103209103, M&S, 2007, DS Gasoline and Electric Vehicles

103209103, M&S, 2007, DS Gasoline and Electric Vehicles, 404 Pages

 

 

 

103209103, M&S, 2007, DS Gasoline and Electric Vehicles, 404 Pages, $68.95

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CONTENTS
SECTION i – INDEX
SECTION 1 – SAFETY
General Warning
SECTION 2 – VEHICLE SPECIFICATIONS
SECTION 3 – GENERAL INFORMATION
Serial Number Identification
Safety Committee
Storage – Gasoline Vehicle
Preparing the Gasoline Vehicle for Extended Off-Season Storage
Returning the Stored Gasoline Vehicle to Service
Storage – Electric Vehicle
Preparing the Electric Vehicle for Extended Off-Season Storage
Returning the Stored Electric Vehicle to Service
SECTION 4 – PERIODIC MAINTENANCE
General Information
Periodic Service Schedules
Periodic Lubrication Schedules
Engine Oil – Gasoline Vehicles
Engine Oil Level Check
Engine Oil and Filter Change
Oil Viscosity
SECTION 5 – BODY AND TRIM
Cleaning the Vehicle
Seat Cleaning
Page 4 2007 DS Golf Car Maintenance and Service Manual
Front and Rear Body Repair
Stress Lines or Streaks
Minor Impact Damage/Deformations
Minor Scratches and Surface Blemishes
Small Scratches That Cannot Be Buffed Out
Gouges, Punctures, Tears, Large Scratches, and Abrasions
Touch-up Paint Color Chart
Canopy
Canopy Removal
Canopy Installation
Front Body
Front Body Removal
Front Body Installation
Rear Body
Rear Body Removal
Rear Body Installation
Floor Mat
Floor Mat Removal
Floor Mat Installation
SECTION 6 – WHEEL BRAKE ASSEMBLIES
Brake Shoe Removal
Brake Assembly Cleaning
Brake Shoe Installation
Brake Adjustment
Brake Cluster Removal and Installation
Brake Cluster Installation
Brake Cable Removal and Installation
SECTION 7 – STEERING AND FRONT SUSPENSION
General Information
Steering Wheel
Steering Wheel Removal
Steering Wheel Installation
Steering Column
Steering Column Removal
Steering Column Disassembly
Steering Column Assembly
Steering Column Installation
Steering Adjustment
2007 DS Golf Car Maintenance and Service Manual Page 5
Rack and Pinion
Rack and Pinion Removal
Rack and Pinion Disassembly
Rack and Pinion Assembly
Rack and Pinion Installation
Tie Rod and Drag Link
Tie Rod and Drag Link Removal
Tie Rod and Drag Link Installation
Front Suspension
Lubrication
Wheel Alignment
Front Suspension Components
Tapered Leaf Spring Removal
Tapered Leaf Spring Installation
Kingpin and Steering Spindle Removal
Kingpin and Steering Spindle Installation
Delta A-Plate Removal
Delta A-Plate Installation
Shock Absorber Removal
Shock Absorber Installation
Front Wheel Bearings and Hubs
Front Wheel Free Play Inspection
Front Hub Removal
Front Hub Installation
SECTION 8 – WHEELS AND TIRES
General Information
Wheels
Wheel Removal
Wheel Installation
Tires
Tire Removal
Tire Repair
Tire Installation
SECTION 9 – REAR SUSPENSION
General Information
Shock Absorbers
Shock Absorber Removal and Inspection
Shock Absorber Installation
2007 DS Golf Car Maintenance and Service Manual
Leaf Springs
Leaf Spring Removal
SECTION 10 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES
General Information
Troubleshooting Guide
Electrical System
Test Procedures
Index of Test Procedures
SECTION 11 – ELECTRICAL COMPONENTS: GASOLINE VEHICLES
Starter/Generator (MODEL G425419)
Starter/Generator (MODEL 114-01-4005)
Voltage Regulator
Key Switch
Solenoid
