2007 Club Car Ds Gasoline And Electric Golf Cart Repair Pdf

2007 MAINTENANCE SERVICE MANUAL

Club C

ar

Club Car, Inc. P.O. Box 204658 Augusta, GA 30917-4658 USA

Web www.clubcar.com Phone 1.706.863.3000 1.800.ClubCar Int’l +1 706.863.3000 Fax 1.706.863.5808

DS GOLF CARS GASOLINE/ELECTRIC MANUAL NUMBER 103209103 EDITION CODE 0407C0312B

FOREWORD 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.

Copyright Š 2007, 2012 Club Car, Inc. Club Car is a registered trademark of Club Car, Inc This manual effective August 1, 2006.

2007 DS Golf Car Maintenance and Service Manual

Page 1

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ý WARNING • Read Section 1 – Safety before attempting any service on the vehicle.

• Before servicing vehicle, read complete section(s) and any referenced information that may be relevant to the service or repair to be performed.

NOTE: This manual represents the most current information at the time of publication. Club Car is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures. Any modification and/or significant change in specifications or procedures will be forwarded to all Club Car dealers and will, when applicable, appear in future editions of this manual.

Club Car reserves the right to change specifications and designs at any time without notice and without the obligation of making changes to units previously sold.

There are no warranties expressed or implied in this manual. See the limited warranty found in the vehicle Owner’s Manual.

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2007 DS Golf Car Maintenance and Service Manual

CONTENTS 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

2007 DS Golf Car Maintenance and Service Manual

Page 3

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

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2007 DS Golf Car Maintenance and Service Manual

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

2007 DS Golf Car Maintenance and Service Manual

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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

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2007 DS Golf Car Maintenance and Service Manual

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 2007 DS Golf Car Maintenance and Service Manual

Page 7

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

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2007 DS Golf Car Maintenance and Service Manual

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

2007 DS Golf Car Maintenance and Service Manual

Page 9

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

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2007 DS Golf Car Maintenance and Service Manual

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

2007 DS Golf Car Maintenance and Service Manual

Page 11

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

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2007 DS Golf Car Maintenance and Service Manual

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

2007 DS Golf Car Maintenance and Service Manual

Page 13

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 .........................................................................................................................

25-5

SECTION i – INDEX

Page 14

2007 DS Golf Car Maintenance and Service Manual

1

SECTION 1 – SAFETY To ensure the safety of those servicing these vehicles, and to protect the vehicles from possible damage resulting from improper service or maintenance, the procedures in this manual must be followed.

It is important to note that throughout this manual there are statements labeled DANGER, WARNING, or CAUTION. These special statements relate to specific safety issues, and must be read, understood, and heeded before proceeding with procedures. There are statements labeled NOTE, which provide other essential service or maintenance information.

ý DANGER • A DANGER indicates an immediate hazard that will result in severe personal injury or death.

ý WARNING • A WARNING indicates an immediate hazard that could result in severe personal injury or death.

ý CAUTION • A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury.

CAUT ION • A CAUTION without 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.

ý DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.

• Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or clothing. Antidotes: - External: Flush with water. Call a physician immediately.

- Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable oil. Call a physician immediately.

- Eyes: Flush with water for 15 minutes. Call a physician immediately.

• Gasoline – Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. Service only in a well-ventilated area.

• Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison.

2007 DS Golf Car Maintenance and Service Manual

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SAFETY

General Warning

ý WARNING • Follow the procedures exactly as stated in this manual, and heed all DANGER, WARNING, and CAUTION statements in this manual as well as those on the vehicle.

• Only trained technicians should service or repair the vehicle. Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair.

The appropriate instructions must be used when performing maintenance, service, or accessory installation.

• Prior to servicing the vehicle or leaving the vehicle unattended, turn the key switch OFF, remove the key, and place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels when servicing the vehicle.

Gasoline vehicles only: • To avoid unintentionally starting the vehicle: - Disconnect battery cables, negative (–) cable first (Figure 1-1, Page 1-3).

- Disconnect the spark plug wire from the spark plug.

• Frame ground – Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wiring. Do not allow a positive wire to touch the vehicle frame, engine, or any other metal component.

Electric vehicles only: • Place Tow/Run switch in the TOW position before disconnecting or connecting the batteries.

• To avoid unintentionally starting the vehicle, disconnect the batteries as shown (Figure 1-2, Page 1-3).

• After disconnecting the batteries, wait 90 seconds for the controller capacitors to discharge.

All vehicles: • Wear safety glasses or approved eye protection when servicing the vehicle. Wear a full face shield and rubber gloves when working on or near batteries.

• Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the vehicle.

• Moving parts! Do not attempt to service the vehicle while it is running.

• Hot! Do not attempt to service hot engine or exhaust system. Failure to heed this warning could result in severe burns.

• Use insulated tools when working near batteries or electrical connections. Use extreme caution to avoid shorting of components or wiring.

• Check the vehicle owner’s manual for proper location of all vehicle safety and operation decals and make sure they are in place and are easy to read.

• Any modification or change to the vehicle that affects the stability or handling of the vehicle, or increases maximum vehicle speed beyond factory specifications, could result in severe personal injury or death.

• Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic floor jack) with 1000 lb. (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.

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2007 DS Golf Car Maintenance and Service Manual

SAFETY

General Warning

• If wires are removed or replaced, make sure wiring and wire harness are properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.

• For vehicles with cargo beds, remove all cargo before raising the bed or servicing the vehicle.

If the vehicle is equipped with a prop rod, ensure that it is securely engaged 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.

• Do not leave children unattended on vehicle.

Place Tow / Run switch in TOW

Place TOW/RUN switch in the TOW position before disconnecting or connecting battery cables.

S

E N

G

P

1 N E G

FRO OF VE NT HICLE

TOW ING

RN WA

O

RUN

AS SEEN FROM PASSENGER SIDE OF VEHICLE

P

O

S

N S

G

O

E

P

DISCONNECT BATTERY CABLES BEFORE WORKING ON VEHICLE

P

2

G

O

E

S

FRONT OF VEHICLE

N

Remove negative cable first.

3 4

Remove negative (–) cable first.

Figure 1-1 Gasoline Vehicle

Figure 1-2 Electric Vehicle

2007 DS Golf Car Maintenance and Service Manual

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