Club Car ONWARD 4 PASSENGER LIFTED GASOLINE, Operator'S Manual

Page 1: ...ONWARD 4 PASSENGER LIFTED GASOLINE Operators Manual APPLICABLE TO ONWARD 4 PASSENGER LIFTED ECH440 GASOLINE VEHICLES WITH SERIAL PREFIX OF BW...

Page 2: ...Copyright 2020 Club Car LLC This manual effective July 1 2020...

Page 3: ...st include this manual with the vehicle when sold to a new owner Registration of the vehicle will make sure Club Car is able to communicate necessary information directly to owners Send your name addr...

Page 4: ...cardealer com Scan the dealer locator Quick Response QR code COMPANY CONTACT INFORMATION Send written correspondence to Club Car LLC Attention Marketing Services P O Box 204658 Augusta Georgia 30917 4...

Page 5: ...ECTRICAL SYSTEM STABILITY OR HANDLING OF THE VEHICLE OR INCREASES THE MAXIMUM VEHICLE SPEED CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH CAUTION THE FUEL SYSTEM AND ENGINE ON YOUR VEHICLE ARE DESIGNED A...

Page 6: ...e before it was delivered to you The dealer or distributor will also supply you a copy of the completed vehicle warranty registration form GOVERNMENTAL AND INDUSTRY STANDARDS AMERICAN NATIONAL STANDAR...

Page 7: ...INDICATORS GAUGES AND DISPLAYS 19 Indicator Gauge And Display Locations 20 Fuel Gauge Hour Meter 20 Low Oil Warning Light 20 Malfunction Indicator Light 21 SECTION 3 VEHICLE CONTROLS 23 Vehicle Contro...

Page 8: ...me 45 Through Water 45 With Cargo 46 SECTION 7 VEHICLE MAINTENANCE 47 Disable The Vehicle 49 Vehicle Cleaning 49 Windshield 49 Vehicle Exterior 49 Vehicle Interior 49 Maintenance Schedule 50 Overview...

Page 9: ...e A Warranty Claim 81 Federal Emissions Component Defect Warranty 81 Warranty Coverage 81 Warranty Period 81 Parts Covered 81 Distribution Center 82 Warranty Service 82 What Is Not Covered 83 Owner s...

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Page 11: ...1 SAFETY INFORMATION ONWARD 4 PASSENGER LIFTED GASOLINE Operators Manual TPCC01BW00EN019 Edition B Page 9 Safety Information Notices 1...

Page 12: ...arts can cause serious injury Keep body hands hair and clothes away from rotating parts Hot surfaces can cause serious burns Allow to cool before servicing Signal words DANGER WARNING CAUTION and NOTI...

Page 13: ...fety committee is safe vehicle operation Safety committee objectives include Approve vehicle operation areas Identify all hazards Identify who is approved to operate the vehicle Keep the vehicles in a...

Page 14: ...LET PEOPLE RIDE ON ANY PART OF THE VEHICLE THAT IS NOT EQUIPPED WITH A SEAT DO NOT LET A PASSENGER HOLD A CHILD IN HIS OR HER LAP WHILE THE VEHICLE MOVES ONLY TRAINED TECHNICIANS SHOULD SERVICE OR REP...

Page 15: ...et the FNR control to NEUTRAL N Turn the key to OFF and remove key UNINTENDED VEHICLE MOVEMENT CAN CAUSE SERIOUS INJURY OR DEATH Ensure wheels are turned in desired direction of travek and path is cle...

Page 16: ...des traffic Do not start the vehicle until all occupants are fully seated Two 2 persons per bench seat maximum Operate the vehicle from the driver side only Remain fully seated while moving Do not lea...

Page 17: ...vernor adjustment 9 Rotating Parts Hot Manifold Warning Decal 10 Gas Governor Warning Decal MAXIMUM TONGUE WEIGHT 150 lb 68 kg NOTICE 101155301 WARNING ROTATING PARTS AND BURN RISK Rotating parts can...

