Club Car Onward 4 Passenger Operator's Manual
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Club Car Onward 4 Passenger Operator's Manual

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ONWARD HP NON-LIFTED 4-PASSENGER
ELECTRIC
Operators Manual
APPLICABLE TO ONWARD HP NON-LIFTED 4-PASSENGER ERIC ELECTRIC
VEHICLES WITH SERIAL PREFIX OF DU

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Summary of Contents for Club Car Onward 4 Passenger

  • Page 1 ONWARD HP NON-LIFTED 4-PASSENGER ELECTRIC Operators Manual APPLICABLE TO ONWARD HP NON-LIFTED 4-PASSENGER ERIC ELECTRIC VEHICLES WITH SERIAL PREFIX OF DU...
  • Page 2 Copyright © 2020 Club Car, LLC This manual effective January 31, 2020...

  • Page 3: Introduction

    Read, understand, and obey all instructions and safety precautions in this manual to prevent the risk of personal injury or property damage. Club Car recommends owners that rent or loan vehicles make sure operators read this manual before vehicle operation.
  • Page 4 APPROVED DEALERS AND DISTRIBUTORS Club Car’s customer support system offers fast and courteous service. Speak with your dealer or distributor for: • Accessories • Technical Advice • Publications • Warranty Work • Replacement Parts To find your nearest dealer or distributor: •...
  • Page 5 LIABILITY AND VEHICLE DESIGN CHANGES 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. Club Car reserves the right to make design changes to vehicles without obligation to make these changes on units previously sold.
  • Page 6 This manual contains proprietary information that is protected by copyright. All rights are reserved. Express written consent of Club Car, LLC is necessary to photocopy, replicate, or translate this manual. The information contained in this publication is subject to change without notice.

  • Page 7: Table Of Contents

    CONTENTS INTRODUCTION ............................I NOTICES ..............................III SECTION 1 – SAFETY INFORMATION ....................9 General Safety Information ........................ 10 Practice Safety..........................10 Safety Signal Words ........................10 Safety Committee .......................... 11 Vehicle Safety Information........................11 Vehicle Safety And Compliance Decals..................12 Vehicle Safety Features ........................
  • Page 8 European Conformity ........................36 Federal Communications Commission ..................36 International Protection Marking....................36 Underwriters Laboratories And Canadian Standards Association ..........37 Features ............................... 37 AC Electrical Cord And Plug ......................37 Status Indicator Lights........................37 Battery Charging Interlock ......................39 External Battery Charger Mounting....................
  • Page 9 Service Schedule ..........................62 Maintenance Tasks..........................63 Lift The Vehicle ..........................63 Lower The Vehicle........................... 65 Tire Pressure Measurement ......................67 Wheel Assembly ..........................67 SECTION 9 – BATTERY MAINTENANCE ....................69 Battery Cleaning ..........................70 Battery Charging ..........................70 Charging With External Charger ....................70 Charging With Onboard Charger ....................
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  • Page 11: Notices

    Safety Information Notices SAFETY INFORMATION ONWARD HP NON-LIFTED 4-PASSENGER ELECTRIC Operators Manual Page 9 TPCC01DU00EN020 (Edition A)

  • Page 12: General Safety Information

    Safety Information General Safety Information GENERAL SAFETY INFORMATION PRACTICE SAFETY Signal words (DANGER, WARNING, CAUTION, and NOTICE) WARNING and safety messages are in this manual and on safety ROTATING PARTS AND BURN RISK decals. Read, understand, and obey all instructions, safety Rotating parts can cause serious injury.

  • Page 13: Safety Committee

    A NOTICE identifies a hazardous situation which could result in property damage. SAFETY COMMITTEE If the vehicle is rented or part of a fleet, Club Car recommends a safety committee. The primary concern of the safety committee is safe vehicle operation. Safety committee objectives include: •...

