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2012 Turf/Carryall Maintenance and Service Manual

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3. ccescceeeeeeeeeeeeeeeeeeeseeeeeeneeeseaeeeeeneeeeeaes 4 15 Trailer Hitch Removal Heavy Duty 0 eee ccceeeeeseeeeeeeeeneeeeeeeeaeeeeeeeeeaeeeeeeeaaeeeeeeesaeeeeeeenaeeeeeseeaaes 4 15 Trailer Hitch Installation Heavy Duty 00 ee ceeeeee scene eee eeeeeaeeeeeeeaeeeeeeeaaeeeeeeeaeeeeeeenaeeeeeseeaaes 4 15 LEE E 4 15 RallSkirt Removal 2 22 205 A Ss Sa eae A ea eee T E TT 4 15 EE lgl Ee EE 4 15 Floor Mats ssrin eio i otek Pees Dara alae ned atied A E aaa acetal i Caria oadednen ced 4 15 Front Floor Mat Eu TEE 4 15 Front Floor Mat EE e RE 4 16 Rear Floor Mat Removal Turf 6 and Carryall 6 Only 0 0 ccceeceeeeeeeeeeeeeeeeeeneeeeeeaeeseteeeseaeeeeeeeeeee 4 16 Rear Floor Mat Installation Turf 6 and Carryall 6 Only cecccceeeseeseeeeeeeeeeeeeeeeseneeeteeeeeeeeeee 4 16 BUM PO EE 4 16 Bumper ue EE 4 16 Bumper Installation EE 4 16 SECTION 5 ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake ccccceceeceeeeeeeeeenneeeeeeeeeeeeeeeecaaeeaeeeeeeeeeeeeeecccaeeeeeeeeeeeeesesceeenieeaeees 5 1 Brake Pedal Removal ccceeeceececeeneeee eee e eee etec eee aaee eee ee steer ete deccaaaeeeeeeeeeeeeesecccaaaaeeeeeeeeeeeeeeeeeee 5 1 Brake Pedal lnetallatert ee eaen ta EEN Eege Sheed vive yess deh ye ede cee aa iaa AAi Eea aa 5 4 Park Brake REMoval NEE 5 5 Park Brake Installation ii a ae aaaea aa aaa eaaa a aE a i aaia 5 5 Accelerator Pedal Gasoline Vehicles ccccccccess
4. TAILSKIRT INSTALLATION 1 Insert upper edge of tailskirt 4 under and in front of back edge of rear body Figure 4 5 Page 4 13 or Figure 4 6 Page 4 14 2 Align holes in tailskirt 4 with holes in vehicle frame Position tailskirt flush against frame 3 Install two thread forming screws 5 and flat washers 13 in tailskirt and tighten to 80 in Ib 9 0 N m FLOOR MAT See General Warning Section 1 Page 1 1 FRONT FLOOR MAT REMOVAL Remove the brake and accelerator pedals See Section 5 Accelerator and Brake Pedal Group k Remove horn switch if so equipped Remove the top edge of the floor mat from the overlapping flange under the dash EON Lift the mat from the vehicle 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 4 15 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 On the driver or passenger side of the vehicle gently pry the edges of the floor mat and pull the floor mat in the direction of the front of the vehicle so that it is no longer under the lip of the body located directly behind the floor mat 2 Slightly bend the floor mat on each side of the vehicle to free it from the center body assembly located in front of the floor mat 3 Lift the floor mat fro
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6. 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 When install ing the shoes on the passenger side of the vehicle the side of the trailing shoe flange marked 17T should be facing out and be visible On the driver side the 17L on the leading shoe should be facing out and be visible When installed on the backing plate the leading shoe stamped 17L is always ori ented toward the rear of the vehicle Figure 6 12 Trailing Shoe 2 Install the shoe retainer clip 1 Compress clip while turning retainer pin 2 into position Figure 6 13 Page 6 6 3 Attach the springs onto the trailing shoe already installed Hold the leading shoe next to the trailing shoe correctly oriented and attach the springs to it Figure 6 14 Page 6 6 SILVER SPRING Note that the silver spring is mounted with the coils to the side of the adjustment lever spring A Figure 6 13 Retainer Clip Figure 6 14 Spring Orientation Page 6 6 2012 Turf Carryall Vehicle Maintenance and Service Manual WHEEL BRAKE ASSEMBLIES Brake Shoe Installation Self Adjusting Brakes e 4 While maintaining spring attachment on both shoes position tips of leading shoe in the mounting slots and then push shoe into place Hold s
7. 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 Ne K LOCKED POSITION Make sure pawl A engages at least 75 of ratchet tooth length B Figure 5 25 Accelerator Pedal Height Measurement Figure 5 26 Ratchet Pawl Tooth Engagement 3 5 With park brake still locked measure the distance from the top of accelerator pedal to floorboard If the measurement has changed ratchet tooth engagement is too deep and must be adjusted 3 6 If ratchet pawl engagement must be adjusted disconnect the ball joint at the top of the brake rod and rotate the ball joint sleeve clockwise to increase engagement or counterclockwise to decrease engagement Reconnect ball joint Figure 5 27 Page 5 18 3 7 Check for proper brake operation prior to driving the vehicle 4 Adjust accelerator pedal height 4 1 Loosen the nut and bolt Figure 5 28 Page 5 18 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 closest to the floorboard Press the accelerator pedal until the end of the tool rests against the floorboard pedal height should be 5 5 8 inches 14 3 cm Us
8. REAR OF CENTER H US DASH VIEWED FROM THE FRONT OF THE VEHICLE FRONT BODY REMOVED amn Figure 3 1 Serial Number Decal Figure 3 2 Serial Number Decal Behind Dash STORAGE GASOLINE VEHICLE See General Warning Section 1 Page 1 1 A DANGER es Never attempt to drain gasoline when the engine is hot or while it is running es Be sure to clean up any spilled gasoline before operating the vehicle e Store gasoline in an approved gasoline container only Store in a well ventilated area away from sparks open flames heaters or heat sources e Keep gasoline out of the reach of children e Do not siphon gasoline from the vehicle A WARNING e Turn the key switch to the OFF position remove the key and leave the Forward Reverse handle in the NEUTRAL position during storage This is to prevent unintentionally starting the vehicle or a fire hazard e Turn fuel shut off valve to closed OFF position Figure 3 3 Page 3 3 Figure 3 4 Page 3 3 Do not attempt to charge frozen batteries or batteries with bulged cases Discard the battery Frozen batteries can explode A CAUTION Batteries in a low state of charge will freeze at low temperatures PREPARING THE GASOLINE VEHICLE FOR EXTENDED STORAGE 1 Unload the vehicle so that tires are supporting only the weight of the vehicle 2 Batteries should be clean and free of corrosion Wash tops and terminals of batteries with a solution of baking sod
9. On Turf 6 and Carryall 6 vehicles there are two equalizer rods The long rod 42 1 4 inches 107 3 cm is secured to the left driver side channel on the brake pedal weldment and the short rod 9 1 4 inches 23 5 cm is secured to the right passen ger side channel on the brake pedal 3 Position and attach brake pedal assembly mounting blocks 26 and washers 27 to vehicle frame as shown Tighten the bolts 28 and nuts to 95 in lb 10 7 N m Figure 5 1 Page 5 2 or Figure 5 2 Page 5 3 4 Adjust the pedal group Refer to the appropriate adjustment procedure e For gasoline vehicles see Pedal Group Adjustment Gasoline Vehicles on page 5 11 e For electric vehicles see Pedal Group Adjustment Electric Vehicles on page 5 16 Figure 5 3 Brake Pedal Weldment Through Floor Figure 5 4 Park Brake Assembly Page 5 4 2012 Turf Carryall Vehicle Maintenance and Service Manual ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake CS 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 Gasoline Vehicles on page 1 3 2 Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack Place jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands See following W
10. Remove bolts 4 flat washers 3 and lock nuts 2 that secure bed to vehicle frame Raise bed and place prop rod 10 in bed support frame Peo Remove four bolts 1 flat washers 2 and lock nuts 3 from trim strips 4 on front and rear edge of bed Figure 4 4 Page 4 11 Remove trim strips from bed 5 Remove two bolts 5 and lock nuts 6 from the bracket 7 on driver side trim strip 8 Remove bracket from bed 6 Remove remaining hardware securing driver side trim strip and remove trim strip from bed 7 Repeat previous two steps to remove passenger side trim strip 9 and brackets FLAT BED TRIM INSTALLATION TURF 6 AND CARRYALL 6 1 Install trim in the reverse order of removal 2 Tighten nuts 3 and 6 to 8 ft lb 10 8 N m Figure 4 4 Page 4 11 3 Install bolts flat washers and lock nuts that secure bed to vehicle frame Tighten bolts to 75 in Ib 8 N m Page 4 10 2012 Turf Carryall Vehicle Maintenance and Service Manual BODY AND TRIM Access Door Turf 6 and Carryall 6 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 TURF 6 AND CARRYALL 6 1 Raise levers on left and right hand door latches 9 rotate them 180 degrees and open access door 1 Figure 4 3 Page 4 9 2 Remove three lock nuts 11 and bolts 12 from access door side of hinge 14 3 Remove access door 1 from cargo
11. and nut 6 from brake cable clamp 5 Figure 6 35 Page 6 20 Remove cable from vehicle TYPICAL BOTH SIDES OF VEHICLE Or ZR Bic Figure 6 35 Front Brake Cables Page 6 20 2012 Turf Carryall Vehicle Maintenance and Service Manual WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation e 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 TYPICAL CLARITY 2 PLACES SC Sr Lo a AG a a GE TYPICAL 2 PLACES Figure 6 36 Brake Equalizer 2 Place brake cable clevis 6 on equalizer 18 and install the clevis pin 10 and new cotter pin 9 3 Route cable towards the rear of vehicle and over to the driver side I beam and secure with wire ties so that the brake cable does not touch the brake equalizer Figure 6 37 Page 6 22 e Turf 6 and Carryall 6 vehicles The cable should also pass over the brake equalizer rods On the Turf 6 and Carryall 6 gasoline vehicle the cable should also pass over the accelerator rod e Turf 2 Carryall 2 and Carryall 2 Plus vehicles The cable should pass over the inside I beam Figure 6 37 Page 6 22 4 Route cable along beam towards front of the vehicle and secure as shown Figure 6 37 Page 6 22 e Turf 2 and Carryall 2 electric and all Turf 6 and Carryall 6 vehicles Route cable through hole in l beam crossmember 5 R
12. ommends the owner operator read and understand this manual and pay special attention to features specific to their vehicle s Each vehicle is equipped with either a two position key switch or a three position key switch Vehicles equipped with a two position key switch are referred to as pedal start and vehicles equipped with a three position key switch are referred to as key start Refer to the owner s manual provided with the vehicle for information on the following topics e Controls and Indicators e Pre Operation and Daily Safety Checklist e Driving Instructions e Bed Latch e Prop Rod e Loading and Unloading e Towing with a Vehicle e Transporting on a Trailer e Subsequent Owner Registration e Warranties SERIAL NUMBER IDENTIFICATION The serial number of the vehicle is printed on a bar code decal mounted on the frame directly above the accel erator pedal Example F0401 123456 for electric or FG0401 123456 for gasoline Figure 3 1 Page 3 2 There is a second serial number decal mounted on the front body frame behind the center dash panel The center dash panel must be removed to view this number Figure 3 2 Page 3 2 See following NOTE NOTE Have the vehicle serial number available when ordering parts or making inquiries 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 3 1 ER GENERAL INFORMATION Storage Gasoline Vehicle n SERIAL NUMBER DECAL GEI Foadi iza4s6
13. the axle assembly will separate from the transaxle and damage the axle assembly and other components Loss of vehicle control could result in severe personal injury or death A CAUTION e Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to installing the axle shaft 8 Install the brake drum and make sure it is properly seated See following NOTE NOTE If drum installation is difficult the brake shoes may need to be adjusted vertically in the mounting slots 9 After drum is installed make sure the axle and drum turn freely then install wheel and tire assembly See Section 8 Wheels and Tires 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 2 Make the brake shoe and drum adjustment by pressing and releasing the brake pedal repeatedly until an audible clicking can no longer be heard 3 Adjust brake pedal free play See following NOTE NOTE Brake pedal free play is the distance the brake pedal can be pressed before the brake actuator arm at the brake cluster moves 3 1 Measuring perpendicular from the floorboard to the back of the brake pedal press the brake pedal and measure the distance that the pedal moves before all of the slack is taken out of the brake ca
14. 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 See following NOTE NOTE If a wheel can still be turned by hand after step 4 inspect the brake clusters and clean and or replace all parts that do not work properly 5 Four wheel brake vehicles only Repeat procedure at front brake clusters 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 6 13 sted Brakes stment Manually Adju Brake Adju el WHEEL BRAKE ASSEMBLIES sted Brake Assembly Figure 6 31 Rear Manually Adju 2012 Turf Carryall Vehicle Maintenance a Page 6 14 Brake Adjustment Manually Adjusted Brakes e WHEEL BRAKE ASSEMBLIES Ce GY lt ES KS IZ ec e OZ ZA g Ui A s DN A FP aw d a N Ed _ Og E EE t 2 ZO Og ed Brake Assembly Figure 6 32 Front Manually Adjust 2012 Turf Carryall Vehicle Maintenance a e 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 Figure 6 33 Set Park Brake and Insert Wedge 2 Equalize the brake cables 2 1 Four wheel brake vehicles only Tighten the nylon lock nut 6 on t
15. washer 14 and snap ring 13 onto the bottom end of the steering shaft 19 Figure 7 5 Page 7 6 4 Insert the shaft 19 from the bottom of the steering tube 20 Figure 7 3 Page 7 3 5 Turn the assembly over and place the shaft 19 on a bench Install the wedge 16 and retaining ring 22 onto the top of the shaft Be sure the prongs on the retaining ring face up and away from the wedge Use a steering column retaining ring tool CC P N 1014259 to seat the retaining ring to the proper depth Support end of tube while pressing If you do not have the recommended tool use the same tube as was used in step 2 to press the retaining ring onto the top of the shaft The retaining ring should be pressed onto the shaft until 2 to 2 1 8 inches 5 1 5 4 cm of the shaft extends from the top of the bearing seat in the steering tube Figure 7 6 Page 7 6 STEERING COLUMN INSTALLATION 1 Install boot 12 Reinstall mount 4 and 5 onto the end of the steering column Tighten bolts 6 to 20 ft lb 27 N m Figure 7 3 Page 7 3 2 For ease of assembly and to prevent corrosion apply a light coat of anti seize or lubricating compound to both splined ends of the steering shaft 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 7 5 STEERING AND FRONT SUSPENSION BEARING PRESS TOOL CCI P N 1014264 De STEP 2 E gt UD Wedge seating into the inner races of bearing Steering Column COLUMN RETAINING TOOL
16. 14 2012 Turf Carryall Vehicle Maintenance and Service Manual STEERING AND FRONT SUSPENSION Rack and Pinion FRONT SUSPENSION See General Warning Section 1 Page 1 1 LUBRICATION Two grease fittings are provided one in each spindle housing Lubricate these fittings at the recommended interval with the proper lubricant See the Periodic Lubrication Schedule in vehicle owner s manual See following CAUTION CAUTION e To ensure proper lubrication of the front suspension and steering linkages raise front of vehicle to lubricate See General Warning Section 1 Page 1 1 WHEEL ALIGNMENT Wheel alignment is limited to equalizing the camber angle of each front wheel and adjusting toe in of the front wheels There is also a drag link adjustment to equalize the turning radius in both directions See Steering Adjustment on page 7 7 See following NOTE NOTE Prior to making any front suspension adjustments inspect components for wear and damage and repair or replace as necessary Camber Adjustment 1 Check each front wheel with a framing square At the floor or ground there should be an equal amount of space between each tire and the framing square Figure 7 15 Page 7 15 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 ADJUSTMENT Loosen 4 bolts 30 Loo
17. 2012 Turf Carryall Vehicle Maintenance and Service Manual WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation e 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 Remove brake cluster assembly from spindle FRONT BRAKE CLUSTER INSTALLATION 1 Install in reverse order of removal Use bolts 22 cone washers 21 lock washers 20 and hex nuts 19 to mount brake assembly Figure 6 32 Page 6 15 2 Tighten bolts to 30 ft lb 41 N m Adjust brakes as previously described in this section for the appropriate vehicle Use new bow tie pins when reconnecting brake cables 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 6 19 e 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 Remove E clip 1 from brake cable housing at the front spindle bracket and remove cable from spindle Figure 6 35 Page 6 20 Remove cotter pin 9 clevis pin 10 and E clip 8 from brake cable at equalizer 18 Figure 6 36 Page 6 21 Remove bolt 4
18. 5 10 Tighten to 18 ft lb 24 5 N m 12 Install the MCOR 2 and drive bar 3 as instructed See MCOR Removal Section 12 in the Power Drive Maintenance and Service Supplement 13 Adjust the pedal group See Pedal Group Adjustment Electric Vehicles on page 5 16 PEDAL GROUP ADJUSTMENT GASOLINE VEHICLES See General Warning Section 1 Page 1 1 1 Disconnect battery and spark plug wire s See Disconnecting The Battery Gasoline Vehicles on page 1 3 2 Adjust brake pedal height 2 1 Chock wheels and release park brake Lift rear of vehicle and place jack stands under the axle tubes to support the vehicle 2 2 To provide slack in the brake cables loosen the equalizer retaining nuts 2 and 3 on the equalizer rod 1 Figure 5 9 Page 5 12 2 3 Four wheel brake vehicles only Loosen the front brake equalizer rod Figure 5 10 Page 5 12 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 5 11 LS ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment Gasoline Vehicles Pedal Group Adjustment Gasoline Vehicles Continued SSS tll Figure 5 9 Loosen Rear Brake Equalizer Rod Nuts Figure 5 10 Loosen Front Brake Equalizer Rod Nuts 2 4 2 5 Loosen the brake stop jam nut 31 then relieve pedal pressure on the stop by pushing down slightly on t
19. AC power is off for 7 days or longer the OBC will not function or charge the vehicle again until it has been restarted To restart the computer make sure AC power has been restored disconnect the DC cord stationary charger from the vehicle or the AC cord onboard charger from the power source wait five seconds then reconnect it 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 3 5 E GENERAL INFORMATION Storage Electric Vehicle CAUTION e 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 Disconnect B battery cable that comes from the OBC and secure it in a way that ensures the cable will not come into contact with battery terminal Figure 1 2 Page 1 4 Figure 1 3 Page 1 4 RETURNING THE STORED ELECTRIC VEHICLE TO SERVICE 1 If necessary connect batteries and tighten hardware to 110 in lb 12 4 N m 2 Fully charge batteries See Section 13 Batteries in the appropriate maintenance and service sup plement 3 Adjust tires to recommended tire pressure See Section 2 Vehicle Specifications 4 Perform the Pre Operation and Daily Safety Checklist See the vehicle owner s manual Page 3 6 2012 Turf Carryall Vehicle Maintenance and Service Manual SECTION 4 BODY AND TRIM A DANGER e See General Warning Section 1 Page 1 1 A
