Club Car Onward 4 Passenger, Operator'S Manual

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: ...must 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 a...

Page 4: ...ubcardealer 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...

Page 5: ...ICLE THAT AFFECT THE OCCUPANT RETENTION ELECTRICAL SYSTEM STABILITY OR HANDLING OF THE VEHICLE OR INCREASES THE MAXIMUM VEHICLE SPEED CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH NOTICE MODIFICATIONS TO...

Page 6: ...sport people and cargo on improved or groomed surfaces CANADIAN STANDARD ICES 002 This vehicle complies with CAN ICES 2 NMB 2 as it was on the date the vehicle was shipped from the Club Car manufactur...

Page 7: ...ols 17 Lead Acid Battery Recycling 17 SECTION 2 INDICATORS GAUGES AND DISPLAYS 19 Indicator Gauge And Display Locations 20 Dash Display 20 SECTION 3 VEHICLE CONTROLS 25 Vehicle Controls Locator 26 Acc...

Page 8: ...EHICLE SPECIFICATIONS 43 Dimensions 44 Performance 44 Tires 44 Electric Motor 44 Batteries 44 Noise And Vibration 45 Transaxle 45 Vehicle Weights And Load Capacities 45 SECTION 7 VEHICLE OPERATION 47...

Page 9: ...Point Watering System 75 Deionizer 77 Add Water To Batteries With Single Point Watering System 77 Watering Intervals 77 Water Quality 77 Overview 77 Preferred Sources 78 Alternate Sources 78 Water Imp...

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Page 11: ...1 SAFETY INFORMATION ONWARD HP NON LIFTED 4 PASSENGER ELECTRIC Operators Manual TPCC01DU00EN020 Edition A Page 9 Safety Information Notices 1...

Page 12: ...aler or distributor Know and understand all laws and regulations for vehicle operation in your area Speak with your dealer or distributor if you have questions about material contained in this manual...

Page 13: ...NSTRUCTIONS IN THIS MANUAL CAN CAUSE PROPERTY DAMAGE SERIOUS PERSONAL INJURY OR DEATH BEFORE YOU OPERATE THE VEHICLE OR DO THE SERVICING OF THE VEHICLE READ AND FULLY UNDERSTAND THE OWNER S MANUAL CLU...

Page 14: ...ICAL AND MECHANICAL REPAIR THE APPROPRIATE INSTRUCTIONS MUST BE USED WHEN PERFORMING MAINTENANCE SERVICE OR ACCESSORY INSTALLATION VEHICLE SAFETY AND COMPLIANCE DECALS WARNING MAKE SURE ALL OF THE SAF...

Page 15: ...Maximum Load 800 lb 360 kg Maximum Grade 20 Vehicle to be operated by licensed or authorized persons only Only operate vehicle in compliance with local and state laws Use caution when operating vehicl...

Page 16: ...T DAMAGE Battery acid can damage the fuse block cover MAXIMUM TONGUE WEIGHT 150 lb 68 kg NOTICE 101155301 9 Fuse Block Notice Decal 10 Trailer Hitch Notice Decal WARNING STAYCLEAR 101609401 CRUSHAREA...

Page 17: ...ge when the AC cord is connected to a power source The vehicle will not operate when the AC cord is connected MULTI PURPOSE BUZZER The vehicle comes equipped with a multi purpose buzzer The multi purp...

Page 18: ...e multi purpose buzzer will make an audible tone when the walk away braking safety device engages for more than two seconds BATTERY SAFETY INFORMATION DANGER BATTERY ACID CAN CAUSE SERIOUS BURNS PREVE...

Page 19: ...not 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 S...

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Page 21: ...2 INDICATORS GAUGES AND DISPLAYS ONWARD HP NON LIFTED 4 PASSENGER ELECTRIC Operators Manual TPCC01DU00EN020 Edition A Page 19 Indicators Gauges And Displays Battery Safety Information 2...

Page 22: ...e dash display gives a visual indication of The battery state of charge SOC Forward Neutral Reverse control FNR position Turn signal lever position Messages The dash display operates when the key swit...

Page 23: ...witch is set to ACC or ON 100 to 10 SOC will show in 10 increments Less than 10 SOC will show in 1 increments Battery SOC is 10 or less Charge the battery as soon as possible Battery SOC is 3 or less...

Page 24: ...nual TPCC01DU00EN020 Edition A 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 deale...

Page 25: ...N 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 dis...

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Page 27: ...3 VEHICLE CONTROLS ONWARD HP NON LIFTED 4 PASSENGER ELECTRIC Operators Manual TPCC01DU00EN020 Edition A Page 25 Vehicle Controls Dash Display 3...

