Golf Cart Preventive Maintenance
Contents
1. Form maintained for each golf cart by the Facilities Manager and kept in a three ringed binder on the cart supply shelf 2009 Club Resources International 5 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Golf Cart Preventive Maintenance and Repair Program Continued These completed forms for each golf cart are subject to inspection by management at any time Preventive maintenance and repair documents will be reviewed quarterly by the Facilities Manager who will prepare a Golf Cart Preventive Maintenance Program Report Form 526 This report will be completed signed and turned in to the General Manager by the 10 of April July Oct and Jan 2009 Club Resources International Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Review I Give two of the purposes of this training manual 1 What are your responsibilities regarding this training material 1 List the six components of the Preventive Maintenance and Repair Program sok Which three form are maintained for each golf cart and what is the purpose of each 1 What form is used to report golf carts needing repair 2009 Club Resources International 7 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Battery Care Batteries should be kept clean and free of corrosion Once a week wash tops and terminals of batteries with a solution of baking soda and water 1 cup baking soda per2. Pivots Accelerator push rod pivots and mounts Forward Reverse Switch Contacts and charger receptacle Brake Slides Front Suspension 5 fittings Check fill trans axle to plug level Inspect front wheel bearings Repack as necessary Place 1 Recommended Lubricant Dry Moly Lube Club Car Part No 1012151 Dry Moly Lube Club Car Part No 1012151 Dry Moly Lube Club Car Part No 1012151 WD 40 Dry Moly Lube Club Car Part No 1012151 Chassis Lube EP NLGI Grade 2 22 oz 67 liter SAE 30 WT API Class SE SF or SG Oil or higher Chassis Lube EP NLGI Grade 2 See Figure 11 Page 17 2009 Club Resources International 18 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Review How do you keep batteries clean and free of corrosion How often do you check the electrolyte level in batteries Once you plug in the charger plug what prevents the cart from operating A computer shuts off the charger when the optimum charge is reached True False When the charger shuts of f by itself batteries are fully charged True False Batteries don t need to be charged if the cart is used for a short time True False Don t twist rock or bend plug when inserting removing from receptacle True False List three cart components checked during the Pre Operation Safety Check 1 2 3 How do you check proper brake performance List three items from the Periodic Service Schedule th
3. noises such as squeaks and rattles Tires e Visually inspect for wear and damage e Check for proper tire inflation 18 20 psi Batteries e Check electrolyte level at least 5 inch above plate 2009 Club Resources International 14 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Pre Operation Safety Check Continued e Check battery posts wires should be tight and free of corrosion e Check battery charge light Is it illuminated Performance Inspection e Brake system when fully depressed under moderate pressure the pedal should not go more than halfway to the floor Vehicle should come to a smooth straight stop within 14 feet e Park brake does it hold the cart still Does it release properly e Reverse warning buzzer does it sound in reverse e Steering and linkages does cart steer easily without excess play e Proper acceleration with key switch on and forward reverse switch in forward position as accelerator pedal is depressed the motor should start and the vehicle should come up smoothly to speed When pedal is released it should return to original position and motor should stop e Maximum speed is the cart sluggish and seem without power 2009 Club Resources International 15 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Periodic Service Schedule The following services should be performed on all golf carts and recorded on each cart s indi
4. timely manner 2009 Club Resources International 2 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Golf Cart Preventive Maintenance and Repair Program The Club has 72 battery powered golf carts for use by its members In addition the Club has a number of gas powered utility carts used in support of operations These carts represent a large investment on the part of the Club The useful life of golf carts can be maintained and even extended by proper preventive maintenance Inoperative or unserviceable golf carts must be repaired in a timely manner Golf Cart Preventive Maintenance Program The Golf Cart Preventive Maintenance Program is a comprehensive series of checks and services to properly maintain golf carts in good working order The program entails six basic components e Battery Care e Battery Charging e Pre Operation Safety Check e Periodic Service Schedule e Periodic Lubrication Schedule Golf Cart Cleaning and Detailing 2009 Club Resources International 3 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Golf Cart Preventive Maintenance and Repair Program Continued Repairs Golf cars needing repairs will be reported to the Facilities Manager on a Facilities Maintenance Work Order Form The Facility Manager will inspect golf carts needing repair to determine the level of work necessary e Repair work that can be done in house by Club staff will be repair