Page 18: ...FACE SHIELD AND RUBBER GLOVES WHEN SERVICING A BATTERY ANTIDOTES EXTERNAL FLUSH WITH WATER CALL A PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOWED WITH MILK OF MAGNESIA...

Page 19: ...smoke No open flames No sparks Keep away from children Explosive gas hazard LEAD ACID BATTERY RECYCLING WARNING LEAD ACID BATTERIES CONTAIN DANGEROUS MATERIALS THAT CAN CONTAMINATE THE WATER AND SOIL...

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Page 21: ...2 INDICATORS GAUGES AND DISPLAYS ONWARD 4 PASSENGER LIFTED GASOLINE Operators Manual TPCC01BW00EN019 Edition B Page 19 Indicators Gauges And Displays Battery Safety Information 2...

Page 22: ...is set to ON The hour meter operates when the engine is on The hour meter should be used by approved technicians to monitor vehicle use as well as determine when periodic inspections and maintenance a...

Page 23: ...f the low oil level warning light stays on have a trained technician examine the vehicle MALFUNCTION INDICATOR LIGHT The Malfunction Indicator Light MIL gives a visual indication of an engine fault co...

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Page 25: ...3 VEHICLE CONTROLS ONWARD 4 PASSENGER LIFTED GASOLINE Operators Manual TPCC01BW00EN019 Edition B Page 23 Vehicle Controls Malfunction Indicator Light 3...

Page 26: ...Page 24 ONWARD 4 PASSENGER LIFTED GASOLINE Operators Manual TPCC01BW00EN019 Edition B VEHICLE CONTROLS LOCATOR 3 Vehicle Controls Vehicle Controls Locator...

Page 27: ...ICLE BEFORE SHIFTING THE FORWARD NEUTRAL REVERSE CONTROL FNR CAN CAUSE PROPERTY DAMAGE AND SERIOUS PERSONAL INJURY STOP THE VEHICLE BEFORE SHIFTING THE FORWARD NEUTRAL REVERSE CONTROL FNR The Forward...

Page 28: ...ITCH The key switch controls the engine 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 is set to OFF Vehicles with th...

Page 29: ...rained technician for maintenance functions PARK BRAKE WARNING FAILURE TO ENGAGE THE PARK BRAKE CAN CAUSE PROPERTY DAMAGE AND SERIOUS PERSONAL INJURY AFTER THE VEHICLE STOPS ENGAGE THE PARK BRAKE UNTI...

Page 30: ...anual TPCC01BW00EN019 Edition B TURN SIGNAL LEVER The turn signal lever controls the operation of the turn signal lights The turn signal light will flash when turned on POSITION FUNCTION Down Left Cen...

Page 31: ...4 VEHICLE FEATURES ONWARD 4 PASSENGER LIFTED GASOLINE Operators Manual TPCC01BW00EN019 Edition B Page 29 Vehicle Features Turn Signal Lever 4...

Page 32: ...ers 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 The USB rece...

Page 33: ...5 VEHICLE SPECIFICATIONS ONWARD 4 PASSENGER LIFTED GASOLINE Operators Manual TPCC01BW00EN019 Edition B Page 31 Vehicle Specifications USB Receptacle 5...

Page 34: ...ng Radius SAE J695 Unknown At Time Of Print Intersecting Aisle Clearance Unknown At Time Of Print Curb To Curb Unknown At Time Of Print Wall To Wall Unknown At Time Of Print Outside Clearance Circle D...

Page 35: ...JURY OR DEATH CAN OCCUR DO NOT EXCEED THE RATED CAPACITY OF THE VEHICLE RATED CAPACITY IS FOR LEVEL SURFACES ONLY TOO MUCH WEIGHT IN THE VEHICLE CAN AFFECT THE VEHICLES HANDLING OR CAUSE COMPONENT FAI...

Page 36: ...tional equipment Maximum Trailer Tongue Weight The trailer tongue weight is the maximum permitted weight applied by the trailer tongue onto the trailer hitch Maximum Gross Trailer Weight The gross tra...

