Club Car Turf 1 Service Manual
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Club Car Turf 1 Service Manual

2012
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See also: Maintenance and Service Manual , Owner's Manual
2012 Turf/Carryall
Maintenance and Service
Manual
Turf 1, Turf 2, Turf 6, Carryall 1, Carryall 2, Carryall 2 Plus,
Carryall 6 G/E
Manual Number 103897404
Edition Code 1211A00000

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Summary of Contents for Club Car Turf 1

  • Page 1 2012 Turf/Carryall Maintenance and Service Manual Turf 1, Turf 2, Turf 6, Carryall 1, Carryall 2, Carryall 2 Plus, Carryall 6 G/E Manual Number 103897404 Edition Code 1211A00000...
  • Page 3 If it appears that a service question is not answered in this manual, you may write to us at: Club Car, LLC, P.O. Box 204658, Augusta, Georgia 30917-4658, USA, Attention: Technical Services, or contact a Club Car Tech- nical Service Representative at (706) 863-3000, extension 3580.
  • Page 4 Club Car, LLC reserves the right to change specifications and designs at any time with- out notice and without the obligation of making changes to units previously sold.

  • Page 5: Table Of Contents

    CONTENTS SECTION 1 – SAFETY General Warning ..........................Disabling The Vehicle ........................Disconnecting The Battery – Gasoline Vehicles ................Connecting The Battery – Gasoline Vehicles ................Disconnecting The Batteries – Electric Vehicles ................Connecting The Batteries – Electric Vehicles ................SECTION 2 –...
  • Page 6 Tilt Bed – Turf 1, 2, Carryall 1, 2 and 2 Plus ..................Tilt Bed Removal .......................... Tilt Bed Installation ........................Flat Bed – Turf 6 and Carryall 6 ....................... Flat Bed Removal – Turf 6 and Carryall 6 ..................
  • Page 7 Accelerator Pedal – Electric Vehicles ....................Accelerator Pedal Removal – Electric Vehicles ................Accelerator Pedal Installation – Electric Vehicles ................. 5-11 Pedal Group Adjustment – Gasoline Vehicles .................. 5-11 Pedal Group Adjustment – Electric Vehicles ..................5-16 SECTION 6 – WHEEL BRAKE ASSEMBLIES General Information ..........................
  • Page 8 Steering Column ..........................Steering Column Removal ......................Steering Column Disassembly ..................... Steering Column Assembly ......................Steering Column Installation ......................Steering Adjustment ......................... Rack and Pinion ..........................Rack and Pinion Inspection ......................Rack and Pinion Removal ......................Rack and Pinion Disassembly ...................... 7-10 Rack and Pinion Assembly ......................
  • Page 9 SECTION 9 – REAR SUSPENSION General Information .......................... Shock Absorbers ..........................Shock Absorber Inspection and Removal ..................Shock Absorber Installation ......................Multi-Leaf Springs ..........................Multi-Leaf Spring Removal ......................Multi-Leaf Spring Installation ......................Snubber ............................Snubber Removal ......................... Snubber Installation ........................Stabilizer Bar ............................

  • Page 11: Section 1 - Safety

    SECTION 1 – SAFETY To ensure the safety of those servicing Club Car 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 CAU- TION.
  • Page 12 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.

  • Page 13: Disabling The Vehicle

    SAFETY General Warning ý WARNING • 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.

  • Page 14: Connecting The Batteries - Electric Vehicles

    SAFETY General Warning CONNECTING THE BATTERIES – ELECTRIC VEHICLES 1. Ensure the Tow/Run switch is in the TOW position. 2. Connect the battery cables, positive (+) cable first. 3. Tighten battery terminals to 110 in-lb (12.4 N·m). 4. Coat terminals with Battery Terminal Protector Spray (CC P/N 1014305) to minimize corrosion. Place Tow/Run FRONT Switch in TOW.

  • Page 15: Section 2 - Vehicle Specifications

    SECTION 2 – VEHICLE SPECIFICATIONS VEHICLE SPECIFICATIONS – ELECTRIC VEHICLES Turf 1/Carryall 1 Turf 2/Carryall 2 Carryall 6 SPECIFICATIONS IQ System IQ Plus IQ Plus POWER SOURCE Drive motor: Direct drive, 48 volts DC, shunt wound, 3.1 hp • •...

  • Page 16: Specifications

    VEHICLE SPECIFICATIONS Vehicle Specifications – Electric Vehicles Turf 1/Carryall 1 Turf 2/Carryall 2 Carryall 6 SPECIFICATIONS IQ System IQ Plus IQ Plus 12-15 mph 14-16 mph 14-16 mph Forward speed (19-24 km/h) (23-26 km/h) (23-26 km/h) 17 ft.-6 in. 20 ft.-8 in.

  • Page 17: Vehicle Specifications - Gasoline Vehicles

    VEHICLE SPECIFICATIONS Vehicle Specifications – Electric Vehicles VEHICLE SPECIFICATIONS – GASOLINE VEHICLES Turf 6 Pedal-Start/ Turf 1/Carryall 1 Turf 2/Carryall 2 Carryall 2 Plus Carryall 6 SPECIFICATIONS Pedal-Start Pedal-Start Key-Start Key-Start Gasoline Gasoline Gasoline Gasoline POWER SOURCE Engine: 4 cycle, OHV, 351 cc, 11.5 maximum hp @ 3600 rpm (per SAE J 1940/1349), single cylinder, air cooled, with pres- •...