5. Club Resources INTERNATIONAL Training Manual Golf Cart Preventive Maintenance Author Ed Rehkopf 2009 Club Resources International Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Table of Contents Ub DOS 1 Responsibilities nd rue een nan 2 Golf Cart Preventive Maintenance and Repair Program 3 UM A P 7 8 Battery Charollig ro e oti D 10 Pre Operation Safety Check nine 14 Periodic Service Schedules us 16 Periodic Lubrication Schedule sss 18 a 19 Golf Cart Cleaning and Detailing sss 20 Golf Cart Storages aedium eam er ona RARE MM RR IN QUE 22 Cart Fleet anseres tecti e ien end cadet 23 REVIEW TT disease ptem 24 Training CU FOE nde n ueritate ope tubo nn ou deu 25 Appendices Al Monthly Cart Detailing Report 26 Golf Cart Service 27 Golf Cart Lubrication 28 A4 Golf Cart Repair Log cete ered eerte ds 29 A5 Monthly Cart Battery Usage 30 B1 Cart Barn Layout scans etc ated erit ru a ea eben FER 31 B2 Cart Supplies and Cart Wash Area
6. L Appendix Al Monthly Cart Detailing Report Monthly Cart Detailing Report Detailer s Detailer s Date Detailed Initials Initials Club Resources International 1st Asst Golf Professional s Signature Form 515 Effective 2 14 00 2009 Club Resources International 26 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Appendix A2 Golf Cart Service Schedule Club Resources International Golf Cart Service Schedule Person performing service must initial in appropriate block below Golf Cart Weekly Service Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 46 17 18 19 20 21 22 23 24 25 26 Check battery electrolyte level Add water as necessary Week 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 3 4 5 6 7 8 9 10 1112 13 14 15 16 17 18 19 20 21 22 23 24 25 26 2 Wash battery tops clean terminals w baking soda solution Week 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 3 4 5 6 7 8 9 10 1112 13 14 15 16 17 18 19 20 21 22 23 24 25 26 3 Check tire air pressure Correct as necessary Week 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Monthly Service i a Aug Sep Oct Nov Dec 1 Check wiper switch Look for damage looseness movable contact 2 Wash battery compartment and underside of vehicle 3 Lubricate brake slides Check brake cables for damage Semi Annual Se
7. Layout 32 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Purpose The purpose of this training manual is e to train you in the knowledge skills and techniques necessary to properly maintain the Club s golf cart fleet e to teach you how to document golf cart servicing and lubrication and e to establish procedures to track and monitor repairs to golf carts 2009 Club Resources International Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Responsibilities It is the responsibility of the Head Golf Professional to ensure that all preventive maintenance is performed according to schedule Further it is his responsibility to ensure that cart attendants are properly trained to perform routine preventive maintenance checks and servicing according to schedule It is the Facility Manager s responsibility to monitor the performance of routine preventive maintenance e assist the Head Golf Professional in establishing and maintaining the Golf Cart Preventive Maintenance Program and e provide expert assistance and advice to the Head Golf Professional and cart attendants in dealing with specific maintenance and repair problems with golf carts It is the cart attendants responsibility to conscientiously perform all specified checks and services called for in the Golf Cart Preventive Maintenance Program and to report problems to the Head Golf Professional in a
8. Maintenance INTERNATIONAL Cart Fleet Rotation Each golf cart has a numbered decal to identify it The Cart Barn has striped parking stalls for all golf carts These parking stalls are also numbered with numbers corresponding to the numbers on carts Cart attendants will be instructed to park all carts in their assigned stalls Each day sufficient carts will be pulled out of the Cart Barn to provide for the expected level of play Carts will be pulled out in sequence beginning with the next numbered cart from the last cart used the previous day Cart Attendants will keep track of which carts are used each day by means of a Cart Usage Tracking Sheet Form 508 This form will be maintained in the Cart Attendants three ringed binder that is kept on the Supplies Storage Shelves in the Cart Barn If any cart is malfunctioning or in need of repair it will be skipped in the normal rotation and noted on the Cart Usage Tracking Sheet Once a month as close to the last day of the month as possible Cart Attendants will read the charge on each cart with the Battery Usage Meter and record it on a Monthly Cart Battery Usage Report Form 509 This form will be turned in to the 1 Assistant Professional when completed O 2009 Club Resources International 23 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Review III List the four daily cleaning procedures for golf carts 1 2 3 4 List the three monthly deta