Page 28: ...Page 26 ONWARD HP NON LIFTED 4 PASSENGER ELECTRIC Operators Manual TPCC01DU00EN020 Edition A VEHICLE CONTROLS LOCATOR 3 Vehicle Controls Vehicle Controls Locator...

Page 29: ...n Tow Switch ACCELERATOR PEDAL The accelerator pedal is used to increase and maintain the speed of the vehicle BRAKE PEDAL The brake pedal is used to decrease speed or stop the vehicle FORWARD NEUTRAL...

Page 30: ...he hazard lights POSITION FUNCTION Top On Bottom Off HEADLIGHT SWITCH The headlight switch controls the operation of the headlights POSITION FUNCTION Out On In Off HORN The horn button is used to cont...

Page 31: ...urn the vehicle back on turn the key to OFF then ON ACC Electrical power from the batteries is available to power some electrical components No electrical power is available to power the motor After 2...

Page 32: ...itch to TOW for maintenance extended storage or when towed Wait 10 seconds before vehicle operation when the switch is set from TOW to RUN Do not quickly operate the switch from RUN to TOW and back to...

Page 33: ...4 VEHICLE FEATURES ONWARD HP NON LIFTED 4 PASSENGER ELECTRIC Operators Manual TPCC01DU00EN020 Edition A Page 31 Vehicle Features Turn Signal Lever 4...

Page 34: ...sengers 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...

Page 35: ...5 BATTERY CHARGER ONWARD HP NON LIFTED 4 PASSENGER ELECTRIC Operators Manual TPCC01DU00EN020 Edition A Page 33 Battery Charger USB Receptacle 5...

Page 36: ...THAT HAS DAMAGE OR A BAD ELECTRICAL CONNECTION CAN CAUSE A FIRE PROPERTY DAMAGE SERIOUS PERSONAL INJURY OR DEATH DO NOT USE A BATTERY CHARGER THAT HAS DAMAGE FELL OR WAS HIT PUT THE CORDS IN AN AREA T...

Page 37: ...of input voltage INTELLIGENT Status indicator lights to identify AC power state of charge and faults Visual signal when charging starts CONNECTED Two way data communication through a USB receptacle Up...

Page 38: ...Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in an industrial environment This equipment generates u...

Page 39: ...Two IC650 battery chargers can be on a single phase branch circuit protected by a 15A circuit breaker or fuse WARNING AN EXTENSION CORD IS NOT RECOMMENDED INCORRECT CONNECTION OF THE CHARGER AC CORD...

Page 40: ...on Green Flash On And Off The USB receptacle is on Do not remove the USB flash drive Green Constant Safe to remove the USB flash drive Green Constant Charging is complete Batteries are fully charged G...

Page 41: ...to the vehicle The vehicle will not operate when the DC cord is connected Note The AC cord does not have to be connected for the battery charging interlock to operate Onboard Battery Charger The batte...

Page 42: ...DC CORD CAN CAUSE THE 30 AMP FUSE TO BLOW IF THERE IS DAMAGE TO THE DC CORD SPEAK WITH YOUR LOCAL DEALER OR DISTRIBUTOR Examine electrical cords for wear and damage before use Immediately replace ele...

Page 43: ...gs and receptacles Refer to the manufacturer instructions 5 Clean the electrical plugs and receptacles 6 Lightly lubricate the electrical plugs and receptacles with WD 40 BATTERY CHARGER USB RECEPTACL...

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Page 45: ...6 VEHICLE SPECIFICATIONS ONWARD HP NON LIFTED 4 PASSENGER ELECTRIC Operators Manual TPCC01DU00EN020 Edition A Page 43 Vehicle Specifications Inspection And Maintenance 6...

Page 46: ...round 19 mph 30 km h Turning Radius SAE J695 9 ft 3 in 2 81 m Intersecting Aisle Clearance 7 ft 1 in 2 16 m Curb To Curb 9 ft 7 in 2 92 m Wall To Wall 9 ft 7in 2 92 m Outside Clearance Circle Diameter...

Page 47: ...T IN THE VEHICLE CAN AFFECT THE VEHICLES HANDLING OR CAUSE COMPONENT FAILURE RESULTING IN LOSS OF CONTROL OF VEHICLE AND SERIOUS PERSONAL INJURY DO NOT EXCEED THE VEHICLE LOAD CAPACITIES DO NOT TOW WH...

