Driving Range Enclosure Kit Installation Instructions

Transcription

1 Gasoline and Electric Vehicles: Carryall Carryall Carryall Plus Carryall 5 Carryall 6 Turf Turf Turf 5 Turf 6 XRT900 TransPorter TransPorter 6 Driving Range Enclosure Kit Installation Instructions Publication 070 Edition Code 0906A00000 These instructions apply to the following kit: 00660

2 GENERAL INFORMATION AND PRECAUTIONS This instruction provides detailed instructions for installing the driving range enclosure kit. Ensure that all necessary replacement parts, the appropriate maintenance and service manual(s), and this document are available before this kit is installed. Thoroughly review this document before any installation procedures are performed. Statements labeled NOTE provide additional information that is essential for the proper installation of this kit. Installation of this driving range enclosure will require two people. Nylon washers have been supplied to provide a weather seal around all exterior hardware. A nylon washer must be installed under each bolt head, directly against the cab exterior. Do not over tighten hardware, which could damage the nylon washers. The following safety statements relate to specific safety issues and must be read, understood, and heeded before a kit is installed. Failure to do so could result in personal injury and/or property damage. ý DANGER 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 space. Wear a full face shield and rubber gloves when working on or near batteries. Battery Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or clothing. Antidotes: - External: Flush with water. Call a physician immediately. - Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable oil. Call a physician immediately. - Eyes: Flush with water for 5 minutes. Call a physician immediately. Gasoline Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. Service only in a well-ventilated area. Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. A Club Car vehicle will not provide protection from lightning, flying objects, or other stormrelated hazards. If caught in a storm while driving a Club Car vehicle, exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location. ý WARNING Follow the procedures exactly as stated in this instruction, and heed all DANGER, WARNING, and CAUTION statements in this instruction as well as those on the vehicle and battery charger. Only trained technicians should service or repair the vehicle or battery charger. 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. 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. WARNING CONTINUED ON NEXT PAGE Copyright 006 Club Car, Inc. Page Driving Range Enclosure Kit Installation Instructions (070)

3 ý WARNING Gasoline vehicles only: To avoid unintentionally starting the vehicle: - Disconnect battery cables, negative ( ) cable first (Figure, Page 6). - Disconnect the spark plug wire from the spark plug. Frame ground Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wiring. Do not allow a positive wire to touch the vehicle frame, engine, or any other metal component. Electric vehicles only: Ensure battery connections are clean and properly tightened. To avoid unintentionally starting the vehicle, disconnect the batteries as shown (Figures through, starting on page 6). 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. After disconnecting the batteries, wait 90 seconds for the controller capacitors to discharge. Use only -gauge (AWG) wires with low-resistance terminals to replace battery wires on IQ Plus models. All vehicles: Wear safety glasses or approved eye protection when servicing the vehicle or battery charger. 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 or battery charger. Moving parts! Do not attempt to service the vehicle while it is running. Hot! Do not attempt to service hot engine, exhaust system, or motor. Failure to heed this warning could result in severe burns. Use insulated tools when working near batteries or electrical connections. Use extreme caution to avoid shorting of components or wiring. Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic floor jack) with 000 lb. (5 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. 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 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. Driving Range Enclosure Kit Installation Instructions (070) Page

4 TOOLS REQUIRED 5/6 INCH DRILL BIT 7/6 INCH /8 DRIVE SOCKET / INCH /8 DRIVE SOCKET HEX SOCKET ELECTRIC HAND DRILL 7/6 INCH OPEN END WRENCH / INCH OPEN END WRENCH /8 DRIVE RATCHET 5-50 FT-LB TORQUE WRENCH PHILLIPS HEAD SCREWDRIVER WIRE STRIPPER AND TERMINAL CRIMPER PLIERS TAPE MEASURE PARTS IN THIS KIT ROOF ROOF SUPPORT BRACKETS FRONT COWL REAR WINDOW FRONT MOUNTING BRACKET (PASSENGER SIDE) REAR PANEL WINDSHIELD WEATHER STRIPPING FRONT MOUNTING BRACKET (DRIVER SIDE) REAR CROSS BRACE REAR MOUNTING BRACKET (PASSENGER SIDE) DOOR SHOCK WINDSHIELD SUPPORT FILLER FILLER (PASSENGER (DRIVER SIDE) SIDE) REAR MOUNTING BRACKET (DRIVER SIDE) FRONT COWL GASKET SIDE FRAME (PASSENGER SIDE) SIDE FRAME (DRIVER SIDE) DOOR (PASSENGER SIDE) Mounted to side frame. DOOR (DRIVER SIDE) Mounted to side frame. Crush area. Can cause severe injury. Stay clear when closing bed. BED LATCH WARNING DECAL CCI 057 L A T C H 0 P E N Page Driving Range Enclosure Kit Installation Instructions (070)

