Summary of Contents for Crown C48-2+2
- Page 1 Owner’s Manual and Service Guide CROWN CARTS - ELITE GOLF SERIES Original Instruction C48- 2 & 2 +2 MODELS...
-
Page 2: Table Of Contents
TABLE OF CONTENTS SAFETY INFORMATION……………………………………………………...1- 7 OPERATION AND SERVICE INFORMATION……………………………..8-43 Before initial use………………………………………………………………………………….8 Key switch…………………………………………………………………………......9 Direction selector, accelerator pedal……………………………………………….......10 Combination brake and park brake pedal, horn, operating the vehicle…………………………..11 Regenerative braking……………………………………………………………………………..12 Diagnostic mode feature, starting and driving, start vehicle on a hill……………………………13 Coasting, sun top and windshield, vehicle cleaning and care……………………………………14 REPAIR Lifting the vehicle………………………………………………………………………………..15... - Page 3 wheel bearing…………………………………………………………………………………..45 Correct the toe-in, replace the front shock absorber, replace the front beam………………….. 46 Replace the front spring armor plate…………………………………………………….....47 Replace the wheel hub…………………………………………………………………………..48 Replace the wheel bearing assembly, Replace the rack ball joint, replace the claw…………….49 Replace the steering axle, Rear axle assembly…………………………………………………..50 Remove the shock absorber, Install the shock absorber, Remove the rear spring armor plate, Assemble the rear spring armor plate, Rear axle maintenance, Check the lubricant level, Disassemble and assemble of the transaxle………………………………………………………51...
-
Page 4: Safety Information
SAFETY INFORMATION This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product. To reduce the chance of personal injury or property damage, the following must by carefully observed: GENERAL Good common sense and prudent driving practices do more to prevent accidents and injury than all of the... - Page 5 SAFETY INFORMATION Reduce speed to compensate for poor terrain or conditions. Apply service brake to control speed on steep grades. Maintain adequate distance between vehicles. Reduce speed in wet areas. Use extreme caution when approaching sharp or blind turns. Use extreme caution when driving over loose terrain. Use extreme caution in areas where pedestrians are present.
- Page 6 SAFETY INFORMATION 4.2.1 The user shall maintain in a legible condition all nameplates, warnings and instructions which are supplied by the manufacturer. 4.2.2 The user shall not perform any modification or addition which affects capacity or safe operation, or make any change not in accordance with the owner’s manual without the manufacturer’s prior written authorization.
- Page 7 SAFETY INFORMATION matter shall be reported immediately to the designated authority and the Cart shall not be operated until it has been restored to sage operating condition. 5.3.4 Do not make repairs or adjustments unless specifically authorized to do so. 5.3.5 Do not operate a Cart with a leak in the battery.
- Page 8 SAFETY INFORMATION Experience has shown that golf cars which comply with the provisions stated in part II of this standard are safe when properly operated in accordance with the safety and operation is enhanced when the golf cars are operated within a specific set of operation instructions, safety rules and practices established to meet actual operating terrain and conditions.
- Page 9 SAFETY INFORMATION MAINTENANCE Introduction Golf cars may become hazardous if maintenance is neglected or improperly performed. Therefore maintenance facilities, trained personnel and procedures in accordance with the manufacturer’s recommendations should be provided by the controlling party. Preventive Maintenance A regularly scheduled inspection and preventive maintenance program in accordance with the manufacturer’s recommendations should be established.