Page 37: ...6 VEHICLE OPERATION ONWARD 4 PASSENGER LIFTED GASOLINE Operators Manual TPCC01BW00EN019 Edition B Page 35 Vehicle Operation Vehicle Weights And Load Capacities 6...

Page 38: ...Y DAMAGE SERIOUS PERSONAL INJURY OR DEATH IF PROBLEMS ARE FOUND DURING SCHEDULED INSPECTION OR SERVICE OPERATE THE VEHICLE ONLY WHEN REPAIRS ARE MADE MAKE SURE THAT ALL PASSENGERS CAN SECURE THEMSELVE...

Page 39: ...CLE ONLY FROM THE DRIVERS SEAT OPERATE THE VEHICLE ONLY IN SPECIFIED AREAS ONLY AN AUTHORIZED LICENSED DRIVER CAN OPERATE THE VEHICLE ONLY OPERATE THE VEHICLE IN COMPLIANCE WITH LOCAL AND STATE LAWS U...

Page 40: ...hat the battery cables are correctly attached Tighten as necessary Examine the battery posts for corrosion If corrosion is found remove the corrosion Engine Oil Examine the oil level Add oil as necess...

Page 41: ...rained technician do a brake system check if The vehicle swerves The brake pedal goes more than half the distance to the floorboard with moderate pressure applied The vehicle does not stop To do the v...

Page 42: ...ITHOUT CORRECT VENTILATION WARNING MOVING PARTS CAN CRUSH AND CUT KEEP CLEAR OF THE ENGINE COMPARTMENT WHILE THE ENGINE IS ON NOTICE TRYING TO START THE VEHICLE AGAIN AND AGAIN WITH AN EMPTY FUEL TANK...

Page 43: ...information located on the vehicle Understand how to operate the vehicle correctly and safely Understand the function of all vehicle controls indicators displays and gauges Make sure that all passeng...

Page 44: ...vehicle in reverse 1 Set the Forward Neutral Reverse control FNR to R Make sure that the multi purpose buzzer operates 2 Disengage the park brake 3 Slowly push the accelerator pedal SLOW OR STOP THE...

Page 45: ...o one side Continue at a stable rate of speed Do not accelerate quickly Do not stop a vehicle with a load on a slope If a vehicle with a load must stop on a slope prevent backwards movement or sudden...

Page 46: ...ownhill slope Prevent driving on slopes that exceed 20 grade Always examine the terrain carefully before driving on a slope Do not drive on a slope with slippery or loose surfaces Keep the heavy end o...

Page 47: ...peration at night is not recommended When driving at night is unavoidable the vehicle must have Headlights Taillights Reflectors Precautions if driving at night is unavoidable Always have headlights o...

Page 48: ...h the load as far forward and as low as possible Always operate the vehicle with extreme caution when hauling or towing loads Secure all loads before operating Unsecured loads can cause unstable opera...

Page 49: ...7 VEHICLE MAINTENANCE ONWARD 4 PASSENGER LIFTED GASOLINE Operators Manual TPCC01BW00EN019 Edition B Page 47 Vehicle Maintenance Driving Conditions 7...

Page 50: ...CLE ONLY WHEN REPAIRS ARE MADE A HOT ENGINE AND EXHAUST SYSTEM WILL CAUSE SERIOUS BURNS DO NOT TOUCH A HOT ENGINE OR EXHAUST BEFORE SERVICING LET THE ENGINE AND EXHAUST SYSTEM COOL MOVING PARTS CAN CR...

Page 51: ...ild soap as necessary Do not use a household window cleaner CLEANING THE VEHICLE EXTERIOR NOTICE MOISTURE CAN CAUSE ELECTRICAL COMPONENT DAMAGE DO NOT USE A PRESSURE WASHER OR STEAM CLEANER TO CLEAN T...

Page 52: ...tion 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 m...

Page 53: ...e system lubricate the shift cable pivots lubricate the front suspension 100 hours 12 months Have a trained technician examine the spark plug pedal components transaxle fluid vehicle top speed safety...