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10. acle fuse link is blown determine the source of the electrical problem and correct it before replacing the fuse Notify the Facilities Manager who will contact our Club Car Distributor or Dealer General Warnings Be sure all wire connections at the receptacle and the fuse link are clean and tight Do not rock or bend the plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 13 Do not pull on the DC cord Do not twist rock or bend the plug To disconnect the charger plug from the vehicle receptacle grasp the plug by the handle and pull the plug straight out of the receptacle Figure 13 Correct Insertion of Charger DC Plug Figure 14 Incorrect Insertion of Charger DC Plug Do not connect a charge to the receptacle if the charger cord plug or the vehicle receptacle is broken damaged in any manner or does not make a good electrical connection Fire or personal injury can result Have it replaced by a qualified service person immediately 2009 Club Resources International 12 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Battery Charging Continued Failure to follow these instructions could result in damage to the charger cord the plug and or the vehicle receptacle Do not use a charger if The plug is too loose or does not make a good connection The plug and receptacle feel hotter than normal during char
11. aol 5 ty ol ol ol TEE EEE Comments S e Nn 24 2 i vo AL oO ole ALATA en 22 23 27 31 Form 509 Comments 2009 Club Resources International Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Appendix B1 Cart Barn Layout 2 E e uv s gt o E a x N e 8 5 lt lt 5 19 20 ie NE E E Ed 5 S j N A vi N N N m 5 a C e gt E en en en en E 55 v aa e 2009 Club Resources International 31 Golf Cart Preventive Maintenance lies and Cart Wash Areas Cart Su INTERNATIONAL Club Resources Appendix B2 WED esog 42245 Jose JE Ira Joysmnsunxg 91M USE AA We O Kvudg sei ddng SUW C qni DRM 1M mo e LII o3e1ojg Seg 7 YAMS 30817 D 151294
12. at you need to check weekly 1 2 3 Who performs semi annual and annual lubrications 2009 Club Resources International 19 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Golf Cart Cleaning Keeping carts clean is an integral part of the preventive maintenance program and it has a major impact on our members perceptions of their golfing experience Cleaning procedures fall into two categories Daily Cleaning and Monthly Detailing Daily Cleaning Procedures Vacuum daily after use Vacuum glove compartments to remove any excess debris Brush daily after use Use soapy brush to wash off foot tread tires bag shelf and top of canopy Wash daily after use e Spray wash the cart while parked over the drain grate in the cart wash area Wipe down all surfaces with soapy water and a cleaning rag e Rinse cart with water e Wipe with shammy cloth to remove excess water e Wash battery compartment with water Windex daily before use Spray Windex on inside and outside of windshield Wipe off with clean rag Monthly Detailing Procedures Wax once a month according to schedule O 2009 Club Resources International 20 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Golf Cart Cleaning Continued e Apply wax to blue body components as per instruction on the can e Wipe off with a terry cloth and polish with a power buffer Armor All once a month according to sch
13. e Facilities Manager on a Work Order Form so they may be replaced or cleaned as necessary Failure to do so may cause them to overheat during operation After use the batteries should be placed on charge The batteries should never be left discharged any longer than absolutely necessary do not leave discharged overnight 2009 Club Resources International 9 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Battery Charging To charge a battery Insert the charger DC plug into the vehicle receptacle The charger will turn on two to ten seconds later The PowerDrive Charger interacts with an onboard computer on the PowerDrive System 48 vehicle The computer records the amount of energy consumed during vehicle use While the charger is plugged in the vehicle s control circuit is locked out preventing operation of the vehicle as well as the possibility of consequent damage to the charger and the vehicle Once the lock out is actuated the charger turns on The onboard computer then records the amount of energy being returned to the batteries When the optimum amount of energy needed to replenish the batteries is returned the charger will shut off The control circuit lock out remains activated until the charger plug is disconnected from the vehicle As long as the charger is allowed to shut off by itself the batteries will be fully charged Overcharging and undercharging will normally be prevented Batteries s
14. ed on property e Major repairs will be done by a golf cart repair contractor ona time and material basis Service Contract The Club has a service contract with an authorized golf cart repair service This contract calls for semi annual and annual servicing of golf carts according to the following schedule Semi Annual Servicing e Batteries check specific gravity amp OCV Jun e Brakes check and adjust Apr Oct e Differential check lubrication Mar Sep e Forward Reverse Switch Jun Dec e Check contacts and lead connection e Lubricate 2009 Club Resources International 4 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Golf Cart Preventive Maintenance and Repair Program Continued e Tires Apr Oct e Check for wear and damage e Check tire pressure Wheel Alignment check Mar Sep Annual Servicing e Batteries test Feb e Front Wheel Bearings check Aug e Motor check Nov Documentation All golf cart preventive maintenance and repair will be documented by cart attendants and the Facilities Manager using the following forms Golf Cart Service Schedule Form 523 maintained for each golf cart by the cart attendant staff and kept in a three ringed binder on the cart supply shelf Golf Cart Lubrication Schedule Form 524 maintained for each golf cart by the cart attendant staff and kept in a three ringed binder on the cart supply shelf Golf Cart Repair Log