Fuse
Accelerator Pedal Limit Switch
Kill Limit Switch
Neutral Lockout Limit Switch
Neutral Lockout Cam
Reverse Warning Buzzer
Reverse Buzzer Limit Switch
Low Oil Warning Light
Fuel Gauge/Hour Meter
Fuel Level Sending Unit
RPM Limiter
Ignition Coil
Oil Level Sensor
Battery
Ground Cables
SECTION 12 – FE290 ENGINE
General Information
Before Servicing
Engine Rotation
Spark Plug
2007 DS Golf Car Maintenance and Service Manual
Cylinder Head
General Information
Breather Valve (Reed Valve)
Crankcase
Engine Removal
Crankcase Cover Removal
Oil Level Sensor
Crankcase Cover Installation
Ignition Coil and Flywheel
Flywheel Installation
Engine Installation
Torque Specifications
Adjustments and Settings
SECTION 13 – FUEL SYSTEM: GASOLINE VEHICLE
General Information
Carburetor
Main Jet Elevation/Size Chart
Changing the Main Jet
Engine Control Linkage
General Information
Accelerator Rod
Governor Cable
Accelerator Cable
Closed Throttle or Idle Adjustment
Engine RPM Adjustment
Choke and Air Intake System
Choke Button Removal
Choke Button Installation
Air Box Removal
Air Box Installation
Intake Duct Removal
Intake Duct Installation
Air Filter
Fuel Filters
Fuel Filter Removal
Fuel Filter Installation
2007 DS Golf Car Maintenance and Service Manual
Fuel Pump
General Information
Fuel Pump Removal
Fuel Pump Disassembly
Fuel Pump Cleaning and Inspection
Fuel Pump Assembly
Fuel Pump Installation
Fuel Tank
General Information
Fuel Tank Removal
Fuel Tank Disposal
Fuel Tank Storage
Fuel Tank Installation
Fuel Lines
Fuel Shut-Off Valve
SECTION 14 – EXHAUST SYSTEM: GASOLINE VEHICLES
Muffler
Muffler Removal
Muffler Installation
SECTION 15 – UNITIZED TRANSAXLE: GASOLINE VEHICLE
General Information
Lubrication
Axle Shaft
Axle Shaft and Oil Seal Removal
Axle Bearing
Axle Shaft Installation
Unitized Transaxle Removal
Unitized Transaxle Installation
Forward/Reverse Shifter Cable
Forward/Reverse Shifter Cable Removal
Forward/Reverse Shifter Cable Installation
Forward/Reverse Shifter Cable Adjustment
SECTION 16 – TORQUE CONVERTER: GASOLINE VEHICLE
General Information
Troubleshooting
2007 DS Golf Car Maintenance and Service Manual
Drive Belt
Drive Belt Removal
Drive Belt Installation
Drive Clutch
Drive Clutch Removal
Drive Clutch Cleaning and Inspection
Drive Clutch Disassembly
Inspection of Drive Clutch Parts
Drive Clutch Assembly
Drive Clutch Installation
Driven Clutch
Driven Clutch Removal
Driven Clutch Disassembly
Driven Clutch Inspection
Driven Clutch Assembly
Driven Clutch Installation
SECTION 17 – ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE
General Information
Wiring Diagram
Troubleshooting
Troubleshooting the Vehicle with the Diagnostic Handset
Troubleshooting Guide 1
Troubleshooting Guide 2
Test Procedures
Index of Test Procedures
Communication Display Module (CDM)
Using the CDM to Retrieve Data from the Onboard Computer
CDM Troubleshooting Guide
SECTION 18 – IQ SYSTEM DISPLAY MODULE SERIES 2 (IQDM-P SERIES 2) DIAGNOSTICS
General Information
Plugging the Handset into the Vehicle
Introductory Display
Menu Navigation
2007 DS Golf Car Maintenance and Service Manual
Monitor Menu
Throttle
Batt Voltage
Heatsink
Arm Current
Field Current
Arm PWM
Field PWM
Speed Pulses
Foot Input
Forward Input
Reverse Input
Main Cont
Key Input
Password Tries
10.3 Transaxle
20+ Speed
Faults Menu
System Faults
HW Failsafe