20. 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 See also Warning on Page 6 1 1 To remove rear brake shoes place chocks at the front wheels loosen the rear wheel lug nuts and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to support the vehicle 2 Release park brake if latched and loosen equalizer retaining nuts 1 on equalizer rod 2 to slightly loosen brake cable Figure 6 1 Page 6 1 Figure 6 1 Loosen Equalizer Nut 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 6 1 el 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 A CAUTION e 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 4 Removing brake drums with badly worn brake shoes 4 1 On the back of each brake cluster assembly locate the heads of two brake shoe retaining pins It may be necessary
21. Figure 6 6 Page 6 3 Figure 6 6 Remove Adjuster Wheel Figure 6 7 Lubricate Slide BRAKE ASSEMBLY CLEANING SELF ADJUSTING BRAKES See General Warning Section 1 Page 1 1 See also Warning on Page 6 1 1 Carefully clean the brake backing plate and all of its mechanical components 2 Remove the rubber boot from backing plate and wipe with a clean damp cloth 3 Lubricate the slide 1 and slide plate 2 with dry moly lubricant CC P N 1012151 on both sides of the backing plate After lubricating work the slide back and forth to ensure it slides smoothly and easily Figure 6 7 Page 6 3 Reinstall rubber boot onto backing plate See following WARNING 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 6 3 e WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning Self Adjusting Brakes Brake Assembly Cleaning Self Adjusting Brakes Continued A WARNING e 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 4 Use a small brush to carefully apply a light coat of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent on each of the six raised bosses on brake backing plate Figure 6 8 Page 6 4 See pre ceding WARNING 5 Use a small brush to carefully apply a light coat of white lithium
22. HUB INSTALLATION 1 Pack the wheel bearings 5 and hub cavities and lubricate cups 7 with wheel bearing grease or chas sis lube Make sure the grease is forced between the rollers Figure 7 24 Page 7 24 2 If bearing cups 7 were removed press new ones in squarely against stops in the hub See following NOTE NOTE Install new cups when new bearings are installed 3 Install the wheel bearings 5 into the hub and install a new seal 6 with the metal edge toward the hub See following NOTE NOTE Apply grease around dust seal inner lip before installation 4 Install the hub assembly 4 and flat washer 8 on the spindle and start the spindle nut 3 5 Tighten the spindle nut until the hub is hard to turn then back the nut 8 off until the hub turns freely Install a new cotter pin 2 See following NOTE NOTE When the cotter pins are bent make sure they do not contact the hub or dust cap 6 Check front wheel free play See Front Wheel Free Play Inspection on page 7 24 7 Install the dust cap 1 8 Repeat the procedure for the opposite wheel 9 Install the wheels and then finger tighten the lug nuts 10 Lower the vehicle and finish tightening lug nuts using a crisscross pattern to 55 ft lb 74 6 N m 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 7 25 SECTION 8 WHEELS AND TIRES A DANGER e See General Warning Section 1 Page 1 1 A WARNING e See General Warning Se
23. S 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 Inspect the park brake pawl and ratchet for excessive wear grooves cracks or chips If either the pawl or ratchet is damaged both must be replaced 3 2 Adjust retaining nut 7 on spring support rod until there is a 0 060 inch 1 5 mm gap between the pawl and the tips of the ratchet teeth Use a feeler gauge to verify the gap Figure 5 24 Page 5 17 The gap should be consistent through range of pawl movement If the gap is not con sistent loosen the four bolts 6 securing the accelerator pivot rod supports and adjust the supports If the gap becomes smaller as the park brake pedal is pressed move the pivot rod supports slightly rearward until the gap is consistent If the gap becomes larger as the park brake pedal is pressed move the pivot rod supports slightly forward until gap is consistent CUTAWAY SIDE VIEW 0 060 inch 1 5 mm BOTTOM VIEW Figure 5 24 Park Brake Ratchet Pawl Gap Adjustment 3 3 With the park brake unlocked measure and note the distance from the top of the accelerator pedal to the floorboard then lock the park brake Figure 5 25 Page 5 18 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 5 17 LS ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment Electric Vehicles
24. WARNING e See General Warning Section 1 Page 1 1 CLEANING THE VEHICLE See General Warning Section 1 Page 1 1 CAUTION Do not use detergents or cleaning solvents that contain ammonia aromatic solvents or alkali materials on body panels or seats e Do not allow battery acid to drip on body panels Battery acid will cause permanent damage Wash spilled battery acid from body panels immediately Each vehicle is equipped with an injection molded ArmorFlex front body and aluminum rear body Use a mild soap or detergent with a sponge or soft cloth for normal cleaning Battery acid fertilizers tars asphalt creo sote paint or chewing gum should be removed immediately to prevent possible stains Because the finish on the front body is the same as the finish on today s automobiles commercial automotive cleaning products should be used For general cleaning of the aluminum rear body use a mild liquid soap and a sponge or soft bristle brush To remove oxidation or discoloration from aluminum use a commercially available aluminum cleaner paste and fine grade 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 The seats of the vehicle will last longer with proper cleaning To preserve seat appearance clean regularly w
25. and new cone lock nuts 19 are used to mount the brake assembly Figure 6 31 Page 6 14 or Figure 6 11 Page 6 5 Tighten nuts to 17 ft lb 23 0 N m If torquing the bolts heads torque to 30 ft lb 40 6 N m See following WARNING A WARNING 4 e Be sure retaining ring is properly seated in groove If ring is not properly installed axle assembly will separate from transaxle and damage axle assembly and other components Loss of vehicle control could result in severe personal injury or death Adjust brakes as previously described in this section for the appropriate vehicle See Brake Adjustment Self Adjusting Brakes on page 6 8 or Brake Adjustment Manually Adjusted Brakes on page 6 12 FRONT BRAKE CLUSTER REMOVAL 1 Co N O oO A Place chocks at rear wheels loosen lug nuts on front wheels and lift the front of the vehicle with a chain hoist or floor jack Place jack stands under the round tube crossmember of the frame to support vehicle Release park brake Loosen the equalizer retaining nuts 1 and 6 on the front equalizer rod 2 to slightly loosen the brake cable Figure 6 28 Page 6 13 Remove the front wheels and then the brake drums Remove bow tie pin 17 and clevis pin 16 from brake cable Figure 6 32 Page 6 15 Remove dust cap 6 on hub and bearing assembly Figure 6 34 Page 6 19 Remove cotter pin 5 and hex nut 7 from spindle shaft Figure 6 34 Page 6 19 Page 6 18
26. bed ACCESS DOOR INSTALLATION TURF 6 AND CARRYALL 6 1 Install access door 1 in the reverse order of removal Figure 4 3 Page 4 9 2 Tighten nuts 11 to 8 ft lb 10 8 N m 3 Close access door 1 and secure both door latches 9 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 4 11 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 Disconnect the three taillight wires All vehicles 2 Remove two nylon lock nuts 3 flat washers 1 and 1 4 x 1 bolts 2 from front of fender 6 Figure 4 5 Page 4 13 or Figure 4 6 Page 4 14 3 Remove two nylon lock nuts 3 flat washers 1 and 1 4 x 1 bolts 2 and flat washers 1 from the top of fender 6 Figure 4 5 Page 4 13 or Figure 4 6 Page 4 14 Turf 6 and Carryall 6 only 4 Remove the rear reverse buzzer 4 1 Remove pan head screws 16 connecting reverse buzzer 17 to rear fender 6 and disconnect the two wires from the reverse buzzer Figure 4 6 Page 4 14 All vehicles 5 Remove fender 6 from vehicle Figure 4 5 Page 4 13 or Figure 4 6 Page 4 14 Page 4 12 2012 Turf Carryall Vehicle Maintenance and Service Manual BODY AND TRIM Rear Fender REAR FENDER INSTALLATION 1 Install rear fender in th
27. bolts Figure 7 8 Page 7 9 2 For ease of assembly and to prevent corrosion apply a light coat of anti seize and lubricating compound to the splined end of the steering column shaft 3 Align the flat portion of the steering shaft spline with the bolt hole in the universal joint and then slide the shaft into the upper universal joint Install the bolt and lock washer on the upper universal joint and tighten it to 15 ft lb 20 N m 4 Tighten the steering rack mounting bolts 30 to 22 ft lb 29 8 N m Figure 7 8 Page 7 9 5 Install the drag link ball joint 23 on the spindle arm riser 33 and secure with retaining nut 25 Tighten nut 25 to 40 ft lb 54 N m 6 Adjust the steering See Steering Adjustment on page 7 7 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 7 13 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 2 Remove ball joint retaining nuts 20 and remove ball joint ends from spindles 3 Remove ball joints from tie rod 11 Figure 7 20 Page 7 19 or Figure 7 22 Page 7 21 4 Remove ball joint retaining nut 25 and remov
28. cm 76 cm 37 6 in x 48 8 in x 48 8 in x 64 2 in x 44 in x ia i i 45 1 in x 49 8 in x 49 8 in x 18 5 in Load bed size Box bedidimgnsions 9 3 in 96 x 10 9 in 124 10 9 in 124 163 x 112 x 115 x 23 cm x126 x 28 cm x126 x 28 cm 47 cm Soe 46 9 in x48 3in 46 9in x48 3in 67 6in x 44 2 in Load bed size Flat bed dimensions 91 Gg 119x 119x 172 x 112 cm 126 cm 126 cm 112 cm Vehicle rated capacity Level surface only e Gi Gw atte a0 vi Standard seating capacity persons 2 2 2 2 LIQUID CAPACITIES i 32 oz 32 oz 32 oz 32 oz Engine crankcase without filter 95 liters 95 liters 95 liters 95 liters d kee Jet 38 oz 38 oz 38 oz 38 oz Engine crankcase with filter 1 12 liters 1 12 liters 1 12 liters 1 12 liters ui 27 Oz 27 Oz 27 Oz 27 Oz Unitized transaxle 8 liters 8 liters 8 liters 8 liters 7 gallons 26 5 liters 7 gallons 26 5 liters TIRE PRESSURE Front and rear 16 18 psi 1 10 1 24 Bars 30 34 psi 2 07 2 34 Bars 30 34 psi 2 07 2 34 Bars 30 34 psi 2 07 2 34 Bars Page 2 4 2012 Turf Carryall Vehicle Maintenance and Service Manual SECTION 3 GENERAL INFORMATION A DANGER e See General Warning Section 1 Page 1 1 A WARNING e 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
29. entire body part or have it repaired by a professional paint and body repair shop with experience repairing TPO bodies 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 4 3 BODY AND TRIM Front Body Repair FRONT BODY See General Warning Section 1 Page 1 1 FRONT BODY REMOVAL 1 Remove screws 8 and lock nuts 9 and lift front bumper 6 from vehicle frame Figure 4 1 Page 4 5 1 1 Turf 1 and Carryall 1 vehicles Remove blind rivets 10 Vehicles equipped with a heavy duty front bumper 1 2 1 Remove the two carriage bolts 5 lock nuts 3 and spacers 4 from the heavy duty bumper mounting positions located on both sides of the front body 2 2 Remove carriage bolts 2 and lock nuts 3 from the heavy duty bumper support braces and remove bumper Remove carriage bolts 15 lock nuts 17 and washers 16 from front body trim Remove screws 14 from top of front body Loosen but do not remove screws 18 holding front body trim against front body Vehicles equipped with headlights Disconnect the light wiring harness from the headlight assemblies Pull front body 12 from under trim 13 and remove from vehicle FRONT BODY INSTALLATION 1 Install front body 12 under trim 13 align holes and finger tighten screws 14 holding front body against frame Figure 4 1 Page 4 5 Install carriage bolts 15 washers 16 and lock nuts 17 onto front body trim Tighten bolts
30. fades 3 It may be necessary to move the gun closer to the body to fade the streak but under no circumstance should the gun be held closer than 6 inches 15 cm to the body See following CAUTION CAUTION e Holding heat gun too close to body could melt body or damage finish MINOR IMPACT DAMAGE DEFORMATIONS Minor impact damage in the front body can be repaired using a procedure similar to the one used to remove stress lines To remove deformations resulting from minor impact damage 1 Hold a heat gun 12 inches 30 cm away from the affected area with the gun on its lowest heat setting 2 Periodically remove the heat gun and bend the body using a push block in the opposite direction of the deformation 3 Continue heating and bending the body until the original shape returns Under no circumstance should the gun be held closer than 6 inches 15 cm to the body See preceding CAUTION MINOR SCRATCHES AND SURFACE BLEMISHES For minor scratches or blemishes in the ArmorFlex body that do not penetrate the finish 1 Thoroughly clean the affected area using a strong non abrasive detergent and hot water then clean with Ultra Kleen Solvent Cleaner to remove any oil based contaminants 2 Lightly buff imperfection with a clean soft cloth or buff pad Do not use any kind of polishing compound on monocoat finished body assemblies 3 Wax the entire body part to restore luster and weather protection SMALL SCRATCHES THAT CANN
31. heed this warning could result in a battery explosion or severe personal injury 3 Disconnect the batteries negative cable first as shown Figure 1 2 or Figure 1 3 4 After disconnecting the batteries wait 90 seconds for the controller capacitors to discharge 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 1 3 a 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 Ib 12 4 N m 4 Coat terminals with Battery Terminal Protector Spray CC P N 1014305 to minimize corrosion Place Tow Run Switch in TOW PRONT OF VEHICLE BLIN 6 PLACE TOW RUN SWITCH Remove negative IN THE TOW POSITION BEFORE cable first DISCONNECTING OR CONNECTING BATTERY CABLES Figure 1 1 Gasoline Vehicle Figure 1 2 IQ System Vehicle Place Tow Run cy FRONT Switch in TOW OF VEHICLE La D Gi Place Tow Run switch in the TOW position before disconnecting or connecting battery cables Remove negative cable first Figure 1 3 Turf 2 Carryall 2 IQ Plus Electric Vehicle and Carryall 6 Electric Vehicle Page 1 4 2012 Turf Carryall Vehicle Maintenance and Service Manual SECTION 2 VEHICLE SPECIFICATIONS VEHICLE SPECIFICATIONS ELECTRIC VEHICLES
32. in 197 cm 77 5 in 197 cm 98 5 in 250 cm 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 2 3 VEHICLE SPECIFICATIONS Vehicle Specifications Electric Vehicles Turf 1 Carryall 1 Turf 2 Carryall 2 Carryall 2 Plus Turf 6 Pedal Start Fuel tank 7 gallons 26 5 liters 7 gallons 26 5 liters SPECIFICATIONS Pedal Start Pedal Start Key Start KE Gasoline Gasoline Gasoline Gasoline 4 5 in 4 5 in 4 5 in 4 5 in Ground clearance 11 cm 11 cm 11 cm 11 cm 34 5 in 34 5 in 34 5 in 34 5 in Front wheel tread 88 cm 88 cm 88 cm 88 cm 38 5 in 38 5 in 38 5 in 38 5 in Rear wheel tread 98 cm 98 cm 98 cm 98 cm Weight Standard gasoline vehicle 658 Ib 749 Ib 786 Ib 893 Ib dry fuel tank 298 kg 340 kg 357 kg 405 kg 12 15 mph 14 16 mph 17 18 mph 14 16 mph Forward speed 19 24 23 26 27 29 23 26 km h km h km h km h Curb clearance circle diameter VE 090 om i e SE P 101 in 120 in 120 in 144 in Turning radius per SAE J 695 257 cm 305 cm 305 cm 366 cm K 72 in 77 in 77 in 89 75 in Intersecting aisle clearance 183 cm 196 cm 196 cm 228 cm F 11 75 in 11 75 in 11 75 in 11 75 in Floorboard height 30 cm 30 cm 30 cm 30 cm 27 in 27 625 in 27 625 in 27 in Load bed height 69 cm 70 cm 70 cm 69 cm P 30 in 30 25 in 30 25 in 30 in Seat height 76 cm 77 cm 77
33. kit Yes No OD P ob ch 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 Cars Technical Publications Department 2012 Turf Carryall Vehicle Maintenance and Service Manual NOTES NOTES iy Ingersoll Rand Industrial Technologies aa Club Car LLC Web www clubcar com P O Box 204658 Phone 1 706 863 3000 Augusta GA 30917 4658 1 800 ClubCar USA Int 1 706 863 3000 Fax 1 706 863 5808
34. lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes Remove the MCOR 2 and drive bar 3 as instructed Figure 5 8 Page 5 10 See MCOR Removal Section 12 in the appropriate maintenance and service supplement Use a 9 16 inch socket and 9 16 inch wrench to remove the nut 7 two washers 5 and bolt 4 secur ing the accelerator pedal 1 to the pivot rod 6 Figure 5 8 Page 5 10 Remove the nut 10 and bolt 8 from the accelerator pivot rod assembly 6 Slide the spring retainer 11 off of the accelerator pivot rod Inspect the pivot support bearing 9 for wear and replace if necessary Use a marker to mark the position of the park brake ratchet 24 on the accelerator pivot rod 6 See fol lowing NOTE NOTE Failure to mark position of the ratchet could cause it to be installed improperly result 13 14 ing in improper adjustment and possible failure of the park brake Remove the lock nut 23 from the accelerator pivot rod Press the brake pedal slightly and slide the park brake ratchet 24 toward the end of the accelerator pivot rod Rotate the ratchet and remove it from the pivot rod Remove the pivot rod 6 and spacer 20 from the accelerato
35. observable movement of the wheel and hub on the spindle remove dust cap 1 and cotter pin 2 and then tighten the spindle nut 3 until the bearing 5 fully seats in the bearing race 7 3 Loosen spindle nut one cotter pin position If the hub does not turn freely loosen spindle nut one more cotter pin position 4 Install a new cotter pin 2 If movement continues replace the wheel bearings 5 as required Figure 7 24 Page 7 24 Figure 7 24 Front Wheel Bearings and Hub Page 7 24 2012 Turf Carryall Vehicle Maintenance and Service Manual 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 Remove the hub assembly 4 from the spindle shaft 3 Remove the seal 6 and the bearings 5 from the hub 4 Inspect the bearing cups 7 If they are worn or pitted remove the cups by inserting a drift punch from the opposite end of the hub and tapping lightly around them 5 Clean all parts and inspect them for wear Replace any damaged or worn parts See following NOTE NOTE Do not use compressed air to dry wheel bearings after cleaning 6 Inspect the surface of the spindle shaft where the seal 6 seats It should be clean and smooth FRONT WHEEL BEARINGS AND
