcase 12-3
Engine Removal 12-3
Crankcase Cover Removal 12-3
Oil Level Sensor 12-5
Crankcase Cover Installation 12-5
Ignition Coil and Flywheel 12-6
Flywheel Installation 12-8
Engine Installation 12-9
Torque Specifications 12-10
Adjustments and Settings 12-10
SECTION 13 – FUEL SYSTEM: GASOLINE VEHICLE
General Information 13-1
Carburetor 13-1
Main Jet Elevation/Size Chart 13-2
Changing the Main Jet 13-2
Engine Control Linkage 13-5
General Information 13-5
Accelerator Rod 13-6
Governor Cable 13-8
Accelerator Cable 13-9
Closed Throttle or Idle Adjustment 13-11
Engine RPM Adjustment 13-11
Choke and Air Intake System 13-12
Choke Button Removal 13-12
Choke Button Installation 13-12
Air Box Removal 13-12
Air Box Installation 13-12
Intake Duct Removal 13-13
Intake Duct Installation 13-13
Air Filter 13-15
Fuel Filters 13-15
Fuel Filter Removal 13-15
Fuel Filter Installation 13-17
Page 8 2007 DS Golf Car Maintenance and Service Manual
Fuel Pump 13-18
General Information 13-18
Fuel Pump Removal 13-18
Fuel Pump Disassembly 13-18
Fuel Pump Cleaning and Inspection 13-19
Fuel Pump Assembly 13-19
Fuel Pump Installation 13-20
Fuel Tank 13-20
General Information 13-20
Fuel Tank Removal 13-21
Fuel Tank Disposal 13-22
Fuel Tank Storage 13-22
Fuel Tank Installation 13-22
Fuel Lines 13-24
Fuel Shut-Off Valve 13-25
SECTION 14 – EXHAUST SYSTEM: GASOLINE VEHICLES
Muffler 14-1
Muffler Removal 14-1
Muffler Installation 14-1
SECTION 15 – UNITIZED TRANSAXLE: GASOLINE VEHICLE
General Information 15-1
Lubrication 15-2
Axle Shaft 15-3
Axle Shaft and Oil Seal Removal 15-3
Axle Bearing 15-4
Axle Shaft Installation 15-6
Unitized Transaxle Removal 15-7
Unitized Transaxle Installation 15-14
Forward/Reverse Shifter Cable 15-19
Forward/Reverse Shifter Cable Removal 15-19
Forward/Reverse Shifter Cable Installation 15-20
Forward/Reverse Shifter Cable Adjustment 15-21
SECTION 16 – TORQUE CONVERTER: GASOLINE VEHICLE
General Information 16-1
Troubleshooting 16-1
2007 DS Golf Car Maintenance and Service Manual Page 9
Drive Belt 16-2
Drive Belt Removal 16-2
Drive Belt Installation 16-3
Drive Clutch 16-4
Drive Clutch Removal 16-4
Drive Clutch Cleaning and Inspection 16-5
Drive Clutch Disassembly 16-7
Inspection of Drive Clutch Parts 16-9
Drive Clutch Assembly 16-10
Drive Clutch Installation 16-12
Driven Clutch 16-12
Driven Clutch Removal 16-12
Driven Clutch Disassembly 16-12
Driven Clutch Inspection 16-13
Driven Clutch Assembly 16-13
Driven Clutch Installation 16-16
SECTION 17 – ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE
General Information 17-1
Wiring Diagram 17-2
Troubleshooting 17-4
Troubleshooting the Vehicle with the Diagnostic Handset 17-4
Troubleshooting Guide 1 17-5
Troubleshooting Guide 2 17-8
Test Procedures 17-10
Index of Test Procedures 17-10
Communication Display Module (CDM) 17-35
Using the CDM to Retrieve Data from the Onboard Computer 17-36
CDM Troubleshooting Guide 17-37
SECTION 18 – IQ SYSTEM DISPLAY MODULE SERIES 2 (IQDM-P SERIES 2) DIAGNOSTICS
General Information 18-1
Plugging the Handset into the Vehicle 18-1
Introductory Display 18-1
Menu Navigation 18-2
Page 10 2007 DS Golf Car Maintenance and Service Manual
Monitor Menu 18-4
Throttle 18-4
Batt Voltage 18-4
Heatsink 18-4
Arm Current 18-5
Field Current 18-5
Arm PWM 18-5
Field PWM 18-5
Speed Pulses 18-5
Foot Input 18-5
Forward Input 18-5
Reverse Input 18-5
Main Cont 18-5
Key Input 18-5
Password Tries 18-6
10 3 Transaxle 18-6
20+ Speed 18-6
Faults Menu 18-6
System Faults 18-6
HW Failsafe 18-8
Throttle Fault 1 18-8
Speed sensor 18-9
Main Welded 18-9
Main Driver On 18-9
Main Driver Off 18-9
Main Cont DNC 18-9
Main Coil FAULT 18-9
Field Missing 18-9
HPD 18-9
Proc/Wiring 18-9
Overvoltage 18-9
Low Battery Voltage 18-10
Thermal Cutback 18-10
Motor Stall 18-10
Main Dropout 18-10
Open Armature 18-10
Incorrect Password 18-10
Max Password Tries 18-10
Fault History 18-10
Clearing Fault History 18-11
Information 18-11