-
Page 10: Safety Information
SAFETY INFORMATION to ensure currency and completeness of entries. 6.2.4.12 The controlling party shall maintain all Danger, Warning and Caution labels, (collectively and individually “safety labels”); nameplates; serial numbers; and instructions, when supplied by the manufacturer, in a legible condition. OPERATING SAFETY RULES AND PRACTICES Operator Qualifications Only authorized persons shall be allowed to operate golf cars, it is recommended that no persons be... -
Page 11: Operation And Service Information
OPERATION AND SERVICE INFORMATION OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Thank you for purchasing this vehicle. Before driving the vehicle, we ask you to spend some time reading this Owner’s Manual and Service Guide. -
Page 12: Key Switch
OPERATION AND SERVICE INFORMATION ! WARNING ! To prevent overheating that may cause serious damage to the charger and create the potential for fire, do not block or obstruct the airways .Portable chargers must be mounted on a platform above the ground or in such a manner as to permit the maximum air flow underneath and around the charger. -
Page 13: Direction Selector, Accelerator Pedal
OPERATION AND SERVICE INFORMATION DIRECTION SELECTOR ! WARNING ! To prevent loss of control, do not move direction selector while the vehicle is in motion. Moving the selector will result in a sudden slowing of the vehicle and the beeping of a warning device. Located on the dash panel, this switch permits the selection of either ‘F’(forward), ‘R’(reverse) or neutral (the position between forward and reverse). -
Page 14: Combination Brake And Park Brake Pedal, Horn, Operating The Vehicle
OPERATION AND SERVICE INFORMATION Depressing the accelerator pedal will release the park brake if it is engaged. This is a feature to assure the vehicle is not driven with the park brake engaged. Depressing the accelerator pedal is not the preferred method of releasing the park brake. -
Page 15: Regenerative Braking
OPERATION AND SERVICE INFORMATION Use extra care and reduced speed when driving on poor surfaces, such as loose dirt, wet grass, gravel, etc. Stay in designated areas and avoid extremely rough terrain. Maintain a safe speed when driving down hill. Use service brake to control speed when traveling down an incline. -
Page 16: Diagnostic Mode Feature, Starting And Driving, Start Vehicle On A Hill
OPERATION AND SERVICE INFORMATION Walk-Away Feature Walk-Away limits vehicle movement without driver input, slowing the vehicle to 3kph and sounding an audible alarm ( reverse beeper). Example: If all of the following events occur a) the vehicle has been stopped for more than 1.5 seconds b) the accelerator pedal has been released for more than one second c) the vehicle begins to roll above 3kph the electronic braking will limit speed to approximately 3 kph and the warning beeper will sound. -
Page 17: Coasting, Sun Top And Windshield, Vehicle Cleaning And Care
OPERATION AND SERVICE INFORMATION START VEHICLE ON A HILL ! WARNING ! To reduce the possibility of roll-back which could result in severe injury or vehicle damage, do not release the service brake until motor has stated. ! CAUTION ! Do not hold vehicle on hill by using accelerator and motor. -
Page 18: Repair
OPERATION AND SERVICE INFORMATION cause severe injury to operator or bystander, damage to seals, plastics, seat material, body finish or electrical system. Do not use pressure in excess of 700 psi to wash exterior of vehicle. Clean windshield with lots of water and a clean cloth. Minor scratches may be removed using a commercial plastic polish. -
Page 19: Wheels And Tires
OPERATION AND SERVICE INFORMATION Lower the jack and test the stability of the vehicle on all four jack stands. If only the front or rear of the vehicle is to be raised, place the chocks in front and behind each wheel not being raised to stabilize the vehicle. -
Page 20: Wheel Installation
OPERATION AND SERVICE INFORMATION To reduce the possibility of severe injury caused by a broken socket when removing wheels, use only sockets designed for impact wrench use. Use caution when inflating tires. Over inflation could cause the tire to separate from the wheel or cause the tire to explode, either of which could cause severe injury. -
Page 21: Light Bulb Replacement
OPERATION AND SERVICE INFORMATION Fig.7 Wheel Installation LIGHT BULB REPLACEMENT ! CAUTION ! To reduce the possibility of premature bulb failure, do not touch new bulbs with bare fingers. Use clean, dry tissue or paper towel to handle the glass portion of the bulb. For vehicles equipped with lights mounted below cowl, locate bulb socket on backside of light bar (Ref Fig. -
Page 22: Service And Maintenance
OPERATION AND SERVICE INFORMATION Fig. 9 Tail and Brake Light Bulb Replacement SERVICE AND MAINTENANCE ! WARNING ! To reduce the possibility of severe injury or death from improper servicing techniques: Do not attempt any type of servicing operations before reading and understanding all notes, cautions and warnings in this manual. -
Page 23: Periodic Service Schedule
OPERATION AND SERVICE INFORMATION Any electrolyte spills should be neutralized with a solution of 2 teaspoons (10ml) sodium bicarbonate ( braking soda) dissolved in 1 quart ( 1 liters ) of water and flushed with water. It is in the best interest of both vehicle owner and service technician, to carefully follow the procedures recommended in this manual. -
Page 24: Tire Inspection
OPERATION AND SERVICE INFORMATION STEERING ASSEMBLY . Check for abnormal play, tightness of all hardware TIE ROD/LINKAGES . Check for excessive play, bent components or loose connections REAR AXLE . Check for leakage, add lubricant level as required QUARTERLY - 50 HOURS FRONT AXLE . - Page 25 OPERATION AND SERVICE INFORMATION NOTE Over time, a subtle loss of performance may take place , therefore, it is important to establish the standard with a new vehicle. The Periodic Brake Performance Test should be performed regularly ( Ref. Fig. 16 ) as an evaluation of braking system performance.