  • Page 14: Vehicle Safety And Compliance Decals

    Safety Information Vehicle Safety Information ELECTRICAL SHORTS CAN CAUSE A FIRE, ELECTRICAL SHOCK, WARNING SERIOUS PERSONAL INJURY, OR DEATH. PREVENT CONTACT BETWEEN POSITIVE VOLTAGE AND THE GROUND CIRCUIT. USE INSULATED TOOLS. TO HELP PREVENT BEING HIT, DO NOT STAND IN FRONT OF OR BEHIND THE VEHICLE.
  • Page 15 Safety Information Vehicle Safety Information OPERATING INSTRUCTIONS Before using vehicle, read owner’s manual and vehicle safety warnings. Study and understand controls. TO OPERATE • Ensure wheels are turned in desired direction of travel and path is clear. • Turn key to ON. •...
  • Page 16 Safety Information Vehicle Safety Information This vehicle complies with Part III of the RISK OF ELECTRONIC COMPONENT DAMAGE Do not expose electrical components to water. Water can ANSI / ILTVA Z135 - PTV Safety Standard NOTICE cause damage to electrical components. when equipped with rear view mirrors •...

  • Page 17: Vehicle Safety Features

    Safety Information Vehicle Safety Features 14. Hold On Warning Decal FALLING OFF CAN CAUSE SERIOUS INJURY OR DEATH WARNING • Two (2) persons per bench seat maximum. 105267301 15. Falling Off Warning Decal VEHICLE SAFETY FEATURES BATTERY CHARGING INTERLOCK External Battery Charger: The battery charging interlock is a safety feature that prevents possible damage to the battery charger and vehicle.

  • Page 18: Walk-Away Braking

    Safety Information Battery Safety Information ACCELERATOR PEDAL CONDITION POSITION Fully Pushed Regenerative braking holds the vehicle at the programmed top speed. Regenerative braking holds the vehicle at a percentage of the Between Fully Pushed And programmed top speed in relation to the accelerator pedal position. Released Regenerative braking will do one of the two based on the controller settings:...

  • Page 19: Battery International Safety Symbols

    Safety Information Battery Safety Information BATTERY WIRES WITH DAMAGE OR CORROSION CAN BECOME TOO HOT AND CAUSE A FIRE, PROPERTY DAMAGE, OR SERIOUS PERSONAL INJURY. REPLACE BATTERY WIRES THAT HAVE DAMAGE OR CORROSION. CLEAN CORROSION FROM THE BATTERY TERMINALS. BATTERY INTERNATIONAL SAFETY SYMBOLS Understand and obey the international safety symbols on the vehicle battery before you use, repair, or service the vehicle.
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  • Page 21: Section 2 - Indicators, Gauges, And Displays

    Indicators, Gauges, And Displays Battery Safety Information INDICATORS, GAUGES, AND DISPLAYS ONWARD HP NON-LIFTED 4-PASSENGER ELECTRIC Operators Manual Page 19 TPCC01DU00EN020 (Edition A)

  • Page 22: Indicator, Gauge, And Display Locations

    Indicators, Gauges, And Displays Indicator, Gauge, And Display Locations INDICATOR, GAUGE, AND DISPLAY LOCATIONS 1. Plastic Insert 2. Dash Display DASH DISPLAY The dash display gives a visual indication of: • The battery state of charge (SOC) • Forward / Neutral / Reverse control (FNR) position •...
  • Page 23 Indicators, Gauges, And Displays Dash Display DISPLAY DESCRIPTION Battery state of charge (SOC) • The dash display will show the SOC when the key switch is set to ACC or ON. • 100% to 10% - SOC will show in 10% increments •...
  • Page 24 Indicators, Gauges, And Displays Dash Display DISPLAY DESCRIPTION FNR is set to F FNR is set to R Left turn signal is on Right turn signal is on Minor fault. The vehicle will log the event. Speak with your local dealer or distributor.
  • Page 25 Indicators, Gauges, And Displays Dash Display DISPLAY DESCRIPTION Malfunction fault. The vehicle may go into limp mode and operate at only 7.6 mph (12.2 kmh). Speak with your local dealer or distributor. Severe fault. When possible, all components except for the dash display will not operate.
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  • Page 27: Section 3 - Vehicle Controls

    Vehicle Controls Dash Display VEHICLE CONTROLS ONWARD HP NON-LIFTED 4-PASSENGER ELECTRIC Operators Manual Page 25 TPCC01DU00EN020 (Edition A)

