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Club Car is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.
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We hope you will consider this owner’s manual a permanent part of your Club Car vehicle. If you sell the vehi- cle, please include the manual so that the next owner will have the important operating, safety, and mainte- nance information it contains.
Vehicle Feature Identification ELECTRIC DS VILLAGER 4 WARNING ROLLOVER OR FALLING OFF MAY CAUSE DEATH. • Before using vehicle, read operating instructions. • Remain seated and hold on to seat handle while moving. • Do not start vehicle until all occupants are seated. •...
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Vehicle Feature Identification ELECTRIC DS VILLAGER 4 BATTERY DANGER (MOLDED ON BATTERY CAPS OR ON BODY UNDER SEAT) CHARGER RECEPTACLE AND FUSE LINK TOW/RUN WARNING DECAL (IQ SYSTEM VEHICLES ONLY) (ON TOW SWITCH BRACKET UNDER SEAT) FORWARD/REVERSE SWITCH CCI 101908601 2006 Transportation Vehicle Owner’s Manual Page 5...
Vehicle Feature Identification GASOLINE DS VILLAGER 4 CCI 101960601 CCI 101621601 DRIVER/PASSENGER OPERATING INSTRUCTIONS WARNING DECAL FUEL GAUGE/HOUR METER DECAL LOW OIL WARNING KEY SWITCH PARK BRAKE LIGHT PEDAL BRAKE PEDAL HAND HOLDS HAND RAIL PASSENGER WARNING DECAL (ON REAR HANDRAIL FACING SEAT) SERIAL NUMBER...
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Vehicle Feature Identification GASOLINE DS VILLAGER 4 CCI 101547601 GASOLINE WARNING DECAL (ON VEHICLE FRAME NEAR FUEL TANK) ROTATING PARTS AND HOT MANIFOLD DECAL OIL FILL FUEL SHUT-OFF (ON STARTER/GENERATOR VALVE AND ENGINE) FORWARD/REVERSE HANDLE CHOKE NEUTRAL LOCKOUT CCI 101915201 FRAME GROUND AND GOVERNOR WARNING DECAL (ON VEHICLE FRAME NEAR BATTERY)
Vehicle Feature Identification ELECTRIC VILLAGER 6 AND 8 CCI 101621601 CCI 102518001 OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS DECAL DECAL (POWERDRIVE SYSTEM 48 VEHICLES) (IQ PLUS VEHICLES) KEY SWITCH BATTERY WARNING LIGHT ACCELERATOR PEDAL BATTERY CONDITION INDICATOR LIGHT SWITCH SERIAL NUMBER PASSENGER PARK BRAKE PEDAL WARNING DECAL DRIVER/PASSENGER...
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Vehicle Feature Identification ELECTRIC VILLAGER 6 BATTERY DANGER (MOLDED ON BATTERY CAPS OR ON BODY UNDER SEAT) PASSENGER WARNING DECAL TOW/RUN WARNING DECAL (IQ PLUS VEHICLES ONLY) (ON TOW SWITCH BRACKET UNDER PASSENGER-SIDE SEAT) CHARGER RECEPTACLE AND FUSE LINK BATTERY WIRE WARNING DECAL (UNDER FRONT SEAT ON ELECTRICAL COMPONENT BOX COVER AND ON DRIVER SIDE I-BEAM UNDER SECOND SEAT) (IQ PLUS VEHICLES ONLY)
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Vehicle Feature Identification ELECTRIC VILLAGER 8 TOW/RUN WARNING DECAL (IQ PLUS VEHICLES ONLY) (ON TOW SWITCH BRACKET UNDER PASSENGER-SIDE SEAT) BATTERY WIRE WARNING DECAL (UNDER FRONT SEAT ON ELECTRICAL COMPONENT BOX COVER AND ON DRIVER SIDE I-BEAM UNDER THIRD SEAT) (IQ PLUS VEHICLES ONLY) CHARGER RECEPTACLE...
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Vehicle Feature Identification GASOLINE VILLAGER 6 AND 8 CCI 101693201 CCI 101960601 OPERATING INSTRUCTIONS DRIVER / PASSENGER DECAL WARNING DECAL KEY SWITCH ACCELERATOR LOW OIL PEDAL WARNING LIGHT FUEL GAUGE /HOUR METER LIGHT SWITCH SERIAL NUMBER PASSENGER WARNING DECAL PARK BRAKE PEDAL BRAKE PEDAL 2006 Transportation Vehicle Owner’s Manual Page 11...