36. the four bolts 22 attaching the pivot rod supports to the frame to 75 in lb 8 5 N m Figure 5 8 Page 5 10 6 Insert the bolt 4 two washers 5 and a new lock nut 7 through the lower hole in the pedal and through the pivot rod Finger tighten lock nut at this time 7 Install the bolt 8 through the pivot rod 6 and spring retainer 11 Secure these parts with the nut 10 Figure 5 8 Page 5 10 Tighten the nut to 75 in lb 8 5 N m 8 Press the brake pedal slightly and with the park brake ratchet oriented so that the tip of the ratchet is pointed toward the rear of the vehicle slide the ratchet onto the pivot rod do not slide the ratchet onto the pivot rod splines Release the brake pedal and allow the ratchet to rotate until its tip is pointed down ward Figure 5 7 Page 5 8 The ratchet should now rotate freely on the rod 9 Rotate the ratchet clockwise until it touches the park brake pawl then slide the ratchet onto the splines of the pivot rod it may be necessary to push the pivot rod toward the driver side of the vehicle to make the splines accessible The ratchet may have to be rotated counterclockwise slightly to align the splines 10 Move the pivot rod back toward the driver side of the vehicle and line up the match marks on the pivot rod and ratchet Rotate the pivot rod back and forth slightly to align the splines and slide the ratchet onto the splines 11 Install lock nut 23 on pivot rod Figure 5 8 Page
37. to 11 ft lb 14 9 N m Tighten screws 14 to 20 in lb 2 3 N m See following NOTE NOTE If installing a new front body two 5 16 inch holes must be drilled after the body has been placed on the vehicle Use the body trim 13 as a guide for drilling the holes Tighten screws 18 holding front body trim against front body to 17 in lb 1 9 N m Vehicles equipped with headlights Reconnect the light wiring harness to the headlight assemblies Vehicles equipped with a heavy duty front bumper 5 1 Install two carriage bolts 2 and lock nuts 3 from the heavy duty front bumper support braces and install bumper 1 Tighten bolts to 65 in Ib 7 3 N m Figure 4 1 Page 4 5 5 2 Install two carriage bolts 5 spacers 4 and lock nuts 3 into heavy duty bumper mounting posi tions located on sides of front body 12 Tighten bolts to 65 in Ib 7 3 N m 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 Install front bumper onto vehicle and install screws 8 and lock nuts 9 Tighten to 65 in Ib 7 3 N m Page 4 4 2012 Turf Carryall Vehicle Maintenance and Service Manual BODY AND TRIM TYPICAL 2 14 PLACES TYPICAL 2 PLACES TURF 1 AND CARRYALL 1 ONLY TURF 2 6 CARRYALL 2 2 PLUS AND 6 Figure 4 1 Front Body Assembly Front Body Repair TYPICAL 6 PLACES TYPICAL 2 PLACES TURF 2 6 CARRYALL 2 2 PLUS AND
38. to remove sealant material around the head of each pin 4 2 Insert a 1 2 x 5 8 inch cold chisel under the head of each pin and shear them off as illustrated Figure 6 2 Page 6 2 This will release the shoes from the backing plate allowing them to pivot away from the inside of the brake drum and allow the brake drum to be pulled free After completing step 5 skip step 6 5 Remove the axle 5 1 Using 90 snap ring pliers CC P N 1012560 remove axle retaining ring 1 Figure 6 3 Page 6 2 5 2 Pull the axle shaft 2 from the axle tube Figure 6 3 Page 6 2 BRAKE DRUM TWO BRAKE SHOE RETAINER PIN J AXLE TUBE 1 2 INCH X 5 8 INCH COLD CHISEL Figure 6 2 Shoe Retainer Pins Figure 6 3 Remove Axle Retaining Ring 6 Using needle nose pliers rotate the clip retainer pin 1 90 to remove the shoe retainer clip 2 on each shoe Figure 6 4 Page 6 3 See following CAUTION A CAUTION e The brake shoes are under spring pressure and can release suddenly when brake shoe retainers are removed Page 6 2 2012 Turf Carryall Vehicle Maintenance and Service Manual WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning Self Adjusting Brakes e 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
39. 1 Page 1 1 JOUNCE BUMPER REMOVAL 1 Grip jounce bumper 19 and pull from bumper mount 20 Figure 9 3 Page 9 4 JOUNCE BUMPER INSTALLATION 1 Insert jounce bumper 19 into bumper mount 20 Figure 9 3 Page 9 4 Make sure the entire circum ference of bumper is seated firmly in mounting hole Page 9 8 2012 Turf Carryall Vehicle Maintenance and Service Manual INDEX A accelerator pedal electric height adjustment AA 5 18 installation seoonnnnnnnnnnnnnennnnnennnenneneeennenenene 5 11 FOMOVAL A EE E EE 5 9 pedal gas height adjustment AA 5 14 EC UE Le BEE 5 8 ET ue UCNE 5 6 access door installation E 4 11 ET ue CT 4 11 B bed flat see flat bed bed tilt see tilt bed body front instalation sie a aAA 4 4 ue TEE 4 4 LOD all isem aie i nan aay 4 2 brake park see park brake brakes adjustment manually adjusted brakes 6 12 adjustment self adjusting brakes eee 6 8 assembly cleaning manually adjusted brakes 6 9 cleaning self adjusting brakes cable equalization manually adjusted brakes 6 16 cable front installation removal cable rear ECHT le In BE 6 23 removal Zubeen Ee 6 22 cluster front adjustment chs 8Argaiia nee 6 13 installatiom WEE 6 19 E EE 6 18 cluster rear adjustment nsee niie Eed 6 13 installation ices aes 6 18 removal sient ee dees 6 17 pedal height adjustment electric eee 5 16 height adjustment gaS
40. 2 6 13 6 16 6 17 6 17 6 17 6 17 6 18 6 18 6 19 6 20 6 20 6 21 6 22 6 22 6 23 7 1 7 1 7 1 7 2 Pagev Steering Colm eene eera aee eaa aaa aa a a reaa aaa A aaa a eaea kiaad 7 2 Steering Column Removal ssssssssesssiessressrrserersristsrttstittsrtnttintsttnttrnsttnnstnnsttnattnnatenastenstennennn nenne 7 2 Steering Column DiSaSSeMbly cceccceeeeeeceeeeeeeeneeeeeeaeeeeeaeeecaeeeeaaeeeaaaeeseaeeseaaeesseaeeeneaeeeseaeeeas 7 5 Steering Column Assembly steiere eee tee ithe tte ae ete Se Ee AN 7 5 Steering Column Installation cecccceceeeceneeeeeeeeeceeeeeeeeeeeeeeeeceeeeseeeeeeecaeeseeeeseaaeesecaeeseeeeseeeeee 7 5 le ee TEE 7 7 Rack ang Pinion Leister EAR EE EE e eee 7 8 Rack and Pinion INSPECTION siuen iratan Eiane Aar R ANN A Ra aAA N RAAEN a ATEA A inn 7 8 Rack and Pinion Removal eech eg geet se eg a a e aR 7 8 Rack and Pinion DiSaSSembly Abee 7 10 Rack and Pinion ASSOMDIY aeaieie eee a e ERE Aa A EE a R aa 7 11 Rack and Pmion Installation seis e ae a e aa a eee ana EE Ei 7 13 Tie Rod and Drag ul 7 14 Tie Rod and Drag Link Removal MAINTENANCE FREE BALL JOINTS A 7 14 Tie Rod and Drag Link Installation MAINTENANCE FREE BALL JOINTS A 7 14 FIOMt SUSPENSION E 7 15 LUD CANON E 7 15 Wheel AliQniment oniinn EERE E chads eevee dt E aA A A a AE A AT RA 7 15 Front Suspension COMPONENMS esnan oeiia aa ia p ea draaien eag aaa a aeaaeai 7 17 eaf Spring REMOVAL set tet alesse leet ae a a ae gen e ae ge
41. 4 If measured resistance does not equal 7 to 15 in lb loosen the lock nut 15 and tighten the screw 16 until it bottoms out then back the screw off one quarter turn Tighten the lock nut to 28 ft lb 38 N m Figure 7 13 Page 7 12 See following NOTE Page 7 12 2012 Turf Carryall Vehicle Maintenance and Service Manual 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 Install the dust seal bellows 1 and hex nut 29 Figure 7 8 Page 7 9 14 Install the universal joint on the pinion Tighten the bolt to 15 ft lb 20 N m 15 Install new bellows clamps wire ties 2 Figure 7 8 Page 7 9 16 Install the drag link 28 by fully threading the ground end into the inner ball joint 3 See following CAU TION CAUTION e The ball joint 23 Figure 7 8 Page 7 9 has left hand threads e The tie rod and drag link have right hand threads on one end and left hand threads on the other end Right hand threads are identified by a groove in the tie rod or drag link 17 Install the ball joint 23 Figure 7 8 Page 7 9 See preceding CAUTION RACK AND PINION INSTALLATION 1 Position the steering gear box assembly on the shock and gear support and install the bolts 30 wash ers 31 and nuts 32 Do not tighten the mounting
42. 6 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 4 5 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 1 Turf 2 Carryall 2 and 2 Plus only Raise bed and secure prop rod 17 in prop rod track 18 Hold bed securely in an upright position Remove cotter pin 23 and flat washer 22 from top end of prop rod where prop rod attaches to bed Remove prop rod 17 from bed and place prop rod between prop rod track 18 and rear body panel Lower bed onto vehicle frame Figure 4 2 Page 4 7 2 Remove two lock nuts 10 from left and right hinge assemblies 3 and 25 3 Apply slight upward pressure by hand on the rear of the bed to relieve pressure on the hinges and remove the hinge bolts 9 from the hinge assemblies Raise rear edge of bed approximately 6 inches 15 2 cm and pull bed assembly toward rear of vehicle approximately 3 inches 7 6 cm to release bed latch assembly 2 from latch plate 1 Lift bed from vehicle TILT BED INSTALLATION 1 Hold bed at a slight angle front of bed lower than rear of bed to vehicle and place front edge of bed onto vehicle frame Bed latches 5 should engage with latch plates 1 Figure 4 2 Page 4 7 2 Lower edge of bed onto vehicle an
43. 7 7 Adjust Steering Alignment RACK AND PINION See General Warning Section 1 Page 1 1 CAUTION es Front impacts that bend tie rods and or drag links can possibly damage internal steering gear components See Rack and Pinion Inspection on page 7 8 The manufacturer recommends inspecting the rack and pinion and replacing if damaged RACK AND PINION INSPECTION Look for obvious damage to the chassis where the rack and pinion is mounted and the rack and pinion hous ing Particularly check the housing for broken mounting points Compare the toe in against the specification See Toe in Adjustment on page 7 16 If obvious visible damage is found such as a bent tie rod check the steering gear for abnormal free play noise binding or clunking while it is under a load With the steering system fully assembled and all four tires on the ground floor turn the steering wheel from stop to stop While turning feel for any binding clunking or tight loose spots Listen for unusual noises Replace the rack and pinion as an assembly if any is found In the event of an known impact and obvious visible damage is not found in the method described above dis connect the tie rods and or drag links from the spindles Turn the steering wheel from stop to stop While turn ing feel for any binding or tight loose spots Listen for unusual noises Replace the rack and pinion as an assembly if any is found RACK AND PINION REMOVAL 1 Remove the front bod
44. 9 25 in overall width 120 cm 127 cm 120 cm Overall height At steering wheel 32 pe 22 Ma a2 K 65 5 in 77 5 in 98 5 in Wheelbase 166 cm 197 cm 250 cm 4 5 in 4 5 in 4 5 in Ground clearance 11 cm 41 cm 11 cm 34 5 in 34 5 in 34 5 in Front wheel tread 88 cm 88 cm 88 cm 38 5 in 38 5 in 38 5 in Rear wheel tread 98 cm 98 cm 98 cm Weight Standard electric vehicle ae Vi ES wi Se wi 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 2 1 2 VEHICLE SPECIFICATIONS Vehicle Specifications Electric Vehicles SPECI FICATIONS Turf 1 Carryall 1 Turf 2 Carryall 2 Carryall 6 IO System 1Q Plus 1Q Plus 12 15 mph 14 16 mph 14 16 mph Forward speed 19 24 km h 23 26 km h 23 26 km h s 17 ft 6 in 20 ft 8 in 24 ft 8 in Curb clearance circle diameter 533 cm 630 cm 752 cm V 5 101 in 120 in 144 in Turning radius per SAE J 695 257 cm 305 cm 366 cm 72 in 77 in 89 75 in Intersecting aisle clearance 183 cm 196 cm 228 cm H 11 75 in 11 75 in 11 75 in Floorboard height 30 cm 30 cm 30 cm 2 27 in 27 625 in 27 in Load bed height 69 cm 70 cm 69 cm i 30 in 30 25 in 30 in Seat height 76 cm 77 cm 76 cm Inen S in 48 8 in x 49 8 in 64 2 nx Sg in x Load bed size Box bed dimensions 96 x 115 x 23 x 10 9 in 124 163 x 112 x 47 cm x126 x 28 cm cm Load bed size Flat bed dimensions 35 8 in x 44 3 in 91
45. ARNING A WARNING e Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 3 Remove the park brake assembly 3 1 To remove the park brake rod and pawl assembly 17 through 20 remove the push nut 19 and disconnect the ball joint sleeve 21 from the park brake pedal 35 Figure 5 1 Page 5 2 and Figure 5 2 Page 5 3 See following NOTE NOTE New push nuts 19 and 32 must be used when reassembling the park brake Figure 5 4 Page 5 4 3 2 To remove the park brake pedal 1 remove the push retainer nut 32 disconnect the torsion spring 22 Figure 5 4 Page 5 4 and slide the pedal off of the shaft See preceding NOTE 3 3 Inspect all parts for wear and damage and replace as necessary PARK BRAKE INSTALLATION 1 From the bottom side of the floorboard insert the park brake rod 17 through the brake pedal assembly opening as shown Figure 5 4 Page 5 4 Then install the park brake pawl 35 onto the shaft on the brake pedal assembly 10 and also insert the park brake rod 17 into the park brake pawl 2 Install the push nut 19 o
46. CCI P N 1014259 b B BEARING PRESS TOOL O CCI P N 1014264 2 to 2 1 8 inches 5 1 5 4 cm E qD o Wedge seating __ ae into the inner races of bearing STEP 3 Figure 7 5 Steering Shaft Bottom End Figure 7 6 Steering Shaft Top End 3 Position the steering column assembly in the vehicle while inserting the steering column shaft into the upper universal joint 1 The flat portion of the steering shaft spline 19 must be aligned with the bolt hole in the universal joint 1 before sliding the spline into the universal joint While holding the steering col umn in place attach it to the frame using bolts 8 washers 7 and nuts 9 Figure 7 3 Page 7 3 Thread the nuts onto the bolts but do not tighten them 4 Install wide washer 35 washer 11 and screw 10 Tighten to 20 ft lb 27 N m Figure 7 3 Page 7 3 5 Install the bolt 2 and lock washer 3 on the upper universal joint and finger tighten 6 Tighten the two nuts 9 and bolts 8 to 18 ft lb 24 4 N m Figure 7 3 Page 7 3 7 Tighten the bolt 2 on the upper universal joint to 15 ft lb 20 N m Figure 7 3 Page 7 3 8 Check the other two bolts of the universal joint 1 to ensure that they are properly tightened to 15 ft lb 20 N m Figure 7 3 Page 7 3 9 Reinstall dash pocket and related hardware 10 Reinstall center dash panel in reverse order of disassembly Make sure the key switch terminals do not touch the frame and t
47. EERING 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 Tighten the nut to 23 ft lb 81 N m 3 Install the wave washer 20 and steering spindle on the kingpin 4 Install the steering spindle on the kingpin 5 Install the thrust washer 38 hardened flat washer 37 upper plate clevis 16 conical washer 36 and nut 35 Tighten the nut to 63 ft lb 83 N m 6 Install tie rod ball joints and drag link into spindles See Tie Rod and Drag Link on page 7 14 7 Vehicles with four wheel brakes Connect the front brake cables on four wheel brake vehicle in reverse order of disassembly Figure 7 19 Page 7 18 8 Vehicles with two wheel brakes Install front hub and wheel See Front Wheel Bearings and Hub Installation on page 7 25 DELTA A PLATE REMOVAL 1 Loosen lug nuts on both front wheels and raise front of the vehicle with a chain hoist or floor jack Place jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands 2 Remove wheel Remove bolts 10 and 24 A Plate straps 14 and nuts 5 Figure 7 20 Page 7 19 or Figure 7 22 Page 7 21 3 Remove the lower shock absorber mounting nut 9 then slide the shock absorber free of the Delta A Plate 4 Remove the Delta A Plate 1 5 Inspect the bush
48. Figure 9 3 Page 9 4 or Figure 9 4 Page 9 5 3 On the lower shock absorber mount install mounting hardware Tighten the nut 5 until the rubber bush ing 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 2 Place chocks at the front wheels and lift rear of vehicle with a chain hoist or floor jack Figure 9 2 Page 9 2 Position jack stands under the frame crossmember between the rear leaf spring front frame mount and the side stringer just forward of each rear wheel Lower the vehicle to let the jack stands sup port the vehicle See WARNING Lift only one end of the vehicle in General Warning Section 1 Page 1 1 LIFTING POSITION FOR STANDARD TURF 1 AND CARRYALL 1 LIFTING POSITION FOR TURF 2 CARRYALL 2 AND CARRYALL 2 PLUS Position floor jack under hitch bracket or frame LIFTING POSITION FOR TURF 6 AND CARRYALL 6 Figure 9 2 Lift Vehicle Page 9 2 2012 Turf Carryall Vehicle Maintenance and Service Manual REAR SUSPENSION Multi Leaf Springs ER 3 Place a floor jack under the transaxle housing to support but not lift the powertrain Raise it just enough to relieve tension on the shock absorbers without compressing them 4 Remove tire and wheel assembly on the side
49. Gren 2012 Turf Carryall Maintenance and Service Manual Manual Number 103897404 FOREWORD Club Car vehicles are designed and built to provide the ultimate in performance efficiency however proper maintenance and repair are essential for achieving maximum service life and continued safe and reliable operation This manual provides detailed information for the maintenance and repair of Turf and Carryall vehicles and should be used in conjunction with the appropriate maintenance and service supplement If you do not have the appropriate maintenance and service supplement you may order one from your local Club Car representative Maintenance and service supplements available include the following 2012 IQ System Vehicle Maintenance and Service Supplement Publication Part No 103897406 2012 FE350 Gasoline Vehicle Maintenance and Service Supplement Publication Part No 103897409 2012 IQ Plus System Vehicle Maintenance and Service Supplement Publication Part No 103897407 This manual and corresponding maintenance and service supplement should be thoroughly reviewed prior to servicing the vehicle The procedures provided must be properly implemented and the DANGER WARNING and CAUTION statements must be heeded This manual was written for the trained technician who already has 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
50. NLGI 2 grease Dow Corning BR2 Plus or equivalent to each end of both brake shoes and into the slots in the brake shoe mounting block as shown Figure 6 9 Page 6 4 See preceding WARNING BOSSES Figure 6 8 Lubricate Raised Bosses Figure 6 9 Lubricate Shoes 6 Use a small brush to carefully apply a light coat of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent to the brake adjuster assembly adjuster wheel shoe slots and the shaft of the adjuster wheel as shown Figure 6 10 Page 6 4 See preceding WARNING 7 Install the adjuster wheel and two washers into the adjuster assembly Figure 6 10 Page 6 4 Figure 6 10 Lubricate Adjuster Page 6 4 2012 Turf Carryall Vehicle Maintenance and Service Manual WHEEL BRAKE ASSEMBLIES Brake Shoe Installation Self Adjusting Brakes e TYPICAL 4 PLACES H TYPICAL 2 PLACES ELECTRIC GASOLINE VEHICLE VEHICLE Figure 6 11 Self Adjusting Brake Assembly 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 See following NOTE 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 6 5 e WHEEL BRAKE ASSEMBLIES Brake Shoe Installation Self Adjusting Brakes
51. OT BE BUFFED OUT 1 Thoroughly clean the affected area and then dry 2 Using 240 grit or finer sandpaper lightly sand scratch to feather edges Finish sand scratch with 320 grit or finer paper to remove gloss from surface Sand as little body surface as possible beyond scratch See following CAUTION CAUTION e Be careful not to sand completely through the finish to the body material If the finish is sanded through and the thermo plastic olefin TPO body material is exposed refer to Gouges Punctures Tears Large Scratches and Abrasions on page 4 3 Page 4 2 2012 Turf Carryall Vehicle Maintenance and Service Manual 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 4 Allow paint to dry completely approximately 10 20 minutes then lightly buff the imperfection 5 Apply wax to the entire body part to restore luster and weather protection TOUCH UP PAINT COLOR CHART COLOR CC P N Beige 101997201 White 101997202 Red 101997203 Gray 101997204 Dark Gray 101997205 Royal Blue Pacific Blue 101997206 Black 101997207 Dark Green 101997209 Classic Blue Navy 101997211 Burgundy 101997212 Orange 101997213 GOUGES PUNCTURES TEARS LARGE SCRATCHES AND ABRASIONS Touch up is not recommended Replace the