15. edule Apply to foot tread and bag shelf as directed on the can Tire Polish once a month according to schedule Apply to tires as directed on the can Detailing Schedule e The following schedule will detail each cart every three weeks allowing a make up week to complete all carts once a month e Tuesdays through Thursdays 5 carts day e Fridays through Sundays 3 carts day Detailing of carts will be tracked on the Monthly Cart Detailing Report Form 515 The report will be signed by the 1 Golf Professional submitted to the Head Golf Professional for review and forwarded to the General Manager by the 5 day of the following month 2009 Club Resources International 21 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Golf Cart Storage The Cart Barn has designated parking stalls for each golf cart The stall designations match the numbered decals on the golf cart Stall designations are located on the wall behind each two stalls Keeping carts in their assigned slots makes it easier to rotate the cart fleet ensuring uniform levels of use for all carts Each stall has a corresponding battery charger cable to recharge the batteries on carts After charging hang the charging cable on wooden cleats to keep the cable off the ground For a diagram of the Cart Barn with stall designations see Cart Barn at Appendix B1 2009 Club Resources International 22 Club Resources Golf Cart Preventive
16. gallon of water Rinse solution off batteries Do not allow this solution to enter the battery e Dispose wastewater properly by allowing it to flow into the cart wash drain e Ensure terminals are tight Let terminals dry and then spray with battery protector spray Club Car Part No 1014305 The electrolyte level in the batteries should be checked weekly Figure 12 Add water only after charging unless the water level is below the top of the plates In this case add just enough water to cover the plates charge and then check the level again Never charge batteries if plates are exposed above water level For best battery life add only distilled water LEVEL BATTERY INDICATOR j CAP PLATES ELECTROLYTE LEVEL AT LEAST 1 2 IN ABOVE PLATES OR TO LEVEL INDICATOR Figure 12 Electrolyte Level in Batteries The hold down straps should be tight enough so that the batteries do not move while the vehicle is in motion but not so tight as to crack or buckle the battery case The 2009 Club Resources International 8 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Battery Care Continued terminal connections should be clean and tight and any worn insulation or frayed wires should be replaced If the hold down straps or terminal connections are loose report the problem to the Facilities Manager on a Work Order Form CAUTION If battery wire terminals are damaged or corroded report the problem to th
17. ge The plug pins powerdrive chargers or blades accu power chargers or receptacle contacts are bent or corroded The plug receptacle or cords are cut worn have any exposed wires or are damaged in any way Using the charger with any of the above symptoms could result in a fire property damage personal injury or death e The DC charger cord and plug are wear items and must be replaced when worn or damaged Note When temperatures fall below 65 F 18 3 C batteries charged in unheated areas should be placed on charge as soon as possible after use Batteries are warmest immediately after use and cold batteries require more time to fully charge After disconnecting the charging cord from a cart wrap the cord loosely around the wooden cleat This keeps the cord out of the way and off the ground O 2009 Club Resources International 13 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Pre Operation Safety Check Inspect and drive the vehicle using the Golf Cart Pre Operation Safety Check Form 527 as guide to check the following items Vehicle warning decals e Lightning Warning Decal on windshield e Driver Passenger Warning Decal center of dashboard e Operating Instruction Decal on steering wheel Motor Braking Decal center of vehicle below dashboard Brake system e All parts in place and properly installed e All nuts bolts and screws are tight e Any unusual
18. hould be put on charge even if they have been used for only a short period 9 holes of golf or 10 minutes The charger is automatic and will turn off when batteries are fully charged If the charger does not seem to be operating properly or if the batteries seem weak notify the Facilities Manager who will contact our local Club Car distributor dealer Plug and Receptacle If the charger plug becomes difficult to insert or disconnect the receptacle contacts should be lightly sprayed with WD 40 brand spray lubricant O 2009 Club Resources International 10 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Battery Charging Continued The plug should then be inserted and removed several times ensure ease of insertion ease of removal and good electrical contact If the warning tag has been damaged or removed from the DC cord notify the Facilities Manager who will have it replaced immediately Receptacle Fuse Link As an additional feature to protect the batteries and charging circuit from an overload the electric vehicle is equipped with a receptacle fuse link Figure 16 48 VOLT FUSE LINK Figure 16 Receptacle Fuse Link for 48 Volt Vehicle If the charger does not come on when the vehicle is placed on charge visually inspect the fuse link 2009 Club Resources International 11 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Battery Charging Continued WARNING If the recept