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Vehicle Feature Identification GASOLINE VILLAGER 6 CCI 101547601 GASOLINE WARNING DECAL (ON VEHICLE FRAME NEAR FUEL TANK) ROTATING PARTS AND HOT MANIFOLD DECAL FUEL SHUT-OFF (ON STARTER/GENERATOR VALVE AND ENGINE) OIL FILL CHOKE NEUTRAL LOCKOUT CAM FORWARD/REVERSE HANDLE FRAME GROUND AND GOVERNOR WARNING DECAL (ON VEHICLE FRAME NEAR BATTERY)
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Vehicle Feature Identification GASOLINE VILLAGER 8 FORWARD/REVERSE HANDLE CHOKE NEUTRAL LOCKOUT CAM (ON FORWARD/REVERSE SHIFTER INSIDE SEAT SUPPORT) FRAME GROUND WARNING DECAL (ON FRAME) CCI 1019152-01 PASSENGER WARNING DECAL GASOLINE OIL FILL WARNING DECAL (ON FRAME) FUEL SHUT-OFF VALVE (ON FUEL TANK) ROTATING PARTS AND HOT MANIFOLD DECAL CCI 101547601...
Vehicle Feature Identification ELECTRIC TRANSPORTER CCI 101931501 TOW/RUN WARNING DECAL (IQ PLUS VEHICLES ONLY) ELECTRICAL COMPONENT COVER CAUTION (ON TOW SWITCH BRACKET UNDER (ON COVER) PASSENGER-SIDE SEAT) ELECTRICAL COMPONENT MOUNTING PLATE NOTICE BATTERY DANGER FORWARD/REVERSE SWITCH (ON PLATE) (MOLDED ON BATTERY CAPS) (IQ PLUS VEHICLES) SIX-PASSENGER TRANSPORTER...
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Vehicle Feature Identification GASOLINE TRANSPORTER CCI 101693201 OPERATING INSTRUCTIONS KEY SWITCH DRIVER/PASSENGER DECAL WARNING DECAL SERIAL LOW OIL NUMBER WARNING LIGHT FUEL GAUGE /HOUR METER LIGHT SWITCH PARK BRAKE BRAKE PEDAL PEDAL ACCELERATOR PEDAL VEHICLE LOADING DECAL Page 16 2006 Transportation Vehicle Owner’s Manual...
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Vehicle Feature Identification GASOLINE TRANSPORTER CCI 101547601 GASOLINE WARNING DECAL (ON FRAME) ROTATING PARTS AND HOT MANIFOLD DECAL (ON STARTER/GENERATOR AND ENGINE) FORWARD/REVERSE PASSENGER WARNING FUEL SHUT-OFF HANDLE DECAL VALVE SIX-PASSENGER TRANSPORTER VEHICLE CHOKE PASSENGER NEUTRAL WARNING DECAL LOCKOUT BED LOAD WARNING DECAL CRUSH AREA DECAL...
Safety signs like you see above may at first seem shocking, but their impact is mild compared with the reality of severe personal injury. Your safety and satisfaction are of the utmost importance to Club Car. That is why before operating the vehicle, we urge you to review the information in this manual.
If any of the operation or safety decals on the vehicle become damaged, have been removed, or cannot be easily read, they should be replaced immediately to avoid possible property damage, personal injury, or death. Contact your Club Car distributor/dealer. ý...
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• A Club Car vehicle will not provide protection from lightning, flying objects, or other storm- related hazards. If caught in a storm while driving a Club Car vehicle, exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location.
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General Warnings ý WARNING PowerDrive System 48 vehicles: • After disconnecting the batteries, discharge the controller capacitors as follows: - Turn the key switch to the ON position and place the Forward/Reverse handle in the REVERSE position. - Slowly press the accelerator pedal and keep it pressed until the reverse warning buzzer can no longer be heard.
General Information Place Tow / Run TRANSPORTER, switch in TOW VILLAGER 6, AND VILLAGER 8 VEHICLES Place TOW/RUN switch in the TOW FRONT position before disconnecting or OF VEHICLE connecting battery cables. FRONT OF VEHICLE Remove DISCONNECT Remove negative (–) negative BATTERY CABLES HERE cable first.
The center dash panel must be removed to view this decal. See following NOTE. NOTE: Have the vehicle serial number available when ordering parts or making inquiries. Club Car SERIAL NUMBER This vehicle is covered by one or more of the...
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F (FORWARD), N (NEUTRAL), and R (REVERSE). Rotate the handle towards the driver (FOR- WARD) to operate the vehicle in the forward direction, or towards the passenger (REVERSE) to operate the vehi- cle in the REVERSE position. Club Car vehicles operate at reduced speed in reverse The reverse buzzer(s) will sound as a warning when the Forward/Reverse handle is in the REVERSE position.