52. RYALL 6 1 Place bed on vehicle with bed front edge 1 inch 2 5 cm from seat back support panel 7 and open access door 1 Figure 4 3 Page 4 9 Raise rear edge of bed 6 inches from vehicle frame and position bed so the left and right hand bed sup ports are resting on the support bumpers 8 3 Lower rear edge of bed onto vehicle and make sure hinge brackets align with bed hinge 4 Start the bolts 6 into left and right hinge assemblies It may be necessary to use an alignment tool to align holes in hinge bracket with steel bushing in hinge assembly 5 Install a nylon lock nut 5 on each bolt and tighten to 14 ft lb 18 9 N m 6 Install 1 4 x 4 bolts 4 flat washers 3 and lock nuts 2 through the bed frame and vehicle frame on both sides of vehicle Tighten to 75 in lb 8 N m Figure 4 3 Page 4 9 Close access door 1 and secure with latches 9 Page 4 8 2012 Turf Carryall Vehicle Maintenance and Service Manual BODY AND TRIM Flat Bed Turf 6 and Carryall 6 3 Val A Ses Figure 4 3 Flat Bed Turf 6 and Carryall 6 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 4 9 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 Release access door latches 9 and open access door 1 Figure 4 3 Page 4 9
53. 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 Install a new tab washer 4 and an inner ball joint 3 Figure 7 11 Page 7 11 Install the ball joint onto the rack by securing the rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack from damage Tighten the ball joint to 60 ft lb 81 N m 2 Bend the edges of the tab washer 4 up against the ball joint 3 Figure 7 11 Page 7 11 3 Apply a light coating of EP grease to the teeth of the rack 17 then slide the rack through the bushing 5 and housing 6 Install the stop washer 18 and retaining ring 19 to the end of the rack Figure 7 8 Page 7 9 CAUTION e In step 4 do not press against the outer race of the bearing 4 Ifthe bearing 9 was removed press on a new bearing exerting all pressure on the inner race grease the bearing before installing it Then install the external snap ring 10 Figure 7 8 Page 7 9 See pre ceding CAUTION 5 If the needle bearing 7 is damaged the steering box assembly CC P N 101878302 must be replaced Figure 7 8 Page 7 9 6 Install pinion 8 and bearing 9 assembly into the housing 6 Figure 7 8 Page 7 9 Make sure the rack gear teeth will mesh with the gear teeth on the pinion The rack may need to be rotated slightly while lightly t
54. SOLINE 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 Make sure the valve is fully open A par tially closed fuel shut off valve combined with the use of the choke can result in a fouled spark plug and engine failure 2 2 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position Crank the engine until fuel is pumped into the carburetor and fuel lines and the engine starts Turn the engine off and return neutral lockout switch to the OPERATE posi tion See following NOTE NOTE Due to the oil added to the engine in preparation for storage engine may smoke excessively for a short while when running it for the first time after storage 3 Adjust tires to recommended tire pressure See Section 2 Vehicle Specifications 4 Perform the Pre Operation and Daily Safety Checklist See the vehicle owner s manual STORAGE ELECTRIC VEHICLE See General Warning Section 1 Page 1 1 A WARNING e Turn the key switch to the OFF position remove the key and leave the Forward Reverse switch in the NEUTRAL position during storage Place Tow Run switch in the TOW position This is to prevent unintentionally starti
55. SPECIFICATIONS Turf 1 Carryall 1 Turf 2 Carryall 2 Carryall 6 IQ System IQ Plus IQ Plus POWER SOURCE Drive motor Direct drive 48 volts DC shunt wound 3 1 hp Drive motor Direct drive 48 volts DC shunt wound 3 7 hp 7 i Transaxle Double reduction helical gear with 12 3 1 direct drive axle Electrical system 48 volts DC reduced speed reverse Batteries High capacity deep cycle e Batteries High capacity deep cycle e e Charger Automatic 17 amp UL and CSA listed STEERING SUSPENSION BRAKES Steering Self adjusting rack and pinion e e Suspension Front mono leaf and rear multi leaf springs with dual hydraulic shocks e e e Brakes Mechanical brake cable system to self adjusting drum brakes on each rear wheel Park brake is automatically released Self adjusting multi latch ratchet and pawl Brakes Mechanical brake cable system to manually adjusted drum brakes on all four d z wheels Park brake is automatically released Self adjusting multi latch ratchet and pawl BODY CHASSIS Frame chassis Twin l Beam welded S D a aluminum Side and rear body All aluminum e e Front body ArmorFlex s Front body finish Automotive grade paint e e Tires 18 x 8 50 8 tubeless 4 ply rated load range front and rear e Tires 18 x 8 50 8 tubeless 6 ply rated load range front and rear e e DIMENSIONS WEIGHT Overall length Standard flatbed 100 in 111 in 134 in configuration 254 cm 282 cm 340 cm i 49 25 in 50 in 4
56. USPENSION BOTH SIDES OF VEHICLE SEH ELECTRIC VEHICLES gg A VEHICLES ONLY Mao E Kg TYPICAL 2 ES PLACES Gs 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 9 REAR SUSPENSION Snubber 4 Turf 1 and Carryall 1 vehicles 4 1 Install spring retainer 22 and shock mount bracket 16 onto locating bolt at bottom center of leaf spring Figure 9 3 Page 9 4 See preceding CAUTION 4 2 Position jounce bumper mount 20 with spacer 21 onto axle tube Install U bolt 11 flat washers 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 5 1 Install U bolt 11 and lock nuts 14 Tighten U bolt to 25 ft lb 34 N m Figure 9 4 Page 9 5 6 Install shock absorber See Shock Absorber Installation on page 9 2 See following NOTE NOTE When installing shock absorbers make sure rear shocks have identical part numbers SNUBBER See General Warning Section 1 Page 1 1 NOTE The snubber is installed on the gasoline vehicle only SNUBBER REMOVAL 1 Support the powertrain with a floor jack under the engine mounting plate so that the snubber is raise
57. Vehicle Specifications Gasoline Vehicles ccccccccceeeeeeeeeneeeeeneeeeeeeeeeaaeeeeaeeeseaeeeseeeeseaeeeteaeeessaes 2 3 SECTION 3 GENERAL INFORMATION General Information c ccceccceceeeeeeeeeeeeeeeeeeeeaeeeeaeesaaaeeeeeaeesaaeeeeaaeeeeaaeeseaaeeesaeeesaeeeeaeeeneaeeessieeessaes 3 1 Serial Number Identification 22 0 2 ccceecceeeeeeeeeeeeeeeeeeeeeeaeeseeaeeseeaeeeecaeeseaaeesesaeeseaeeeseaaeeeseaeeeseaeeeseeeetaas 3 1 Storage Gasoline Vehicle AA 3 2 Preparing the Gasoline Vehicle for Extended Storage cccccceseeeeeeneeeeeaeeeeseeeeeeeeseeeeeeneeesaas 3 2 Returning the Stored Gasoline Vehicle to Service c ccceccceceeeeeeeeeeeeeeeeeeeaeeeeaeeesseeeteeeeeeeneeeeaas 3 4 Storage Electric Vehicle eeececeeeeceeneeeeeeeeeeeeeeeeaeeeeaaeeseaaeeeseaeeeseaeeeeaaeeeseaeesseaeeeseeeeseaeeeseueeessaes 3 4 Preparing the Electric Vehicle for Extended Storage cccccceceeceeeeeeeeeeeeeeeeeseeeeeeeeeseeeeseneeeseas 3 4 Returning the Stored Electric Vehicle to Service ceeeceeeeeeceeeeeeeeeeeeeeeeeeaeeeeeeeeeeeeeeeaeeeeneeetias 3 6 SECTION A BODY AND TRIM Cleaning the VEINS E 4 1 Front Body TEE 4 2 Stress Lines Or Streaks esses searen aa a E ae e A a eae at aaaeeeaa laisai 4 2 Minor Impact Damage Deformations ccccceceseeeeeneeeeeeeeteaeeeseaeeeseaeeeeeaeeeseaeeeeeeaeessnaeeeseaeetennees 4 2 Minor Scratches and Surface Blemishes A 4 2 Small Scratches That Cannot Be Buffed Out 0 0
58. a and water 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse solution off bat teries Do not allow this solution to enter the batteries Be sure terminals are tight Let the terminals dry and then coat them with Battery Terminal Protector Spray CC P N 1014305 Page 3 2 2012 Turf Carryall Vehicle Maintenance and Service Manual GENERAL INFORMATION Storage Gasoline Vehicle ES 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 4 Drain carburetor and seal the fuel tank 4 1 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position Turn the fuel shut off valve to the closed OFF position Figure 3 3 Page 3 3 Figure 3 4 Page 3 3 and run the engine until fuel remaining in the carburetor and fuel lines is depleted and the engine stalls Return the neutral lockout switch to the OPERATE position Figure 3 3 Fuel Shut off Valve 49 State Fuel Tank Figure 3 4 Fuel Shut off Valve California Fuel Tank 1 Fuel Shut off Valve 2 Closed OFF 3 Open ON 1 Fuel Shut off Valve 2 Closed OFF 3 Open ON NOTE When selecting valve position ensure that it is fully NOTE When selecting valve position ensure that it is fully opened or fully closed opened or fully closed 4 2 Loosen b
59. al group adjustment ElCom ea aeeaiei 5 16 gasoline epe a a an 5 11 R rack and pinion Ee EE 7 11 GISASSOMIDIY silsin aeeiiaii iinei 7 10 ET ET BEE 7 13 removal ccs etek cih hice 7 8 S Saf ty EE 1 1 serial number vehicle cccccceceeeeseeeees 3 1 shock absorber front ET E Lee DE 7 24 Cl ue CT 7 23 shock absorber rear Natalee o A ME EEFE E TE 9 1 installation cceesssssccceceeeeeeeeeeeeseseeseseesseeeeenes 9 2 removal anae e a a aae tae dadd 9 1 snubber installation KEE 9 6 ue TEE 9 6 specifications vehicle AAA 2 1 spring multi leaf see multi leaf spring steering adjustment e accident ahi heen 7 7 rack and pinion EASSOMPMY eiaa adap cee eetan an ETE nEn disassembly AEE EE e EE steering column EE le disassembly installation erre essen iene TETON EE steering wheel JEC HIE Le EE 7 2 Page i 2 CT ue VIE 7 1 storage electric vehicle ccseeessecsscecceceeeeeeeseeeeseseeseeeees 3 4 gasoline vehicle AAA 3 2 suspension front Camber adjustment AA 7 15 COMPONENTS soiien aniisi 7 17 delta a plate installation 7 23 REMOVAL oiekin ehe e 7 23 kingpin and steering spindle installation i ul VIE leaf spring installation 7 17 removal shock absorber installation EE 7 24 FOMOVA EE E E 7 23 wheel bearings and hubs installation removal front wheel free play inspection lubrication ssni i ied dite toe in adjustment AA wheel alignment AAA suspension rear j
60. alve core and allow air to escape from the tire 3 If possible use a tire machine to remove the tire from the rim 3 1 Ifa tire machine is not available loosen both tire beads by applying pressure to the tire side walls and pushing the tire bead away from the rim flange and into the rim well Figure 8 1 Page 8 2 Detail A 3 2 With the valve stem side of the wheel up use a tire tool to carefully start the upper bead over the edge of the wheel rim Figure 8 1 Page 8 2 Detail B See following CAUTION CAUTION e To avoid damage to the tire do not use excessive force when starting the bead over the edge of the rim 3 3 When top bead is free of the rim pull the bead from the bottom side of the rim up into the upper part of the rim well Insert the tire tool under the lower bead as shown Figure 8 1 Page 8 2 Detail C and carefully pry the lower bead over the rim flange 3 4 Once the lower bead is started over the rim flange the tire can be removed from the rim by hand TIRE TOOL UPPER TIRE TIRE BEADS POSITIONED IN RIM WELL TIRE BEADS VALVE STEM SIDE UP A Figure 8 1 Tire Removal Page 8 2 2012 Turf Carryall Vehicle Maintenance and Service Manual WHEELS AND TIRES Wheels ER 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 ma
61. apping on the pinion bearing assembly with a rubber mallet See following CAUTION CAUTION e Do not force the pinion bearing assembly into the housing The gear teeth or the small bearing could be damaged 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 7 11 STEERING AND FRONT SUSPENSION Rack and Pinion 15 16 INCH DEEP WELL SOCKET Figure 7 13 Rack and Pinion Adjustment 8 IN 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 Using a socket to apply pressure evenly press in a new dust seal Figure 7 12 Page 7 12 9 Apply a small amount of grease to the rack guide 13 where it comes into contact with the rack 17 Figure 7 8 Page 7 9 10 Place a few drops of Loctite 222 to the threads of the screw 16 Figure 7 8 Page 7 9 11 Install the rack guide 13 pressure spring 14 and screw 16 The screw should be threaded in until a rotational torque of 10 in lb 1 13 N m is achieved Figure 7 8 Page 7 9 11 1 Reposition the rack and pinion in a vise 11 2 Insert a 3 8 inch deep well socket into the steering column end of the universal joint 2 and tighten the bolt 1 to 15 ft lb 20 3 N m Figure 7 14 Page 7 12 11 3 Use a torque wrench connected to the 3 8 inch deep well socket to measure the resistance of the rack and pinion Rotational resistance should measure 7 to 15 in lb 0 8 to 1 7 N m 11
62. bles Figure 6 18 Page 6 9 3 2 Tighten the nut on the equalizer rod so that the brake pedal free play is 1 4 to 1 2 inch 6 35 mm to 12 7 mm 3 3 Tighten the jam nut 3 while holding the adjustment nut 2 in the correct position Page 6 8 2012 Turf Carryall Vehicle Maintenance and Service Manual WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning Manually Adjusted Brakes e 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 2 Carefully clean the brake backing plate and all mechanical components Remove rubber boot from backing plate and wipe with a clean damp cloth Lubricate slide 1 and slide plate 2 with dry moly lubricant CC P N 1012151 on both sides of the back ing plate After lubricating work slide back and forth to ensure it slides smoothly and easily Figure 6 19 Page 6 9 Reinstall rubber boot onto backing plate See following WARNING U A BOSSES WS eil SZ of Figure 6 19 Lubricate Slide Figure 6 20 Lubricate Raised Bosses 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 6 9 e WHEEL BRAKE ASSEMBLIES Brake Shoe Installation Manually Adjusted Brakes Brake Assembly Cleaning Manually Adjusted Brakes Continued A WARNING e Apply grease carefully when perfor
63. cable tension and brakes See Brake Cable Equalization on page 6 16 See also Final Brake Cluster Adjustment on page 6 17 2 Pedal free play should be less than 1 inch 2 5 cm If free play exceeds 1 inch 2 5 cm check pedal group adjustment and readjust cable tension and brakes See Brake Cable Equalization on page 6 16 See also Final Brake Cluster Adjustment on page 6 17 See following NOTE NOTE Brake pedal free play is the distance the brake pedal can be pressed before the brake actuator arm at the brake cluster moves 3 Test drive vehicle Be sure the brakes function properly When brake pedal is fully pressed under mod erate pressure it should not go more than halfway to floor and the vehicle should come to a smooth straight stop If the brake pedal goes more than halfway to the floor or if the vehicle swerves or fails to stop check pedal group adjustment and readjust cable tension and brakes See Brake Cable Equal ization on page 6 16 See also Final Brake Cluster Adjustment on page 6 17 Brake adjustment must be maintained so the brake pedal cannot be pressed to the floor under any circumstance BRAKE CLUSTER REMOVAL AND INSTALLATION See General Warning Section 1 Page 1 1 See also Warning on Page 6 1 REAR BRAKE CLUSTER REMOVAL 1 Place chocks at the front wheels loosen the lug nuts on the rear wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to suppor
64. 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 1 Install the steering wheel 3 on the splines of the steering shaft 4 Be sure to align the match marks placed on the wheel and steering column shaft in step 3 above Figure 7 1 Page 7 2 2 Install the steering wheel nut 5 and tighten to 156 in Ib 17 6 N m 3 Install the plate 2 and screws 1 Tighten screws to 16 in Ib 1 8 N m 4 Connect the battery cables See Connecting The Batteries Electric Vehicles on page 1 4 See Con necting The Battery Gasoline Vehicles on page 1 3 STEERING COLUMN See General Warning Section 1 Page 1 1 STEERING COLUMN REMOVAL 1 Remove the steering wheel See Steering Wheel Removal on page 7 1 2 Remove the front body See Front Body Removal Section 4 Page 4 4 Page 7 2 2012 Turf Carryall Vehicle Maintenance and Service Manual 2 Q La S a D Lo E Z 2 we Q zZ lt Vi lt G GG Loi Figure 7 3 Steering Column Page 7 3 vice Manual 2012 Turf Carryall Vehicle Maintenance and Ser STEERING AND FRONT SUSPENSION Steering Column 3 Remove the center dash panel Figure 7 4 Page 7 4 3 1 3 2 3 3 3 4 3 5 3 6 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 L
65. ction 1 Page 1 1 GENERAL INFORMATION Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care e 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 e Keep lug nuts properly tightened e Keep the front end properly aligned and adjusted WHEELS See General Warning Section 1 Page 1 1 WHEEL REMOVAL 1 Slightly loosen the lug nuts on the wheel to be removed 2 Raise the end of the vehicle from which the wheel is to be removed Make sure the wheels are off the ground See WARNING Lift only one end of the vehicle in General Warning Section 1 Page 1 1 3 Remove the lug nuts and remove the wheel WHEEL INSTALLATION 1 Install wheel s and use a crisscross pattern to tighten the lug nuts until they are snug 2 Lower the vehicle and use a crisscross pattern finish tightening the lug nuts to 55 ft lb 74 6 N m 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 8 1 sl 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 Remove the valve cap and v
66. d slightly and does not rest on the vehicle frame 2 Remove the two bolts 2 and two lock nuts 1 securing the snubber bracket to the engine mounting plate Figure 9 5 Page 9 6 3 Slide snubber and bracket assembly toward battery to remove it from vehicle SNUBBER INSTALLATION 1 Install in the reverse order of removal 2 Tighten snubber bracket mounting nuts 1 to 13 ft lb 17 6 N m Figure 9 5 Page 9 6 SNUBBER MOUNTING 2 BRACKET SNUBBER Figure 9 5 Snubber Brackets Page 9 6 2012 Turf Carryall Vehicle Maintenance and Service Manual REAR SUSPENSION Stabilizer Bar ER 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 Lower vehicle to let the jack stands support the vehicle See General Warning Section 1 Page 1 1 2 Remove bolt 6 lock washer 7 flat washers 4 compression mounts 3 and spacer 2 from left and right stabilizer bar links 5 Do not remove the stabilizer bar links from frame Figure 9 6 Page 9 7 TYPICAL 8 REFERENCE REAR SUSPENSION TYPICAL 2 PLACES Figure 9 6 Stabilizer Bar 2012 Turf Ca
67. d align hinge brackets 3 with bed hinge 25 3 Start the bolts 9 into left and right hinge assemblies 3 and 25 It may be necessary to use an alignment tool to align holes in hinge bracket with steel bushing in hinge assembly 4 Use a small hammer to lightly tap bolts through hinge assembly 5 Install a nylon lock nut 10 on each bolt 9 and tighten to 15 ft lb 21 N m 6 Turf 2 Carryall 2 and 2 Plus only Lift bed and place the prop rod 17 in bed mounting hole Install a 3 8 inch flat washer 22 and a new cotter pin 23 on prop rod Figure 4 2 Page 4 7 Page 4 6 2012 Turf Carryall Vehicle Maintenance and Service Manual BODY AND TRIM Front Body Repair Ne N gl Se 2 i ne C o ae a a EE 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 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 Open access door in bed 1 and remove two lock nuts 2 four flat washers 3 and two 1 4 x 4 bolts 4 Close and latch access door Figure 4 3 Page 4 9 2 Remove two lock nuts 5 from left and right flat bed hinge assemblies 3 Remove two 3 8 x 3 3 8 bolts 6 Lift bed from vehicle FLAT BED INSTALLATION TURF 6 AND CAR