  • Page 18: Specifications

    VEHICLE SPECIFICATIONS Vehicle Specifications – Electric Vehicles Turf 6 Pedal-Start/ Turf 1/Carryall 1 Turf 2/Carryall 2 Carryall 2 Plus Carryall 6 SPECIFICATIONS Pedal-Start Pedal-Start Key-Start Key-Start Gasoline Gasoline Gasoline Gasoline 4.5 in. 4.5 in. 4.5 in. 4.5 in. Ground clearance...

  • Page 19: Section 3 - General Information

    • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION Important features unique to the different models covered in this manual are highlighted. Club Car, LLC rec- ommends the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s).

  • Page 20: Storage - Gasoline Vehicle

    GENERAL INFORMATION Storage – Gasoline Vehicle SERIAL NUMBER DECAL SERIAL NUMBER DECAL REAR OF CENTER Club Car SERIAL NUMBER F0401-123456 P O BOX 204658 AUGUSTA GA 30917 DASH VIEWED FROM THE FRONT OF THE VEHICLE (FRONT BODY REMOVED) Club Figure 3-1 Serial Number Decal Figure 3-2 Serial Number Decal Behind Dash STORAGE –...
  • Page 21 GENERAL INFORMATION Storage – Gasoline Vehicle 3. Store vehicle in a cool, dry place. This will minimize battery self-discharge. If the battery appears to be weak, have it charged by a trained technician. Use an automotive-type 12-volt battery charger rated at 10 amps or less.

  • Page 22: Returning The Stored Gasoline Vehicle To Service

    GENERAL INFORMATION Storage – Electric Vehicle RETURNING THE STORED GASOLINE VEHICLE TO SERVICE 1. Connect battery and spark plug wire(s). See Connecting The Battery – Gasoline Vehicles on page 1-3. 2. Restore fuel system to operation. 2.1. Remove plug from the fuel tank vent nipple and connect fuel vent line to nipple. Open the fuel shut- off valve (Figure 3-3, Page 3-3) (Figure 3-4, Page 3-3).
  • Page 23 GENERAL INFORMATION Storage – Electric Vehicle 1. Check the water levels in each battery cell. If water is required, fill the cells to cover the plates, charge the batteries, and then use distilled water to fill each cell to the correct level. Electrolyte level should be from 1/2 inch (13 mm) above plates to 1/4 inch (6 mm) below the level indicator.

  • Page 24: Returning The Stored Electric Vehicle To Service

    GENERAL INFORMATION Storage – Electric Vehicle CAUT ION • Be sure to check the batteries and charger monthly to maintain correct battery water level and to ensure the charger is operating correctly during storage. 12. To disconnect the batteries for storage: 12.1.

  • Page 25: Section 4 - Body And Trim

    (no. 00) steel wool. Club Car does not recommend any type of pressure washing or steam cleaning. Such a process will expose electrical components to moisture. Moisture entering electrical components can result in water damage and subsequent component failure.

  • Page 26: Front Body Repair

    BODY AND TRIM Front Body Repair FRONT BODY REPAIR See General Warning, Section 1, Page 1-1. STRESS LINES OR STREAKS Repeatedly flexing the front body may cause white stress lines or streaks in the finish. To remove them: 1. Hold a heat gun 12 inches (30 cm) away from the affected area, with the gun on its lowest heat setting. 2.

  • Page 27: Touch-Up Paint Color Chart

    BODY AND TRIM Front Body Repair 3. Using the brush provided with the touch-up paint (available from Club Car Service Parts, see following color chart), apply paint to the scratch. Multiple layers of paint may be required to fill the scratch.

  • Page 28: Front Body

    (12). Tighten bolts to 65 in-lb (7.3 N·m). 6. Turf 1 and Carryall 1 vehicles: Install two push type blind rivets (10) that secure lower front body to frame (Figure 4-1, Page 4-5).
  • Page 29 PLACES TURF 2, 6, CARRYALL 2, 2 PLUS AND 6 TYPICAL 2 PLACES TURF 2, 6, CARRYALL 2, TURF 1 AND 2 PLUS AND 6 CARRYALL 1 ONLY Figure 4-1 Front Body Assembly 2012 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 30: Tilt Bed - Turf 1, 2, Carryall 1, 2 And 2 Plus

    BODY AND TRIM Front Body Repair TILT BED – TURF 1, 2, CARRYALL 1, 2 AND 2 PLUS See General Warning, Section 1, Page 1-1. NOTE: Tilt bed removal and installation will be easier with a helper. TILT BED REMOVAL For Turf 6 and Carryall 6 flat bed removal, see page 4-8.
  • Page 31 BODY AND TRIM Front Body Repair TYPICAL 2 PLACES Figure 4-2 Tilt Bed – Turf 1, 2, Carryall 1, 2, and 2 Plus 2012 Turf/Carryall Vehicle Maintenance and Service Manual Page 4-7...

  • Page 32: Flat Bed - Turf 6 And Carryall 6

    BODY AND TRIM Flat Bed – Turf 6 and Carryall 6 FLAT BED – TURF 6 AND CARRYALL 6 See General Warning, Section 1, Page 1-1. NOTE: Flat bed removal and installation will be easier with a helper. FLAT BED REMOVAL – TURF 6 AND CARRYALL 6 1.
  • Page 33 BODY AND TRIM Flat Bed – Turf 6 and Carryall 6 TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 4-3 Flat Bed – Turf 6 and Carryall 6 2012 Turf/Carryall Vehicle Maintenance and Service Manual Page 4-9...