  • Page 28: Vehicle Controls Locator

    Vehicle Controls Vehicle Controls Locator VEHICLE CONTROLS LOCATOR ONWARD HP NON-LIFTED 4-PASSENGER ELECTRIC Page 26 Operators Manual TPCC01DU00EN020 (Edition A)

  • Page 29: Accelerator Pedal

    Vehicle Controls Accelerator Pedal 1. Accelerator Pedal 2. Brake Pedal 4. Key Switch 3. Park Brake 5. Headlight Switch 6. Turn Signal Lever 7. Hazard Lights Switch 8. Horn Button 9. Forward / Neutral / Reverse Control (FNR) 10. Run/Tow Switch ACCELERATOR PEDAL The accelerator pedal is used to increase and maintain the speed of the vehicle.

  • Page 30: Hazard Light Switch

    Vehicle Controls Hazard Light Switch The Forward / Neutral / Reverse control (FNR) POSITION FUNCTION sets the direction of vehicle movement. Forward Stop the vehicle to change the FNR position. Neutral (Center) Reverse HAZARD LIGHT SWITCH POSITION FUNCTION The hazard light switch controls the operation of the hazard lights.

  • Page 31: Park Brake

    Vehicle Controls Park Brake The key switch controls the motor and electrical system. A key is used to select the key switch position. The key can only be inserted or removed when the key switch set to OFF. POSITION CONDITION Normal position when the vehicle is not in use.

  • Page 32: Run/Tow Switch

    Vehicle Controls Run/Tow Switch RUN/TOW SWITCH UNINTENDED VEHICLE MOVEMENT CAN CAUSE PROPERTY WARNING DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH. WHEN THE RUN/TOW SWITCH IS IN THE TOW POSITION, ALL MOTOR BRAKING FUNCTIONS, INCLUDING WALK-AWAY BRAKING, ARE DISABLED. The Run/Tow switch is used during towing, maintenance, or extended storage. Set the switch to RUN for normal operation.

  • Page 33: Section 4 - Vehicle Features

    Vehicle Features Turn Signal Lever VEHICLE FEATURES ONWARD HP NON-LIFTED 4-PASSENGER ELECTRIC Operators Manual Page 31 TPCC01DU00EN020 (Edition A)

  • Page 34: Vehicle Features Description

    Vehicle Features Vehicle Features Hazard Statements The vehicle features listed are standard and optional. FOLD-DOWN REAR SEAT The fold-down rear seat is for two additional passengers and increased cargo space. USB RECEPTACLE The 5-volt, 2.1-amp USB receptacle supplies electricity to power and charge portable devices. The USB receptacle is not for the movement of data.

  • Page 35: Section 5 - Battery Charger

    Battery Charger USB Receptacle BATTERY CHARGER ONWARD HP NON-LIFTED 4-PASSENGER ELECTRIC Operators Manual Page 33 TPCC01DU00EN020 (Edition A)

  • Page 36: Introduction

    Battery Charger Battery Charger Hazard Statements A BATTERY CHARGER, CORD, PLUG, OR VEHICLE CHARGER DANGER RECEPTACLE THAT HAS DAMAGE OR A BAD ELECTRICAL CONNECTION CAN CAUSE A FIRE, PROPERTY DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH. DO NOT CONNECT THE DAMAGED BATTERY CHARGER TO AN AC POWER SOURCE.

  • Page 37: Eric Ic650 Specifications

    Battery Charger ERIC IC650 Specifications • 93.5% peak, California Energy Commission compliant. • 7.5 maximum AC amperage that lets two chargers operate on one 20- amp circuit. EFFICIENT • Automatically checks and charges the batteries. Lets the charger to be connected to the vehicle during extended storage.

  • Page 38: Ac Input

    Battery Charger Governmental And Industry Certifications AC INPUT 85 to 270 VAC minimum/maximum Voltage 100 to 240 VAC maximum efficiency range Current 7.5 A maximum Frequency 50 to 60 Hz DC OUTPUT 48 VDC nominal Voltage 72 VDC maximum Current 13.5 A maximum GOVERNMENTAL AND INDUSTRY CERTIFICATIONS EUROPEAN CONFORMITY...