68. det 7 17 Leat Spring Installation miresei an a aene a nae alleles 7 17 Kingpin and Steering Spindle Removal ccceccecceeeeeeeneeeeeneeeeeeeeeeeaeeeesaeeseeaeeeeeeeseeeeseieeeeseaeeeas 7 17 Kingpin and Steering Spindle Installation c cccccececeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseaaeeseneeeseaeeeseeeeee 7 23 Delta A Plate Removal kk 7 23 Delta A Plate Installation onini ainnean a aA Na EAA NEONATE E RELER NAARAAN RREAN VEA ai 7 23 Shock Absorber Pemoval 7 23 Shock Absorber Installation 0 cccccceceeeeeeneeeeeeeeeeeeeeeeeeeeeaeeeecaeeeccaeeegeaeeeseaeeeseaaeeseaeeseeeeeseeeeees 7 24 Front Wheel Bearings and HUBS niiserisicciriiaena s ea eede AEE TERREA EERE E TEERDE 7 24 Front Wheel Free Play INSPe ction seeriana arae E a A EER EE R REE 7 24 Front Wheel Bearings and Hub Hemoval 7 25 Front Wheel Bearings and Hub Installation 0 0 cceeeeeeeeeeeeeeeneeeeeeeeeeeeeeeeeaeeeeesenaeeeeeeenaaeeeeneeaas 7 25 SECTION 8 WHEELS AND TIRES General INformation eege EE OL es a ad a Le ee ae 8 1 WINEGIS REEE fe echtcated ocd Sra ihe te adit A td ida E E E A TE Meta 8 1 Wheel Removal raaa a aa ain aia atin id geet eee 8 1 Wheel Installation 22 2 2 ccc ccccecceeccee cece cece ee eeeeeeeeeaeeee eee eeeee et ecaaaaaaaeeeeeeeeeecegeasaaaaeaaeeeeeeeeeeeseeeeneeneeeaees 8 1 RT EE 8 2 Tre ee 8 3 ICH EE ue EE 8 3 Page vi 2012 Turf Carryall Vehicle Maintenance and Service Manual SECTION 9 REAR SUSPENSION General INFOrmation
69. e a rubber strap to hold pedal in position against the floorboard and then tighten nut to 26 ft lb 35 3 N m Figure 5 29 Page 5 19 1 2 INCH SOCKET 1 2 INCH WRENCH Figure 5 27 Brake Rod Adjustment Figure 5 28 Accelerator Pedal Height Adjustment Page 5 18 2012 Turf Carryall Vehicle Maintenance and Service Manual ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment Electric Vehicles Ea CN O i ACCELERATOR PEDAL 2 ADJUSTMENT TOOL Xi CCI P N 101871001 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 SECTION 6 WHEEL BRAKE ASSEMBLIES A DANGER e See General Warning Section 1 Page 1 1 A WARNING e See General Warning Section 1 Page 1 1 e Some aftermarket brake shoes contain asbestos fiber and asbestos dust is created when these brake mechanisms are handled Wear approved eye and respiratory protection when disassembling and cleaning brake mechanisms Inhalation of asbestos could result in severe personal injury or death Do not use compressed air or aerosol sprays to clean the brake mechanism Clean brake mechanism using the negative pressure enclosure hepa vacuum system or low pressure wet cleaning method per OSHA 29 CFR 1910 1001 GENERAL INFORMATION The Club
70. e drag link ball joint 23 from drag link 28 Figure 7 8 Page 7 9 TIE ROD AND DRAG LINK INSTALLATION MAINTENANCE FREE BALL JOINTS Tie Rod 1 Thread ball joints 6 and 13 onto tie rod 11 to a depth of 1 2 inch 12 5 mm Figure 7 20 Page 7 19 or Figure 7 22 Page 7 21 See following WARNING and CAUTION A WARNING e The ball joints must be threaded into the rod at least 5 16 of an inch 8 mm Failure to thread ball joints in deep enough may cause a ball joint to separate from the rod during adjustment or while being operated possibly resulting in loss of vehicle control and severe personal injury CAUTION e The tie rod and drag link have right hand threads on one end and left hand threads on the other end Right hand threads are identified by a groove in the tie rod or drag link 2 Attach tie rod ball joints 6 and 13 to the left and right hand spindle arms 23 then install and tighten retaining nuts 20 to 40 ft lb 54 N m Figure 7 20 Page 7 19 or Figure 7 22 Page 7 21 Drag Link 3 Thread ball joint 23 onto drag link 28 left hand threads to full thread depth Figure 7 8 Page 7 9 4 Install the ball joint 23 on the spindle arm riser 33 and secure with retaining nut 25 Figure 7 8 Page 7 9 Tighten nut to 40 ft lb 54 N m 5 Adjust camber and toe in See Camber Adjustment on page 7 15 and Toe in Adjustment on page 7 16 6 Adjust steering See Steering Adjustment on page 7 7 Page 7
71. e end of the drag link toward the spindle has left hand threads and the end toward the rack has right hand threads To prevent damage to threaded parts care should be taken when servicing the drag link 3 When all adjustments have been completed tighten the nuts 27 and 29 on the drag link assembly with an open end wrench Tighten nuts to 21 ft lb 28 4 N m Figure 7 8 Page 7 9 See following CAU TION CAUTION e When tightening the nuts 27 and 29 make sure the drag link 28 does not turn Figure 7 8 Page 7 9 4 Straighten wheels and turn steering wheel from lock to lock Wheel should turn smoothly and easily If steering wheel does not turn smoothly and easily inspect steering assemblies as follows e ball joint 23 Figure 7 8 Page 7 9 and 6 and 13 Figure 7 20 Page 7 19 or Figure 7 22 Page 7 21 e spindle bushings 3 and 4 Figure 7 21 Page 7 20 or Figure 7 23 Page 7 22 e wave washers 20 Figure 7 21 Page 7 20 or Figure 7 23 Page 7 22 e rack assembly 17 Figure 7 8 Page 7 9 5 Also inspect front suspension assemblies as follows e A plates 1 Figure 7 20 Page 7 19 or Figure 7 22 Page 7 21 e urethane bushings 2 Figure 7 20 Page 7 19 or Figure 7 22 Page 7 21 e leaf springs 6 Figure 7 21 Page 7 20 or Figure 7 23 Page 7 22 6 Replace components as necessary 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 7 7 STEERING AND FRONT SUSPENSION Rack and Pinion Figure
72. e reverse order of removal Tighten bolts 2 to 35 in Ib 4 0 N m 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 BODY AND TRIM Rear Fender g e m D EES NS a B Se CAS NTS eb GP 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 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 3 Where the hitch 7 is mounted to hitch brace 8 remove the nut 12 lock washer 11 flat washer 10 and bolt 9 4 Remove hitch 7 from vehicle TRAILER HITCH INSTALLATION HEAVY DUTY 1 Install trailer hitch 7 in the reverse order of removal Figure 4 5 Page 4 13 Tighten hardware to 15 ft lb 20 3 N m TAILSKIRT See General Warning Section 1 Page 1 1 TAILSKIRT REMOVAL 1 Remove two thread forming screws 5 and flat washers 13 from tailskirt 4 and lift tailskirt from vehicle frame Figure 4 5 Page 4 13 or Figure 4 6 Page 4 14
73. e spark plug e Frame ground Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wiring Do not allow a positive wire to touch the vehicle frame engine or any other metal component Electric vehicles only e Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning could result in a battery explosion or severe personal injury e To avoid unintentionally starting the vehicle disconnect the batteries as shown Figure 1 2 Page 1 4 or Figure 1 3 Page 1 4 e After disconnecting the batteries wait 90 seconds for the controller capacitors to discharge e IQ Plus vehicles only Use only 4 gauge AWG with low resistance terminals to replace battery wires All vehicles e Wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle Moving parts Do not attempt to service the vehicle while it is running Ensure battery connections are clean and properly tightened See Battery Care in the appropriate Maintenance and Service Manual Hot Do not attempt to service hot engine or exhaust system Failure to heed this warning could result in severe burns Use insulated tools when working near batteries or electrical connections Use ext
74. e to specific safety issues and must be read understood and heeded before proceeding with procedures There are statements labeled NOTE which provide other essential ser vice or maintenance information A DANGER es A DANGER indicates an immediate hazard that will result in severe personal injury or death A WARNING es A WARNING indicates an immediate hazard that could result in severe personal injury or death A CAUTION e A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury CAUTION e A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could result in property damage GENERAL WARNING The following safety statements must be heeded whenever the vehicle is being operated repaired or ser viced Service technicians should become familiar with these general safety statements Also other specific safety statements appear throughout this manual and on the vehicle A DANGER e Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries e Battery Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes External Flush with water Call a physician immediately Internal D
75. ervice Manual ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake es TYPICAL 4 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES 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 Ra 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 2 Secure the equalizer rod s 14 and 36 to the brake pedal assembly 10 with clevis pin s 16 and bow tie pin s 15 as shown Figure 5 1 Page 5 2 or Figure 5 2 Page 5 3 See following NOTE NOTE On two wheel brake vehicles the equalizer rod is secured to the left driver side channel on the brake pedal weldment For Turf 2 and Carryall 2 vehicles with four wheel brakes and Carryall 2 Plus vehicles there are two equalizer rods The long rod 21 1 4 inches 54 cm is secured to the left driver side channel and the short rod 9 1 4 inches 23 5 cm is secured to the right passenger side channel on the brake pedal weldment
76. flat washers 19 and lock nuts 18 Finger tighten nuts at this time Figure 5 6 Page 5 7 Insert the lower end of the accelerator pedal 1 through the floorboard and install the accelerator pivot rod 6 through the uppermost hole in the pedal Install the plastic spacer 20 on the pivot rod 6 Insert the pivot rod through the pivot rod supports on the vehicle frame Tighten the four bolts 22 attaching the pivot rod supports to the frame to 75 in lb 8 5 N m Install the bolt 4 two washers 5 and a new lock nut 7 through the lower hole in the pedal and through the pivot rod Finger tighten nut at this time Install the ball stud 8 through the pivot rod Install the spring retainer 11 onto the ball stud Secure these parts with the nut 10 Figure 5 6 Page 5 7 Tighten the nut to 75 in lb 8 5 N m Press the brake pedal slightly and with the park brake ratchet oriented so that the tip of the ratchet is pointed toward the rear of vehicle slide the ratchet onto the pivot rod do not slide the ratchet onto the pivot rod splines Release the brake pedal and allow the ratchet to rotate until its tip is pointed downward Figure 5 7 Page 5 8 The ratchet should now rotate freely on the rod J Rotate ratchet clockwise Figure 5 7 Ratchet Installation Rotate the ratchet clockwise until it touches the park brake pawl then slide the ratchet onto the splines of the pivot rod it may be necessary to
77. frame On the gasoline vehicle the engine is mounted on an engine mounting plate that moves with the suspension At the front of the mounting plate a snubber limits the mounting plate motion The rear suspension on the gasoline Turf 2 6 Carryall 2 2 Plus and 6 vehicles also includes a stabilizer bar that reduces side to side sway SHOCK ABSORBERS See General Warning Section 1 Page 1 1 SHOCK ABSORBER INSPECTION AND REMOVAL 1 Check shock absorbers 7 for damage and fluid leakage around the lower housing of the shock absorber body Replace damaged or leaking shock absorbers Figure 9 3 Page 9 4 or Figure 9 4 Page 9 5 2 To remove a shock absorber 7 remove the nut 5 cup washer 9 and rubber bushing 10 from the upper shock absorber stem 3 Remove lower mounting hardware 5 9 and 10 on shock absorber lower mount Figure 9 3 Page 9 4 or Figure 9 4 Page 9 5 See also Figure 9 1 Page 9 1 4 Compress the shock absorber to remove it Figure 9 1 Shock Absorber Removal 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 9 1 9 REAR SUSPENSION Multi Leaf Springs SHOCK ABSORBER INSTALLATION When installing shock absorbers make sure front shocks have identical part numbers and rear shocks have identical part numbers 1 Install shock absorber in the reverse order of removal 2 On the upper shock absorber mount tighten nut 5 until rubber bushing 10 expands to size of cup washer 9
78. from which the spring is to be removed Thread one lug nut onto a stud on the rear hub This will keep the brake drum on the hub 5 Remove lower nut 5 cup washer 9 and rubber bushing 10 from shock absorber 7 Figure 9 3 Page 9 4 or Figure 9 4 Page 9 5 6 Turf 1 and Carryall 1 vehicles 6 1 Remove the lock nuts 14 and flat washers 13 if present attaching the U bolt 11 to the shock mount bracket 16 Remove jounce bumper mount 20 and spacer 21 Figure 9 3 Page 9 4 6 2 Allow shock mount bracket 16 to rotate downward and remove spring retainer 22 Do not dis connect brake cable from bracket 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 8 Raise axle with floor jack until axle saddle 23 is 1 inch 2 5 cm above spring Figure 9 3 Page 9 4 9 Remove bolt 15 and lock nut 2 attaching the leaf spring 12 to the rear shackle 1 Figure 9 3 Page 9 4 or Figure 9 4 Page 9 5 10 Allow rear of leaf spring 12 to rest on the ground and remove the bolt 24 and lock nut 25 attaching the front of the spring to the vehicle frame Figure 9 3 Page 9 4 or Figure 9 4 Page 9 5 Remove spring from vehicle 11 Inspect the rubber bushings 4 and steel sleeves 3 in the spring eyes and replace them if they are worn
79. he center dash panel is properly seated and snapped into place 11 Install front body and bumper See Front Body Installation Section 4 Page 4 4 12 Install the steering wheel See Steering Wheel Installation on page 7 2 Page 7 6 2012 Turf Carryall Vehicle Maintenance and Service Manual 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 If simultaneous contact occurs steering is in correct adjustment proceed to step 4 If simultaneous contact does not occur proceed to step 2 2 Loosen the nuts 27 and 29 and turn the drag link 28 Figure 7 8 Page 7 9 to adjust the drag link rod Adjust the link rod with the steering wheel turned all the way to the right so the passenger side spindle stop lightly touches the passenger side A plate The internal stop on the rack must reach its limit of travel at the same time the spindle stops against the passenger side A plate with vehicle wheels turned to the right See following CAUTION CAUTION The drag link has both left and right hand threads Th
80. he disconnected ball joint with locking pliers 5 3 Reconnect the accelerator rod at the accelerator pedal 5 4 Before tightening jam nuts on accelerator rod set park brake to first ratchet and pawl position Press accelerator pedal and make sure the following events occur in the exact order shown EVENT PEDAL TRAVEL Park brake release 2 4 Solenoid activation 4 8 Carburetor throttle actuation 8 12 5 5 Ifthe events above occur as they should hold the ball joint at each end of the accelerator rod with pliers and tighten the accelerator rod jam nut against it 5 6 Ensure that the events occur as described in step 5 4 above See following NOTE 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 5 15 LS 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 5 7 Install the electrical box cover and screw 6 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 PEDAL GROUP ADJUSTMENT ELECTRIC VEHICLES See General Warning Section 1 Page 1 1 1 Disconnect the batteries and discharge the controller See D
81. he front equalizer rod 2 to 35 in Ib 4 N m Figure 6 28 Page 6 13 2 2 Tighten the jam nut 5 on the rear equalizer rod 2 clockwise to 35 in lb 4 N m Figure 6 27 Page 6 13 2 3 Repeat steps 2 1 and 2 2 until the nuts remain on the torque setting 2 4 Hold the lock nut 6 on the front equalizer rod 2 in place with a wrench and tighten the jam nut 1 to 13 ft lb 17 6 N m Figure 6 28 Page 6 13 2 5 Hold the jam nut 5 on the rear equalizer rod 2 in place with a wrench and tighten the lock nut 1 to 13 ft lb 17 6 N m Figure 6 27 Page 6 13 See following CAUTION A CAUTION e If the brake pedal return spring 6 was disconnected while equalizing the brake cables be sure to reconnect it before proceeding Figure 6 27 Page 6 13 Page 6 16 2012 Turf Carryall Vehicle Maintenance and Service Manual WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation e 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 4 Carefully support the vehicle with the lifting device remove jack stands and lower the vehicle to the ground TEST DRIVE VEHICLE 1 With the vehicle on a level surface release the park brake and push the vehicle by hand If brake drag exists readjust
82. he pedal Next adjust the brake stop bumper 22 up or down Figure 5 11 Page 5 12 Adjusting the bumper upward decreases distance between pedal and floorboard Adjusting the bumper downward increases distance between pedal and floorboard Proper brake pedal height is 6 inches 15 2 cm Figure 5 12 Page 5 12 Tighten the jam nut 31 to 8 ft lb 9 5 N m Figure 5 11 Page 5 12 Correct pedal position is 04 5 6 inches 15 2 cm from floormat to back of brake pedal Figure 5 11 Brake Pedal Height Adjustment Figure 5 12 Brake Pedal Height Measurement 3 Adjust park brake ratchet pawl gap and pawl engagement 3 1 3 2 Page 5 12 Inspect the park brake pawl and ratchet for excessive wear grooves cracks or chips If either the pawl or ratchet is damaged both must be replaced Adjust retaining nut 7 on spring support rod until there is a 0 060 inch 1 5 mm gap between the pawl and the tips of the ratchet teeth Use a feeler gauge to verify the gap Figure 5 13 Page 5 13 The gap should be consistent through range of pawl movement If the gap is not con sistent loosen the four bolts 6 securing the accelerator pivot rod supports and adjust the supports If the gap becomes smaller as the park brake pedal is pressed move the pivot rod supports slightly rearward until the gap is consistent If the gap becomes larger as the park brake pedal is pressed move the pivot rod supports slightly forward until gap is co
83. he steering shaft to slide out of the steering tube when removing the snap ring 3 Remove the washer 14 spring 15 and wedge 16 4 Turn the steering column over and slide the shaft out of the tube to expose the retaining ring 22 Use pliers to twist the retaining ring 22 until it breaks off then remove the wedge 16 5 Remove the shaft 19 from the bottom of the tube 20 6 Use steering shaft 19 to push bearing seat 18 out from the opposite end of the steering tube 20 7 Insert a flat blade screwdriver between the bottom of the outer race of the bearing 17 and the bottom lip of the bearing seat 18 and remove the bearing 17 See following NOTE NOTE Use new retaining rings and bearings for reassembly STEERING COLUMN ASSEMBLY 1 Insert bearing seat 18 into both ends of steering tube 20 Place a block of wood on bearing seat and tap lightly on block until bearing seat 18 is fully seated in steering tube 20 Figure 7 5 Page 7 6 2 Press the bearing 17 all the way into the bearing seat 18 using a steering column bearing press tool CC P N 1014264 or a metal tube approximately six inches 15 2 cm long with a maximum outer diam eter of 1 3 16 inches 3 3 cm and a minimum inside diameter of 7 8 inch 2 2 cm Be sure the bearing is installed in the bearing seat as shown Figure 7 5 Page 7 6 so the wedge 16 will ride against the inner race of the bearing 3 Install the wedge 16 spring 15