Page 48: ...weight applied by the trailer tongue onto the trailer hitch Maximum Gross Trailer Weight The gross trailer weight is the trailer weight plus the weight of the load on the trailer Vehicle Rated Capaci...

Page 49: ...7 VEHICLE OPERATION ONWARD HP NON LIFTED 4 PASSENGER ELECTRIC Operators Manual TPCC01DU00EN020 Edition A Page 47 Vehicle Operation Vehicle Weights And Load Capacities 7...

Page 50: ...IRE PROPERTY 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 SECUR...

Page 51: ...EHICLE 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 LAW...

Page 52: ...re correctly attached Tighten as necessary Examine the battery posts for corrosion If corrosion is found remove the corrosion Make sure that the batteries are fully charged Examine the battery acid le...

Page 53: ...e brake pedal 3 Set the Forward Neutral Reverse control FNR to R Make sure that the multi purpose buzzer operates 4 Release the brake pedal 5 Slowly push the accelerator pedal Make sure the vehicle mo...

Page 54: ...ng Instructions Indicators Gauges Displays Controls MOTOR START Before motor start Read and obey all safety decals and information located on the vehicle Understand how to operate the vehicle correctl...

Page 55: ...hat 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 turne...

Page 56: ...edal PARK THE VEHICLE 1 Stop the vehicle 2 Engage the park brake to prevent vehicle movement 3 Set the Forward Neutral Reverse control FNR to N 4 Turn the key to OFF 5 Remove the key Keep the key in a...

Page 57: ...tacles sharp drop offs other vehicles or persons could be on the other side of the hill SIDE HILL SLOPE WARNING TO PREVENT ROLL OVER PROPERTY DAMAGE AND SERIOUS PERSONAL INJURY OPERATE THE VEHICLE SLO...

Page 58: ...ngle An offset angle will cause the vehicle to lean sharply to one side Continue at a stable rate of speed Do not accelerate quickly Decrease the vehicle speed Push the brake pedal gradually to slow t...

Page 59: ...ert for hazards Drive slowly and use caution when operating on unfamiliar terrain Not all obstacles are immediately visible THROUGH WATER WARNING DRIVING THROUGH WATER CAN DECREASE BRAKE PERFORMANCE A...

Page 60: ...e all loads before operating Unsecured loads can cause unstable operating conditions which could cause loss of vehicle control Operate only with stable and safely arranged loads When handling off cent...

Page 61: ...8 VEHICLE MAINTENANCE ONWARD HP NON LIFTED 4 PASSENGER ELECTRIC Operators Manual TPCC01DU00EN020 Edition A Page 59 Vehicle Maintenance Driving Conditions 8...

Page 62: ...OR SERIOUS PERSONAL INJURY SET THE RUN TOW SWITCH TO TOW DISCONNECT THE BATTERIES WAIT 90 SECONDS FOR THE CONTROLLER DISCHARGE DO NOT WORK ON THE VEHICLE POWERTRAIN WHEN THE VEHICLE IS LOADED DO NOT W...

Page 63: ...m cleaner paste and fine grade No 00 steel wool to remove oxidation or discoloration from aluminum Use non abrasive wax products Battery acid fertilizers tars asphalt creosote paint or chewing gum sho...

Page 64: ...L DESCRIPTION Initial 6 weeks Single Point Watering System SPWS Establish a watering interval SPWS Make sure the valves operate correctly Examine the battery acid level of all the batteries Add water...

Page 65: ...roller Output Regulator MCOR 100 hours 12 months Have a trained technician examine the pedal components transaxle fluid batteries safety decals MAINTENANCE TASKS LIFT THE VEHICLE LIFT THE FRONT OF THE...

Page 66: ...the vehicle onto the jack stands LIFT THE REAR OF THE VEHICLE WARNING LIFTING THE VEHICLE WITH CARGO CAN CAUSE PROPERTY DAMAGE SERIOUS PERSONAL INJURY OR DEATH REMOVE ALL CARGO FROM THE CARGO BED BEF...

Page 67: ...in the center of the lift point 2 Lift the rear of the vehicle 3 Put jack stands under the frame rails 4 Lower the vehicle onto the jack stands LOWER THE VEHICLE LOWER THE FRONT OF THE VEHICLE Before...

Page 68: ...e front 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...

Page 69: ...ire pressure measurement Disable the vehicle To measure the tire pressure 1 Remove the valve stem cap 2 Use a pressure gauge to measure the tire pressure 3 Adjust to meet the recommended tire pressure...

Page 70: ...ft 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 stem points to the outer side of the vehicle Note Ma...