Page 54: ...ll the air filter 3 3 Install the air cleaner cover 2 ENGINE OIL ENGINE OIL VISCOSITY Select the engine oil viscosity for your environmental conditions ENGINE OIL LEVEL INSPECTION Before the engine oi...

Page 55: ...s 11 If the oil level is below the minimum indicator add engine oil 12 Install the dipstick Note Make sure that the arrow points towards the engine ENGINE OIL REPLACEMENT CAUTION HOT ENGINE OIL WILL C...

Page 56: ...a around the oil drain plug 2 3 Put a drain pan below the oil drain plug 4 Remove the oil drain plug 5 Drain the oil fully 6 Clean the oil drain plug 7 Examine the gasket on the oil drain plug for dam...

Page 57: ...ealer or distributor to get more information on how to recycle the used engine oil correctly ADD ENGINE OIL CAUTION DO NOT REMOVE THE DIPSTICK WHILE THE ENGINE IS ON NOTICE TOO MUCH ENGINE OIL CAN DEC...

Page 58: ...ANGER FUEL IS FLAMMABLE AND EXPLOSIVE DO NOT ADD FUEL WITH THE KEY SWITCH SET TO ON BEFORE FUEL IS ADDED TURN THE KEY SWITCH TO OFF FUEL IS FLAMMABLE AND EXPLOSIVE DO NOT FILL THE FUEL TANK WHEN THE E...

Page 59: ...NG DEVICE MUST BE GROUNDED IF THE PUMP IS NOT GROUNDED THE VEHICLE MUST BE GROUNDED TO THE PUMP BEFORE AND DURING THE FUELING OPERATION NOTICE A FUEL WITH AN ALCOHOL CONTENT THAT EXCEEDS 10 BY VOLUME...

Page 60: ...EATH REMOVE ALL CARGO FROM THE CARGO BED BEFORE THE VEHICLE IS LIFTED Before the vehicle is lifted Disable the vehicle Disconnect the battery Use a jack and jack stands rated for the vehicle To lift t...

Page 61: ...Before the vehicle is lifted Disable the vehicle Disconnect the battery Use a jack and jack stands rated for the vehicle To lift the rear of the vehicle 1 Place the jack in the center of the lift poin...

Page 62: ...ront of the vehicle 1 Place the jack in the center of the lift point 2 Lift the vehicle off of the jack stands 3 Remove the jack stands 4 Lower the vehicle LOWER THE REAR OF THE VEHICLE Before the rea...

Page 63: ...hicle 1 Place the jack in the center of the lift point 2 Lift the vehicle off of the jack stands 3 Remove the jack stands 4 Lower the vehicle SPARK PLUG SPARK PLUG REMOVAL Before the spark plug remova...

Page 64: ...hten the spark plug to 20 lb ft 27 N m 3 Connect the spark plug wire 1 4 Connect the battery TIRE PRESSURE MEASUREMENT Before the tire pressure measurement Disable the vehicle To measure the tire pres...

Page 65: ...le the vehicle To install the wheel assembly 1 Lift the vehicle to allow for installation of the wheel assembly 2 Align the wheel assembly onto the hub of the vehicle Note Make sure that the valve ste...

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Page 67: ...316V 8 BATTERY MAINTENANCE ONWARD 4 PASSENGER LIFTED GASOLINE Operators Manual TPCC01BW00EN019 Edition B Page 65 Battery Maintenance Maintenance Tasks 8...

Page 68: ...the battery cables are tight If a battery cable is not tight tighten the hardware to 41 lb in 4 3 N m 6 Let the terminals dry 7 Apply battery terminal protector spray to the terminals BATTERY CHARGIN...

Page 69: ...e 1 2 Disconnect the positive cable 2 CONNECT THE BATTERY 1 Connect the positive cable 2 2 Connect the negative cable 1 WARNING LOOSE BATTERY WIRES CAN CAUSE A FIRE PROPERTY DAMAGE OR SERIOUS PERSONAL...