84. hoe in position and install retaining clip Figure 6 15 Page 6 7 LEADING SHOE Kee SSN Figure 6 15 Install Leading Shoe 5 After the shoes are installed move them together up and down and side to side to make sure that they will easily slide approximately 1 4 to 3 8 inch 6 3 to 9 5 mm without binding Make sure the shoes are positioned vertically so that the tips of the shoes are positioned flush at the top with the top surfaces of the wedge shapes on the shoe mounting blocks as shown Figure 6 16 Page 6 7 6 Place a flat blade screwdriver under the adjusting arm and raise arm off of the adjusting wheel While holding the arm up turn the wheel upward until it stops Figure 6 17 Page 6 7 Remove the screw driver See following CAUTION A CAUTION e Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to installing the axle shaft ADJUSTING ADJUSTING WHEEL Figure 6 16 Slide Shoes Figure 6 17 Turn Adjusting Wheel Self Adjusting Brakes 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 6 7 e WHEEL BRAKE ASSEMBLIES Brake Adjustment Self Adjusting Brakes Brake Shoe Installation Self Adjusting Brakes Continued 7 Install axle shaft 2 into axle tube and install retaining ring 1 Figure 6 3 Page 6 2 See following WARNING and CAUTION A WARNING e Be sure retaining ring is properly seated in groove If ring is not properly installed
85. ic floor jack with 1000 Ib 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 3 Remove the brake pedal assembly 3 1 Disconnect the equalizer rod s 14 and 36 from the pedal shaft by removing the clevis pin s 16 and bow tie pin s 15 Figure 5 1 Page 5 2 or Figure 5 2 Page 5 3 3 2 Remove the nuts 34 flat washers 27 bolts 28 and mounting blocks 26 If the mounting blocks 26 show signs of excessive wear or are damaged they must be replaced with new ones before installing pedal assembly Figure 5 1 Page 5 2 or Figure 5 2 Page 5 3 3 3 Remove the nut 25 and brake stop bumper 24 Figure 5 1 Page 5 2 or Figure 5 2 Page 5 3 3 4 Lift the pedal assembly 10 through the floorboard Figure 5 3 Page 5 4 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 5 1 Ra ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake TYPICAL 4 PLACES Es l NS WW S e TYPICAL TYPICAL 4PLACES KM T Ds 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 S
86. ings 2 and sleeves 3 and 4 in the Delta A Plate and replace them if necessary DELTA A PLATE INSTALLATION 1 Install the A Plate in reverse order of removal Tighten the A Plate suspension bolts 10 and 24 to 20 ft lb 27 N m Figure 7 20 Page 7 19 or Figure 7 22 Page 7 21 2 Install the wheels and adjust the wheel alignment See Wheel Alignment on page 7 15 SHOCK ABSORBER REMOVAL 1 Inspect the shock absorbers for fluid leakage at the point where the shaft enters the shock absorber body Leaking shock absorbers should be replaced 2 Remove the nut 9 attaching the shock absorber to the A Plate Figure 7 20 Page 7 19 or Figure 7 22 Page 7 21 3 Remove the nut 32 and bolt 8 attaching the shock absorber to the shock and gear support 4 Remove the shock absorber 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 7 23 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 Tighten the nuts to 20 ft lb 27 N m FRONT WHEEL BEARINGS AND HUBS See General Warning Section 1 Page 1 1 FRONT WHEEL FREE PLAY INSPECTION 1 Raise the front of the vehicle 2 Using your hands attempt to rock the wheel and hub assembly back and forth on the spindle If there is any
87. isconnecting The Batteries Electric Vehicles on page 1 3 2 Adjust brake pedal height 2 1 Chock wheels and release park brake Lift rear of vehicle and place jack stands under the axle tubes to support the vehicle 2 2 To provide slack in the brake cables loosen the equalizer retaining nuts 2 and 3 on the equalizer rod 1 Figure 5 20 Page 5 16 2 3 Four wheel brake vehicles only Loosen the front brake equalizer rod Figure 5 21 Page 5 16 tll 200000000 Figure 5 20 Loosen Rear Brake Equalizer Rod Nuts Figure 5 21 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 Next adjust the brake stop bumper 22 up or down Figure 5 22 Page 5 17 Adjusting the bumper upward decreases distance between pedal and floorboard Adjusting the bumper downward increases distance between pedal and floorboard Proper brake pedal height is 6 inches 15 2 cm Figure 5 23 Page 5 17 2 5 Tighten the jam nut 31 to 8 ft lb 9 5 N m Figure 5 22 Page 5 17 Page 5 16 2012 Turf Carryall Vehicle Maintenance and Service Manual ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment Electric Vehicles Ea Correct pedal position is y 6 inches 15 2 cm from floormat to back of
88. ith mild soap or detergent applied with a sponge or soft cloth Use a soft bristle brush to clean areas that are especially soiled Use the following guidelines Light Soiling A solution of 10 liquid soap and warm water applied with a soft damp cloth is recom mended A soft bristle brush may be used if necessary Wipe off any residue with a water dampened cloth For Difficult Stains Dampen a soft white cloth with a solution of 10 household bleach sodium hypochlorite and 90 water Rub gently to remove stain then rinse with a water dampened cloth to remove bleach concentration For More Difficult Stains Perform previous procedure using full strength bleach or allow bleach to puddle on affected area for approximately 30 minutes Rinse with a water dampened cloth to remove any remaining bleach concentration CAUTION To prevent damage to the vehicle when removing difficult stains or heavy soiling remove the seat bottom from the vehicle first 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 4 1 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 Slowly wave the heat gun back and forth over the affected area until the streak
89. lly Adjusted Brakes A Brake Cluster Adjustment Brake Cable Equalization Final Brake Cluster Adjustment 0 cecceceeeceeeeeeeeeeeeeeeeeeeeeeeaeeeseaeeeeeaeeesaaeeeseaeeeseeeeseeeeneneeessaaees Test Drive Vehicle Brake Cluster Removal and Installation cccccccccccccecceecceceesceeeeeuecsesseeuaeseseseseuaegeseeseeauaegeseeeeeeanes Rear Brake Cluster Removal c cccccccccececcccsceeeeececeeeeeeeueceeeseeeeeseuseueuuaueueeeeeeuaaeeseeseeuaeeeeeeeeeeaaees Rear Brake Cluster Installation cccccccccccccesceeecccececeseeeueeseeseeeueseeeueuueuaeeeeeeuaeeuueesseeuaeueeeeeesaaees Front Brake Cluster Removal cccccccceccccccsceeececesceeueuueceeseeeaueuceeeseuaeesusesseeaeeueeeeeeeeaeueeeeeeeaneaees Front Brake Cluster Installation Front Brake Cables Front Brake Cable Removal Front Brake Cable Installation cccccccccccccccccceeeeececccesueeuesceeseeeeuseeseusaeaeuseeeeseuaeaeveeeeeuuaeaeeeeeuenaees Rear Brake Cables Rear Brake Cable Removal Rear Brake Cable Installation cccccccccccccccceccccccesseeeeeeceeseueaaeuceeeeeuaeeuuseseesuuaeaeseeeseauaeseeeeeeeneaees SECTION 7 STEERING AND FRONT SUSPENSION General Information Steering Wheel aiee Steering Wheel Removal Steering Wheel Installation 2012 Turf Carryall Vehicle Maintenance and Service Manual 5 16 6 1 6 1 6 3 6 5 6 8 6 9 6 10 6 1
90. m the vehicle REAR FLOOR MAT INSTALLATION TURF 6 AND CARRYALL 6 ONLY 1 Install the floor mat in the reverse order of removal BUMPER See General Warning Section 1 Page 1 1 BUMPER REMOVAL 1 Remove four lock nuts 10 six flat washers 11 four phillips bolts 12 and mounting plate 9 from rear bumper 8 Figure 4 6 Page 4 14 2 Lift bumper from vehicle BUMPER INSTALLATION 1 Install the rear bumper in the reverse order of removal Tighten nuts to 65 in lb 7 3 N m Figure 4 6 Page 4 14 Page 4 16 2012 Turf Carryall Vehicle Maintenance and Service Manual SECTION 5 ACCELERATOR AND BRAKE PEDAL GROUP A DANGER e See General Warning Section 1 Page 1 1 A WARNING e 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 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 Gasoline Vehicles on page 1 3 2 Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack Place jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands See following WARNING A WARNING Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraul
91. ment must be within specifications prior to beginning brake adjustment Perform the appropriate pedal group adjustment For gasoline vehicles refer to Pedal Group Adjustment Gasoline Vehicles Section 5 Page 5 11 For electric vehicles refer to Pedal Group Adjustment Electric Vehicles Section 5 Page 5 16 NOTE All brake cluster components must be clean lubricated and in good working condition prior to beginning brake adjustment All wheels must be installed on the vehicle and lug nuts tightened to 55 ft lb 74 6 N m Page 6 12 2012 Turf Carryall Vehicle Maintenance and Service Manual WHEEL BRAKE ASSEMBLIES Brake Adjustment Manually Adjusted Brakes e BRAKE CLUSTER ADJUSTMENT 1 Chock wheels 1 1 To provide slack in the brake cables loosen the equalizer retaining nuts 1 and 5 on the equalizer rod 2 Figure 6 27 Page 6 13 2 Four wheel brake vehicles only Loosen the front brake equalizer rod Figure 6 28 Page 6 13 3 Remove the dust cover 4 on the left and right rear brake cluster assemblies Figure 6 29 Page 6 13 and Figure 6 30 Page 6 13 Figure 6 28 Front Equalizer Adjustment Figure 6 29 Front Brake Adjustment Bolt 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
92. ming 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 4 Use a small brush to carefully apply a light coat of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent on each of the six raised bosses on brake backing plate Figure 6 20 Page 6 9 See pre ceding WARNING 5 Use a small brush to carefully apply a light coat of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent to each end of both brake shoes and into the slots in the brake shoe mounting block as shown Figure 6 21 Page 6 10 See preceding WARNING 6 Use a small brush to carefully apply a light coat of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent to the brake actuator assembly as shown Figure 6 22 Page 6 10 See preceding WARNING Figure 6 21 Lubricate Shoes Figure 6 22 Lubricate Actuator BRAKE SHOE INSTALLATION 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 NOTE Components of the front wheel brake assembly are identical to the rear wheel manu ally adjusted brake assembly The front brake assembly is rotated 90 when com pared to the rear brake assembly so the adjusting bolt on each assembly is oriented to the rear of the vehicle rather
93. mm below the level indicator Immediately Prior to Storage Perform the Following Steps 1 Turn the key switch to the OFF position remove the key and leave the Forward Reverse switch in the NEUTRAL position during storage 2 If so installed turn off all accessories including GPS units fans etc 3 Place the tow run switch in the TOW position Because the battery warning light does not illuminate with the key in the OFF position and the tow switch in TOW do not use the warning light as an indication of the batteries state of charge 4 Batteries should be clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse solution off bat teries Do not allow this solution to enter the batteries Let the terminals dry and then coat them with Bat tery Terminal Protector Spray CC P N 1014305 Tighten all battery cable connections to 110 in lb Store vehicle in a cool dry place This will minimize battery self discharge Adjust tires to recommended tire pressure See Section 2 Vehicle Specifications D NO Om Perform all semiannual periodic lubrication See Periodic Lubrication Schedule Section 10 Peri odic Maintenance in the appropriate maintenance and service supplement Thoroughly clean front body rear body seats battery compartment and underside of vehicle 10 Do not engage the park brake Chock
94. n to the park brake pawl shaft 3 Install the spacer 23 and torsion spring 22 on the park brake pedal shaft on the brake pedal assembly 4 Install the two bushings 30 in the park brake pedal and position the park brake pedal on the shaft on the brake pedal assembly weldment 10 Figure 5 4 Page 5 4 Then attach the ends of the torsion spring to the park brake pedal and to the brake pedal weldment as shown Figure 5 5 Page 5 6 5 Install the push nut 32 on the park brake pedal shaft Figure 5 4 Page 5 4 6 Connect park brake rod 17 with ball joint 21 to the ball stud on the park brake pedal assembly Figure 5 4 Page 5 4 7 Adjust the pedal group Refer to the appropriate adjustment procedure e For gasoline vehicles see Pedal Group Adjustment Gasoline Vehicles on page 5 11 e For electric vehicles see Pedal Group Adjustment Electric Vehicles on page 5 16 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 5 5 e ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal Gasoline Vehicles Hook one end of spring 20 on park brake weldment 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 GASOLINE VEHICLES See General Warning Section 1 Page 1 1 ACCELERATOR PEDAL REMOVAL GASOLINE VEHICLES 1 Disconnect battery and spark plug wire s See Disconnecting The Bat
95. ng the vehicle or a fire hazard Do not attempt to charge frozen batteries or batteries with bulged cases Discard the battery Frozen batteries can explode A CAUTION e Batteries in a low state of charge will freeze at low temperatures e To avoid exposing electrical components to moisture and subsequent damages do not use any type of pressure washing or steam cleaning equipment to wash the vehicle es IQ System and IQ Plus vehicles only Place the Tow Run switch in the TOW position PREPARING THE ELECTRIC VEHICLE FOR EXTENDED STORAGE Check Battery Water Levels Two Weeks Prior to Storage Check water levels at least two weeks prior to winter storage to ensure proper mixing of water and electrolyte Note that it takes approximately five charge cycles with a minimum of 10 energy units EUs removed to prop erly mix the water with electrolyte Do NOT water batteries immediately prior to storage because this will not provide sufficient charge time to mix the water with the electrolyte Freezing can occur when batteries are stored in this condition Page 3 4 2012 Turf Carryall Vehicle Maintenance and Service Manual GENERAL INFORMATION Storage Electric Vehicle EN 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
96. nsistent See following NOTE 2012 Turf Carryall Vehicle Maintenance and Service Manual ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment Gasoline Vehicles Ea 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 BOTTOM VIEW Figure 5 13 Park Brake Ratchet Pawl Gap Adjustment 3 3 With the park brake unlocked measure and note the distance from the top of the accelerator pedal to the floorboard then lock the park brake Figure 5 14 Page 5 13 3 4 With the park brake locked make sure at least 75 of ratchet tooth length engages the pawl Figure 5 15 Page 5 13 Tooth engagement should be between the two lines marked on the pawl LOCKED POSITION Make sure pawl A engages at least 75 of ratchet tooth length B Figure 5 14 Accelerator Pedal Height Measurement Figure 5 15 Ratchet Pawl Tooth Engagement 3 5 With park brake still locked measure the distance from the top of accelerator pedal to floorboard If the measurement has changed ratchet tooth engagement is too deep and must be adjusted 3 6 If ratchet pawl engagement must be adjusted disconnect the ball joint at the top of the brake rod and rotate the ball joint sleeve clockwise to increase engagemen
97. oint Pry or bump pinion gear out with universal Le PRESS RAM joint reinstalled PINION GEAR NI Ir BEARING WIES 2 Figure 7 9 Remove Pinion from Housing Figure 7 10 Remove Bearing from Pinion If necessary remove the dust seal 12 See following NOTE NOTE If the dust seal 12 is removed replace with a new one 9 Use snap ring pliers to remove the internal snap ring 11 Figure 7 8 Page 7 9 11 12 13 Install the universal joint onto the pinion and place a large open end wrench under the universal joint Figure 7 9 Page 7 10 Use the wrench as a lever to pull the pinion from the housing If the ball bearing 9 has been damaged remove the external snap ring 10 Figure 7 8 Page 7 9 and press the bearing off Figure 7 10 Page 7 10 Remove retaining ring 19 and stop washer 18 then remove rack 17 from housing 6 Figure 7 8 Page 7 9 If the inner ball joint 3 is excessively worn remove the ball joint and tab washer 4 from the rack Figure 7 11 Page 7 11 13 1 Secure the rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack from damage Figure 7 11 Page 7 11 13 2 Loosen and remove the inner ball joint with a wrench Page 7 10 2012 Turf Carryall Vehicle Maintenance and Service Manual STEERING AND FRONT SUSPENSION Rack and Pinion BO INNER BALL WOOD BLOCKS Figure 7 11 Secure
98. on e To prevent accidentally starting the vehicle disconnect the battery cables as instructed in WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 2 This will prevent the possibility of the vehicle running over you when you are adjusting the accelerator rod Page 5 14 2012 Turf Carryall Vehicle Maintenance and Service Manual ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment Gasoline Vehicles Ea 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 See following CAU TION RETAINING NUTS CAM PARALLEL WITH BOX TOP VIEW OF THE ELECTRICAL COMPONENT Figure 5 19 Accelerator Cable A CAUTION e After accelerator rod adjustment make sure that approximately the same number of threads are exposed at each end of the accelerator rod e If the lever on the limit switch in the electrical box is bent replace the limit switch e When loosening jam nuts on the accelerator rod with one end disconnected hold the disconnected accelerator rod with locking pliers e When tightening jam nuts on the accelerator rod hold t
99. onverter Automatic variable speed dry type STEERING SUSPENSION BRAKES Steering Self adjusting rack and pinion Suspension Front mono leaf and rear multi leaf springs with dual hydraulic shocks Suspension Front and rear multi leaf springs with dual hydraulic shocks Brakes Mechanical brake cable system to self adjusting drum brakes on each rear wheel Park brake is automatically released Self adjusting multi latch ratchet and pawl Manually Adjusted Brakes Mechanical brake cable system to manually adjusted drum brakes on all four wheels Park brake is auto matically released Self adjusting multi latch ratchet and pawl BODY CHASSIS Frame chassis Twin I Beam welded aluminum Side and rear body All aluminum Front body ArmorFlex Front body finish Automotive grade paint Tires 18 x 8 50 8 tubeless 4 ply rated load range front and rear Tires 18 x 8 50 8 tubeless 6 ply rated load range front and rear DIMENSIONS WEIGHT Overall length Standard flatbed configuration Overall width 100 in 254 cm 49 25 in 120 cm 111 in 282 cm 50 in 127 cm 111 in 282 cm 50 in 127 cm 134 in 340 cm 49 25 in 120 cm Overall height At steering wheel 48 in 122 cm 48 in 122 cm 48 in 122 cm 48 in 122 cm Wheelbase Specifications continued on next page 65 5 in 166 cm 77 5