Page 71: ...316V 9 BATTERY MAINTENANCE ONWARD HP NON LIFTED 4 PASSENGER ELECTRIC Operators Manual TPCC01DU00EN020 Edition A Page 69 Battery Maintenance Maintenance Tasks 9...

Page 72: ...ttery cable has corrosion have a trained technician replace the battery cable 5 Make sure the battery cables are tight If a battery cable is not tight tighten the hardware to 110 lb in 12 4 N m 6 Let...

Page 73: ...urn off all accessories 3 Connect the AC cord to the charger 4 Connect the AC cord to the power source NOTICE INCORRECT REMOVAL AND INSTALLATION OF THE DC CORD CAN CAUSE DC CORD DAMAGE AND VEHICLE CHA...

Page 74: ...ROM SPARKS AND OPEN FLAMES CHARGING BATTERIES EMIT HYDROGEN HYDROGEN BECOMES AN EXPLOSIVE GAS AT 2 AIR CONCENTRATION INDIVIDUAL VEHICLES REQUIRE ONE AIR EXCHANGE PER HOUR FLEET 5 TIMES PER HOUR THE TO...

Page 75: ...rged CHARGD will show on the dash display 4 Before vehicle operation 4 A Disconnect the AC cord from the power source 4 B Retract the AC cord BATTERY ELECTRICAL CONNECTION DISCONNECT THE BATTERIES Bef...

Page 76: ...econds for the controller capacitors to discharge CONNECT THE BATTERIES DANGER BATTERIES DISCONNECTED OR CONNECTED WITH THE RUN TOW SWITCH SET TO RUN CAN CAUSE A BATTERY EXPLOSION AND SERIOUS PERSONAL...

Page 77: ...pply battery terminal protector spray to the battery terminals 6 Set the Run Tow switch to RUN BATTERY HOLD DOWN Each hold down must be tight to prevent the battery movement while the vehicle is in op...

Page 78: ...If the battery acid is below the top of the plates 4 A Add water until the battery acid is level with the top of the plates 4 B Install and lock the cap 4 C Fully charge the batteries 5 Unlock and re...

Page 79: ...r to the installation operation and maintenance manual hand pump manual and deionizer operator and maintenance manual WATERING INTERVALS The watering intervals are affected by Age of the batteries App...

Page 80: ...ncy 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...

Page 81: ...Intense lowering of on charge voltage Nitrates 10 0 Increased sulfation of negative plate Nitrites 5 0 Plate corrosion loss of capacity and decreased life Platinum None allowed Violent self discharge...

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Page 83: ...10 TRANSPORT AND TOW ONWARD HP NON LIFTED 4 PASSENGER ELECTRIC Operators Manual TPCC01DU00EN020 Edition A Page 81 Transport And Tow Water Quality 10...

Page 84: ...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 4 Set the Run Tow switch to TOW TOWING A TRAILER OR VEHICLE CAUTION US...

Page 85: ...he windshield from the vehicle 8 Secure all doors access panels seat bottoms and windshield 9 Examine the vehicle for loose parts Tighten as necessary 10 Secure the vehicle to the trailer VEHICLE TRAN...

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Page 87: ...11 EXTENDED STORAGE ONWARD HP NON LIFTED 4 PASSENGER ELECTRIC Operators Manual TPCC01DU00EN020 Edition A Page 85 Extended Storage Vehicle Transport Recovery 11...

Page 88: ...et the Forward Neutral Reverse control FNR to N 3 Turn the key to OFF 4 Remove the key Keep the key in a safe area 5 Put chocks against the wheels Note Do not engage the park brake 6 Remove all cargo...

Page 89: ...ly connect when necessary 14 B Examine the battery acid level and charger function monthly Note The charger is operating correctly when the blue light is on and the triangular light is off RETURN TO S...

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Page 91: ...12 WARRANTIES ONWARD HP NON LIFTED 4 PASSENGER ELECTRIC Operators Manual TPCC01DU00EN020 Edition A Page 89 Warranties Return To Service From Extended Storage 12...

Page 92: ...horized Dealer or Distributor 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 ret...

Page 93: ...ng 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 water in batteries including tap water that co...

Page 94: ...t thereof that Club Car deems to be defective Replacement shall mean furnishing during the applicable limited warranty period a new vehicle or factory reconditioned vehicle or component thereof that i...

Page 95: ...and you may also have other rights which vary from state to state HOW TO MAKE A WARRANTY CLAIM To make a warranty claim under this limited warranty you must present the vehicle or defective component...

Page 96: ...Publication Part Number TPCC01DU00EN020 Edition Code A 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...