Summary of Contents for Club Car Trans-Porter 1998
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1998 1998 T T rans-P rans-Por orter ter, , T T rans-Sender rans-Sender, , Resort V Resort Villager illager, , and T T ourall ourall V V ehic ehicles Manual Number 1019682-03 ual Number 1019682-03 Print Code 0897B1297A Print Code 0897B1297A...
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WARNING • THE ENGINE EXHAUST FROM THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS, OR OTHER REPRODUCTIVE HARM.
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No other warranties, express or implied, are contained herein. Please complete and return the war- ranty registration card included in this manual. 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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For the name and address of the Club Car representative nearest you, call 706- 863-3000, Ext. 2601. If you would prefer to write to us, direct your letter to: Club Car, Attention: Product Development Department, P.O. Box 204658, Augusta, Ga. 30917-4658 USA. Your local authorized Club Car representative can also provide technical advice, parts, and service manuals.
TABLE OF CONTENTS Safety Details ..............General Warnings .
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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 we urge you to study this owner’s manual, and to read, understand, and heed the warnings in this manual, as well as the safety decals on your vehicle, before operat- ing the vehicle.
Any operating or warning decals on the vehicle that are damaged, have been removed or cannot be easily read should be replaced immediately to avoid possible personal injury, property damage, or death. Contact your CLUB CAR distributor/dealer. DANGER • A DANGER INDICATES AN IMMEDIATE HAZARD WHICH WILL RESULT IN SEVERE PER- SONAL INJURY OR DEATH.
GENERAL WARNINGS The safety procedures listed must be followed whenever the vehicle is being operated, repaired, or serviced. Other specific warnings appear throughout this manual and on the vehicle. DANGER • GASOLINE VAPORS - FLAMMABLE! EXPLOSIVE! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE.
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WARNING ELECTRIC VEHICLES ONLY: • TO AVOID UNINTENTIONALLY STARTING THE VEHICLE, DISCONNECT THE BATTERIES AS SHOWN (SEE FIGURES 1 AND 2) AND DISCHARGE THE CONTROLLER AS FOLLOWS: - TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD/REVERSE HANDLE IN THE REVERSE POSITION.
TOURALL GASOLINE VEHICLE DRIVER/PASSENGER WARNING LABEL OPERATING INSTRUCTIONS KEY SWITCH LABEL OIL WARNING PARK BRAKE LIGHT PEDAL BRAKE PEDAL ARM RESTS HAND RAIL SERIAL NUMBER PASSENGER WARNING LABEL ACCELERATOR (ON REAR HANDRAIL PEDAL FACING SEAT)
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FEATURE IDENTIFICATION FRAME GROUND AND GOVERNOR WARNING DECAL (ON VEHICLE FRAME NEAR BATTERY) GASOLINE WARNING DECAL MOVING PARTS AND (ON VEHICLE FRAME NEAR FUEL TANK) HOT MANIFOLD DECAL (ON STARTER/GENERATOR AND ENGINE) OIL FILL PASSENGER FORWARD / REVERSE WARNING DECAL HANDLE (ON REAR HANDRAIL FACING SEAT)
TOURALL ELECTRIC VEHICLE DRIVER / PASSENGER WARNING DECAL OPERATING INSTRUCTIONS BATTERY DECAL WARNING KEY SWITCH LIGHT PARK BRAKE PEDAL BRAKE SERIAL PEDAL NUMBER ARM RESTS HAND RAIL PASSENGER WARNING DECAL (ON REAR HANDRAIL FACING SEAT) ACCELERATOR REGENERATIVE PEDAL BRAKING DECAL (POWERDRIVE PLUS VEHICLE ONLY)
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FEATURE IDENTIFICATION WARNING HOT RESISTORS (COILED WIRE) CAN CAUSE SEVERE BURNS. RESISTOR WARNING DECAL (ON BODY UNDER ACCESS PANEL) (FOR POWERDRIVE PLUS 48 VOLT VEHICLE) ELECTRICAL COMPONENT MOUNTING PLATE NOTICE (ON PLATE) DANGER / POISON FLUSH EYES SULFURIC IMMEDIATELY WITH WATER ACID SHIELD ¥...
RESORT VILLAGER GASOLINE OFF ON START OPERATING INSTRUCTIONS KEY SWITCH DECAL DRIVER / PASSENGER WARNING DECAL ACCELERATOR PEDAL OIL WARNING LIGHT SERIAL NUMBER PASSENGER WARNING DECAL PARK BRAKE PEDAL BRAKE PEDAL...