  • Page 34: Flat Bed Trim - Turf 6 And Carryall 6

    BODY AND TRIM Flat Bed Trim – Turf 6 and Carryall 6 FLAT BED TRIM – TURF 6 AND CARRYALL 6 See General Warning, Section 1, Page 1-1. FLAT BED TRIM REMOVAL – TURF 6 AND CARRYALL 6 1. Release access door latches (9) and open access door (1) (Figure 4-3, Page 4-9). 2.

  • Page 35: Access Door - Turf 6 And Carryall 6

    BODY AND TRIM Access Door – Turf 6 and Carryall 6 TYPICAL 4 PLACES Figure 4-4 Flat Bed Trim – Turf 6 and Carryall 6 ACCESS DOOR – TURF 6 AND CARRYALL 6 See General Warning, Section 1, Page 1-1. ACCESS DOOR REMOVAL –...

  • Page 36: Rear Fender

    BODY AND TRIM Rear Fender REAR FENDER See General Warning, Section 1, Page 1-1. REAR FENDER REMOVAL Turf 6, Carryall 6 and other vehicles with taillights: 1. Remove taillight assembly. 1.1. Remove the two screws (14) that secure taillight (15) to the rear fender (Figure 4-6, Page 4-14). 1.2.

  • Page 37: Rear Fender Installation

    1. Install rear fender in the reverse order of removal. Tighten bolts (2) to 35 in-lb (4.0 N·m). TYPICAL 2 PLACES Figure 4-5 Rear Fender, Trailer Hitch (Heavy Duty), and Tailskirt – Turf 1, 2, Carryall 1, 2, and 2 Plus 2012 Turf/Carryall Vehicle Maintenance and Service Manual Page 4-13...
  • Page 38 BODY AND TRIM Rear Fender TYPICAL 2 PLACES TYPICAL AT EACH FENDER 2 PLACES TYPICAL 2 PLACES AT EACH FENDER TYPICAL TYPICAL 2 PLACES 2 PLACES REAR REVERSE BUZZER MOUNTING Figure 4-6 Rear Fender and Tailskirt – Turf 6 and Carryall 6 Page 4-14 2012 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 39: Trailer Hitch - Heavy Duty (Optional On Some Models)

    BODY AND TRIM Tailskirt TRAILER HITCH – HEAVY DUTY (OPTIONAL ON SOME MODELS) See General Warning, Section 1, Page 1-1. TRAILER HITCH REMOVAL – HEAVY DUTY 1. Remove the tailskirt. See Tailskirt Removal on page 4-15. 2. Where the hitch (7) is mounted to frame, remove two nuts (12), lock washers (11), flat washers (10), and bolts (9) (Figure 4-5, Page 4-13).

  • Page 40: Front Floor Mat Installation

    BODY AND TRIM Bumper FRONT FLOOR MAT INSTALLATION 1. Install the floor mat in the reverse order of removal. 2. Install the brake and accelerator pedals. See Section 5 – Accelerator and Brake Pedal Group. REAR FLOOR MAT REMOVAL – TURF 6 AND CARRYALL 6 ONLY 1.

  • Page 41: Section 5 - Accelerator And Brake Pedal Group

    SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. BRAKE PEDAL AND PARK BRAKE See General Warning, Section 1, Page 1-1. BRAKE PEDAL REMOVAL 1.
  • Page 42 Brake Pedal and Park Brake TYPICAL 4 PLACES TYPICAL 2 PLACES TURF 1 AND CARRYALL 1 VEHICLES ONLY Figure 5-1 Brake and Park Brake Pedal Assembly and Mounting – Two-Wheel Brake Vehicles Page 5-2 2012 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 43 ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake TYPICAL 2 PLACES Figure 5-2 Brake and Park Brake Pedal Assembly and Mounting – Four-Wheel Brake Vehicles 2012 Turf/Carryall Vehicle Maintenance and Service Manual Page 5-3...

  • Page 44: Brake Pedal Installation

    ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake BRAKE PEDAL INSTALLATION 1. From the top side of the floorboard, insert the brake pedal assembly (10) (Figure 5-1, Page 5-2 or Figure 5-2, Page 5-3) through the opening in the floor as shown (Figure 5-3, Page 5-4) and install the brake pedal stop bumper (24) (Figure 5-1, Page 5-2 or Figure 5-2, Page 5-3) on the brake pedal assembly, but do not tighten the jam nut (25) at this time.

  • Page 45: Park Brake Removal

    ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake PARK BRAKE REMOVAL 1. Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s). See Disconnecting The Batteries – Electric Vehicles on page 1-3. See Disconnecting The Battery –...

  • Page 46: Accelerator Pedal - Gasoline Vehicles

    ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles Hook one end of spring (20) on park brake weldment. SHAFT Lift other end of spring (20) up and over brake weldment by prying down on shaft with small screwdriver. Figure 5-5 Torsion Spring Installation ACCELERATOR PEDAL –...
  • Page 47 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles 9. Remove the lock nut (26) from the accelerator pivot rod (Figure 5-6, Page 5-7). 10. Press the brake pedal slightly and slide the park brake ratchet (23) toward the end of the accelerator pivot rod.

  • Page 48: Accelerator Pedal Installation - Gasoline Vehicles

    ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles ACCELERATOR PEDAL INSTALLATION – GASOLINE VEHICLES 1. If the accelerator pivot rod supports were replaced, position the supports (21) on the vehicle frame and install the four bolts (22), flat washers (19), and lock nuts (18). Finger-tighten nuts at this time (Figure 5-6, Page 5-7).