  • Page 39: Underwriters Laboratories And Canadian Standards Association

    Battery Charger Features UNDERWRITERS LABORATORIES AND CANADIAN STANDARDS ASSOCIATION Listed by Underwriters Laboratories (UL) and Canadian Underwriters. Meets the criteria of the Canadian Standards Association (CSA). FEATURES AC ELECTRICAL CORD AND PLUG The AC electric cord has an equipment-grounding conductor and grounding type plug. The AC plug must be connected to a correctly rated ground fault circuit interrupter (GFCI) receptacle with arc flash protection.
  • Page 40 Battery Charger Features SYMBOL STATUS CONDITION Charger fault condition. See the display panel for more (Constant) information. External fault condition. See Orange the display panel for more (Flash On And Off) information. The USB receptacle is on. Do Green not remove the USB flash (Flash On And Off) drive.

  • Page 41: Battery Charging Interlock

    Battery Charger Features SYMBOL STATUS CONDITION Yellow The charger output is on. There (Constant) is a risk of electric shock. Internal fault condition caused the charge process to stop. F code Speak with your dealer or Display Panel distributor. External fault condition caused the charge process to stop.

  • Page 42: How To Make Strain Relief And Drip Loop

    Battery Charger Inspection And Maintenance A strain relief and drip loop is necessary to prevent damage to the charger. The strain relief prevents tension on the AC plug. The drip loop prevents water damage to the AC plug. HOW TO MAKE STRAIN RELIEF AND DRIP LOOP Connect the AC cord (1) into the AC plug.

  • Page 43: Clean The Electrical Plugs And Receptacles

    Battery Charger Inspection And Maintenance • Corrosion • Cracks • Loose connections • Missing pins • Worn pins CLEAN THE ELECTRICAL PLUGS AND RECEPTACLES LUBRICATING THE PLUG AND RECEPTACLE WITH THE AC CORD DANGER CONNECTED TO A POWER SOURCE CAN CAUSE PROPERTY DAMAGE, ELECTRICAL SHOCK, SERIOUS PERSONAL INJURY, AND DEATH.
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  • Page 45: Section 6 - Vehicle Specifications

    Vehicle Specifications Inspection And Maintenance VEHICLE SPECIFICATIONS ONWARD HP NON-LIFTED 4-PASSENGER ELECTRIC Operators Manual Page 43 TPCC01DU00EN020 (Edition A)

  • Page 46: Dimensions

    Vehicle Specifications Dimensions DIMENSIONS 108 in (274.3 cm) Length 48.75 in (123.8 cm) Width 47.5 in (120.6 cm) - at steering wheel Height 76 in (193 cm) - with canopy 4.5 in (11 cm) Ground Clearance 36 in (91.4 cm) - front wheel Wheel Tread 40 in (101.6 cm) - rear wheel 65.5 in (166 cm)

  • Page 47: Noise And Vibration

    Vehicle Specifications Noise And Vibration NOISE AND VIBRATION Drive-by Noise Level To Operator 68.4 dBA (±2) (EN 12053–2001) Vibration At Driver’s Seat 0.8 (m/s²)² (±0.04) (EN 13059–2002) TRANSAXLE Fluid Capacity 22 fl-oz (0.67 l) VEHICLE WEIGHTS AND LOAD CAPACITIES IF THE RATED CAPACITIES OF THE VEHICLE ARE EXCEEDED, WARNING PROPERTY DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH CAN OCCUR.
  • Page 48 Vehicle Specifications Vehicle Weights And Load Capacities TERM DEFINITION Vehicle Dry Weight The vehicle dry weight is the weight of the vehicle with no batteries. Vehicle Curb The vehicle curb weight is the weight of the vehicle with the batteries installed. Weight Maximum The occupant capacity is the maximum permitted weight of occupants to...