100. oosen but do not remove the screw 2 on each side of the center dash panel 3 Insert screwdriver at the top center of the dash between dash and cowl brace Gently pry center dash out slightly from under edge of cowl brace Pull center dash out from the frame and disconnect the wires from the electrical components mounted on the dash panel Do not allow wires to touch See following NOTE Take care to prevent key switch terminals and wires from touching the metal frame around the dash Slide center dash panel up the steering column Figure 7 4 Dash Removal 4 Remove the driver side dash pocket 4 1 4 2 4 3 Remove the flange lock screw from the top of the dash pocket Drill out the two pop rivets holding the dash pocket in place Slide dash pocket out of vehicle 5 Remove the upper bolt 2 and lock washer 3 from the universal joint Figure 7 3 Page 7 3 6 Remove the nuts 9 bolts 8 and 10 and washers 7 and 11 from the steering column mount 4 and 5 Figure 7 3 Page 7 3 7 Remove the steering column from the vehicle Page 7 4 2012 Turf Carryall Vehicle Maintenance and Service Manual 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 NOTE Do not allow t
101. or damaged Figure 9 3 Page 9 4 or Figure 9 4 Page 9 5 MULTI LEAF SPRING INSTALLATION NOTE When installing rear leaf springs make sure that both springs have identical part numbers 1 Install rubber bushings 4 and steel sleeves 3 into leaf spring eyes if bushings were removed Figure 9 3 Page 9 4 or Figure 9 4 Page 9 5 2 Place front of leaf spring 12 into vehicle frame and insert bolt 24 through frame and leaf spring eye Install lock nut 25 and tighten to 15 ft lb 20 3 N m 3 Align the other end of leaf spring with the holes in the spring shackles 1 Insert bolt 15 through leaf spring eye and shackles Install lock nut 2 and tighten to 15 ft lb 20 3 N m Lower transaxle onto leaf spring 12 See following CAUTION CAUTION e When placing transaxle on spring be sure to position locating bolt on the spring in the locating hole in the transaxle saddle 23 Figure 9 3 Page 9 4 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 9 3 9 REAR SUSPENSION Multi Leaf Springs TURF 1 amp CARRYALL 1 GAS ONLY TYPICAL el SSG TYPICAL ON BOTH SIDES A BOTH SIDES OF VEHICLE _ REAR BRAKE CABLE H ELECTRIC VEHICLES A Ze i C L 2 2 D d cb S wz Se oE TYPICAL 2 nas SEN PLACES Figure 9 3 Rear Suspension Turf 1 and Carryall 1 Vehicles Page 9 4 2012 Turf Carryall Vehicle Maintenance and Service Manual Multi Leaf Springs ER REAR S
102. orm a proper seal as the tire is inflated Figure 8 2 Page 8 4 See following WARNING A WARNING e Do not use a compressed air source with pressure over 100 psi 6 90 Bars Due to the low pressure requirements of a small tire over inflation could be reached almost instantly when using a high pressure air supply Over inflation could cause the tire to explode possibly resulting in personal injury 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 8 3 8 WHEELS AND TIRES Tire Installation Continued 7 Quickly remove the air nozzle and install the valve core Push tire against wall Figure 8 2 Inflate Tire 8 Adjust air pressure in the tire to e 16 18 psi 1 10 1 24 Bars for Turf 1 and Carryall 1 gasoline vehicles e 18 20 psi 1 24 1 38 Bars for Turf 1 and Carryall 1 electric vehicles e 30 34 psi 2 07 2 34 Bars for all other vehicles 9 Immerse the wheel and tire assembly in water to make sure there are no leaks Page 8 4 2012 Turf Carryall Vehicle Maintenance and Service Manual Wheels SECTION 9 REAR SUSPENSION A DANGER e See General Warning Section 1 Page 1 1 A WARNING e 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
103. ounce bumper installation 9 8 Ce TEE 9 8 multi leaf spring installation une TEE shock absorber INSPOCHON sioctha ha eee 9 1 Installation EE 9 2 removal ege e 9 1 snubber INStallatiON EE 9 6 Ce TEE 9 6 stabilizer bar Installation dee aoaia 9 8 ue TEEN 9 7 T tailskirt installation EE 4 15 ET ue ELE 4 15 tie rod and drag link installation ee ee 7 14 ue LEE 7 14 tilt bed EC UE Le EE 4 6 2012 Turf Carryall Vehicle Maintenance and Service Manual INDEX removal tire installation pressure removal repair trailer hitch installation removal Ww WARNING definition of wheel seealso tire installation removal 2012 Turf Carryall Vehicle Maintenance and Service Manual Page i 3 Your Comments Are Appreciated Contact Information Optional Name am Title Company Distributor Dealer Address Individual Owner Club Car Associate Representative City State Zip Technician Phone Fax Golf Course Superintendent E mail Other Rate Our Publication In order to help us better serve you please rate this publication in the following categories Poor Fair Average Good Excellent Ease of Understanding Ease of Finding Information Clarity of Illustrations Photos Index Usability If you are reviewing a Kit Instruction were all indicated parts included in your
104. oute brake cable between the shock support 8 and brake cable guide bracket 7 Figure 6 35 Page 6 20 Secure brake cable retainer clips 5 with a bolt 4 and nut 6 6 Install brake cable through the front spindle brackets and install E clip 1 7 Install brake cable clevis onto brake lever arm and install clevis pin 3 and a new bow tie pin 2 8 Adjust brakes as described in this section for the appropriate vehicle 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 6 21 el 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 Release park brake if latched and loosen equalizer retaining nuts 1 on equalizer rod 2 to slightly loosen brake cables 3 Figure 6 38 Page 6 23 3 Rotate brake cables upward and pull ends through holes in top of equalizer 4 Disconnect brake cables at rear wheels 4 1 Remove bow tie pins 1 clevis pins 2 and E clips 3 Figure 6 39 Page 6 23 4 2 Remove cable 4 from cable support bracket 5 4 3 No
105. ower the vehicle and finish tightening lug nuts using a crisscross pattern to 55 ft lb 74 6 N m oa EF o Adjust camber and toe in See Camber Adjustment on page 7 15 and Toe in Adjustment on page 7 16 KINGPIN AND STEERING SPINDLE REMOVAL 1 Remove the front hub See Front Wheel Bearings and Hubs on page 7 24 e For vehicles with four wheel brakes proceed to step 2 e For vehicles with two wheel brakes proceed to step 3 2 Disconnect the front brake cables 2 1 Remove the cotter pins 1 brake cable clevis pins 2 and cable retaining clips 3 Remove the brake cables 4 from the spindle brackets Figure 7 19 Page 7 18 3 Disconnect tie rod ball joints and drag link from spindles See Tie Rod and Drag Link on page 7 14 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 7 17 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 Raise the upper clevis 16 from the kingpin 4 3 Remove the hardened flat washer 37 and thrust washer 38 5 Slide the spindle off the kingpin 26 6 Remove the wave washer 20 and inspect it If the washer is broken or has a wave bottom to wave crest height dimension of less than 0 040 inch 0 10 cm it must be replaced 7 Remove bolt 25 and nut 14 from bo
106. push the pivot rod toward the driver side of the vehicle to make the splines accessible The ratchet may have to be rotated counterclockwise slightly to align the splines Move the pivot rod back toward the driver side of the vehicle and line up the match marks on the pivot rod and ratchet Rotate the pivot rod back and forth slightly to align the splines and slide the ratchet onto the splines Install the nylon lock nut 26 on the pivot rod and tighten the nut to 18 ft lb 24 N m Figure 5 6 Page 5 7 Install the accelerator rod assembly 17 25 and 24 Figure 5 6 Page 5 7 Adjust the pedal group See Pedal Group Adjustment Gasoline Vehicles on page 5 11 Page 5 8 2012 Turf Carryall Vehicle Maintenance and Service Manual ACCELERATOR AND BRAKE PEDAL GROUP ACCELERATOR PEDAL ELECTRIC VEHICLES See General Warning Section 1 Page 1 1 ACCELERATOR PEDAL REMOVAL ELECTRIC VEHICLES 1 2 Disconnect the batteries and discharge the controller See Disconnecting The Batteries Electric Vehicles on page 1 3 Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack Place jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands See following WARNING A WARNING oOo N OD WO e Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 454 kg minimum
107. r pivot rod supports 21 Figure 5 8 Page 5 10 Inspect the accelerator pivot rod supports 21 for wear and damage and replace as necessary If the pivot rod supports do not require replacement loosen but do not remove the four bolts 22 and lock nuts 15 to make installation of the pivot rod easier Remove the accelerator pedal 1 from the vehicle Figure 5 8 Page 5 10 Inspect all parts for wear and damage Replace as necessary 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 5 9 Accelerator Pedal Electric Vehicles e ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal Electric Vehicles TYPICAL 4 PLACES Figure 5 8 Accelerator Pedal Electric Vehicle Page 5 10 2012 Turf Carryall Vehicle Maintenance and Service Manual ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment Gasoline Vehicles EC 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 2 Insert the lower end of the accelerator pedal 1 through the floorboard and install the accelerator pivot rod 6 through the uppermost hole in the pedal 3 Install plastic spacer 20 on pivot rod 6 4 Insert the pivot rod through the pivot rod supports 21 on the vehicle frame 5 Tighten
108. re s See Disconnecting The Batteries Electric Vehicles on page 1 3 See Disconnecting The Battery Gasoline Vehicles on page 1 3 2 Remove the two mounting screws 1 and plate 2 Figure 7 1 Page 7 2 3 Match mark the steering wheel 3 and steering column shaft 4 so when the steering wheel is removed it can be placed back in exactly the same position on steering column shaft 4 Loosen the steering wheel nut 5 and back it off approximately 1 4 inch 6 mm Do not remove the nut 5 Use the steering wheel puller CC P N 102061201 to remove steering wheel 5 1 Place the puller anvil 6 through the top opening of the steering wheel Figure 7 2 Page 7 2 5 2 Insert the anvil feet through the two slots in the base plate marked B 7 as shown 5 3 Rotate the anvil screw 8 clockwise until the base plate contacts the bottom of the steering wheel where it attaches to the steering column 5 4 Use a 1 2 inch drive air impact wrench to tighten the anvil screw 8 until the steering wheel breaks free from the steering shaft 5 5 Remove the steering wheel puller 5 6 Remove the steering wheel nut 5 and the steering wheel 3 from the steering column 9 Figure 7 1 Page 7 2 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 7 1 STEERING AND FRONT SUSPENSION Steering Column Figure 7 1 Steering Wheel Removal Figure 7 2 Steering Wheel Puller STEERING WHEEL INSTALLATION NOTE To minimize
109. reme caution to avoid shorting of components or wiring Check the vehicle owner s manual for proper location of all vehicle safety and operation decals and make sure they are in place and are easy to read Any modification or change to the vehicle that affects the electrical system stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications could result in severe personal injury or death Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes If wires are removed or replaced make sure wiring and wire harness are properly routed and secured Failure to properly route and secure wiring could result in vehicle malfunction property damage personal injury or death WARNING CONTINUED ON NEXT PAGE Page 1 2 2012 Turf Carryall Vehicle Maintenance and Service Manual SAFETY General Warning ieee A WARNING e 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 Do not close bed
110. render the vehicle unsafe For this reason Club Car advises that all repairs and or service be performed by an authorized Club Car distributor dealer representative or by a Club Car factory trained tech nician It is the policy of Club Car LLC to assist its distributors and dealers in continually updating their service knowl edge and facilities so they can provide prompt and efficient service for vehicle owners Regional technical rep resentatives 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 manual used in conjunction with the appropriate maintenance and service supplement covers all aspects of typical vehicle service however unique situations do sometimes occur when servicing a vehicle 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 Copyright 2011 Club Car LLC Club Car and Carryall are registered trademarks of Club Car LLC This manual effective August 1 2011 2012 Turf Carryall Vehicle Maintenance and Service Manual Page i A WARNING e Read Section 1 Safety before attempting any service on the vehicle e Before servicing vehicle read complete
111. rink large quantities of milk or water Follow with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately e Gasoline Flammable Explosive Do not smoke Keep sparks and flames away from the vehicle and service area Service only in a well ventilated area e Do not operate gasoline vehicle in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 1 1 SAFETY General Warning A WARNING es 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 e 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 The appropriate instructions must be used when performing maintenance service or accessory installation e Prior to servicing the vehicle or leaving the vehicle unattended turn the key switch OFF remove the key and place the Forward Reverse handle in the NEUTRAL position Chock the wheels when servicing the vehicle Gasoline vehicles only e To avoid unintentionally starting the vehicle Disconnect battery cables negative cable first Figure 1 1 Page 1 4 Disconnect the spark plug wire from th
112. rk the point where bubbles are formed by escaping air 1 3 Determine the cause of the air leak and repair as required See following NOTE NOTE An air leak could be due to a punctured tire faulty valve core improperly seated valve stem or improperly seated tire bead Small holes in the tire can be plugged using a standard automotive tubeless tire repair kit available at auto supply stores TIRE INSTALLATION A WARNING e While mounting or inflating tire keep hands fingers etc from exposed areas between the tire bead and rim 1 Clean both tire beads to remove dirt or other foreign matter 2 Where the tire beads seat clean the rim with a wire brush Wipe away any debris with a clean cloth See following NOTE NOTE Because tubeless tires require a perfect seal in order to seat keeping the tire and rim clean is very important 3 Apply a light coating of tire mounting lubricant soap and water solution to both tire beads and rim flanges 4 Install the tire on the rim from the valve stem side If there is no tire machine available use a rubber mallet and tire iron 5 Remove the valve core and position the tire so both beads are on the rim flange narrow bead seats 6 Place the tire and wheel assembly against a wall in an upright position and push it against the wall while inflating the tire to 30 34 psi 2 07 2 34 Bars The three point contact wall floor and hand will help ensure that beads snap into place and f
113. rryall Vehicle Maintenance and Service Manual Page 9 7 9 REAR SUSPENSION Jounce Bumpers 3 4 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 Remove bushings 13 from stabilizer bar 1 STABILIZER BAR INSTALLATION 1 Position stabilizer bar at the transaxle mounting brackets Install a bushing 13 onto bar making sure the bushing is located in the center of the four mounting holes in the bracket Figure 9 6 Page 9 7 Place the bushing support 12 onto the bushing Install four hex head bolts 14 through the bushing support and transaxle mounting bracket 3 Install four lock nuts 15 and tighten to 75 in Ib 8 4 N m 4 Repeat steps 1 2 and 3 for the other side of the stabilizer bar 5 Place lock washer 7 flat washer 4 spacer 2 and compression mount 3 onto bolt 6 Install bolt oon OD through mounting hole in stabilizer bar and place another compression mount 3 and flat washer 4 onto bolt Figure 9 6 Page 9 7 Install the bolt 6 with hardware into the stabilizer bar link 5 and finger tighten Repeat steps 5 and 6 for the other side of the stabilizer bar Tighten bolts 6 in the stabilizer bar links 5 to 17 ft lb 23 N m Place jack under transaxle and raise vehicle enough to remove jack stands Lower the vehicle to the ground JOUNCE BUMPERS See General Warning Section
114. scceeseeneeeceeseneeeeecceaeecessceaaeeeesseneeeeessenseeeessseaaes 5 6 Accelerator Pedal Removal Gasoline Vehicles ccccccscccecesssceeessenneeeeeesneeeeesssneeeesseseeeeess 5 6 Accelerator Pedal Installation Gasoline Vehicles ccccecsscceeeeeseeeeeeseneeeeeseseeeeessnaeeeeessenaes 5 8 Page iv 2012 Turf Carryall Vehicle Maintenance and Service Manual Accelerator Pedal Electric Vehicles Accelerator Pedal Removal Electric VeniCleS est gett Age ee et dE Accelerator Pedal Installation Electric Vehicles Pedal Group Adjustment Gasoline Vehicles ccccesscccceseneeeeeeeesneeeeseseeesesseeeeeesesneeeeessseeeess Pedal Group Adjustment Electric Vehicles A SECTION 6 WHEEL BRAKE ASSEMBLIES General Information Brake Shoe Removal Brake Assembly Cleaning Self Adjusting Brakes c ccccceeeseceeeeeeeeeneeeeeeeeeseaeeeeseaeeseeeeseneeeteeees Brake Shoe Installation Self Adjusting Brakes cccceceeeceeeeeeeeeeeeeeeeeeeeeseeeseaeeeeeaeeeseeeeseneeeteaees Brake Adjustment Self Adjusting Brakes cccsceceseeeeeeeeeseneeeseeeeseaeeeseeeeseaeeeseaeeescaeeeseneeeneaeees Brake Assembly Cleaning Manually Adjusted Brakes cccccccesceeeeeeeeeeneeeseneeeseaeeeeneeeteeeeeeeeens Brake Shoe Installation Manually Adjusted Brakes 0 cccececeeeceeeeeseeeeeeeeeeeeeeeeeeeeeeseaeeeeeeeeseeeeee Brake Adjustment Manua
115. section s and any referenced information that may be relevant to the service or repair to be performed NOTE This manual represents the most current information at the time of publication Club Car LLC is continually working to further improve its vehicles and other products These improvements may affect servicing procedures Any modification and or signif icant change in specifications or procedures will be forwarded to all Club Car distribu tors and dealers and will when applicable appear in future editions of this manual 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 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 LLC P O Box 204658 Augusta GA 30917 4658 USA Attention Warranty Administration Page ii 2012 Turf Carryall Vehicle Maintenance and Service Manual CONTENTS SECTION 1 SAFETY General Warning dasri eesi ie cain ae Ee Eerad 1 1 Disabling The Vehicle srne r Ea E TA EAA EA EO A A ESNE N 1 3 Disconnecting The Battery Gasoline Vehicles A 1 3 Connecting The Battery Gasoline Vehicles A 1 3 Disconnecting The Batteries Electric Vehicles AAA 1 3 Connecting The Batteries Electric Vehicles A 1 4 SECTION 2 VEHICLE SPECIFICATIONS Vehicle Specifications Electric Vehicles A 2 1