  • Page 49: Accelerator Pedal - Electric Vehicles

    ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles ACCELERATOR PEDAL – ELECTRIC VEHICLES See General Warning, Section 1, Page 1-1. ACCELERATOR PEDAL REMOVAL – ELECTRIC VEHICLES 1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries – Electric Vehicles on page 1-3.
  • Page 50 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles Figure 5-8 Accelerator Pedal – Electric Vehicle Page 5-10 2012 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 51: Accelerator Pedal Installation - Electric Vehicles

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles ACCELERATOR PEDAL INSTALLATION – ELECTRIC VEHICLES 1. If the accelerator pivot rod supports were replaced, position the supports (21) on the vehicle frame and install the four bolts (22), flat washers (16), and lock nuts (15) (Figure 5-8, Page 5-10). Finger-tighten nuts at this time.
  • Page 52 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles Pedal Group Adjustment – Gasoline Vehicles, Continued: Figure 5-9 Loosen Rear Brake Equalizer Rod Nuts Figure 5-10 Loosen Front Brake Equalizer Rod Nuts 2.4. Loosen the brake stop jam nut (31), then relieve pedal pressure on the stop by pushing down slightly on the pedal.
  • Page 53 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles NOTE: The accelerator rod must also be checked if the ratchet/pawl gap is adjusted. See step 5 of Pedal Group Adjustment – Gasoline Vehicles on page 5-14. The accelerator rod must be disconnected before proceeding to step 3.3. CUTAWAY SIDE VIEW 0.060 inch (1.5 mm)
  • Page 54 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles Pedal Group Adjustment – Gasoline Vehicles, Continued: 1/2-INCH SOCKET 1/2-INCH WRENCH Figure 5-16 Brake Rod Adjustment Figure 5-17 Accelerator Pedal Height Adjustment 4. Adjust accelerator pedal height. 4.1. Loosen the nut and bolt (Figure 5-17, Page 5-14) securing the accelerator pedal to the pivot plate. Clamp the accelerator pedal adjustment tool (CC P/N 101871001) to the accelerator pedal, with the end marked ‘accelerator pedal height’...
  • Page 55 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles 5.1. Remove the electrical box screw and cover. See preceding DANGER. 5.2. Loosen the jam nuts (25) and disconnect the accelerator rod (17) at the accelerator pedal (Figure 5-6, Page 5-7). Adjust the length of the rod so the indicated cam edge is parallel with the edge of the electrical component box as shown (Figure 5-19, Page 5-15).

  • Page 56: Pedal Group Adjustment - Electric Vehicles

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles Pedal Group Adjustment – Gasoline Vehicles, Continued: NOTE: After the pedal group and accelerator rod are adjusted, the final governed engine RPM should be set. See Engine RPM Adjustment in Section 14 of the appropriate maintenance and service supplement.
  • Page 57 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles Correct pedal position is 6 inches (15.2 cm) from floormat to back of brake pedal. Figure 5-22 Brake Pedal Height Adjustment Figure 5-23 Brake Pedal Height Measurement 3. Adjust park brake ratchet/pawl gap and pawl engagement. 3.1.
  • Page 58 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles Pedal Group Adjustment – Electric Vehicles, Continued: 3.4. With the park brake locked, make sure at least 75% of ratchet tooth length engages the pawl (Figure 5-26, Page 5-18). Tooth engagement should be between the two lines marked on the pawl. RATCHET (B) TOOTH LENGTH LOCKED POSITION...
  • Page 59 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles ACCELERATOR PEDAL ADJUSTMENT TOOL (CCI P/N 101871001) RUBBER STRAP Figure 5-29 Accelerator Pedal Height Adjustment 5. Adjust the brakes. See Brake Adjustment (Self-Adjusting Brakes), Section 6, Page 6-8 or Brake Adjustment (Manually-Adjusted Brakes), Section 6, Page 6-12 2012 Turf/Carryall Vehicle Maintenance and Service Manual Page 5-19...

  • Page 61: Section 6 - Wheel Brake Assemblies

    OSHA/29 CFR - 1910.1001. GENERAL INFORMATION The Club Car vehicles covered in this manual are equipped with two-wheel self-adjusting brakes or four- wheel manually-adjusted brakes. See Section 2 – Specifications. BRAKE SHOE REMOVAL See General Warning, Section 1, Page 1-1.
  • Page 62 WHEEL BRAKE ASSEMBLIES Brake Shoe Removal Brake Shoe Removal, Continued: 3. Remove the rear wheels and remove the brake drums. If the brake drums were easily removed, proceed to step 5. See following CAUTION and NOTE. ý CAUTION • Worn or damaged brake drums cannot be machined to refinish them. Replace as necessary. NOTE: When servicing vehicles with self-adjusting brakes with badly worn brake shoes and when the drums cannot be removed by normal methods, proceed to step 4 to mini- mize damage to the brake cluster and brake components.

  • Page 63: Brake Assembly Cleaning (Self-Adjusting Brakes)

    WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning (Self-Adjusting Brakes) Figure 6-4 Rotate Clip Retainer Figure 6-5 Remove Shoes 7. Grasp both brake shoes and pull them, with the springs, out of brake assembly (Figure 6-5, Page 6-3). 8. Self-adjusting brake vehicles only: Remove the adjuster wheel (1) with two washers (2 and 3) from the backing plate (Figure 6-6, Page 6-3).
  • Page 64 WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning (Self-Adjusting Brakes) Brake Assembly Cleaning (Self-Adjusting Brakes), Continued: ý WARNING • Apply grease carefully when performing the following steps. Do not allow any grease to get on the friction surfaces of the brake shoe pads. Failure to heed this warning could cause diminished brake performance, possibly resulting in property damage or severe personal injury.