Throttle Fault 1
Speed sensor
Main Welded
Main Driver On
Main Driver Off
Main Cont DNC
Main Coil FAULT
Field Missing
HPD
Proc/Wiring
Overvoltage
Low Battery Voltage
Thermal Cutback
Motor Stall
Main Dropout
Open Armature
Incorrect Password
Max Password Tries
Fault History
Clearing Fault History
Information
2007 DS Golf Car Maintenance and Service Manual
Programmer Setup
Program
Faults|
Information
IQDM-P Series 2 Handset Troubleshooting
Test Procedures
Index of Test Procedures
SECTION 19 – ELECTRICAL COMPONENTS: ELECTRIC VEHICLE
Key Switch
Forward/Reverse Rocker Switch
Tow/Run Switch
Motor Controller Output Regulator (MCOR)
Reverse Buzzer
Solenoid
Onboard Computer (OBC)
Solid State Speed Controller
Charger Receptacle
Receptacle Fuse Link
Battery Warning Light
Pin 9 Diode
SECTION 20 – BATTERIES: ELECTRIC VEHICLE
General Information
Battery Replacement
Battery Care
Preventive Maintenance
Self-Discharge
Electrolyte Level
Mineral Content
Vibration Damage
Battery Charging
Charger Shuts Off After 16 Hours
Deep-Discharge
Early Excessive Discharging
Incoming AC Service
Fleet Rotation
Numbering Vehicles and Chargers
Battery Troubleshooting Chart
2007 DS Golf Car Maintenance and Service Manual
Battery Testing
Battery Charger Test
On-Charge Voltage Test
Hydrometer Test
Discharge Test
Battery Troubleshooting Examples
Charging a Battery Pack that has Low Voltage
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
Brake Pedal Removal
Brake Pedal Installation
Park Brake Removal
Park Brake Installation
Accelerator Pedal – Gasoline Vehicles
Accelerator Pedal Removal
Accelerator Pedal Installation
Accelerator Pedal – Electric Vehicles
Accelerator Pedal Removal
Accelerator Pedal Installation
Pedal Group Adjustment – Gasoline Vehicle
Pedal Group Adjustment – Electric Vehicle
SECTION 23A – MOTOR (MODEL 5BC59JBS6365)
General Information
Motor Identification
External Motor Testing
Motor
2007 DS Golf Car Maintenance and Service Manual
Motor Component Testing and Inspection
Armature
Field Windings Inspection
Motor Components
Bearing Inspection
Bearing Removal
Bearing Installation
Speed Sensor Magnet Inspection
Speed Sensor Magnet Removal
Speed Sensor Magnet Installation
Reconditioning the Motor
Motor Assembly
Motor Installation
Motor Speed Sensor
SECTION 23B – MOTOR (MODEL EJ4-4001)
General Information
Motor Identification
External Motor Testing
Motor
Motor Removal
Motor Disassembly
Motor Component Testing and Inspection
Armature Inspection and Testing
Motor Frame and Field Windings Inspection
Motor Brush, Spring, and Terminal Insulator Inspection
Reconditioning the Motor
Motor Assembly
Motor Installation
SECTION 24 – TRANSAXLE (TYPE G): ELECTRIC VEHICLE
Transaxle Identification
Lubrication
Axle Bearing and Shaft
Axle Shaft
Axle Bearing
Transaxle
Transaxle Removal
2007 DS Golf Car Maintenance and Service Manual
Transaxle Disassembly, Inspection, and Assembly
Transaxle Disassembly and Inspection
Transaxle Assembly
Transaxle Installation
SECTION 25 – IQ SYSTEM DISPLAY MODULE SERIES 2 (IQDM-P SERIES 2) PROGRAMMING
General Information
Plugging the Handset into the Vehicle
Program Menu
Speed Setting
Fast Accel
Pedal Up Mode
Speed Cal
Code A, Code B, and Code C
Functions Menu
Get Settings From Controller
Write Settings to Controller
Reset All Settings

 

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