Rops Installation - Club Car Carryall 1500 Maintenance And Service Manual

4
Roll-Over Protective Structure (ROPS)
4. Remove the two hex-head bolts (24) and two flanged lock nuts (25) securing the top brace (23). Remove
top brace from vehicle.
5. Remove the hex-head bolts (18) and flanged lock nuts (19) securing the rear support tubes (16) to the rear
seat support (17).
6. Remove the hex-head bolts (21) and flanged lock nuts (22) securing the rear support tubes (16) to the tube
brackets (20) and to the forward side support tubes (4).
7. Remove the tube brackets (20) and rear support tubes (16) from the vehicle.
8. Remove the forward side supports (4).

ROPS INSTALLATION

NOTE: Follow steps 1 through 3 for 2-passenger vehicles and steps 1 through 8 for 4-passenger vehicles. ROPS
installation will be easier with the aid of an assistant.
1. Position the side support tubes (4) to the seat support (7) and front cowl supports (8) and secure with hex-head
bolts (5), and flanged lock nuts (6). Do not tighten hardware at this time. See following NOTE.
NOTE: Make sure the front cowl support bolt heads are oriented to outside of the ROPS and the seat support bolt
heads are oriented to the inside of the ROPS.
It may be necessary to tap the side support tubes (4) with a rubber mallet in order for them to align properly
with the front and rear support tubes.
2. Position the top structure (3) to the top of the side support tubes (4) and secure with hex-head bolts (1), and
flanged lock nuts (2). Do not tighten hardware at this time. See following NOTE.
NOTE: Orient the top structure (3) so the grab handle is on the passenger side and the warning decal is visible to
the driver.
3. Tighten all hardware to 33 ft-lb (45 N·m). See following WARNING and NOTE.
NOTE: If any ROPS joints remain loose, apply additional torque up to 40 ft-lb (54 N·m).
WARNING
• Exceeding the maximum torque value could result in damage to the ROPS tubing and stripped threads
on the hardware.
• Ensure that the ROPS is properly installed before operating the vehicle.
4. Position the two rear support tubes (16) loosely to the rear seat support (17). Do not install hardware at this time.
5. Secure the rear support tubes (16) to the forward side support tubes (4) with tube brackets (20), using hex-head
bolts (21) and flanged lock nuts (22). Do not tighten hardware at this time. See following NOTE.
NOTE: Make sure bolt heads are oriented to the inside of the ROPS.
6. Lower the two rear support tubes (16) fully into position on the rear seat support (17) and secure with hex-head
bolts (18) and flanged lock nuts (19). Do not tighten hardware at this time. See following NOTE.
NOTE: It may be necessary to tap the side support tubes (4) with a rubber mallet in order for them to align properly
with the front and rear support tubes.
7. Position the top brace (23) to the top of the rear side supports (16) and secure with hex-head bolts (24) and
flanged lock nuts (25).
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