  • Page 65: Brake Shoe Installation (Self-Adjusting Brakes)

    See General Warning, Section 1, Page 1-1. See also Warning, on Page 6-1. Turf 1 and Carryall 1 vehicles 1. Turn the adjusting wheel screw so the shoe slot is vertical, then position the trailing shoe in the slots in the shoe mounting block and adjuster assembly (Figure 6-12, Page 6-6).
  • Page 66 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation (Self-Adjusting Brakes) Brake Shoe Installation (Self-Adjusting Brakes), Continued: NOTE: The trailing shoe has 17T stamped into the tip of the shoe flange (Figure 6-12, Page 6-6). The leading shoe is stamped 17L. When installing the shoes, the stamp- ings on both shoes should be oriented to the top of the brake assembly.
  • Page 67 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation (Self-Adjusting Brakes) 4. While maintaining spring attachment on both shoes, position tips of leading shoe in the mounting slots and then push shoe into place. Hold shoe in position and install retaining clip (Figure 6-15, Page 6-7). TRAILING LEADING SHOE SHOE...

  • Page 68: Brake Adjustment (Self-Adjusting Brakes)

    BRAKE ADJUSTMENT (SELF-ADJUSTING BRAKES) See General Warning, Section 1, Page 1-1. See also Warning, on Page 6-1. Turf 1 and Carryall 1 vehicles 1. When cleaning or repair on both wheels is complete, and with brake cable still loose, lower vehicle to floor.

  • Page 69: Brake Assembly Cleaning (Manually-Adjusted Brakes)

    WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning (Manually-Adjusted Brakes) 1/4 INCH TO 1/2 INCH (6.3 TO 12.7 MM) Figure 6-18 Brake Pedal Free Play Adjustment BRAKE ASSEMBLY CLEANING (MANUALLY-ADJUSTED BRAKES) See General Warning, Section 1, Page 1-1. See also Warning, on Page 6-1. Turf 2, Carryall 2, 2 Plus, and 6 vehicles 1.

  • Page 70: Brake Shoe Installation (Manually-Adjusted Brakes)

    WHEEL BRAKE ASSEMBLIES Brake Shoe Installation (Manually-Adjusted Brakes) Brake Assembly Cleaning (Manually-Adjusted Brakes), Continued: ý WARNING • Apply grease carefully when performing the following steps. Do not allow any grease to get on the friction surfaces of the brake shoe pads. Failure to heed this warning could cause diminished brake performance, possibly resulting in property damage or severe personal injury.
  • Page 71 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation (Manually-Adjusted Brakes) 1. Position one shoe in the slots in the mounting block anchor piston and brake actuator (Figure 6-23, Page 6-11). See following WARNING. ý WARNING • When installing brake shoes, the shoes must be oriented with tips stamped J10 inserted into the mounting block anchor piston slots rather than into the brake actuator slots (Figure 6-23, Page 6-11).

  • Page 72: Brake Adjustment (Manually-Adjusted Brakes)

    WHEEL BRAKE ASSEMBLIES Brake Adjustment (Manually-Adjusted Brakes) Brake Shoe Installation (Manually-Adjusted Brakes), Continued: TIPS Figure 6-25 Insert Shoes Figure 6-26 Position Shoes ý CAUTION • Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to installing the axle shaft.

  • Page 73: Brake Cluster Adjustment

    Figure 6-30 Rear Brake Adjustment Bolt 4. Use a torque wrench and a 7-mm 8-point socket or Club Car brake adjustment tool (CC P/N 1013582) to turn the brake adjustment bolt (5) on each brake clockwise until it is tightened to 15 ft-lb (20.3 N·m) then back off 5 clicks.
  • Page 74 WHEEL BRAKE ASSEMBLIES Brake Adjustment (Manually-Adjusted Brakes) TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 6-31 Rear Manually-Adjusted Brake Assembly Page 6-14 2012 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 75 WHEEL BRAKE ASSEMBLIES Brake Adjustment (Manually-Adjusted Brakes) Figure 6-32 Front Manually-Adjusted Brake Assembly 2012 Turf/Carryall Vehicle Maintenance and Service Manual Page 6-15...

  • Page 76: Brake Cable Equalization

    WHEEL BRAKE ASSEMBLIES Brake Adjustment (Manually-Adjusted Brakes) BRAKE CABLE EQUALIZATION 1. Set park brake in the third tooth of the ratchet. Place a wedge between the park brake pedal and brake pedal to prevent the park brake from disengaging while equalizing the brake cables (Figure 6-33, Page 6-16).

  • Page 77: Final Brake Cluster Adjustment

    WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation FINAL BRAKE CLUSTER ADJUSTMENT 1. To adjust the brake shoes, turn the adjustment bolt counterclockwise five clicks. 2. Repeat step 1 at other brake cluster(s). 3. Install the rubber dust covers (4) over the brake adjustment bolts (5) (Figure 6-29, Page 6-13 and Figure 6-30, Page 6-13).

  • Page 78: Rear Brake Cluster Installation

    WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation Rear Brake Cluster Removal, Continued: 5. Remove cotter pin (17) and clevis pin (16) from brake cable (Figure 6-31, Page 6-14 or Figure 6-11, Page 6-5). 6. Remove 4 bolts (20) and cone lock nuts (19) that mount the brake assembly to the transaxle (Figure 6-31, Page 6-14 or Figure 6-11, Page 6-5).