  • Page 49: Section 7 - Vehicle Operation

    Vehicle Operation Vehicle Weights And Load Capacities VEHICLE OPERATION ONWARD HP NON-LIFTED 4-PASSENGER ELECTRIC Page 47 Operators Manual TPCC01DU00EN020 (Edition A)
  • Page 50 Vehicle Operation Vehicle Operations Hazard Statements OPERATING THE VEHICLE WHILE OCCUPANTS ARE NOT FULLY DANGER SEATED CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH. START THE VEHICLE ONLY WHEN ALL OCCUPANTS ARE FULLY SEATED. FALLING OBJECTS CAN CAUSE PROPERTY DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH.

  • Page 51: Daily Pre-Operational Safety And Performance Checks

    Vehicle Operation Daily Pre-Operational Safety And Performance Checks THE VEHICLE IS NOT DESIGNED TO MEET CHILD SAFETY SEAT COMPATIBILITY REQUIREMENTS. CHILDREN REQUIRING A CHILD SAFETY SEAT MUST NOT RIDE ON THE VEHICLE. COMPLY WITH STATE AND LOCAL LAWS PERTAINING TO CHILD SAFETY. THIS VEHICLE IS NOT INTENDED FOR USE BY PERSONS, INCLUDING CHILDREN, WITH REDUCED PHYSICAL, SENSORY OR MENTAL CAPABILITIES, OR LACK OF EXPERIENCE AND...

  • Page 52: Daily Pre-Operational Safety Checklist

    Vehicle Operation Daily Pre-Operational Safety And Performance Checks DAILY PRE-OPERATIONAL SAFETY CHECKLIST INSPECTION INSPECTION CRITERIA AREA • Make sure that all parts are correctly installed. • Make sure that all nuts, bolts, and screws are tight. General • Replace missing, worn, or damaged items. •...
  • Page 53 Vehicle Operation Daily Pre-Operational Safety And Performance Checks • Understand the function of all vehicle controls, indicators, displays, and gauges. • Front wheels are turned in the direction of travel. • No obstructions are in the vehicle’s path. During the vehicle performance inspection: •...

  • Page 54: Vehicle Movement

    Vehicle Operation Vehicle Movement Park the vehicle on a grade of 20% or less. Make sure that the park brake holds the vehicles position. Slowly push the accelerator pedal. Increase the vehicle to maximum speed down a grade of 20% or less.

  • Page 55: Forward Movement

    Vehicle Operation Vehicle Movement Push and hold the brake pedal. Set the Forward / Neutral / Reverse control (FNR) to N. Turn the key to OFF. Engage the park brake to lock the wheels. Remove the key. Keep the key in a safe area. FORWARD MOVEMENT FAILURE TO DECREASE THE VEHICLE SPEED IN BAD DRIVING WARNING...

  • Page 56: Slow Or Stop The Vehicle

    Vehicle Operation Driving Conditions • Make sure that all passengers are seated with seat belts fastened (if equipped) and use the hand holds or handrails. The operator must have both hands on the steering wheel. • Make sure that the front wheels are turned in the direction of travel. •...

  • Page 57: Side Hill Slope

    Vehicle Operation Driving Conditions VEHICLE ROLLBACK WHEN STARTING ON AN INCLINE CAN CAUSE PROPERTY DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH. USE THE BRAKE PEDAL TO HOLD THE VEHICLE UNTIL THE DRIVETRAIN IS FULLY ENGAGED. Precautions when on an uphill slope: •...

  • Page 58: Over Obstacles

    Vehicle Operation Driving Conditions TO PREVENT ROLL-OVER, OPERATE THE VEHICLE SLOWLY STRAIGHT UP AND DOWN SLOPES. DO NOT OPERATE THE VEHICLE ON SLOPES THAT ARE MORE THAN A 20% GRADE. USE THE BRAKE PEDAL TO CONTROL THE VEHICLE SPEED WHEN DRIVING DOWN A SLOPE.

  • Page 59: Night Time

    Vehicle Operation Driving Conditions • Drive slowly and use caution when operating on unfamiliar terrain. Not all obstacles are immediately visible. NIGHT TIME OPERATING THE VEHICLE AT NIGHT WITHOUT THE CORRECT DANGER EQUIPMENT CAN CAUSE PROPERTY DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH. TO OPERATE THE VEHICLE AT NIGHT, THE VEHICLE MUST HAVE HEADLIGHTS, TAILLIGHTS, AND REFLECTORS.
  • Page 60 Vehicle Operation Driving Conditions Hauling cargo incorrectly can change the vehicles handling and may cause loss of control or brake instability, which can cause serious injury or death. Precautions when operating with cargo: • Always read and understand the load distribution warnings listed on the safety labels. The total load (operator, passenger, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle.