5 PARTS IN THIS KIT /-0 x HEX-HEAD BOLT /-0 x -/ HEX-HEAD BOLT /-0 x -/ HEX-HEAD BOLT 5/6-8 x -/ PHILLIPS-HEAD MACHINE SCREW / FLAT WASHER /-0 NYLON LOCKNUT 5/6 WASHER 5/6-8 NYLON LOCKNUT 5/6-8 x / ALLEN-HEAD BOLT 5/6-8 x ALLEN-HEAD BOLT 7/6 NYLON WASHER WINDOW SPACER RUBBER WASHER 5/6 ID X OD FENDER WASHER REAR PANEL PLUGS SPACERS 5/6-8 x / CARRIAGE BOLT Driving Range Enclosure Kit Installation Instructions (070) Page 5

6 . DISCONNECT THE BATTERY CABLES.. Disconnect the battery cables as instructed. See "To avoid unintentionally starting..." WARNING on page... Gasoline vehicles: remove the spark plug wire from the spark plug. AS SEEN FROM PASSENGER SIDE OF VEHICLE FRONT OF VEHICLE Place Tow/Run Switch in TOW. WARNING TOW RUN FRONT OF VEHICLE DISCONNECT BATTERY CABLES BEFORE WORKING ON VEHICLE Remove negative cable first. 5 Remove negative cable first. 6 PLACE TOW/RUN SWITCH IN THE TOW POSITION BEFORE DISCONNECTING OR CONNECTING BATTERY CABLES Figure Gasoline Vehicles Figure IQ System Electric Vehicles - Carryall and Turf Place Tow/Run Switch in TOW. FRONT OF VEHICLE Place Tow/Run Switch in TOW. VILLAGER 6 AND 8 VEHICLES TOW RUN WARNING Remove negative cable first. 8 7 Place Tow/Run switch in the TOW position before disconnecting or connecting battery cables. Remove negative cable first. FRONT OF VEHICLE 8 Place Tow/Run switch in the TOW position before disconnecting or connecting battery cables. Figure IQ Plus Electric Vehicles - Carryall and Turf Figure IQ Plus Electric Vehicles - Carryall 6, TransPorter and 6 Page 6 Driving Range Enclosure Kit Installation Instructions (070)

7 . ASSEMBLE WINDSHIELD COWL.. Secure the passenger and driver side fillers ( and ) to the windshield cowl () with 5/6-8 x /-inch carriage bolts (), nylon washers (), flat washers (), and lock nuts () as shown (Figure 5)... Install windshield cowl gasket (5) onto the inside edge of windshield cowl assembly. Trim any extra gasket. 5 Figure 5 Assemble Front Cowl. INSTALL THE FRONT MOUNTING BRACKETS.. Secure the passenger and driver front mounting brackets ( and ) under the dash with four /-0 x inch hex head bolts (), four washers (), and four lock nuts (5) as shown (Figures 6 and 7). Do not tighten hardware at this time. 5 5 Figure 6 Install Pass- Side Front Mounting Bracket Figure 7 Install Driver Side Front Mounting Bracket Driving Range Enclosure Kit Installation Instructions (070) Page 7

8 . INSTALL THE REAR MOUNTING BRACKETS.. Secure the passenger side rear mounting bracket (7) to the passenger side frame with a 5/6-8 x / -inch carriage bolt (9), flat washer (0), and lock nut () as shown (Figure 8). Tighten the hardware to 7 ft-lb (.0 N m)... Repeat using same procedure for the driver side mounting bracket (8) (Figure 9) Figure 8 Install Passenger Side Rear Mounting Bracket Figure 9 Install Driver Side Rear Mounting Bracket 5. ASSEMBLE REAR PANEL 5.. Remove hip restraints and seat back frame assembly from vehicle. Retain hardware for reuse. 5.. Remove the bed seal (), and disassemble the seat back (), and the two hip restraints () from the seat back frame () (Figure 0). Retain hardware for reuse. 5.. Secure bed seal () to new rear panel () positioned as shown (Figure ). Figure 0 Disassemble Existing Seat Back Assembly Page 8 Driving Range Enclosure Kit Installation Instructions (070)