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VEHICLE FEATURE IDENTIFICATION FRAME GROUND AND GOVERNOR WARNING DECAL (ON VEHICLE FRAME NEAR BATTERY) MOVING PARTS AND GASOLINE WARNING DECAL HOT MANIFOLD DECAL (ON VEHICLE FRAME NEAR FUEL TANK) (ON STARTER/GENERATOR AND ENGINE) OIL FILL CHOKE FORWARD - REVERSE HANDLE PERIODIC SERVICE DECAL (ON AIR INTAKE BOX)
RESORT VILLAGER ELECTRIC KEY SWITCH DRIVER/PASSENGER WARNING DECAL OPERATING INSTRUCTIONS LABEL BATTERY WARNING LIGHT ACCELERATOR PEDAL BATTERY CONDITION INDICATOR SERIAL NUMBER PASSENGER WARNING LABEL PARK BRAKE PEDAL BRAKE PEDAL...
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VEHICLE FEATURE IDENTIFICATION DANGER / POISON FLUSH EYES SULFURIC IMMEDIATELY WITH WATER ACID SHIELD ¥ SPARKS CAN CAUSE EYES ¥ FLAMES BLINDNESS OR MEDICAL EXPLOSIVE ¥ SMOKING HELP SEVERE BURNS GASES CAN CAUSE FAST BLINDNESS OR INJURY KEEP OUT OF THE REACH OF CHILDREN — DO NOT TIP — KEEP VENT CAPS TIGHT AND LEVEL DANGER DECAL (ON BODY) PASSENGER...
TRANS-PORTER/TRANS-SENDER COMMON FEATURES - GASOLINE AND ELECTRIC VEHICLES OPERATING INSTRUCTIONS GASOLINE VEHICLE OFF ON START KEY SWITCH GASOLINE VEHICLE KEY SWITCH ELECTRIC VEHICLE DRIVER/PASSENGER WARNING DECAL OIL WARNING LIGHT (GAS VEHICLE) BATTERY WARNING LIGHT (ELECTRIC VEHICLE) OPERATING INSTRUCTIONS ELECTRIC VEHICLE BATTERY CONDITION INDICATOR (ELECTRIC VEHICLE)
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VEHICLE FEATURE IDENTIFICATION GASOLINE VEHICLE FEATURES GASOLINE TANK FORWARD AND FORWARD AND DANGER DECAL HOT MANIFOLD AND REVERSE REVERSE (ON FRAME) MUFFLER LABEL HANDLE LEVER (ON STARTER/GENERATOR PASSENGER AND ENGINE) WARNING DECAL CHOKE TRANS-SENDER VEHICLE PASSENGER WARNING DECAL TILT BED WARNING DECAL PINCH POINT TRANS-PORTER...
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TRANS-PORTER/TRANS-SENDER VEHICLE FEATURE IDENTIFICATION ELECTRIC VEHICLE FEATURES DANGER / POISON FLUSH EYES SULFURIC IMMEDIATELY WITH WATER ELECTRICAL COMPONENT COVER CAUTION ACID SHIELD ¥ SPARKS CAN CAUSE EYES ¥ FLAMES (ON COVER) BLINDNESS OR MEDICAL EXPLOSIVE ¥ SMOKING HELP GASES SEVERE BURNS CAN CAUSE FAST BLINDNESS OR INJURY...
Use the following checklist as a guide to inspect your new vehicle. This same checklist should also be used in conjunction with the Periodic Service Schedules, pages 37 through 41. Any problems should be corrected by your CLUB CAR distributor/dealer or a trained technician only.
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After you have familiarized yourself with the vehicle controls and have read and understood the driving instructions, take the vehicle for a test drive. Use the following checklist as a guide to inspect your new vehi- cle. Any problems should be corrected only by your CLUB CAR distributor/dealer or a trained technician. All vehicles: •...
CONTROLS - TRANS-PORTER/TRANS-SENDER ELECTRIC, RESORT VILLAGER ELECTRIC, TOURALL GASOLINE, AND TOURALL ELECTRIC VEHICLES DANGER • DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI- LATION. GASOLINE ENGINES PRODUCE CARBON MONOXIDE GAS, WHICH IS AN ODOR- LESS, DEADLY POISON. WARNING •...
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N (neutral) position, the vehicle will not operate. The engine in a gasoline powered Tourall will shut down if the vehicle is shifted to NEUTRAL while the engine is running. All Club Car transportation vehi- cles operate at reduced speed in REVERSE NOTE •...
