1999 Club Car Carryall Turf II Gas Factory Service & Work Shop Manual

CARRYALL I, CARRYALL II, CARRYALL II PLUS AND CARRYALL VI VEHICLES MANUAL NUMBER 1 01968402 EDITION CODE 0299B0500A 1998-1999 MAINTENANCE SERVICE MANUAL

1998/1999 Carryall Vehicle Maintenance and Service Manual Page i FOREWORD Club Car Carryall vehicles are designed and built to provide maximum efficiency and performance. How- ever, proper maintenance and repair is essential for achieving maximum service life and continued safe and reliable operation. This maintenance and service manual provides detailed procedures for the maintenance and repair of those components that are common to all Club Car Carryall vehicles, and should be used in conjunction with the appropriate maintenance and service supplement. The supplement will provide maintenance and repair procedures for those components specific to a particular type of vehicle. If you do not have the appropriate supplement for your vehicle(s), you may obtain one of the following from your Club Car distributor: This manual and the supplement should be thoroughly read prior to servicing the vehicle. The procedures provided must be properly implemented, and the DANGER, WARNING, and CAUTION statements must be understood and followed. This manual was written for the vehicle 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 it unsafe. For this reason, we advise that all repairs and/or service be performed by an authorized Club Car distributor’s/dealer’s representative or by a Club Car factory trained technician. It is the policy of Club Car, Inc. 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 service manual, used in conjunction with the appropriate supplement, covers all aspects of typical Car- ryall service. However, unique situations do sometimes occur when servicing a Carryall vehicle. If it appears that a service question is not answered in this manual or the supplement, you may write to us at: Club Car, Inc.; P.O. Box 204658; Augusta, GA 30917; Attention: Technical Services, or contact a Club Car Technical Service Representative at (706) 863-3000, ext. 3580. ©1999 Club Car, Inc. Club Car, Carryall, ArmorFlex and PowerDrive are registered trademarks of Club Car, Inc. This manual effective August 18, 1997 1998/1999 PowerDrive System 48 Vehicle Maintenance & Service Supplement Publication Part No. 101968404 1998/1999 FE290 Gasoline Vehicle Maintenance & Service Supplement Publication Part No. 101968407 1998/1999 FE350 Gasoline Vehicle Maintenance & Service Supplement Publication Part No. 101968408

Page ii 1998/1999 Carryall Vehicle Maintenance and Service Manual • READ SECTION 1–SAFETY BEFORE ATTEMPTING ANY SERVICE ON THIS VEHICLE. • BEFORE SERVICING VEHICLE, READ COMPLETE SECTION(S) AND ANY REFERENCED INFORMATION THAT MAY BE RELEVANT TO THE SERVICE OR REPAIR TO BE PERFORMED. • THIS MANUAL REPRESENTS THE MOST CURRENT INFORMATION AT THE TIME OF PUBLICATION. CLUB CAR, INC. IS CONTINUALLY WORKING TO FURTHER IMPROVE OUR 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 DISTRIBUTORS AND DEALERS AND WILL, WHEN APPLICABLE, APPEAR IN FUTURE EDITIONS OF THIS MANUAL. • DAMAGE TO A VEHICLE OR COMPONENT THEREOF NOT RESULTING FROM A DEFECT OR WHICH OCCURS DUE TO UNREASONABLE OR UNINTENDED USE, OVERLOADING, ABUSE, OR NEGLECT (INCLUDING FAILURE TO PROVIDE REASONABLE OR NECESSARY MAINTENANCE AS INSTRUCTED IN THE VEHICLE OWNER’S MANUAL), ACCIDENT OR ALTERATION, INCLUDING INCREASING VEHICLE SPEED BEYOND FACTORY SPECIFICATIONS OR MODIFICATIONS WHICH AFFECT THE STABILITY OF THE VEHICLE OR THE OPERATION THEREOF, WILL VOID THE WARRANTY. • CLUB CAR, INC. RESERVES THE RIGHT TO CHANGE SPECIFICATIONS AND DESIGNS AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION OR LIABILITY WHATSOEVER. • THERE ARE NO WARRANTIES EXPRESSED OR IMPLIED IN THIS MANUAL. SEE THE LIMITED WARRANTY FOUND IN THE VEHICLE OWNER’S MANUAL OR WRITE TO CLUB CAR, INC. WARNING NOTE