9 5.. On opposite side of rear panel, install seat back () using hardware previously removed Install four plastic plugs () in rear panel mounting holes after seat back hardware is tightened. Set rear panel assembly aside. TYPICAL FOUR PLACES Figure Assemble Rear Panel 6. POSITION SIDE FRAMES 6.. Remove doors from side frames by opening the doors, then lifting the doors off the pin hinges. 6.. Access the engine compartment. See following WARNING. ý WARNING For vehicles with cargo beds, remove all cargo before raising the bed or servicing the vehicle. If the vehicle is equipped with a prop rod, ensure that it is securely engaged while bed is raised. Do not close bed 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. 6.. Lift the bed and ensure that the prop rod is engaged. 6.. With the aide of an assistant, hold the driver side frame () in place as shown (Figure ) Secure the front mounting bracket () to the side frame mounting tab with a 5/6-8 x /-inch carriage bolt (6), washer (7), and lock nut (8) as shown (Figure ). Do not tighten hardware at this time Secure the passenger side frame using the same procedure. Driving Range Enclosure Kit Installation Instructions (070) Page 9

10 INSTALL REAR PANEL Figure Position and Secure Side Frames 7.. Position the rear panel () as shown, aligning holes in rear panel with holes in the mounting brackets on the side frame () (Figure ). 7.. At each side of vehicle, install a 5/6-8 x carriage bolt (), with nylon washer (), flat washer (5) and lock nut (6) through the lower hole in the rear panel () and side frame as shown (Figure ). 7.. Install a 5/6-8 x /-inch carriage bolt (0), with flat washer () and lock nut () through the horizontal flange of the rear panel and side frame as shown. (The top row of fasteners will be installed during the rear window panel installation). 7.. Align ends of rear panel with beginning of radius on the outside corners of the side frame tube. Tighten hardware to 75 in-lb (8.5 N m) Install a 5/6-8 x /-inch carriage bolt (), nylon washer (5), and lock nut () through the open hole in each rear mounting bracket as shown (Figure ). Tighten hardware to 75 in-lb (8.5 N m). Page 0 Driving Range Enclosure Kit Installation Instructions (070)

11 Figure Rear Panel Installation 7.6. Secure bottom flange of rear panel () to seat frame with hardware () removed in step 5. (Figure ) Insert two 5/6-8 x /-inch carriage bolts with nylon washers through back of rear panel and hip restraint () and secure with flat washers and nylon locknuts () (Figure ) Place two spacers (5) between bracket of the hip restraint () and the seat frame, and secure with the hardware (6) removed in step Repeat procedure to install remaining hip restraint. 6 5 Figure Install Hip Restraints Driving Range Enclosure Kit Installation Instructions (070) Page

12 8. INSTALL REAR CROSS BRACE 8.. Align the holes in the rear cross brace () with the holes in the mounting tabs on the side frames and secure with two 5/6-8 x /-inch carriage bolts (), flat washers () and lock nuts () through rearfacing holes as shown (Figure 5). Tighten hardware to 7 ft-lb (.0 N m). 9. INSTALL FRONT COWL Figure 5 Rear Cross Brace Installation NOTE: Do not install hardware into the top mounting holes (indicated) at this time (Figure 6). This hardware will be installed later in this procedure when the windshield is installed. 9.. Install the 5/6-8 x /-inch carriage bolt (0), flat washer () and lock nut () through the top of the cowl into the mounting tab on the side frame as shown (Figure 6). 9.. Install the 5/6-8 x /-inch carriage bolts (5), flat washers () and lock nuts () through the tabs on the filler and into the mounting tabs on the side frame as shown (Figure 6). 9.. Align ends of the front cowl with beginnings of radius on the outside corners of the side frame tubes. Tighten hardware to 7 ft-lb (.0 N m) Secure the passenger side of the cowl using same procedure. Page Driving Range Enclosure Kit Installation Instructions (070)

13 Do not install hardware at this mounting hole at this time Figure 6 Cowl Installation 0. INSTALL WINDSHIELD AND WINDSHIELD SUPPORT NOTE: Installation of the windshield and windshield support will require the aide of an assistant. 0.. With the aide of an assistant, position the windshield () onto the vehicle with the bend along the top as shown (Figure 7). 0.. Align the mounting holes of the driver and passenger side roof support bracket (8), windshield (), windshield support () with the mounting tabs on the side frames (). 0.. Secure the windshield and windshield support to the side frames with 5/6-8 x /-inch carriage bolts (), nylon washers (5), flat washers (6) and lock nuts (7) as shown (Figure 7). Do not tighten hardware at this time. See following NOTE. NOTE: Hardware will be installed in the top holes of the windshield support during roof installation. The nylon washers (5 and 9) are installed under the carriage bolt heads directly against the cab exterior provide a weather seal (Figure ). Overtightening this hardware could damage the nylon washers. Driving Range Enclosure Kit Installation Instructions (070) Page