  • Page 79: Front Brake Cluster Installation

    WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation TYPICAL 4 PLACES Figure 6-34 Front Spindle Assembly (Four-Wheel Brake Vehicles) 8. Remove hub and bearing assembly from spindle shaft. Remove four bolts (22), cone washers (21), lock washers (20) and hex nuts (19) that mount the brake assembly to the spindle (Figure 6-32, Page 6-15). 9.

  • Page 80: Front Brake Cables

    WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation FRONT BRAKE CABLES See General Warning, Section 1, Page 1-1. See also Warning, on Page 6-1. FRONT BRAKE CABLE REMOVAL 1. Remove bow-tie pin (2) and clevis pin (3) from brake lever arm on front brake cluster (Figure 6-35, Page 6-20).

  • Page 81: Front Brake Cable Installation

    WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation FRONT BRAKE CABLE INSTALLATION 1. Place brake cable through frame mounting hole behind equalizer and install E-clip (8) on cable housing (Figure 6-36, Page 6-21). FLOORBOARD REMOVED FOR CLARITY TYPICAL 2 PLACES Figure 6-36 Brake Equalizer 2.

  • Page 82: Rear Brake Cables

    WHEEL BRAKE ASSEMBLIES Rear Brake Cables Front Brake Cable Installation, Continued: Figure 6-37 Front Brake Cable Routing REAR BRAKE CABLES See General Warning, Section 1, Page 1-1. See also Warning, on Page 6-1. REAR BRAKE CABLE REMOVAL 1. Chock wheels to keep vehicle from unintentionally moving. 2.

  • Page 83: Rear Brake Cable Installation

    WHEEL BRAKE ASSEMBLIES Rear Brake Cables Figure 6-38 Loosen Equalizer Nut Figure 6-39 Disconnect Cables at Rear Brakes REAR BRAKE CABLE INSTALLATION 1. Place the cable ends in the equalizer (4) (Figure 6-38, Page 6-23). Route cables through hangers in the same manner as the ones removed.

  • Page 85: Section 7 - Steering And Front Suspension

    SECTION 7 – STEERING AND FRONT SUSPENSION ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION Steering is controlled through a rack and pinion steering assembly that is connected by a steering column to a steering wheel.

  • Page 86: Steering Wheel Installation

    STEERING AND FRONT SUSPENSION Steering Column Figure 7-1 Steering Wheel Removal Figure 7-2 Steering Wheel Puller STEERING WHEEL INSTALLATION NOTE: To minimize corrosion and to make future removal of the steering wheel easier, apply a small amount of oil or anti-seize compound to steering shaft splines and taper before installing the steering wheel.
  • Page 87 STEERING AND FRONT SUSPENSION Steering Column TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 7-3 Steering Column 2012 Turf/Carryall Vehicle Maintenance and Service Manual Page 7-3...
  • Page 88 STEERING AND FRONT SUSPENSION Steering Column 3. Remove the center dash panel (Figure 7-4, Page 7-4). 3.1. Remove the plastic cap (1) covering the mounting screw (2) on each side of the center dash panel (3) (Figure 7-4, Page 7-4). 3.2.

  • Page 89: Steering Column Disassembly

    STEERING AND FRONT SUSPENSION Steering Column STEERING COLUMN DISASSEMBLY 1. Remove bolts (6) and mounts (4 and 5) from steering column. Remove boot (12) (Figure 7-3, Page 7-3). 2. While supporting steering column (20) on a workbench, remove snap ring (13) from shaft. See following NOTE.
  • Page 90 STEERING AND FRONT SUSPENSION Steering Column COLUMN RETAINING TOOL (CCI P/N 1014259) STEP 1 STEP 1 BEARING BEARING PRESS TOOL PRESS TOOL 2 to 2-1/8 inches (CCI P/N 1014264) (CCI P/N 1014264) (5.1-5.4 cm) STEP 2 Wedge seating into the inner Wedge seating races of bearing.

  • Page 91: Steering Adjustment

    STEERING AND FRONT SUSPENSION Steering Column STEERING ADJUSTMENT See General Warning, Section 1, Page 1-1. 1. Turn the steering wheel all the way to the right. Note the distance between the passenger side spindle stop (2) and passenger side A-plate (3) (Figure 7-7, Page 7-8). The internal stop on the rack must reach its limit of travel against rack and pinion housing at exactly the same time the spindle stops against the passenger side A-plate (with vehicle wheels turned to the right).

  • Page 92: Rack And Pinion

    STEERING AND FRONT SUSPENSION Rack and Pinion Figure 7-7 Adjust Steering Alignment RACK AND PINION See General Warning, Section 1, Page 1-1. CAUT ION • Front impacts that bend tie rods and/or drag links can possibly damage internal steering gear components.
  • Page 93 STEERING AND FRONT SUSPENSION Rack and Pinion 3. Remove the bolts (30), washers (31), and lock nuts (32) from the steering rack assembly mounting bracket (Figure 7-8, Page 7-9). 4. Remove the bolt (2) and flat washer (3) on the upper universal joint, then remove the rack assembly and universal joint from the vehicle (Figure 7-3, Page 7-3).

  • Page 94: Rack And Pinion Disassembly

    STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION DISASSEMBLY CAUT ION • The ball joint (23) (Figure 7-8, Page 7-9) has left-hand threads. 1. Remove ball joint from the spindle and inspect it for excessive wear. 2. Remove the drag link (28) (Figure 7-8, Page 7-9). 3.