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ACCELERATOR PEDAL The accelerator pedal is the pedal on the right, with the word GO molded into it (Figure 7). NOTE • THE OPERATION OF THE ACCELERATOR PEDAL DIFFERS FROM THAT OF AN AUTOMO- BILE. WHEN THE KEY SWITCH IS ON, AND THE FORWARD/REVERSE HANDLE IS IN EITHER FORWARD OR REVERSE, DEPRESSING THE ACCELERATOR PEDAL WILL AUTOMATICALLY RELEASE THE PARK BRAKE AND START THE VEHICLE MOVING IN THE DIRECTION SELECTED (FORWARD OR REVERSE).
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Neutral Lock-out, Continued: For the convenience of the trained mechanic, there is a neutral lock-out cam (yellow knob) located on the back of the Forward/Reverse shifter, inside the engine compartment. If the neutral lock-out cam is pulled out approximately 3/8 inch (10 millimeters) and then rotated one-half turn until it snaps into place, the cam will be in the SERVICE position (Figure 10, Page 19).
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30 minutes. However, the vehicle should be charged at the first opportunity. If the warning light comes on and the vehicle is unable to operate for 30 minutes, have your Club Car distributor/ dealer check the vehicle for a possible battery or electrical system problem.
CAUTION • AFTER PLACING THE TOW/RUN SWITCH IN THE RUN POSITION, ALLOW 10 SECONDS BEFORE OPERATING THE VEHICLE. The Tourall electric vehicle with PowerDrive Plus (motor braking) is equipped with a TOW/RUN switch, located under the seat just above the Forward/Reverse switch (Figure 14). The TOW/RUN switch must be in the RUN position in order to operate the vehicle.
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WARNING • THE VEHICLE IS NOT SPECIALLY EQUIPPED FOR HANDICAPPED PERSONS. MAKE SURE ALL PASSENGERS ARE CAPABLE OF SECURING THEMSELVES IN A MOVING TRANSPORTA- TION VEHICLE BEFORE ALLOWING THEM TO RIDE IN ONE. • FOR NIGHT USE, THE VEHICLE MUST BE EQUIPPED WITH HEADLIGHTS, TAILLIGHTS, AND REFLECTORS.
Starting The Vehicle, Continued: 6. Slowly depress accelerator pedal. The park brake will release automatically and the vehicle will start to move. As the accelerator pedal is depressed, speed will increase until full speed is reached. See WARNING below. WARNING •...
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WARNING • BEFORE ASSIGNING A DRIVER TO THE VEHICLE, MAKE SURE THE DRIVER IS FAMILIAR WITH ALL CONTROLS AND OPERATING PROCEDURES BEFORE ALLOWING THE VEHICLE TO BE DRIVEN. • BEFORE ALLOWING ANYONE TO DRIVE THE VEHICLE, BE SURE HE OR SHE IS FAMILIAR WITH ALL CONTROLS AND OPERATING PROCEDURES.
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ACCELERATOR PEDAL The accelerator pedal is the pedal on the right, with the word GO molded into it (Figure 18). See NOTE below. NOTE • THE OPERATION OF THE ACCELERATOR PEDAL DIFFERS FROM THAT OF AN AUTOMO- BILE. WHEN THE ENGINE IS RUNNING, AND THE SHIFT HANDLE IS IN EITHER FORWARD OR REVERSE, DEPRESSING THE ACCELERATOR PEDAL WILL AUTOMATICALLY RELEASE THE PARK BRAKE AND START THE VEHICLE MOVING IN THE SELECTED DIRECTION (FORWARD OR REVERSE).
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handle is placed in either the FORWARD or REVERSE position. To put the cam back into the OPERATE position, pull the cam out approximately 3/8 inch (10 millimeters) and rotate it one-half turn until it snaps into place (Figure 21, Page 28). See WARNING and NOTE below. WARNING •...
OIL LIGHT The gasoline powered vehicle is equipped with a low oil warning light, located on the dash panel just above the steering column (Figure 23). If the oil warning light comes on, oil should be checked and added to the engine as necessary before continuing to use the vehicle.
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WARNING • MAKE SURE THE DRIVER IS FAMILIAR WITH ALL CONTROLS AND OPERATING PROCE- DURES BEFORE ALLOWING THE VEHICLE TO BE DRIVEN. • NO MORE THAN TWO PEOPLE PER SEAT AT ONE TIME. • DO NOT ALLOW PASSENGERS IN THE CARGO BED. •...
Starting the Vehicle, Continued: 3. Read safety warnings located above pedals. 4. Place the Forward/Reverse handle in the NEUTRAL position. Make sure wheels are turned in desired direction and nothing is in your path. 5. Depress and hold the brake pedal. Turn the key all the way to the START position and release after the engine is started.