1998/1999 Carryall Vehicle Maintenance and Service Manual Page iii CONTENTS SAFETY SECTION General Warning ............................................................................................................................... 1-1 VEHICLE SPECIFICATIONS SECTION General Information .......................................................................................................................... 2-1 GENERAL INFORMATION SECTION Model Identification ........................................................................................................................... 3-1 Pre-Operation Checklist .................................................................................................................... 3-1 Controls ............................................................................................................................................ 3-3 Driving Instructions ........................................................................................................................... 3-9 Bed Latch ......................................................................................................................................... 3-11 Loading and Unloading ..................................................................................................................... 3-12 Towing with the Vehicle ..................................................................................................................... 3-13 Transporting on a Trailer ................................................................................................................... 3-13 Storage–Gasoline Vehicle ................................................................................................................. 3-14 Storage–Electric Vehicle ................................................................................................................... 3-16 BODY AND TRIM SECTION Cleaning the Vehicle ......................................................................................................................... 4-1 Front Body Repair ............................................................................................................................. 4-2 Front Body ........................................................................................................................................ 4-4 Seat .................................................................................................................................................. 4-2 Tilt Bed–Carryall I, II, Turf II And II Plus ............................................................................................ 4-5 Flat Bed–Carryall VI .......................................................................................................................... 4-7 Flat Bed Trim–Carryall VI .................................................................................................................. 4-7 Access Door–Carryall VI ................................................................................................................... 4-10 Side Door–Carryall VI ....................................................................................................................... 4-10 Rear Fender ...................................................................................................................................... 4-10 Tailskirt .............................................................................................................................................. 4-13 Floor Mat ........................................................................................................................................... 4-13 ACCELERATOR AND BRAKE PEDAL GROUP SECTION Pedal Group Adjustment ................................................................................................................... 5-2 Pedal Group Disassembly and Assembly ......................................................................................... 5-12 WHEEL BRAKE ASSEMBLIES SECTION General Information .......................................................................................................................... 6-2 Brake Shoe Removal ......................................................................................................................... 6-3 1 2 3 4 5 6

Page iv 1998/1999 Carryall Vehicle Maintenance and Service Manual Brake Assembly Cleaning (Self-Adjusting Brakes) ........................................................................... 6-4 Brake Shoe Installation (Self-Adjusting Brakes) ............................................................................... 6-6 Brake Adjustment (Self-Adjusting Brakes) ........................................................................................ 6-8 Brake Assembly Cleaning (Manually Adjusted Brakes) .................................................................... 6-8 Brake Shoe Installation (Manually Adjusted Brakes) ........................................................................ 6-9 Rear Brake Cable Adjustment (Manually Adjusted Brakes) .............................................................. 6-11 Front Brake Cable Adjustment (Manually Adjusted Brakes) ............................................................. 6-12 Brake Cluster Removal and Installation ............................................................................................ 6-13 Front Brake Cables ........................................................................................................................... 6-18 STEERING AND FRONT SUSPENSION SECTION General Information .......................................................................................................................... 7-1 Steering Wheel ................................................................................................................................. 7-2 Steering Column ............................................................................................................................... 7-3 Steering Adjustment ......................................................................................................................... 7-7 Rack and Pinion ................................................................................................................................ 7-7 Tie Rod and Drag Link ...................................................................................................................... 7-12 Front Suspension .............................................................................................................................. 7-13 Front Suspension Components ........................................................................................................ 7-15 Front Wheel Bearings and Hubs ....................................................................................................... 7-22 WHEELS AND TIRES SECTION General Information .......................................................................................................................... 8-1 Wheels .............................................................................................................................................. 8-2 Tires .................................................................................................................................................. 8-3 REAR SUSPENSION SECTION General Information .......................................................................................................................... 9-1 Shock Absorbers ............................................................................................................................... 9-2 Multi-leaf Springs .............................................................................................................................. 9-2 Snubber ............................................................................................................................................ 9-7 Stabilizer Bar ..................................................................................................................................... 9-7 Jounce Bumpers ............................................................................................................................... 9-9 7 8 9

1998/1999 Carryall Vehicle Maintenance and Service Manual Page 1-1 SECTION 1–SAFETY To ensure the safety of those servicing Club Car Carryall 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 contained within boxes labeled DAN- GER, WARNING, or CAUTION. These special statements relate to specific safety issues, and must be read, understood, and heeded before proceeding with procedures. There are also boxes labeled NOTE, which provide other essential service or maintenance information. GENERAL WARNING The following safety procedures must be followed whenever the vehicle is being operated, repaired, or ser- viced. Service technicians should become familiar with these general statements, which can be found throughout this manual. Also, other specific warnings appear throughout this manual and on the vehicle. • A DANGER INDICATES AN IMMEDIATE HAZARD WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH. • A WARNING INDICATES AN IMMEDIATE HAZARD WHICH COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH. • A CAUTION INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN PRODUCT OR PROPERTY DAMAGE OR MINOR PERSONAL INJURY. • A NOTE PROVIDES KEY INFORMATION TO MAKE PROCEDURES MORE EASILY UNDERSTOOD. • BATTERY - EXPLOSIVE GASES! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY FROM THE VEHICLE. VENTILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE. ALWAYS WEAR A FULL FACE SHIELD 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 WATER. FOLLOW WITH MILK OF MAGNESIA OR VEGETABLE OIL. CALL A PHYSICIAN IMMEDIATELY. - EYES: FLUSH WITH WATER FOR FIFTEEN MINUTES. CALL A PHYSICIAN IMMEDIATELY. DANGER WARNING CAUTION NOTE DANGER