  • Page 95: Rack And Pinion Assembly

    STEERING AND FRONT SUSPENSION Rack and Pinion INNER BALL TAB WASHER JOINT WOOD BLOCKS Figure 7-11 Secure Rack in Vise 14. Inspect the bushing (5) for excessive wear. If wear is excessive, replace the steering box assembly (CC P/N 101878302) (Figure 7-8, Page 7-9). RACK AND PINION ASSEMBLY 1.
  • Page 96 STEERING AND FRONT SUSPENSION Rack and Pinion 15/16-INCH DEEP WELL SOCKET DUST SEAL Figure 7-12 Press In Dust Seal Figure 7-13 Rack and Pinion Adjustment VISE 3/8-INCH 1/4 DRIVE DEEP WELL SOCKET Figure 7-14 Rack and Pinion Resistance 7. Install the internal snap ring (11) (Figure 7-8, Page 7-9). 8.

  • Page 97: Rack And Pinion Installation

    STEERING AND FRONT SUSPENSION Rack and Pinion NOTE: When tightening the lock nut (15) make sure the screw (16) does not change adjust- ment (Figure 7-13, Page 7-12). 12. Install the dust seal bellows (20) and retaining ring (21) (Figure 7-8, Page 7-9). 13.

  • Page 98: Tie Rod And Drag Link

    STEERING AND FRONT SUSPENSION Rack and Pinion TIE ROD AND DRAG LINK See General Warning, Section 1, Page 1-1. TIE ROD AND DRAG LINK REMOVAL – MAINTENANCE-FREE BALL JOINTS 1. Using locking pliers to hold tie rod (11) and drag link, loosen jam nuts (7 and 12) on tie rod ball joints (6 and 13) (Figure 7-20, Page 7-19 or Figure 7-22, Page 7-21) and loosen jam nuts (27 and 29) on the drag link (Figure 7-8, Page 7-9).

  • Page 99: Front Suspension

    2. Loosen, but do not remove, the four bolts (30) that secure the leaf spring (6) to the bottom spring plate (29) (Figure 7-21, Page 7-20 or Figure 7-23, Page 7-22). See also Figure 7-16, Page 7-15. PROPER CAMBER Club Car Loosen 4 bolts (30). ADJUSTMENT Loosen hex nut (8) on eccentric.
  • Page 100 (Figure 7-17, Page 7-16). Club Car Figure 7-17 Check Toe-In Figure 7-18 Adjust Toe-In 4.

  • Page 101: Front Suspension Components

    STEERING AND FRONT SUSPENSION Front Suspension Components 7. Tighten nuts (loosened in step 6) to 21 ft-lb (28 N·m) and recheck toe-in. 8. After toe-in adjustment is made and with wheels in the straight ahead position, the steering wheel should be at the center of its travel.
  • Page 102 STEERING AND FRONT SUSPENSION Front Suspension Components Figure 7-19 Connect Front Brake Cables 4. Remove kingpin hardware. 4.1. Remove the nut (35) and conical washer (36) from the top of the kingpin (26) (Figure 7-21, Page 7-20 or Figure 7-23, Page 7-22). 4.2.
  • Page 103 STEERING AND FRONT SUSPENSION Front Suspension Components Figure 7-20 Two-Wheel Brake Vehicle – Upper Portion 2012 Turf/Carryall Vehicle Maintenance and Service Manual Page 7-19...
  • Page 104 STEERING AND FRONT SUSPENSION Front Suspension Components Figure 7-21 Two-Wheel Brake Vehicle – Lower Portion Page 7-20 2012 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 105 STEERING AND FRONT SUSPENSION Front Suspension Components Figure 7-22 Four-Wheel Brake Vehicle – Upper Portion 2012 Turf/Carryall Vehicle Maintenance and Service Manual Page 7-21...
  • Page 106 STEERING AND FRONT SUSPENSION Front Suspension Components Figure 7-23 Four-Wheel Brake Vehicle – Lower Portion Page 7-22 2012 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 107: Kingpin And Steering Spindle Installation

    STEERING AND FRONT SUSPENSION Front Suspension Components KINGPIN AND STEERING SPINDLE INSTALLATION 1. Inspect all parts and replace them as necessary. 2. Install the kingpin (26) over the leaf spring eye. Insert the bolt (25) and install the nut (14) (Figure 7-21, Page 7-20 or Figure 7-23, Page 7-22).

  • Page 108: Shock Absorber Installation

    STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs SHOCK ABSORBER INSTALLATION NOTE: When installing shock absorbers, make sure front shocks have identical part numbers and rear shocks have identical part numbers. 1. Install the shock absorber by reversing the removal procedure. 2.

  • Page 109: Front Wheel Bearings And Hub Removal

    STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs FRONT WHEEL BEARINGS AND HUB REMOVAL 1. Remove the front wheels. See Wheel Removal, Section 8, Page 8-1. 2. Remove the front wheel hubs. 2.1. Remove dust cover (1), cotter pin (2), spindle nut (3), and flat washer (8) (Figure 7-24, Page 7-24). 2.2.

  • Page 111: Section 8 - Wheels And Tires

    Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care. • Keep tires properly inflated as follows: - 16-18 psi (1.10-1.24 Bars) for Turf 1 and Carryall 1 gasoline vehicles - 18-20 psi (1.24-1.38 Bars) for Turf 1 and Carryall 1 electric vehicles - 30-34 psi (2.07-2.34 Bars) for all other vehicles.

  • Page 112: Tires

    WHEELS AND TIRES Wheels TIRES See General Warning, Section 1, Page 1-1. NOTE: Tire Removal NOTE: Tire must be removed or installed from the valve stem side of the rim. 1. Remove the tire and wheel assembly from the vehicle as instructed. See Wheel Removal on page 8-1. 2.