-
Page 26: Rear Axle
OPERATION AND SERVICE INFORMATION Fig.10 Typical Brake Performance Test marker in the test area and remove foot from pedal. The vehicle should stop aggressively. The wheel brakes may or may not lock. Observe the vehicle stopping location or measure the vehicle stopping distance from the point at which the brakes were latched. -
Page 27: Lubrication
OPERATION AND SERVICE INFORMATION 11) (Ref Fig. 12). Unless leakage is evident, the lubricant need only be replaced after three years. Fig.11 Add, Check and Drain Axle Lubricant-Early Production Fig.12 Add, Check and Drain Axle Lubricant-Late Production Checking the Lubricant Level Clean the area around the check/fill plug and remove plug. -
Page 28: Hardware
OPERATION AND SERVICE INFORMATION Fig.13 Lubrication Points-Early Production Fig.14 Lubrication Points-Late Production HARDWARE Periodically, the vehicle should be inspected for loose fasteners. Fasteners should be tightened in accordance with the Torque Specifications table (Ref Fig. 15). Bolt size D/MM Bolt Grad Torque （N·M）... -
Page 29: Batteries And Charging
OPERATION AND SERVICE INFORMATION 12-15 25-31 44-54 69-88 108-137 147-186 206-265 14-18 29-39 49-64 83-98 127-157 176-216 245-314 9-12 22-29 44-58 76-102 121-162 189-252 260-347 369-492 13-1 10.9 29-35 64-76 108-127 176-206 274-323 372-441 529-637 15-2 12.9 37-50 74-88 128-171 204-273 319-425 489-565... -
Page 30: Battery Maintenance
OPERATION AND SERVICE INFORMATION Expelled electrolyte may cause damage to the vehicle and storage facility. Aerosol containers of battery terminal protectant must be used with extreme care. Insulate metal container to prevent can from contacting battery terminals which could result in an explosion. Wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench from ‘shorting out’... - Page 31 OPERATION AND SERVICE INFORMATION ! WARNING ! To reduce the possibility of fire, never attach a battery charger to a vehicle that is to be unattended beyond the normal charging cycle. Overcharging could cause damage to the vehicle batteries and result in extreme overheating. The charger should be checked after 24 hours and unplugged after the charge cycle is complete.
- Page 32 OPERATION AND SERVICE INFORMATION A battery being charged will ‘gas’ with the majority of the gassing taking place at the end of the charging cycle. This gas is hydrogen which is lighter than air. Water and sulfuric acid droplets will be carried out of the battery vents by the hydrogen gas;...
-
Page 33: Battery Replacement
OPERATION AND SERVICE INFORMATION When cleaning the outside of batteries and terminals, first spray with a solution of sodium bicarbonate (baking soda) and water to neutralize any acid deposits before rinsing with clear water. Use of a water hose without first neutralizing any acid will move acid from the top of batteries to another area of the vehicle or storage facility where it will attack the metal structure or the concrete/asphalt floor. -
Page 34: Prolonged Storage
OPERATION AND SERVICE INFORMATION If the batteries have been cleaned and any acid in the battery rack area neutralized as recommended, no corrosion to the battery racks or surrounding area should be present. Any corrosion found should be immediately removed with a putty knife and a wire brush. The area should be washed with a solution of sodium bicarbonate (baking soda) and water and thoroughly dried before priming and painting with a corrosion resistant paint. -
Page 35: Battery Charging
OPERATION AND SERVICE INFORMATION charged battery has a specific gravity of 1.275, and the battery is allowed to sit unused, it will become partially discharged. When it reaches 1.240, which it will do in less than twenty days, it should be recharged. If a battery is left in a discharged state, sulfating takes place on and within the plates. - Page 36 OPERATION AND SERVICE INFORMATION Fig.20 Freezing Point of Electrolyte The charging must take place in an area that is well ventilated and capable of removing the hydrogen gas that is generated by the charging process. A minimum of five air exchanges per hour is recommended. The charging connector components are in good condition and free from dirt or debris.