  • Page 61: Section 8 - Vehicle Maintenance

    Vehicle Maintenance Driving Conditions VEHICLE MAINTENANCE ONWARD HP NON-LIFTED 4-PASSENGER ELECTRIC Operators Manual Page 59 TPCC01DU00EN020 (Edition A)

  • Page 62: Disable The Vehicle

    Vehicle Maintenance Vehicle Maintenance Hazard Statements A WHEEL OR TIRE THAT HAS DAMAGE CAN CAUSE PROPERTY DANGER DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH. DO NOT TRY TO REPAIR A WHEEL OR TIRE. SPEAK WITH YOUR LOCAL DEALER OR DISTRIBUTOR FOR REPAIRS. UNINTENDED VEHICLE OPERATION CAN CAUSE SERIOUS WARNING PERSONAL INJURY OR DEATH.

  • Page 63: Vehicle Cleaning

    Vehicle Maintenance Vehicle Cleaning Park the vehicle on a solid level surface. Engage the park brake to prevent vehicle movement. Turn the key to OFF. Remove the key. Set the Forward / Neutral / Reverse control (FNR) to N. Put the chocks against the wheels. VEHICLE CLEANING CLEANING THE WINDSHIELD Use a soft towel and water to clean the windshield.

  • Page 64: Service Schedule

    Vehicle Maintenance Maintenance Schedule If a vehicle is found to be in bad operational condition, remove it from operation. Removal from operation will prevent more damage to the vehicle and prevent the possible injury because of dangerous conditions. Speak with your dealer or distributor for maintenance and repairs. MAINTENANCE SERVICE SCHEDULE Note: The Maintenance Service Schedule must be done more frequently on vehicles that are...

  • Page 65: Maintenance Tasks

    Vehicle Maintenance Maintenance Tasks INTERVAL DESCRIPTION Use WD-40 ® to lubricate the battery charger receptacle. Have a trained technician: • examine and lubricate the brake system 50 hours / 6 months • examine the electrical system • examine the front wheel alignment •...
  • Page 66 Vehicle Maintenance Maintenance Tasks Place the jack in the center of the lift point. Lift the front of the vehicle. Put jack stands under the frame rails. Lower the vehicle onto the jack stands. LIFT THE REAR OF THE VEHICLE LIFTING THE VEHICLE WITH CARGO CAN CAUSE PROPERTY WARNING DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH.

  • Page 67: Lower The Vehicle

    Vehicle Maintenance Maintenance Tasks Place the jack in the center of the lift point. Lift the rear of the vehicle. Put jack stands under the frame rails. Lower the vehicle onto the jack stands. LOWER THE VEHICLE LOWER THE FRONT OF THE VEHICLE Before the front of the vehicle is lowered: •...
  • Page 68 Vehicle Maintenance Maintenance Tasks To lower the front of the vehicle: Place the jack in the center of the lift point. Lift the vehicle off of the jack stands. Remove the jack stands. Lower the vehicle. LOWER THE REAR OF THE VEHICLE Before the rear of the vehicle is lowered: •...

  • Page 69: Tire Pressure Measurement

    Vehicle Maintenance Maintenance Tasks To lower the rear of the vehicle: Place the jack in the center of the lift point. Lift the vehicle off of the jack stands. Remove the jack stands. Lower the vehicle. TIRE PRESSURE MEASUREMENT Before the tire pressure measurement: •...
  • Page 70 Vehicle Maintenance Maintenance Tasks • Disable the vehicle. To remove the wheel assembly: Remove the wheel cover. Loosen the lug nuts. Lift the vehicle to allow for removal of the wheel assembly. Remove the lug nuts. Remove the wheel assembly. WHEEL ASSEMBLY INSTALLATION Before wheel assembly installation: •...