  • Page 113: Tire Repair

    WHEELS AND TIRES Wheels TIRE REPAIR 1. Determine the location and cause of the air leak. 1.1. Remove the wheel as instructed. See Wheel Removal on page 8-1. Inflate the tire to no more than 20 psi (1.38 Bars). 1.2. Immerse the tire in water and then mark the point where bubbles are formed by escaping air. 1.3.
  • Page 114 Figure 8-2 Inflate Tire 8. Adjust air pressure in the tire to: • 16-18 psi (1.10-1.24 Bars) for Turf 1 and Carryall 1 gasoline vehicles • 18-20 psi (1.24-1.38 Bars) for Turf 1 and Carryall 1 electric vehicles • 30-34 psi (2.07-2.34 Bars) for all other vehicles.

  • Page 115: General Information

    SECTION 9 – REAR SUSPENSION ý DANGER • See General Warning, Section 1, Page 1-1. ý WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION The rear suspension and powertrain of the vehicle move independently from the vehicle frame. The suspen- sion includes two multi-leaf springs controlled by two hydraulic shock absorbers mounted between the spring mounting plate and the frame.

  • Page 116: Shock Absorber Installation

    (10) expands to the same diameter as the cup washer. MULTI-LEAF SPRINGS See General Warning, Section 1, Page 1-1. NOTE: Turf 1 and Carryall 1 vehicles are equipped with jounce bumpers (Figure 9-3, Page 9-4). MULTI-LEAF SPRING REMOVAL 1. Loosen the lug nuts on the wheel(s) to be removed.

  • Page 117: Multi-Leaf Spring Installation

    (Figure 9-3, Page 9-4). 7. All Turf and Carryall vehicles except Turf 1 and Carryall 1: Remove the lock nuts (14) attaching the U-bolt (11) to the shock mount bracket (16). Do not disconnect brake cable from bracket (Figure 9-4, Page 9-5).
  • Page 118 TYPICAL ON TYPICAL BOTH SIDES BOTH SIDES OF VEHICLE REAR BRAKE CABLE REAR BRAKE CABLE ELECTRIC VEHICLES ONLY TYPICAL 2 PLACES Figure 9-3 Rear Suspension – Turf 1 and Carryall 1 Vehicles Page 9-4 2012 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 119 BOTH SIDES OF VEHICLE REAR BRAKE CABLE ELECTRIC VEHICLES ONLY ELECTRIC VEHICLES ONLY TYPICAL 2 PLACES Figure 9-4 Rear Suspension – All Turf and Carryall Vehicles Except Turf 1 and Carryall 1 2012 Turf/Carryall Vehicle Maintenance and Service Manual Page 9-5...

  • Page 120: Snubber

    (13) (if present), and lock nuts (14). Tighten U-bolt to 25 ft-lb (34 N·m) (Figure 9-3, Page 9-4). 5. All Turf and Carryall vehicles except Turf 1 and Carryall 1: Install shock mount bracket (16) onto locating bolt at bottom center of leaf-spring (Figure 9-4, Page 9-5). See following NOTE.

  • Page 121: Stabilizer Bar

    REAR SUSPENSION Stabilizer Bar STABILIZER BAR See General Warning, Section 1, Page 1-1. NOTE: A stabilizer bar is installed on gasoline Turf 2, Turf 6, Carryall 2, Carryall 2 Plus and Carryall 6 vehicles. STABILIZER BAR REMOVAL 1. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame crossmember between the spring mount and the side stringer, just forward of each rear wheel.

  • Page 122: Stabilizer Bar Installation

    REAR SUSPENSION Jounce Bumpers 3. Remove bolts (14) and lock nuts (15) from the left and right stabilizer bar bushing support (12) and remove supports and stabilizer bar (1) from vehicle. 4. Remove bushings (13) from stabilizer bar (1). STABILIZER BAR INSTALLATION 1.
  • Page 123 INDEX shoe installation (manually-adjusted brakes) ..6-10 accelerator installation (self-adjusting brakes) ....6-5 pedal (electric) removal ............6-1 height adjustment ........5-18 bumper installation ...........5-11 installation ............4-16 removal ............5-9 removal ............4-16 pedal (gas) height adjustment ........5-14 installation .............5-8 CAUTION removal ............5-6 definition of ............1-1 access door cleaning installation ............4-11...
  • Page 124 INDEX removal .............. 7-1 storage multi-leaf spring electric vehicle ........... 3-4 installation ............9-3 gasoline vehicle ..........3-2 removal .............. 9-2 suspension, front camber adjustment .......... 7-15 components ............. 7-17 park brake delta a-plate adjustment (electric) ........5-17 installation ..........7-23 adjustment (gas) ..........
  • Page 125 INDEX removal ..............4-6 tire installation ............8-3 pressure .............8-1 removal ..............8-2 repair ..............8-3 trailer hitch installation ............4-15 removal ............4-15 WARNING definition of ............1-1 wheel see also tire installation ............8-1 removal ..............8-1 2012 Turf/Carryall Vehicle Maintenance and Service Manual Page i-3...
  • Page 127 5. If you are reviewing a Kit Instruction, were all indicated parts included in your kit? Yes / No Your Comments and Suggestions: Please send a copy of this page to: Fax: (706) 228-2662 or Thank You! E-mail: Tech_Pubs@clubcar.com Club Car’s Technical Publications Department 2012 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 129 Club Car NOTES...
  • Page 130 Club Car NOTES...
  • Page 132 Club Car, LLC www.clubcar.com P.O. Box 204658 Phone 1.706.863.3000 Augusta, GA 30917-4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...

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