Controls and Indicators Figure 10 Forward/Reverse Handle Figure 11 Forward/Reverse Rocker Switch ACCELERATOR PEDAL The accelerator pedal is the pedal on the right, with the word GO molded into it (Figure 12). The operation of the accelerator pedal differs from that of an automobile. •...
Once vehicle speed slows to below approximately 11 mph (17.7 km/h), with the accelerator pedal still released, motor braking will be deac- tivated and the vehicle will coast freely. This feature is selectable. Contact your Club Car dealer/distrib- utor to inquire about this selectable feature.
If indicator display does not reset back to full after recharging, there may be a problem with the battery charger or with one of the batteries. In either case the vehicle should be checked by a Club Car dealer or a trained tech- nician.
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16 hours and the batteries are not sufficiently charged. See the battery charger owner’s man- ual. This indicates an abnormal charge cycle. The charger and batteries should be checked by your Club Car distributor/dealer. • The warning light will repeatedly illuminate for 10 seconds, with 4 second intervals during a charge cycle (DC plug is still connected) if AC power to the charger is interrupted.
In the event of a tripped circuit breaker, bring the vehicle to a complete stop, remove seat, and push the breaker to reset. If the circuit breaker trips again when vehicle operation is resumed, contact a local Club Car distributor/dealer. NEUTRAL LOCKOUT...
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Controls and Indicators NEUTRAL NEUTRAL MAINTENANCE POSITION OPERATE POSITION Figure 17 Neutral Lockout – Maintenance Figure 18 Neutral Lockout – Operate To put the cam back into the OPERATE position, pull the cam out approximately 3/8 inch (10 mm) and rotate it one-half turn until it snaps into place (Figure 18).
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Controls and Indicators Figure 19 Button Choke Figure 20 Cable Choke LOW OIL WARNING LIGHT Gasoline Vehicles Only The vehicle is equipped with a low oil warning light (1), located on the dash panel just above the steering col- umn (Figure 21). If the warning light comes on, oil should be checked and added to the engine as necessary before continuing to use the vehicle.
Gasoline Vehicles Only The gasoline-powered Club Car vehicle is equipped with a fuel gauge/hour meter (2), located on the dash panel (Figure 21). The fuel gauge allows the operator to monitor the fuel level in the vehicle. The hour meter should be used by a trained technician to track vehicle usage and to help determine when periodic service is required.
(17.7 km/h) for IQ System vehicles and at the programmed speed for IQ Plus vehicles. This feature is selectable for IQ System vehicles and programmable for IQ Plus vehicles. Contact your local Club Car dealer/ distributor to inquire about this adjustable feature.
Reverse handle in the FORWARD position, as the accelerator pedal is pressed, the engine should start and the vehicle should accelerate smoothly to full speed. When the pedal is released it should return to the original position and the engine should stop. All Club Car vehicles operate at reduced speed in reverse.
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Driving Instructions ý WARNING • To help avoid possible injury to inattentive passengers and (or) damage to the vehicle, avoid sudden starts, sudden stops, and abrupt turns. • To help avoid the possibility of losing control of or overturning the vehicle, reduce speed for adverse driving conditions such as wet grass or rough terrain.
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Driving Instructions ý WARNING • Operator must control speed when going downhill. IQ System and IQ Plus vehicles only: • Pedal down or pedal up motor braking may be used to help control speed when going downhill; however, steep terrain or other conditions may require that pedal braking be used in conjunction with motor braking.
Loading and Unloading LOADING AND UNLOADING ý WARNING • Firmly engage the park brake before loading the vehicle. • Do not allow riders in the cargo bed. • Reduce vehicle load and speed when driving up or down slopes or on uneven terrain. •...
• For use on public roads, the trailer must meet all federal, state, and local requirements such as taillights, brake lights, etc. • Do not tow a Club Car vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer.
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Storage – Electric Vehicles ý CAUT ION • Batteries in a low state of charge will freeze at low temperatures. • To avoid exposing electrical components to moisture and subsequent damage, do not use any type of pressure washing or steam cleaning equipment to wash the vehicle. PREPARING THE ELECTRIC VEHICLE FOR EXTENDED STORAGE 1.
Storage – Gasoline Vehicles STORAGE – GASOLINE VEHICLES See General Warnings on page 19. ý DANGER • Do not attempt to drain gasoline when the engine is hot or while it is running. • Be sure to clean up any spilled gasoline before operating the vehicle. •...