  • Page 71: Section 9 - Battery Maintenance

    Battery Maintenance Maintenance Tasks 316V BATTERY MAINTENANCE ONWARD HP NON-LIFTED 4-PASSENGER ELECTRIC Operators Manual Page 69 TPCC01DU00EN020 (Edition A)

  • Page 72: Battery Cleaning

    Battery Maintenance Battery Maintenance Hazard Statements WATER MAY BOIL OVER AND LEAK BATTERY ACID AND CAUSE CAUTION PERSONAL INJURY OR PROPERTY DAMAGE. CHARGE THE BATTERIES BEFORE WATER IS ADDED. LEAD-ACID BATTERIES CONTAIN DANGEROUS MATERIALS THAT CAN CONTAMINATE THE WATER AND SOIL, CAUSE ENVIRONMENTAL DAMAGE, CAUSE PROPERTY DAMAGE, AND CAUSE SERIOUS PERSONAL INJURY.
  • Page 73 Battery Maintenance Battery Charging THE BATTERY CHARGER BECOMES HOT WHEN IT IS ON AND CAN WARNING CAUSE A FIRE, PROPERTY DAMAGE, OR SERIOUS PERSONAL INJURY. DO NOT COVER THE BATTERY CHARGER. DO NOT TOUCH. MAKE SURE THAT THE BATTERY CHARGER HAS ADEQUATE AIRFLOW.

  • Page 74: Charging With Onboard Charger

    Battery Maintenance Battery Charging IF THE DC CORD IS REMOVED TOO FAST, ARCING AND BURNING DANGER CAN CAUSE DAMAGE TO THE PLUG, RECEPTACLE, AND CAUSE THE BATTERIES TO EXPLODE. REMOVE THE DC CORD SLOW. Before vehicle operation, disconnect the DC cord from the vehicle charger receptacle. CHARGING WITH ONBOARD CHARGER CHARGING LEAD-ACID BATTERIES EMIT HYDROGEN GAS, THAT DANGER...

  • Page 75: Battery Electrical Connection

    Battery Maintenance Battery Electrical Connection Connect the AC cord (1) to the power source. Note: The vehicle will start to charge in 2 to 10 seconds. When the vehicle starts to charge: • ON CHG will show on the dash display. •...

  • Page 76: Connect

    Battery Maintenance Battery Electrical Connection Disconnect the negative (-) cable (1). Disconnect the positive (+) cable (2). Wait 90 seconds for the controller capacitors to discharge. CONNECT THE BATTERIES BATTERIES DISCONNECTED OR CONNECTED WITH THE RUN/ DANGER TOW SWITCH SET TO RUN CAN CAUSE A BATTERY EXPLOSION AND SERIOUS PERSONAL INJURY.

  • Page 77: Battery Hold-Down

    Battery Maintenance Battery Hold-Down Connect the positive (+) cable (2). Connect the negative (-) cable (1). LOOSE BATTERY WIRES CAN CAUSE A FIRE, PROPERTY DAMAGE, WARNING OR SERIOUS PERSONAL INJURY. MAKE SURE THAT ALL BATTERY WIRES AND TERMINALS ARE CLEAN AND TIGHTENED CORRECTLY.
  • Page 78 Battery Maintenance Add Water To A Battery Without Single Point Watering System Unlock and remove the cap (1). Make sure that the battery acid (2) is level with or above the top of the plates (3). If the battery acid is level with or above the top of the plates: Install and lock the cap.

  • Page 79: Deionizer

    Water purity is one of the more important factors in the performance and life of the vehicle batteries. Club Car has put an increased importance on water purity and battery maintenance. Club Car recommends the use of distilled water or a deionizer because of the cost of water testing and fluctuations in the daily changes to water quality.