14 0.. Position the center roof support bracket (8) to the windshield support and secure with one 5/6-8 x /-inch carriage bolt (), nylon washer (5), flat washer (6), and lock nut (7). Tighten the hardware to 7 ft-lb (.0 N m) Club Car Figure 7 Windshield and Windshield Support Installation 0.5. Align the ends of the windshield support () to the beginning with the radius on the outside corners of the side frame tubes Align the holes in the bottom of the windshield with the holes in the tabs on the side frames. Secure the windshield with 5/6-8 x /-inch carriage bolts (8), nylon washers (9), flat washers (0) and lock nuts () as shown (Figure 7) Tighten hardware at top and bottom of windshield to 7 ft-lb (.0 N m). Page Driving Range Enclosure Kit Installation Instructions (070)

15 . INSTALL REAR WINDOW Figure 8 Install Rear Window.. Peel the protective film off the rear window () (Figure 8)... Position the window as shown. Secure each side mounting location with /-0 x -/ hex head bolt (0), fender washers (), rubber washer (), window spacer (5), and lock nut (7) as shown (Figure 8)... Secure window at the bottom corner holes with /-0 x -/ hex head bolts (), fender washers (), rubber washers (), window spacers (), fender washers () and lock nuts (5) (Figure 9). 5 Figure 9 Secure Rear Window Corners.. Secure window at the three remaining holes along the bottom with /-0 x -/ bolts (0), fender washers (), rubber washers (), window spacers (), flat washers () and lock nuts (5) as shown (Figure 0). See following NOTE. NOTE: Use a flat washer instead of a fender washer on the inside of the cab at each of the three bottom mounting locations..5. Tighten all rear window hardware to 75 in-lb (8.5 N m). Driving Range Enclosure Kit Installation Instructions (070) Page 5

16 5 0 Figure 0 Secure Bottom Edge of the Rear Window. INSTALL ROOF.. Install the /-inch weather-strip (). Remove the backing tape and apply the weatherstrip to the top surface of the windshield support (), rear cross brace (5), and side frames () as shown (Figure 7)... With the aide of an assistant, position the roof (5) on top of the side frames (6) (Figure )... Secure the four corners of the roof (5) to the rear cross brace (5) and side frames (6) with 5/6-8 x allen head bolts (7), nylon washers (8), flat washers (9), and lock nuts (0) (Figure )... Install the 5/6-8 x /-inch allen head bolts (), nylon washers (8), flat washers () and lock nuts () in remaining roof holes. Tighten all hardware to 5 ft-lb (6.78 N m). Page 6 Driving Range Enclosure Kit Installation Instructions (070)

17 Club Car Figure Roof Installation Driving Range Enclosure Kit Installation Instructions (070) Page 7

18 . SECURE SIDE FRAMES TO VEHICLE.. Using the slots in the door frame mounting flanges as templates, drill four 5/6 inch (8 mm) holes in vehicle floor (two per side). See following CAUTION. ý CAUTION Before drilling, check the underside of the floorboard and inside the body to make sure no vehicle components will be damaged by this drilling operation... Secure side frames to vehicle floor with /-0 x -/ hex head bolt (), inch fender washers (), inch fender washers () and lock nuts (5) as shown (Figure ). Tighten the hardware to 8 ft-lb (0.8 N m)... Using holes in the mounting brackets as templates, drill six 5/6 inch (8 mm) holes in sides of the vehicle (Figure 8). See preceding CAUTION... Secure side frames to side of the vehicle with 5/6-8 x /-inch carriage bolts (0), flat washers () and lock nuts () as shown (Figure ). Tighten all 5/6 inch mounting hardware to 7 ft-lb (.0 N m). Tighten all / inch mounting hardware to 8 ft-lb (0.8 N m). 5 0 Figure Secure Side Frames to Vehicle Page 8 Driving Range Enclosure Kit Installation Instructions (070)

19 . INSTALL DOORS.. Install doors onto hinge pins... Install door shocks.... Place the black cylinder end () of the door shock on the ball stud () mounted to the side frame as shown (Figure ).... Press the button on the compression fastener to lock the door shock to the ball stud as shown in the lower illustration (Figure ).... Place the rod end (5) of the door shock on the ball stud (6) mounted to the door (Figure ).... Press the button on the compression fastener to lock the door shock to the ball stud as shown (Figure )...5. Install door shock on other door using same procedure. SIDE FRAME DRIVER SIDE DOOR 6 5 Figure Door Shock Installation Driving Range Enclosure Kit Installation Instructions (070) Page 9