116. sen hex nut 8 Ge on eccentric See Se ER EQUAL SPACE ECCENTRIC BETWEEN TIRES AND ADJUSTER 7 FRAMING SQUARES Use 7 mm deep well IMPROPER CAMBER socket to adjust ADJUSTMENT eccentric UNEQUAL SPACE BETWEEN TIRES AND FRAMING SQUARES LLLI Figure 7 15 Check Camber Figure 7 16 Adjust Camber 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 7 15 STEERING AND FRONT SUSPENSION Rack and Pinion 3 Loosen but do not remove the hex nut 8 on the adjustment eccentric 7 Figure 7 21 Page 7 20 or Figure 7 23 Page 7 22 in the center of the spring See also Figure 7 16 Page 7 15 4 Use a 7 mm deep well socket to rotate the eccentric Figure 7 16 Page 7 15 5 After adjusting camber tighten the four spring retaining bolts 30 Figure 7 21 Page 7 20 or Figure 7 23 Page 7 22 to 23 ft lb 31 N m Then roll the vehicle forward one full tire revolution and recheck the camber See also Figure 7 15 Page 7 15 6 Tighten the hex nut 8 on the adjustment eccentric 7 to 23 ft lb 31 N m Figure 7 21 Page 7 20 or Figure 7 23 Page 7 22 See also Figure 7 16 Page 7 15 Toe in Adjustment 1 Ona level surface roll the vehicle forward then stop Make sure the front wheels are pointed straight ahead Do not turn the steering wheel again during this procedure 2 On each front tire mark as closely as possible the center of the tread face that is oriented toward the rear of the vehicle The marks sho
117. t or counterclockwise to decrease engagement Reconnect ball joint Figure 5 16 Page 5 14 3 7 If the accelerator push rod was disconnected from the accelerator pedal reconnect it 3 8 Check for proper brake operation prior to driving the vehicle 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 5 13 LS 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 closest to the floorboard Press the accelerator pedal until the end of the tool rests against the floorboard pedal height should be 5 5 8 inches 14 3 cm Use a rubber strap to hold pedal in position against the floorboard and then tighten nut to 26 ft lb 35 3 N m Figure 5 18 Page 5 14 ACCELERATOR PEDAL ADJUSTMENT TOOL CCI P N 101871001 e Figure 5 18 Accelerator Pedal Height Adjustment 5 Adjust the accelerator rod See following DANGER A DANGER e Before servicing turn the key switch to the OFF position and place the Forward Reverse handle in the NEUTRAL positi
118. t the center of its travel There should be equal travel to the left and right See following NOTE NOTE If the minimum turning radius is not the same for both left and right turns adjust the steering See Steering Adjustment on page 7 7 FRONT SUSPENSION COMPONENTS See General Warning Section 1 Page 1 1 LEAF SPRING REMOVAL 1 Loosen lug nuts on both front wheels and raise front of vehicle with a chain hoist or floor jack Place jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands 2 Remove both front wheels 3 Remove the nuts 14 and bolts 25 from the bottom of each king pin 26 Figure 7 21 Page 7 20 or Figure 7 23 Page 7 22 4 Remove the four bolts 30 four nuts 32 four lock washers 31 and bottom spring plate 29 5 Remove tapered leaf spring 6 6 Check the condition of the urethane bushings 27 and steel sleeves 28 Replace any that are worn or damaged LEAF SPRING INSTALLATION 1 Install urethane bushings 27 and steel sleeves 28 into leaf spring eyes Figure 7 21 Page 7 20 or Figure 7 23 Page 7 22 2 Install tapered leaf spring 6 bottom spring plate 29 four bolts 30 four lock washers 31 and four nuts 32 Using a crisscross pattern sequence tighten bolts to 23 ft lb 31 N m Install spring in king pins 26 with bolts 25 and nuts 14 Tighten to 23 ft lb 81 N m Install the wheels and finger tighten the lug nuts L
119. t the vehicle 2 Release park brake and loosen equalizer retaining nuts 1 and 5 on equalizer rod 2 to slightly loosen brake cable Figure 6 27 Page 6 13 3 Remove the rear wheels and then the brake drums See following NOTE NOTE When servicing vehicles with self adjusting brakes with badly worn brake shoes and when the drums cannot be removed by normal methods perform step 4 of Brake Shoe Removal on page 6 2 then continue with this procedure 4 Remove the axle 4 1 Using 90 snap ring pliers remove the axle retaining ring 1 Figure 6 3 Page 6 2 4 2 Pull the axle shaft 2 from the axle tube Figure 6 3 Page 6 2 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 6 17 e 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 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 Remove rear brake cluster assembly from transaxle REAR BRAKE CLUSTER INSTALLATION 1 Install in reverse order of disassembly Use new bow tie pins when installing brake cables See follow ing CAUTION A CAUTION e Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to installing the axle shaft Be sure bolts 20
120. t to be reinstalled improperly resulting in improper adjustment and possible failure of the park brake Page 5 6 2012 Turf Carryall Vehicle Maintenance and Service Manual ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal Gasoline Vehicles Ea 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 Rotate the ratchet and remove it from the pivot rod 11 Remove the pivot rod 6 and spacer 20 from the accelerator pivot rod supports 21 12 Inspect the accelerator pivot rod supports 21 for wear and damage and replace if necessary If the pivot rod supports do not require replacement loosen but do not remove the four bolts 22 and lock nuts 18 to make installation of the pivot rod easier 13 Remove the accelerator pedal 1 from the vehicle 14 Inspect all parts for wear and damage Replace as necessary TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 5 6 Accelerator Pedal Gasoline Vehicles 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 5 7 LS ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal Gasoline Vehicles ACCELERATOR PEDAL INSTALLATION GASOLINE VEHICLES 1 oa F p 10 11 12 13 If the accelerator pivot rod supports were replaced position the supports 21 on the vehicle frame and install the four bolts 22
121. te location of hangers for installation of cables Pull cables out of vehicle Page 6 22 2012 Turf Carryall Vehicle Maintenance and Service Manual WHEEL BRAKE ASSEMBLIES Rear Brake Cables e 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 2 At the rear wheel brakes connect the cables to the brake actuator arms using clevis pins 2 and new bow tie pins 1 Figure 6 39 Page 6 23 3 Place cables in cable support bracket 5 and secure with E clips 4 Adjust brakes as described in this section for the appropriate vehicle 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 6 23 SECTION 7 STEERING AND FRONT SUSPENSION A DANGER e See General Warning Section 1 Page 1 1 A WARNING e 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 No manual adjustment to the rack and pinion gear assembly is required A spring loaded self adjusting mechanism is incorporated into the assembly STEERING WHEEL See General Warning Section 1 Page 1 1 STEERING WHEEL REMOVAL 1 Disconnect the battery cables and either discharge the controller or disconnect the spark plug wi
122. tery Gasoline Vehicles on page 1 3 2 Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack Place jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands See following WARNING A WARNING e Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 3 Disconnect the accelerator rod assembly 17 25 and 24 Figure 5 6 Page 5 7 at the front and rear ball studs and remove it from the vehicle 4 Use a 9 16 inch socket and 9 16 inch wrench to remove the nut 7 two washers 5 and bolt 4 secur ing the accelerator pedal 1 to the pivot rod 6 Remove the nut 10 and ball stud 8 from the accelerator pivot rod assembly 6 Slide the spring retainer 11 off of the accelerator pivot rod Inspect the pivot support bearing 9 for wear and replace if necessary oN OO Use a marker to mark the position of the park brake ratchet 23 on the accelerator pivot rod 6 See fol lowing NOTE NOTE Failure to mark position of the ratchet could cause i
123. than at the top of the assembly Figure 6 32 Page 6 15 Page 6 10 2012 Turf Carryall Vehicle Maintenance and Service Manual WHEEL BRAKE ASSEMBLIES Brake Shoe Installation Manually Adjusted Brakes e 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 A WARNING e 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 Incorrectly installed brake shoes will be too tight and make adjustment of the brake impossible J10 STAMPING ON SHOE BS A PGs Y J 9 IT J UAA on h 1 Figure 6 23 Position Shoes Figure 6 24 Retainer Clip 2 Install shoe retainer clip 1 using pliers to compress clip while turning clip retainer pin 2 into position Figure 6 24 Page 6 11 3 Attach the springs with hooks pointing outwards onto the shoe already installed Then hold the other shoe next to it correctly oriented and attach the springs to it Figure 6 25 Page 6 12 See following NOTE NOTE With brake shoe tips marked J10 oriented to the mounting block the stamping will be visible on one shoe only The other J10 stamping will be facing the backing plate and will not be visible 4 While maintaining spring attachment on both shoes position the tips of the second shoe into mounting slo
124. the wheels to prevent the vehicle from rolling NOTE It is recommended that the vehicles be plugged in and the electrolyte level main tained throughout the storage period If any of the following conditions exist how ever then disconnect the batteries for storage 1 The charger cannot remain plugged in 2 AC power will not be available during extended storage or 3 Electrolyte levels will not be maintained To disconnect batteries for storage go to step 12 11 To keep batteries fully charged during storage 11 1 Plug the battery charger into the car Leave battery chargers plugged in during storage The onboard computer OBC will automatically activate the charger when necessary 11 2 Check the electrolyte level and charger function monthly to ensure that proper operation is main tained To check charger function disconnect the DC cord stationary charger from the vehicle or the AC cord onboard charger from the power source wait five seconds then reconnect it The charger is functioning properly if the ammeter indicates current NOTE The OBC keeps track of the time spent in storage mode When the OBC detects that the storage charge cycles may have depleted the available elec trolyte it will stop the charger from further operation Disconnecting then reconnecting the DC cord stationary charger or AC cord onboard charger indicates the electrolyte levels have been maintained and allows the OBC to resume operation 11 3 If
125. ts and then push shoe into place Hold shoe in position and install the retaining clip and pin Figure 6 25 Page 6 12 5 After the shoes are installed move them together up and down and side to side to make sure that they will easily slide approximately 1 4 to 3 8 inch 6 3 to 9 5 mm without binding Make sure the shoes are positioned vertically so the tips of the shoes are positioned flush with the top surface of the shoe mount ing blocks as shown Figure 6 26 Page 6 12 See following CAUTION 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 6 11 e WHEEL BRAKE ASSEMBLIES Brake Adjustment Manually Adjusted Brakes Brake Shoe Installation Manually Adjusted Brakes Continued Figure 6 25 Insert Shoes Figure 6 26 Position Shoes A CAUTION e Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to installing the axle shaft 6 Install axle shaft 2 into axle tube and install retaining ring 1 Figure 6 3 Page 6 2 See WARNING on page 6 8 7 Install the brake drum and make sure that it is properly seated See following NOTE NOTE If drum installation is difficult the brake shoes may need to be adjusted vertically in the mounting slots 8 After the drum is installed make sure the axle and drum turn freely BRAKE ADJUSTMENT MANUALLY ADJUSTED BRAKES See General Warning Section 1 Page 1 1 See also Warning on Page 6 1 A CAUTION e Pedal group adjust
126. ttom of kingpin 26 and remove kingpin 8 Inspect the kingpin and spindle If either is worn or damaged it must be replaced 9 Inspect the bushings 3 and 4 If the bushings are worn or damaged remove them and press in new ones See following NOTE NOTE If the bushings are replaced ream new bushings to 0 750 0 752 3 4 inch 19 05 19 10 mm in diameter The reamer should be long enough to ream both bushings from one direction Page 7 18 2012 Turf Carryall Vehicle Maintenance and Service Manual Loi E Ou E Q E Q a E Ou gt 5 Lo E ES LL STEERING AND FRONT SUSPENSION Figure 7 20 Two Wheel Brake Vehicle Upper Portion 2012 Turf Carryall Vehicle Maintenance a 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 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 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 STEERING AND FRONT SUSPENSION Front Suspension Components KINGPIN AND ST
127. uld be even with the bottom surfaces of the vehicle frame beams 3 Measure the distance between the marks on the rear facing surfaces of the tires and then roll the vehicle forward one and one half wheel revolutions until the marks appear on the forward facing surfaces of the tires at about the same height from the floor Figure 7 17 Page 7 16 Club Get Figure 7 17 Check Toe In Figure 7 18 Adjust Toe In 4 Measure the distance between the marks on the forward facing surfaces of the tires See following NOTE NOTE The front measurement must be less than the rear measurement 5 Subtract the measurement on the front of the tires from the measurement on the rear of the tires The difference is the toe in Proper toe in is 1 8 to 3 8 of an inch 3 2 to 9 5 mm 6 If adjustment is necessary loosen the jam nut on each tie rod ball joint and rotate the tie rod to increase or decrease toe in Figure 7 18 Page 7 16 See following CAUTION CAUTION e The tie rod has right hand threads on one end and left hand threads on the other end Right hand threads are identified by a groove in the tie rod Page 7 16 2012 Turf Carryall Vehicle Maintenance and Service Manual 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 a
128. until all persons are clear of cargo bed area Keep hands clear of all crush areas Do not drop cargo bed lower gently and keep entire body clear Failure to heed this warning could result in severe personal injury or death es Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance severe personal injury or death e Do not leave children unattended on vehicle DISABLING THE VEHICLE Set the park brake k Turn the key switch OFF and remove the key Place the Forward Reverse control in the NEUTRAL position Fb pm DN In addition chock the wheels if servicing or repairing the vehicle DISCONNECTING THE BATTERY GASOLINE VEHICLES 1 Disable the vehicle See Disabling The Vehicle on page 1 3 2 Disconnect the battery cables negative cable first as shown Figure 1 1 Page 1 4 3 Disconnect the spark plug wire s from the spark plug s CONNECTING THE BATTERY GASOLINE VEHICLES Connect the battery cables positive cable first k Tighten battery terminals to 80 in Ib 9 N m Coat terminals with Battery Terminal Protector Spray CC P N 1014305 to minimize corrosion PF o DN Connect the spark plug wire s to the spark plug s DISCONNECTING THE BATTERIES ELECTRIC VEHICLES 1 Disable the vehicle See Disabling The Vehicle on page 1 3 2 Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to
129. ut do not remove the carburetor drain screw and drain fuel remaining in bowl into a small container then pour the fuel from the container into vehicle fuel tank Tighten the carburetor drain screw 4 3 Fill fuel tank to about 1 inch 2 5 cm from top of fuel tank and following manufacturer s directions add a commercially available fuel stabilizer such as Sta Bil 4 4 Disconnect fuel vent line from fuel tank vent nipple 4 5 Plug the fuel tank vent nipple so that it is air tight We recommend using a slip on vinyl cap 5 Disconnect battery and spark plug wire s See Disconnecting The Battery Gasoline Vehicles on page 1 3 6 To protect the engine remove spark plug and pour 1 2 ounce 14 2 mL of SAE 10 weight oil into engine through the spark plug hole Rotate engine crankshaft by hand several times and then install the spark plug 7 Adjust tires to recommended tire pressure See Section 2 Vehicle Specifications 8 Perform semiannual periodic lubrication See Periodic Lubrication Schedule Section 10 Periodic Maintenance in the appropriate maintenance and service supplement 9 Thoroughly clean front body rear body seats cargo bed engine compartment and underside of vehicle 10 Do not engage the park brake Chock the wheels to prevent the vehicle from rolling 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 3 3 ES GENERAL INFORMATION Storage Electric Vehicle RETURNING THE STORED GA
130. x 112 cm 46 9 in x 48 3 in 119 x 126 cm 67 6 in x 44 2 in 172 x 112 cm Front and rear 1 24 1 38 Bars Page 2 2 2012 Turf Carryall Vehicle Maintenance and Service Manual Vehicle rated capacity Level surface only e Gi Gw wi Standard seating capacity 2 2 2 LIQUID CAPACITIES 22 Oz Transaxle 0 67 liters TIRE PRESSURE 18 20 psi 30 34 psi 30 34 psi 2 07 2 34 Bars 2 07 2 34 Bars VEHICLE SPECIFICATIONS VEHICLE SPECIFICATIONS GASOLINE VEHICLES Vehicle Specifications Electric Vehicles SPECIFICATIONS Turf 1 Carryall 1 Pedal Start Gasoline Turf 2 Carryall 2 Pedal Start Gasoline Carryall 2 Plus Key Start Gasoline Turf 6 Pedal Start Carryall 6 Key Start 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 sure lubrication system Fuel system Side draft carburetor with float bowl fixed jets fuel filter and impulse fuel pump Governor Automatic ground speed sensing internally geared in unitized transaxle Ignition Transistor electronic ignition with electronic RPM limiter Unitized transaxle Fully synchronized forward and reverse with neutral 11 8 1 forward 17 1 1 reverse Electrical system 12 volt 500 cca at 0 F 17 8 C 650 cca at 32 F 0 C 105 minute reserve capacity and 35 amp charging capacity Torque c
131. y See Section 4 Body and Trim 2 Remove ball joint retaining nut 25 and remove ball joint 23 from spindle 33 Figure 7 8 Page 7 9 Page 7 8 2012 Turf Carryall Vehicle Maintenance and Service Manual 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 TYPICAL 3 PLACES TYPICAL We ee WU Figure 7 8 Steering Gear 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 7 9 STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION DISASSEMBLY CAUTION DOV RO Jo zs 8 e The ball joint 23 Figure 7 8 Page 7 9 has left hand threads Remove ball joint from the spindle and inspect it for excessive wear Remove the drag link 28 Figure 7 8 Page 7 9 Remove both bellows clamps 2 plastic wire ties Remove the hex nut 29 and slide off the dust seal bellows 1 Remove the retaining ring 21 then slide off dust seal bellows 20 Remove the rack screw lock nut 15 rack guide screw 16 rack guide pressure spring 14 and the rack guide 13 Figure 7 8 Page 7 9 Remove the universal joint assembly from the pinion 8 by fully removing the bolt and then sliding off the universal j

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