  • Page 80: Preferred Sources

    The selection of membranes and usage frequency determines the quantity of solids or impurities which get caught and hence the purity quality of the filtered water. Because of the variance in water quality consistency, Club Car recommends the use of the deionizer or distilled water. TAP WATER Because of the levels of dissolved minerals and chemicals that can degrade battery performance and life the use of tap water without filtering should be limited.
  • Page 81 Battery Maintenance Water Quality PERMITTED CONTENT (PARTS IMPURITY IMPURITY EFFECTS PER MILLION) Increased self-discharge and lower on-charge voltage Iron Magnesium 40.0 Decreased life Intense lowering of on-charge voltage Nickel None allowed Increased sulfation of negative plate Nitrates 10.0 Plate corrosion, loss of capacity, and decreased life Nitrites Violent self-discharge and lower on-charge voltage Platinum...
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  • Page 83: Section 10 - Transport And Tow

    Transport And Tow Water Quality TRANSPORT AND TOW ONWARD HP NON-LIFTED 4-PASSENGER ELECTRIC Operators Manual Page 81 TPCC01DU00EN020 (Edition A)

  • Page 84: Prepare The Vehicle To Be Towed

    TOWING A TRAILER OR VEHICLE. Use only a Club Car approved tow kit. Prepare the vehicle to be towed. Use a Club Car approved tow kit to tow the vehicle. Tow the trailer or vehicle under 5 mph (8 kmh). VEHICLE TRANSPORT PREPARATION...

  • Page 85: Vehicle Transport Recovery

    Transport And Tow Vehicle Transport Recovery Set the park brake. Set the Forward / Neutral / Reverse control (FNR) to N. Turn the key to OFF. Remove the key. Keep the key in a safe area. Set the Run/Tow switch to TOW. Remove all cargo from the vehicle.
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  • Page 87: Section 11 - Extended Storage

    Extended Storage Vehicle Transport Recovery EXTENDED STORAGE ONWARD HP NON-LIFTED 4-PASSENGER ELECTRIC Operators Manual Page 85 TPCC01DU00EN020 (Edition A)

  • Page 88: Extended Storage Preparation

    Extended Storage Extended Storage Hazard Statements FROZEN BATTERY ACID CAN CAUSE DAMAGE INCLUDING LEAKS WARNING AND EXPLOSIONS. IF THE BATTERY ACID FREEZES, REPLACE THE BATTERY BEFORE CHARGING OR USE. BATTERIES IN A LOW STATE OF CHARGE WILL FREEZE AT LOW TEMPERATURES. KEEP THE BATTERIES IN A HIGH STATE OF CHARGE.

  • Page 89: Return To Service From Extended Storage

    Extended Storage Return To Service From Extended Storage If all conditions shown can be done while in storage, do as follows: • The battery charger must stay connected to an electric outlet • AC electrical power will be available during storage •...
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  • Page 91: Section 12 - Warranties

    Warranties Return To Service From Extended Storage WARRANTIES ONWARD HP NON-LIFTED 4-PASSENGER ELECTRIC Operators Manual Page 89 TPCC01DU00EN020 (Edition A)

  • Page 92: Limited Warranty

    Club Car will provide only the replacement parts or components. If the warranty registration form is not completed and returned to Club Car at the time of the original retail sale, the Purchaser must provide proof of date of purchase with any warranty claim.

  • Page 93: Exclusions

    EXCLUSIONS Excluded from any Club Car warranty is damage to a vehicle or component resulting from a cause other than a defect including poor maintenance, neglect, abuse, accident and collision, maintenance adjustments, unreasonable or unintended strain or use, improper installation of accessories, installation of parts or accessories that are not original equipment including Club Car approved or non- approved GPS systems, non-approved alteration, and acts of God.

  • Page 94: Voiding Of Warranty

    Purchaser. Club Car makes no other representation or warranty of any kind, and no representative, employee, distributor or dealer of Club Car has the authority to make or imply any representation, promise or agreement, which in any way varies the terms of this warranty.

  • Page 95: How To Make A Warranty Claim

    To make a warranty claim under this limited warranty, you must present the vehicle or defective component with evidence of proof of purchase date and number of amp hours (if applicable) to an authorized Club Car dealer. For warranty-related communication, contact: E-mail cci_warrantyadministration@clubcar.com...
  • Page 96 Publication Part Number TPCC01DU00EN020 Edition Code Club Car, LLC www.clubcar.com Phone 1 706 258 2225 P.O. Box 204658 1 800 ClubCar Augusta, GA 30917-4658 1 706 863 5858...

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