-
Page 37: Troubleshooting
OPERATION AND SERVICE INFORMATION TROUBLESHOOTING In general, troubleshooting will be done for two distinct reasons. First, a battery that performs poorly and is outside of the manufacturers specification should be identified in order to replace it under the terms of the manufacturer’s warranty. - Page 38 OPERATION AND SERVICE INFORMATION Fig.22 Hydrometer Specific gravity is the measurement of a liquid that is compared to a baseline. The baseline is water which is assigned a base number of 1.000. The concentration of sulfuric acid to water in a new golf car battery is 1.280 which means that the electrolyte weighs 1.280 times the weight of the same volume of water.
-
Page 39: Battery Maintenance
OPERATION AND SERVICE INFORMATION contacting the top or bottom of the cylinder. 3. Hold the hydrometer in a vertical position at eye level and note the reading where the electrolyte meets the scale on the float. 4. ρ25℃ = ρt +0.0007（t-25) ρ25℃... -
Page 40: Specific Gravity Testing
OPERATION AND SERVICE INFORMATION Inspection Batteries should be carefully inspected on a regular basis in order to detect and correct potential problems before they can do harm. It is a great idea to start this routine when the batteries are first received. Inspection Guildlines: 1. -
Page 41: Open-Circuit Voltage Test
OPERATION AND SERVICE INFORMATION If any specific gravity readings still register low then follow the steps below. 1. Check voltage level(s). 2. Perform charging. Refer to the charging section for the proper procedure. 3. Take specific gravity readings again. If any specific gravity reading still registers lower than the specification of 1.280±0.01g/cm3 then one or more of the following conditions may exist: 1. - Page 42 OPERATION AND SERVICE INFORMATION open ci rc uit v oltage P er cen tag e S pe c ifi c Gr avi ty(g/cm ) o f Cha rg e( %) ℃ Co rre cte d to 25 1 2V 1 00 1 .28 6 .37 8 .49...
-
Page 43: Charging, Cleaning
OPERATION AND SERVICE INFORMATION of the plates. 2. If there is no electrolyte visible, add just enough distilled/deionized water to cover the plates. 3.Replace and tighten all water vent caps. 4. Put batteries on a complete charge before adding any additional water (refer to the Charging section). 5. -
Page 44: Storage
OPERATION AND SERVICE INFORMATION Battery System:6 Volt,452 AH Using Two DT106 Deep Cycle Batteries(6 Volts,226AH) To increase both voltage and amp-hour capacity, connect batteries in series/parallel. Battery System: 12 Volt, 452 AH Using Four DT106 Deep Cycle Batteries(6 Volts,226 AH) NOTE These systems can also be configured using 12-volt batteries. -
Page 45: Battery Terms Explained
OPERATION AND SERVICE INFORMATION The most important things to avoid: 1. Freezing: Avoid locations where freezing temperature is expected. Keeping a battery at a high state of charge will also prevent freezing. (See Table2) 2. Heat: Avoid direct exposure to heat sources, such as radiators or space heaters. Temperatures above 80°F accelerate the battery's self-discharge characteristics. - Page 46 OPERATION AND SERVICE INFORMATION open circuit has a broken path. 7. Cycle——One discharge of a battery plus one recharge. 8. Depth of Discharge (DOD)——The percentage of capacity actually removed from a battery compared to the total rated capacity. 9. Electrolyte——In a deep cycle battery, it is a dilute solution of sulfuric acid and water. 10.