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Page 71: ...9 TRANSPORT AND TOW ONWARD 4 PASSENGER LIFTED GASOLINE Operators Manual TPCC01BW00EN019 Edition B Page 69 Transport And Tow Battery Electrical Connection 9...

Page 72: ...AKE LIGHTS PREPARE THE VEHICLE TO BE TOWED 1 Turn the key to OFF 2 Remove the key Keep the key in a safe area 3 Set the Forward Neutral Reverse control FNR to N TOWING A TRAILER OR VEHICLE CAUTION USE...

Page 73: ...igned to be towed at speeds over 5 mph If movement over long distances or on public roads is necessary transport the vehicle on a trailer Use a trailer with appropriate load rating 1 Set the park brak...

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Page 75: ...10 EXTENDED STORAGE ONWARD 4 PASSENGER LIFTED GASOLINE Operators Manual TPCC01BW00EN019 Edition B Page 73 Extended Storage Vehicle Transport Recovery 10...

Page 76: ...W TEMPERATURES KEEP THE BATTERIES IN A HIGH STATE OF CHARGE UNINTENDED VEHICLE OPERATION CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH BEFORE LEAVING THE VEHICLE OR DURING VEHICLE MAINTENANCE DISABLE THE...

Page 77: ...le 14 D Turn the engine crankshaft by hand several times 14 E Apply a thin layer of high temperature anti seize lubricant to the spark plug threads 14 F Use a spark plug socket to install and tighten...

Page 78: ...he battery 5 Set the Maintenance Operate switch to MAINTENANCE 6 Start and run the engine Note The engine exhaust may smoke for a short time after returning to service 7 Turn the key to OFF 8 Set the...

Page 79: ...11 WARRANTIES ONWARD 4 PASSENGER LIFTED GASOLINE Operators Manual TPCC01BW00EN019 Edition B Page 77 Warranties Return To Service From Extended Storage 11...

Page 80: ...cy approved by Club Car For repairs made by qualified technicians other than Club Car s factory technicians or an Authorized Dealer or Distributor Club Car will provide only the replacement parts or c...

Page 81: ...hall not apply to failure due to the following conditions Batteries Improper charging of a vehicle due to the use of a battery charger model not approved by Club Car for use with the vehicle Use of an...

Page 82: ...all mean remedying a defect in the vehicle or component thereof at no cost to the purchaser during the applicable limited warranty period Club Car reserves the right to test and recharge any component...

Page 83: ...es Of America Environmental Protection Agency EPA and that the engine is free of defects in materials and workmanship which would cause this engine to fail to conform with EPA regulations during its w...

Page 84: ...ine Fittings Clamps Fuel Tank Fuel Cap Vapor Hoses Carbon Canister Carbon Canister Mounting Brackets Air Cleaner Purge Port Connector DISTRIBUTION CENTER Replacement parts are provided to the market u...

Page 85: ...esponsible for the performance of the required maintenance listed in your operator s manual Club Car recommends that you retain all receipts covering maintenance on your engine but Club Car cannot den...

Page 86: ...nes SORE must be designed built and equipped to meet the State s stringent anti smog standards Club Car must warrant the evaporative emission control system on your vehicle engine for the period liste...

Page 87: ...the written instructions supplied is warranted for the warranty period stated above Any such part repaired or replaced under warranty will be warranted for the remaining original warranty period 3 An...

Page 88: ...neglected or improperly maintained and that such abuse neglect or improper maintenance was the direct cause of the need for repair or replacement of the part That notwithstanding any adjustment of a c...

Page 89: ...ors Manual TPCC01BW00EN019 Edition B Page 87 Valves hosing tubing fittings seals gaskets clamps and fittings as they relate to the evaporative emissions control system Warranties California Evaporativ...

Page 90: ...Publication Part Number TPCC01BW00EN019 Edition Code B Club Car LLC P O Box 204658 Augusta GA 30917 4658 USA Web Phone Fax www clubcar com 1 706 258 2225 1 800 ClubCar 1 706 863 5858...