SAFETY General Warning Page 1-2 1998/1999 Carryall Vehicle Maintenance and Service Manual 1 General Warning, Continued: • GASOLINE - FLAMMABLE! EXPLOSIVE! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY FROM 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. • A CLUB CAR VEHICLE WILL NOT PROVIDE PROTECTION FROM LIGHTNING, FLYING OBJECTS, OR OTHER STORM RELATED HAZARDS. IF CAUGHT IN A STORM WHILE DRIVING A CLUB CAR VEHICLE EXIT THE VEHICLE AND SEEK SHELTER IN ACCORDANCE WITH APPLICABLE SAFETY GUIDELINES FOR YOUR LOCATION. • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THE VEHICLE. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN ELECTRICAL AND MECHANICAL REPAIR. • FOLLOW THE PROCEDURES EXACTLY AS STATED IN THIS MANUAL, AND HEED ALL DANGER, WARNING, AND CAUTION STATEMENTS LISTED IN THIS MANUAL AS WELL AS THOSE AFFIXED TO THE VEHICLE. • IMPROPER USE OF THE VEHICLE OR FAILURE TO PROPERLY MAINTAIN IT, COULD RESULT IN DECREASED VEHICLE PERFORMANCE OR SEVERE PERSONAL INJURY. • ANY MODIFICATION OR CHANGE TO THE VEHICLE WHICH AFFECTS THE STABILITY OR HANDLING OF THE VEHICLE, OR INCREASES MAXIMUM VEHICLE SPEED BEYOND FACTORY SPECIFICATIONS, COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH. • CHECK THE VEHICLE OWNER’S MANUAL FOR PROPER LOCATION OF ALL VEHICLE WARNING DECALS AND MAKE SURE THEY ARE IN PLACE AND ARE EASY TO READ. • WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN SERVICING THE VEHICLE. • DO NOT WEAR LOOSE CLOTHING. REMOVE JEWELRY SUCH AS RINGS, WATCHES, CHAINS, ETC. BEFORE SERVICING VEHICLE. • MOVING PARTS! DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING. • HOT! DO NOT ATTEMPT TO SERVICE HOT MOTOR, ENGINE, OR EXHAUST SYSTEMS. FAILURE TO HEED THIS WARNING COULD RESULT IN SEVERE BURNS. • USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL CONNECTIONS. • LIFT ONLY ONE END OF VEHICLE AT A TIME. BEFORE LIFTING, UNLOAD CARGO BED, LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR. 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. ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT VEHICLE. • TURN THE KEY SWITCH TO OFF AND REMOVE KEY. CHOCK THE WHEELS, PLACE THE FORWARD/REVERSE HANDLE IN NEUTRAL, AND DISCONNECT BATTERY(IES) PRIOR TO SERVICING THE VEHICLE. WARNING CONTINUED ON NEXT PAGE... DANGER WARNING

SAFETY General Warning 1998/1999 Carryall Vehicle Maintenance and Service Manual Page 1-3 1 GASOLINE VEHICLES ONLY: • TO AVOID UNINTENTIONALLY STARTING THE VEHICLE: - DISCONNECT BATTERY CABLES, NEGATIVE (–) 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 ELECTRIC WIRING. NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME, ENGINE, OR OTHER METAL COMPONENT. ELECTRIC VEHICLES ONLY: • TO AVOID UNINTENTIONALLY STARTING THE VEHICLE, DISCONNECT BATTERIES AS SHOWN (FIGURE 1-2, PAGE 1-3). • AFTER DISCONNECTING BATTERIES, DISCHARGE THE CONTROLLER AS FOLLOWS: - TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD/REVERSE HANDLE IN THE REVERSE POSITION. - SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THE REVERSE WARNING BUZZER CAN NO LONGER BE HEARD. WHEN THE BUZZER STOPS SOUNDING, THE CONTROLLER IS DISCHARGED. Figure 1-1 Gasoline Vehicle Figure 1-2 PowerDrive Battery Configuration WARNING FRONT OF VEHICLE AS SEEN FROM PASSENGER'S SIDE OF VEHICLE REMOVE NEGATIVE CABLE FIRST DISCONNECT BATTERY CABLES BEFORE WORKING ON VEHICLE BATTERY BANK FOR CARRYALL I 1 2 3 4 6 5 BATTERY BANK FOR CARRYALL II AND CARRYALL VI 1 2 3 4 6 5 FRONT OF VEHICLE FRONT OF VEHICLE REMOVE NEGATIVE CABLE FIRST REMOVE NEGATIVE CABLE FIRST DISCONNECT BATTERY CABLES HERE DISCONNECT BATTERY CABLES HERE

1999 Club Car Carryall Turf II Gas Factory Service & Work Shop Manual

You're Reading a Preview

Recently Viewed