-
Page 47: Maintenanceinformation
MAINTENANCE INFORMATION MAINTENANCE INFORMATION Troubleshooting Problem Possible reason Processing methods 1. Tire air pressure is over lower 1. According to the requirement, to inflate the Under steering 2. Lubrication of turning part is not tire. good. 2. Daub lubrication Abnormal 1．... -
Page 48: Wheel Bearing
MAINTENANCE INFORMATION Front / Rear bridge Maintain the front suspension and steering system regularly. 1) Check all the spare parts for loose, abrasion and damage. 2) Lubricate the ball head joint and wheel bearing. 3) Check the caddie pedal, armrest and the bolts whether they are in a good condition. Tool Butter gun 1 Pcs... -
Page 49: Correct The Toe-In, Replace The Front Shock Absorber, Replace The Front Beam
MAINTENANCE INFORMATION fixed spare parts of wheel on the cart. 3) Rotating the tire whilst fastening the nut of the tire till there is resistance. 4) Rotate the tire for 2-3 circles to let the butter spread in the bearing equally. According to the factual situation to fasten the nut till the cotter pin(2) can be installed. -
Page 50: Replace The Front Spring Armor Plate
MAINTENANCE INFORMATION Tool Speedness spanner,1/2”couplier 1 pcs 3/4”jacket,1/2”couplier 1 pcs 9/16”Spanner 1 pcs 3/4” Spanner 1 pcs Plastic hammerhead 1 pcs 5/8”Spanner 1 pcs 11/16”Spanner 1 pcs 9/16” jacket,1/2”couplier 1 pcs 5/8” jacket,1/2”couplier 1 pcs Torque wrench,1/2”couplier 1 pcs 1) Loosen the front wheel, then jack up the cart. 2) Remove the spare parts(1,4,5) which connect with the shock absorber(2) 3) Remove the locknut(6) ,washer(8,9), screw(7),... -
Page 51: Replace The Wheel Hub
MAINTENANCE INFORMATION 3) Remove both the 1 ¾ screws(18) and locknuts(19) and the locknuts can not be used again. 4) Remove the nut(21),long screw(20) and the armor plate(24). The spare parts 20-24 should be kept well to install the former position. 5) Undraw the skidproof foot cushion to take out the spare parts for fixing the armor plate(25-27). -
Page 52: Replace The Wheel Bearing Assembly, Replace The Rack Ball Joint, Replace The Claw
MAINTENANCE INFORMATION 6) Install the outer bearing(4) and fasten the wheel hub to the proper position with nut. Then install the wheel and fasten the screws by hand. 7) Adjust the bearing. Details are give in the “Adjust the wheel bearing” part. 8) Install the dustproof cover(1). -
Page 53: Replace The Steering Axle, Rear Axle Assembly
MAINTENANCE INFORMATION 6) The torque applied to the locknut(5) should be 75-95N.M. After fasten it, it is necessary to check the core pin to make sure it can running freely in the claw. 7) The torque applied to the locknut(2) should be 50N.M and fasten it till the cotter pin could be inserted into it. - Page 54 MAINTENANCE INFORMATION Jack 4pcs 9/16” spanner 1pcs ¾ “spanner 1pcs ½”sleeve 1pcs 9/16” sleeve 1pcs 9/16” long sleeve 1pcs Rear suspension includes rear axle and other accessories for connecting the spring armor plate and shock absorber. Remove the shock absorber (Fig14) 1) Jack up the cart safely.
-
Page 55: Disassemble And Assemble Of The Transaxle
MAINTENANCE INFORMATION 1) All the lubrication should be replaced if it become black or without lubricative feel. Please jack up the cart to remove the bottom cover of the gear-box or let all the lubrication flow out from the Disassemble the rear axle Disassemble and assemble of the transaxle Required tool Bearing puller... - Page 56 MAINTENANCE INFORMATION Mechanical brake The mechanical self-adjusting brake that compensates to the abrasion of the brake shoes and decrease the requirement for adjusting the brake by hand. Owner’s Manual and Service Guide...