19. iling cleaning procedures for golf carts 1 2 3 How many carts a day must you detail on Tuesday through Thursday How many carts a day must you detail on Friday through Sunday What form do you record detailing of golf carts on What is the purpose of numbering cart stalls in the Cart barn What should you do with charger cords after you disconnect them from carts What form is used to record battery charge How often do you read battery usage 2009 Club Resources International 24 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Training Critique The development of training material is an ongoing process Some things don t work as well as we envisioned Our members don t respond as we hoped New things come up Employees suggest better ways of doing things The aim of all of our training is to equip you with the right knowledge skills and abilities to serve our members well and to help you do your job as professionally and effortlessly as possible As a result we need to hear from you Tell us what works What doesn t work Do you have a better idea What are our members saying What are their comments and suggestions Provide us with the necessary feedback to make our training current relevant helpful and of the highest possible quality You and your fellow employees deserve nothing less O 2009 Club Resources International 25 Club Resources Golf Cart Preventive Maintenance INTERNATIONA
20. ire connections Make sure connections are tight Front Wheel Alignment Check and adjust as required and Camber See Maintenance amp Service Manual Section 7 Annual Service by Contracted Batteries Perform battery tests per Mechanic Only Every 100 Maintenance amp Service Manual hrs of operation or 200 Rounds of golf Warnings If any problems are found do not operate the vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal injury or death Note The periodic service schedule must be followed to keep vehicle in optimum operating condition If the vehicle is constantly subjected to heavy use or severe operating conditions the preventive maintenance procedures should be performed more often than recommended in the service schedule 2009 Club Resources International 17 Club Resources INTERNATIONAL Golf Cart Preventive Maintenance Periodic Lubrication Schedule The following lubrications should be performed on all golf carts and recorded on each cart s individual Golf Cart Lubrication Schedule Form 524 These forms are maintained in a three ringed binder kept on the Cart Supply Shelf Interval Semi Annually by Contracted Technician Every 50 hrs of operation or 100 rounds of golf Annually by Contracted Technician Only Every 100 hours of operation or 200 rounds of golf Service Brake shaft bearings Brake Linkage and
21. rvice 1 Check electrical wiring amp connections for tightness and damage 2 Check forward reverse switch contacts amp connection tightness Annual Service Form 523 Effective 3 1 00 O 2009 Club Resources International 27 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Appendix Golf Cart Lubrication Schedule Club Resources International Golf Cart Lubrication Schedule Person performing service must initial in appropriate block below Golf Cart Semi Annual Lubrication Jan receptacles 5 Brake slides 6 Front suspension 5 fittings Annual Lubrication 1 Check fill trans axle to plug level 2 Inspect front wheel bearings Repack as necessary Form 524 Effective 3 1 00 2009 Club Resources International 28 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Appendix A4 Golf Cart Repair Log Golf Cart Repair Log Club Resources International Golf Cart Describe all repairs to this golf cart 5 Completed Form 525 Effective 3 1 00 2009 Club Resources International 29 w v 4 o E 221 m E s gt Comments Effective 2 14 00 30 Golf Cart Preventive Maintenance Cart Battery Usage Report Club Resources INTERNATIONAL Appendix A5 Monthl A sal pe
22. vidual Golf Cart Service Schedule Form 523 These forms are maintained in a three ringed binder kept on the Cart Supply Shelf Interval Service Detail Daily Service by Attendant Batteries Charge batteries after each use only Weekly Service by Attendant Batteries Check electrolyte level Add water as necessary per Maintenance and Service Manual Batteries Wash battery tops and clean terminals with baking soda water solution Dispose of waste water properly Tires Check air pressure and adjust as necessary See Vehicle Capacities Chart on Page 17 Monthly Service by Attendant Wiper Switch Check for cracks or other damage make sure switch is securely fastened to frame Check movable contact for correct operation General Vehicle Wash battery compartment and underside of vehicle Dispose of waste water properly Check brake shoes replace if necessary See DS Maintenance and Service Manual 2009 Club Resources International 16 Club Resources Golf Cart Preventive Maintenance INTERNATIONAL Periodic Service Schedule Continued Brake System Lubricate brake slides per Lubrication Schedule See DS Maintenance and Service Manual Check brake cables for damage replace as required Semi annual Service by Electrical Wiring Check for tightness and damage Contracted Mechanic Only and Connections Every 50 hrs of operation or 100 rounds of golf Forward and Reverse Check condition of contacts Switch and w
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