WARNING COULD CAUSE THE VEHICLE TO OVERTURN, POSSIBLY RESULTING IN SEVERE PERSONAL INJURY. • REDUCE NORMAL DRIVING SPEED WHEN TOWING A CLUB CAR VEHICLE ON A TRAILER. • FOR USE ON PUBLIC ROADS, THE TRAILER MUST MEET ALL FEDERAL, STATE, AND LOCAL REQUIREMENTS SUCH AS TAILLIGHTS, BRAKE LIGHTS, ETC.
WARNING • NEVER TOW A CLUB CAR VEHICLE BEHIND A PASSENGER VEHICLE OR TRUCK ON A PUB- LIC ROAD UNLESS IT IS ON AN APPROVED TRAILER. • THE VEHICLE TO BE TOWED SHOULD BE TIED SECURELY TO THE TRAILER, WITH THE FOR- WARD/REVERSE HANDLE IN NEUTRAL, THE KEY SWITCH OFF, AND THE PARK BRAKE FIRMLY DEPRESSED AND LOCKED.
3.3. Disconnect fuel vent line from fuel tank vent nipple. 3.4. Plug the fuel tank vent nipple so that it is air tight. Club Car recommends using a slip-on vinyl cap. 4. To protect the engine, remove the spark plug and pour 1/2 ounce SAE 10 weight oil into the engine through the spark plug hole.
3. Wash off any corrosion around the terminals with a solution of baking soda and water, then rinse the baking soda solution from the batteries. Do not allow this solution to enter the batteries. Let the termi- nals dry and coat them with CLUB CAR battery terminal spray, Part No. 1014305. CAUTION •...
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Contact your local Club Car distributor/dealer to perform all repairs and semi-annual and annual periodic service. • See Page 37 for Gasoline Vehicle Periodic Service Schedule. • See Page 39 for Electric Vehicle Periodic Service Schedule. • See Page 42 for Gasoline Vehicle Periodic Lubrication Schedule.
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WARNING ELECTRIC VEHICLES ONLY: • POWERDRIVE PLUS VEHICLES ONLY: PLACE TOW SWITCH IN THE TOW POSITION. • TO AVOID UNINTENTIONALLY STARTING THE VEHICLE, DISCONNECT THE BATTERIES AS SHOWN (SEE FIGURES 24 AND 25) AND DISCHARGE THE CONTROLLER AS FOLLOWS: - TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD/REVERSE HANDLE IN THE REVERSE POSITION.
PERIODIC SERVICE SCHEDULE - GASOLINE VEHICLE REGULAR INTERVAL SERVICE Check for proper operation (See Performance Inspec- Accelerator pedal/rod tion, Page 16). Adjust as necessary. Check for proper operation (See Performance Inspec- Accelerator/governor linkage and cables tion, Page 16). Adjust as necessary. Check for proper operation (See Performance Inspec- Brake System tion, Page 16).
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PERIODIC SERVICE SCHEDULE - GASOLINE VEHICLE REGULAR INTERVAL SERVICE Exhaust System Check for leaks. Monthly Service by Owner Check for wear and damage. or Trained Mechanic, Con- Tires Check air pressure and adjust as necessary tinued (See Capacities Chart on Page 44). Check all daily and weekly items listed above.
PERIODIC SERVICE SCHEDULE - GASOLINE VEHICLE REGULAR INTERVAL SERVICE Check engine oil level and filter - change as require (See Gas Vehicle Lubrication Chart, Page 42). Dis- pose of used oil properly. Engine Check for leaks around gaskets, fill plugs, etc. Inspect, clean, and regap spark plug;...
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PERIODIC SERVICE SCHEDULE - ELECTRIC VEHICLE REGULAR INTERVAL SERVICE Tires Check for wear and damage. Daily Service by Owner, Continued: Make sure all are in place (See Electric Vehicle Fea- Vehicle warning decals ture Identification, Pages 6-7 and 10-12 & 14). Clean terminals and wash dirt from case, check elec- Batteries trolyte level (See Page 48).
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PERIODIC SERVICE SCHEDULE - ELECTRIC VEHICLE REGULAR INTERVAL SERVICE Electrical Wiring Check for cracked or worn insulation. Check and adjust as required (See Maintenance & Semi-annual Service by Front Wheel Alignment and Camber Service Manual). Trained Mechanic Only (Every 50 hours Lubricate per Electric Vehicle Lubrication Chart on General Vehicle of operation)
REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT PLACE Brake shaft bearings Dry Moly Lube - Club Car Part No. 1012151 Brake Linkage and Pivots Dry Moly Lube - Club Car Part No. 1012151 Quarterly by Owner Accelerator push rod pivots and Dry Moly Lube - Club Car Part No. 1012151...
REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT PLACE Brake shaft bearings Dry Moly Lube - Club Car Part No. 1012151 Brake Linkage and Pivots Dry Moly Lube - Club Car Part No. 1012151 Quarterly by Owner Accelerator pivots Dry Moly Lube - Club Car Part No. 1012151...
ENGINE OIL - GASOLINE VEHICLE Even though the oil warning light on the dash should warn you if your oil is getting low, engine oil level should be checked monthly (Figure 29). NOTE • TO CHECK ENGINE OIL, THE ENGINE MUST BE IN A LEVEL POSITION. REMOVE THE OIL LEVEL DIPSTICK FROM THE OIL FILLER TUBE AND WIPE OIL FROM STICK.
CAUTION • TO ALLOW FOR EXPANSION, DO NOT FILL HIGHER THAN ONE INCH FROM TOP OF THE FUEL TANK. AVOID FUEL SPILLAGE. 1. Lift and remove seat bottom. • Tourall Vehicles: Lift and remove the driver seat bottom. • Trans-Porter/Trans-Sender and Resort Villager: Lift and remove the second forward-facing seat. 2.
(1 cup per gallon of water), and then the baking soda solution rinsed off the battery. Do not allow the solution to get into the battery. Be sure terminals are tight. Let the terminals dry and then spray them with CLUB CAR battery terminal spray (Club Car Part No.1014305). See WARNING on page 46 and CAUTION below.
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(NOTE: Do not allow this solution to enter the battery). Be sure terminals are tight. Let the terminals dry and then spray them with CLUB CAR battery protector spray (Club Car Part No. 1014305). 2. The water level in the batteries should be checked weekly (See Figure 32, Page 47, for proper level).
WARNING • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THE CHARGER. CONTACT YOUR NEAREST CLUB CAR DISTRIBUTOR/DEALER. • EACH CHARGER SHOULD HAVE ITS OWN DEDICATED 15 OR 20 AMPERE SEPARATELY PRO- TECTED (CIRCUIT BREAKER OR FUSE) SINGLE PHASE BRANCH CIRCUIT, IN ACCORDANCE WITH ALL APPLICABLE ELECTRICAL CODES FOR THE LOCATION.
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WARNING • DO NOT OPERATE THE CHARGER IF IT HAS RECEIVED A SHARP BLOW, WAS DROPPED, OR OTHERWISE DAMAGED IN ANY WAY. • NEVER PUSH OBJECTS OF ANY KIND INTO THE CHARGER THROUGH CABINET SLOTS. THEY MAY TOUCH DANGEROUS VOLTAGE POINTS OR CAUSE AN ELECTRICAL SHORT CIR- CUIT THAT COULD RESULT IN FIRE OR ELECTRICAL SHOCK.
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Because of these unique features, only PowerDrive System 48 vehicles are compatible with the Power- Drive Charger (neither vehicles made by other manufacturers, nor other Club Car models are compatible). As long as the charger is allowed to shut off by itself, the batteries will be fully charged. Overcharging and...
Batteries should be put on charge even if they have been used for only a short period (10 minutes). The charger is automatic and will turn off when batteries are fully charged. If the charger does not seem to be operating properly, or if the batteries seem weak, contact your local CLUB CAR distributor/dealer. Receptacle Fuse Link As an additional feature to protect the batteries and charging circuit from an overload, the electric vehicle is equipped with a receptacle fuse link (Figure 35).
In the event a vehicle is bought used from another individual or from a distributor/dealer, we strongly urge the new owner to re-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. Box 204658, Augusta.
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This limited warranty covers materials, workmanship and repair labor cost as to those items specifically listed above for the periods specified. Such repair labor shall be performed only by CLUB CAR, its authorized deal- ers, or a service agency approved by CLUB CAR.
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CLUB CAR’S ONLY LIABILITY UNDER THIS LIMITED WARRANTY, OR IN ANY ACTION WHETHER BASED UPON WARRANTY, CONTRACT, NEGLIGENCE, STRICT PRODUCT LIABILITY OR OTHER- WISE, IS LIMITED TO THE REPAIR OR REPLACEMENT, AT CLUB CAR’S OPTION, OF A VEHICLE OR COMPONENT THEREOF THAT CLUB CAR DEEMS TO BE DEFECTIVE. REPLACEMENT SHALL MEAN...
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Transportation and Utility Vehicles Club Car Inc. P.O. Box 204658 Augusta, GA 30917-4658...
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