-
Page 57: Check The Brake Pedal And Connection
MAINTENANCE INFORMATION Check the brake pedal and connection 1) Check the brake pedal bumper When releasing the brake arm must be contacted with the pedal bumper, and the clearance between the brake pedal arm and cam is 1/4~3/8” （6~9.5mm）. Please according the requirement to adjust or replace the pedal bumper. -
Page 58: Test The Brake Function Regularly, Check The Wheel Brake
MAINTENANCE INFORMATION 9) Check the mechanical function of brake bolt The latch should be released quickly when depressing the accelerate pedal. 10) Check the catch bracket and latch arm Check the catch bracket and latch arm for abrasion, if so please replace it. -
Page 59: Maintenanceinformation
MAINTENANCE INFORMATION 2) Check the break hub to see if there is blue moulage and peel; Is there obvious nick, special abrasion? If the spline axle is damaged, attrited or erodent? If there is any problem referred above please replace the brake hub. 3) Clean the brake power with brush. -
Page 60: Specification
SPECIFICATION GOLF CART DG-C1 POWER SUPPLY Battery : 12V80AH*3 Power of Motor : 36V/1200W Controller : American Curtis Electronics Controller Accelerator : Hall Accelerator Continuously Variable Speed System Charger : Full Automatic Efficiency Pulse Charger SUSPENSION Rear-Suspension : Leaf Spring With Hydraulic Shock Absorbers Steering : "Rack &... - Page 61 SPECIFICATION DG-C2 POWER SUPPLY Battery : 6V226AH*6 or 8V192AH*6 Power of Motor : 36V2.2KW or 48V3KW Controller : American Curtis Electronics Controller Accelerator : Adjustable Inductive Accelerator Continuously Variable Speed System Charger : Full Automatic Efficiency Pulse Charger SUSPENSION Suspension : Leaf Spring With Hydraulic Shock Absorbers Steering : Self Compensating "Rack &...
- Page 62 SPECIFICATION DG-C4 POWER SUPPLY Battery : 8V192AH*6 Power of Motor : 48V4KW Controller : American Curtis Electronics Controller Accelerator : Adjustable Inductive Accelerator Continuously Variable Speed System Charger : Full Automatic Efficiency Pulse Charger PERFORMANCE Maximum Speed: 18-24 km/h Maximum Travel Distance : 80-100 km Slope Climbing Capacity : Brake Range :...
- Page 63 SPECIFICATION DG-C6 POWER SUPPLY Battery : 8V192AH*6 Power of Motor : 48V4KW Controller : American Curtis Electronics Controller Accelerator : Adjustable Inductive Accelerator Continuously Variable Speed System Charger : Full Automatic Efficiency Pulse Charger SUSPENSION Suspension : Leaf Spring With Hydraulic Shock Absorbers Steering : Self Compensating "Rack &...
-
Page 64: Parts And Assembly Procedure
PARTS AND ASSEMBLY PROCEDURE ITEM IDENTIFICATION 1.Sun top; 2. Rear sun top strut; 3.Upper bag holder; 4. Basket; 5.Backrest bracket; 6. Rear cover; 7.Rear wheel; 8. Seat; 9.Charger socket 10. Pedal; 11.Front wheel; 12. Front protective cover; 13.Front cover; 14. Steering column; 15.Steering wheel;... -
Page 65: Assembly Procedure
PARTS AND ASSEMBLY PROCEDURE ASSEMBLY PROCEDURE 1. Take out the cart and the spare parts. 2. Assemble the front strut as per following method. Insert the bolt into the Insert the bolt and rubber Lock the bolts with front strut. (Fig 1) cushion into the cover (Fig 2) wrench. - Page 66 PARTS AND ASSEMBLY PROCEDURE 4. Assemble the sun top as per following methods. Put the sun top on the front and rear Inset the screw and rubber cushion supporting strut (Fig.8) into the front strut (Fig9) Lock the bolt with wrench ( Fig.10) After whole assembling (Fig.11) 5.
- Page 67 PARTS AND ASSEMBLY PROCEDURE Lock the bolt and nut by Assemble the sash which with windshield wrench (Fig 15) onto front strut and make sure the sash is at suitable position (Fig 14) After assembling the windshield (Fig.16) 6. Usage of the bag holder Firstly, put the bag well and let the bag fixing strap through the bag clip and bag support .(Fig.17).
-
Page 68: Parts And Assembly Procedure
PARTS AND ASSEMBLY PROCEDURE Fig 17 Fig18 Fig 19 ! WARNING ! Lead-acid battery major composition is electrolytic liquor and heavy metal lead. They are contamination, so do not dismantle the battery and throw it in the garbage can at your will.