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Storage – Gasoline Vehicles CLOSED (OFF) POSITION (SELECTOR IS ALIGNED WITH OFF MARKINGS ON THE SIDES OF VALVE) VIEWED FROM SELECTOR SIDE OF VALVE Figure 22 Fuel Shut-off Valve – Closed Position 3.2. Loosen, but do not remove, the carburetor drain screw and drain fuel remaining in bowl into a small, clean container, then pour the fuel from the container into vehicle fuel tank.
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Storage – Gasoline Vehicles RETURNING THE STORED GASOLINE VEHICLE TO SERVICE 1. Restore fuel system to operation. 1.1. Remove plug from the fuel tank vent (Figure 35, Page 57). 1.2. Connect vent tube to fuel tank vent. 2. Connect battery cables, positive (+) cable first, and tighten terminals to 12 ft-lb (16 N·m). 3.
Any vehicle not functioning correctly should be removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic ser- vice.
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Periodic Service Schedules PERIODIC SERVICE SCHEDULE – ELECTRIC VEHICLES REGULAR INTERVAL SERVICE Daily service by owner Batteries Charge batteries (after each use only). Weekly service by owner Check electrolyte level. Add water if Batteries necessary. See page 49. Monthly service by owner Wash battery tops and clean terminals Batteries or trained technician...
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Periodic Service Schedules PERIODIC SERVICE SCHEDULE – GASOLINE VEHICLES REGULAR INTERVAL SERVICE Monthly service by owner Check engine oil level; change if or trained technician necessary. See Periodic Lubrication Schedules on page 46. Dispose of used oil properly. Engine Check engine cooling air intake; visually inspect unshrouded area around engine exhaust for grass and debris and clean if necessary.
VEHICLE CONTROLLER – ELECTRIC VEHICLES The Club Car electric vehicle is equipped with solid state speed controllers. In order to properly service and maintain the solid state speed controller vehicle, it is necessary to understand the electrical circuitry and the functions of all components in the system.
Batteries – Electric Vehicles BATTERY CARE To keep batteries in good working condition, follow this maintenance program on a regular basis. Proper bat- tery maintenance is critical not only for good performance, but also for safe operation. See following WARN- ING.
ý WARNING • Only trained technicians should repair or service the charger. Contact a Club Car distributor/ dealer. • Each charger should have its own dedicated 15 or 20 ampere separately protected (circuit breaker or fuse) single phase branch circuit, in accordance with all applicable electrical codes for the location.
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Battery Charger – Electric Vehicles ý WARNING • Do not use a charger if: - The plug is too loose or does not make a good connection. - The plug and receptacle feel hotter than normal during charge. - The plug pins or contacts are bent or corroded. - The plug, receptacle or cords are cut, worn, have any exposed wires, or are damaged in any way.
The control circuit lockout remains activated until the charger plug is discon- nected from the vehicle. PowerDrive and IQ Plus battery chargers are not interchangeable, nor can they be used with other Club Car models or vehicles made by other manufacturers. Charger compatibility for each vehicle is as follows: •...
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Battery Charger – Electric Vehicles Figure 28 Correct Insertion of Charger DC Plug Figure 29 Incorrect Insertion of Charger DC Plug PLUG AND RECEPTACLE Villager vehicles: The charger cord, plug, and receptacle are wear items and should be inspected daily. Visu- ally inspect them for cracks, loose connections, and frayed wiring;...
Battery – Gasoline Vehicles 48-VOLT FUSE LINK SENSE LEAD FUSE Figure 30 Receptacle Fuse Link BATTERY – GASOLINE VEHICLES See General Warnings on page 19. ý DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area.
Fueling Instructions – Gasoline Vehicles 3. If the oil level is at or below the low level mark on the dipstick gauge, add oil until the level is between low and full levels (safe level). 4. Reinsert dipstick into the oil filler tube. °...
(No. 00) steel wool. Club Car does not recommend any type of pressure washing or steam cleaning. Such a process (especially if the vehicle has an ArmorFlex rear body that has been removed) will expose electrical components to mois- ture.
In the event a vehicle is bought as a used vehicle, we strongly urge the new owner to register the vehicle with Club Car. This will enable us to contact you if the need arises. Please send your name, address, and serial number(s) of the vehicle(s) to Club Car, Inc., P.O.
Vehicle Specifications – Electric Vehicles VEHICLE SPECIFICATIONS – ELECTRIC VEHICLES Villager 6 TransPorter TransPorter Villager 6 TransPorter TransPorter Villager 4 Villager 8 SPECIFICATIONS Villager 8 IQ System Power-Drive Power-Drive Power-Drive IQ Plus IQ Plus IQ Plus System 48 System 48 System 48 POWER SOURCE Drive motor: Direct drive, 48 volts...