20 0 P E N 5. APPLY DECAL 5.. A warning decal will need to be applied on vehicles when the bed latch warning decal is covered by the cab mounting bracket located on the driver side body panel as shown (Figure ). See following NOTE. NOTE: For best results, apply the decal when ambient temperature is 50 F (0 C) or above. L A Crush area. T Can cause severe injury. C Stay clear when closing bed. H L A Crush area. T Can cause severe injury. C Stay clear when closing bed. H 0 P E N L A Crush area. Crush area. T Can cause severe injury. Can cause C severe injury. Stay clear when closing Stay bed. clear H when closing bed. 0 P E N L A T C H 0 P E N Figure Decal Covered by Cab Figure 5 Apply Warning Decal 5.. Clean the surface of the driver side panel directly behind the cab mounting location (Figure 5). Use a detergent solution or mild soap with warm water and a soft cloth. Before applying decal, make sure surface is dry. 5.. Peel backing paper from the top half of decal. 5.. Using the top edge on the metal body to align the decal. Using a small plastic squeegee, stiff cardboard, or soft cloth, wipe the top half of the decal to press down exposed adhesive surface. Remove remaining adhesive backing paper and firmly press remaining decal to the surface (Figure 5) If air bubbles form under the decal, use a needle to make a small hole in the decal, and remove air bubble with the squeegee. 6. CONNECT BATTERY CABLES ý WARNING IQ System and PowerDrive Plus vehicles (with serial number 980 and greater): 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. Connect the battery cables, positive (+) cable first. For gasoline vehicles, tighten hardware to ft-lb (6. N m) (Figure ). For electric vehicles, tighten hardware to 0 in-lb (. N m) (Figures through, starting on page 6). Coat terminals with Battery Terminal Protector Spray (CCI P/N 005) to minimize corrosion. Page 0 Driving Range Enclosure Kit Installation Instructions (070)

21 QUESTIONS Questions or comments regarding these kit instructions should be referred to your local Club Car dealer or distributor. Please know your vehicle model and have these kit instructions available when you call. 7. CARE AND MAINTENANCE INSTRUCTIONS 7.. Check and tighten hardware after 0 hours of operation. Periodically inspect and tighten hardware for the remainder of the unit s service life. 7.. Wash the painted surfaces of the unit with commercial automotive cleaning products. 7.. Care and maintenance for the driving range enclosure windshield and rear window is as follows: 7... Washing Use a solution of mild soap or detergent and lukewarm water. Use a clean soft cloth, applying only light pressure. Rinse with clean water and dry by blotting with a damp cloth or chamois. Remove grease, oil or tar with a good grade of hexane, aliphatic naphtha, or kerosene. These solvents should be used in accordance with manufactures recommendations. Any oily film left behind by solvents should be removed immediately by washing. See following DANGER and CAUTION. ýdanger Flammable! Explosive! Do not smoke. Keep sparks and flames away from window area while cleaning. Use in a well-ventilated area. ý CAUTION Do not use glass cleaner, kitchen scouring compounds, or solvents such as acetone, gasoline, benzene, alcohol, carbon tetrachloride or lacquer thinner on the windshield or rear window. These items can scratch the windshield surface and/or weaken the material causing small surface cracks. - Be careful when cleaning snow or frost from the windshield. - Keep windshield clean. Dirt, pollution and excessive sun exposure can damage windows Dusting Dust with a soft, damp cloth or chamois. See following CAUTION. ý CAUTION Do not use dry or gritty cloth. These items can scratch the windshield surface and/or weaken the windshield causing small surface cracks and creating a static electric charge on the surface Polishing Keep surface gloss by occasional polishing with a good plastic cleanser and polish or auto paste wax. Apply a thin, even coat with soft clean cloth and polish lightly with cotton flannel. Then wipe with a damp cloth to help eliminate electrostatic charges which can attract dust particles Removing Scratches Fine scratches can be removed by hand polishing. Apply a plastic scratch remover or compound such as Simonize cleaner to a soft flannel pad and rub the scratched area. When the scratches have disappeared, remove all residue, then polish. For deeper scratches, first sand lightly with a 00 grit "wet or dry" sandpaper using plenty of water and rinsing the sandpaper frequently. Follow by buffing with a clean muslin wheel and a good polishing compound. For the highest gloss, use a clean-up wheel made of soft cotton or flannel sections with no compound. An electric drill with a buffing wheel is also ideal. Driving Range Enclosure Kit Installation Instructions (070) Page