2007 DS Golf Car Maintenance and Service Manual Page 11
Programmer Setup 18-11
Program 18-11
Faults 18-11
Information 18-12
IQDM-P Series 2 Handset Troubleshooting 18-12
Test Procedures 18-14
Index of Test Procedures 18-14
SECTION 19 – ELECTRICAL COMPONENTS: ELECTRIC VEHICLE
Key Switch 19-1
Forward/Reverse Rocker Switch 19-2
Tow/Run Switch 19-4
Motor Controller Output Regulator (MCOR) 19-5
Reverse Buzzer 19-5
Solenoid 19-6
Onboard Computer (OBC) 19-7
Solid State Speed Controller 19-9
Charger Receptacle 19-11
Receptacle Fuse Link 19-12
Battery Warning Light 19-13
Pin 9 Diode 19-13
SECTION 20 – BATTERIES: ELECTRIC VEHICLE
General Information 20-1
Battery Replacement 20-1
Battery Care 20-2
Preventive Maintenance 20-2
Self-Discharge 20-3
Electrolyte Level 20-3
Mineral Content 20-4
Vibration Damage 20-4
Battery Charging 20-4
Charger Shuts Off After 16 Hours 20-5
Deep-Discharge 20-5
Early Excessive Discharging 20-5
Incoming AC Service 20-5
Fleet Rotation 20-5
Numbering Vehicles and Chargers 20-5
Battery Troubleshooting Chart 20-6
Page 12 2007 DS Golf Car Maintenance and Service Manual
Battery Testing 20-7
Battery Charger Test 20-7
On-Charge Voltage Test 20-7
Hydrometer Test 20-7
Discharge Test 20-9
Battery Troubleshooting Examples 20-11
Battery Storage 20-12
Charging a Battery Pack that has Low Voltage 20-12
SECTION 21 – BATTERY CHARGER: ELECTRIC VEHICLE
Refer to the appropriate 2006 Battery Charger Maintenance and Service Manual
SECTION 22 – ACCELERATOR AND BRAKE PEDAL GROUP
Brake Pedal and Park Brake 22-1
Brake Pedal Removal 22-1
Brake Pedal Installation 22-2
Park Brake Removal 22-3
Park Brake Installation 22-4
Accelerator Pedal – Gasoline Vehicles 22-5
Accelerator Pedal Removal 22-5
Accelerator Pedal Installation 22-7
Accelerator Pedal – Electric Vehicles 22-8
Accelerator Pedal Removal 22-8
Accelerator Pedal Installation 22-10
Pedal Group Adjustment – Gasoline Vehicle 22-11
Pedal Group Adjustment – Electric Vehicle 22-16
SECTION 23A – MOTOR (MODEL 5BC59JBS6365)
General Information 23a-1
Motor Identification 23a-1
External Motor Testing 23a-1
Motor 23a-2
2007 DS Golf Car Maintenance and Service Manual Page 13
Motor Component Testing and Inspection 23a-5
Armature 23a-5
Field Windings Inspection 23a-6
Motor Components 23a-6
Bearing Inspection 23a-7
Bearing Removal 23a-7
Bearing Installation 23a-7
Speed Sensor Magnet Inspection 23a-9
Speed Sensor Magnet Removal 23a-9
Speed Sensor Magnet Installation 23a-9
Reconditioning the Motor 23a-9
Motor Assembly 23a-10
Motor Installation 23a-12
Motor Speed Sensor 23a-15
SECTION 23B – MOTOR (MODEL EJ4-4001)
General Information 23b-1
Motor Identification 23b-1
External Motor Testing 23b-1
Motor 23b-2
Motor Removal 23b-2
Motor Disassembly 23b-4
Motor Component Testing and Inspection 23b-6
Armature Inspection and Testing 23b-6
Motor Frame and Field Windings Inspection 23b-8
Motor Brush, Spring, and Terminal Insulator Inspection 23b-8
Reconditioning the Motor 23b-11
Motor Assembly 23b-11
Motor Installation 23b-13
SECTION 24 – TRANSAXLE (TYPE G): ELECTRIC VEHICLE
Transaxle Identification 24-1
Lubrication 24-1
Axle Bearing and Shaft 24-1
Axle Shaft 24-1
Axle Bearing 24-4
Transaxle 24-4
Transaxle Removal 24-4
Page 14 2007 DS Golf Car Maintenance and Service Manual
Transaxle Disassembly, Inspection, and Assembly 24-7
Transaxle Disassembly and Inspection 24-7
Transaxle Assembly 24-10
Transaxle Installation 24-11
SECTION 25 – IQ SYSTEM DISPLAY MODULE SERIES 2 (IQDM-P SERIES 2) PROGRAMMING
General Information 25-1
Plugging the Handset into the Vehicle 25-1
Program Menu 25-2
Speed Setting 25-2
Fast Accel 25-3
Pedal Up Mode 25-3
Speed Cal 25-3
Code A, Code B, and Code C 25-3
Functions Menu 25-3
Get Settings From Controller 25-3
Write Settings to Controller 25-4
Reset All Settings
SCREENSHOT OF THE MANUAL:
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PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.