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Vehicle Specifications – Electric Vehicles Villager 6 TransPorter TransPorter Villager 6 TransPorter TransPorter Villager 4 Villager 8 SPECIFICATIONS Villager 8 IQ System Power-Drive Power-Drive Power-Drive IQ Plus IQ Plus IQ Plus System 48 System 48 System 48 47.3 in. 47.3 in. 49.3 in.
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Vehicle Specifications – Gasoline Vehicles Villager 6 DS Villager 4 TransPorter 4 TransPorter 6 Villager 8 SPECIFICATIONS Pedal-Start Key-Start Key-Start Key-Start Gasoline Gasoline Gasoline Gasoline Vil. 6: 98.5 in. (250 65.5 in. 98.5 in. 98.5 in. Wheelbase (166 cm) Vil. 8: 131.5 in. (334 (250 cm) (250 cm) 4.5 in.
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Repair shall mean remedying a defect in the vehicle or component thereof at no cost to the purchaser during the applicable limited warranty period. If CLUB CAR elects to repair the vehicle, it may provide factory-reconditioned parts or components.
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CLUB CAR, INC., ("CLUB CAR") hereby warrants to the original retail purchaser that the new "Trojan T-105" 6-Volt Battery installed in its new electric utility vehicle purchased from CLUB CAR or an authorized distributor or dealer will be free from defects in material and workmanship and will provide for a period of four years or 18,000 energy units whichever occurs first, subject to the terms and conditions contained herein.
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Without limiting the generality of the foregoing in any way, and as part of its limited warranty exclusion, CLUB CAR does not warrant that its battery is suitable for use in any application other than in its products. As in the use of any battery, a prudent owner will read and study the charger owner's manual, the electric vehicle owner's manual, the operator instructions, and the battery warning labels;...
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5) A battery damaged by a defective charger. Without limiting the generality of the foregoing in any way, and as part of its limited warranty exclusion, CLUB CAR does not warrant that its battery is suitable for use in any application other than in its products. As in the use of any battery, a prudent owner will read and study the charger owner's manual, the electric vehicle owner's manual, the operator instructions, and the battery warning labels;...
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5)A battery damaged by a defective charger. Without limiting the generality of the foregoing in any way, and as part of its limited warranty exclusion, CLUB CAR does not warrant that its PowerDrive battery is suitable for use in any application other than in its products. As in the use of any battery, a prudent owner will read and study the charger owner's manual, the electric vehicle owner's manual, the operator instructions, and the battery warning labels;...
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5) A battery damaged by a defective charger. Without limiting the generality of the foregoing in any way, and as part of its limited warranty exclusion, CLUB CAR does not warrant that its PowerDrive battery is suitable for use in any application other than in its products. As in the use of any battery, a prudent owner will read and study the charger owner’s manual, the electric vehicle owner’s manual, the operator...
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The limited warranty with respect to parts and labor only covers defects in material and workmanship for a period of four years from the date of purchase. Such repair labor shall be performed only by CLUB CAR or by an authorized distributor or dealer.
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4) Vehicles charged by systems other than the CLUB CAR PowerDrive Charger. Without limiting the generality of the foregoing in any way, and as part of its limited warranty exclusion, CLUB CAR does not warrant that the Computer or Controller is suitable for use in any application other than its PowerDrive System 48, PowerDrive Plus, and IQ System products.
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WAY VARIES THE TERMS OF THIS WARRANTY. This computer or controller is intended to be used only in CLUB CAR PowerDrive System 48, PowerDrive Plus, and IQ System electric vehicles. Any other use renders the Limited Warranties expressed herein and all implied warranties null and void and same are hereby excluded.
5. NO CONSEQUENTIAL DAMAGES: In no event shall Club Car be liable for any incidental or consequential damages including, but not limited to, loss related to property other than the vehicle, loss of use, loss of time, inconvenience, or any other economic loss. This warranty is applicable only where the California or U.S. EPA emission control system warranty regulation is in effect.
System Warranty requires that you return your • Magneto or electronic ignition system blow-by gases are led to the breather chamber engine to an authorized Club Car Dealer for • Fuel filter element through the crankcase.Then, it is led to the air remedy under warranty.Please read the warranty...
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2. Ease of Finding Information 3. Clarity of Illustrations 4. Periodic Service and Periodic Lubrication Schedules Comments/Suggestions Please fax a copy of this page to (706) 228-2662. Thank You! Club Car Technical Publication Department Page 74 2006 Transportation Vehicle Owner’s Manual...
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