Club Car Onward, Operator'S Manual

Page 1: ...ONWARD HP 4 PASSENGER LITHIUM ION Operators Manual APPLICABLE TO VEHICLES WITH SERIAL PREFIX OF DL...

Page 2: ...Copyright 2019 Club Car LLC This manual effective April 3 2019...

Page 3: ...tion of the vehicle will make sure Club Car is able to communicate necessary information directly to owners Send your name address and serial number of the vehicle to Club Car LLC Attention Vehicle Re...

Page 4: ...CT INFORMATION Send written correspondence to Club Car LLC Attention Marketing Services P O Box 204658 Augusta Georgia 30917 4658 United States Of America CUSTOMER SATISFACTION SURVEY Let your voice b...

Page 5: ...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 THE...

Page 6: ...o on improved or groomed surfaces EUROPEAN UNION VIBRATION AND NOISE PREN 15997 European Union specification prEN 15997 was used to measure the vibration and noise levels of the vehicle The vibration...

Page 7: ...Symbols 16 Lithium Ion 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...

Page 8: ...al Plugs And Receptacles 40 Clean The Electrical Plugs And Receptacles 41 Battery Charger USB Receptacle 41 Clean The USB Receptacle 41 SECTION 6 VEHICLE SPECIFICATIONS 43 Dimensions 44 Performance 44...

Page 9: ...Overview 72 Battery Charging 72 Charging With External Charger 72 Charging With Onboard Charger 73 SECTION 10 TRANSPORT AND TOW 75 Prepare The Vehicle To Be Towed 76 Towing A Trailer Or Vehicle 76 Tow...

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Page 11: ...1 SAFETY INFORMATION ONWARD HP 4 PASSENGER LITHIUM ION Operators Manual TPCC01DL00EN019 Edition A Page 9 Safety Information Notices 1...

Page 12: ...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 or t...

Page 13: ...UCTIONS 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 CLUB CA...

Page 14: ...PAIR THE VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN ELECTRICAL AND MECHANICAL REPAIR THE APPROPRIATE INSTRUCTIONS MUST BE USED WHEN PERFORMING MAINTENA...

Page 15: ...dshield does not provide protection from golf balls or other flying objects 47592393001 RISK OF EYE INJURY ROLLOVERS OR FALLING OFF CAN CAUSE SERIOUS INJURY OR DEATH WARNING Read and understand the Op...

Page 16: ...CAUSE SERIOUS INJURY Towing this vehicle Extended storage Servicing the vehicle Read the vehicle service manual before servicing Keep electronic components dry The battery compartment is not a storage...

Page 17: ...MULTI PURPOSE BUZZER The vehicle comes equipped with a multi purpose buzzer The multi purpose buzzer makes an audible tone when The Forward Neutral Reverse control FNR is set to R The walk away braki...

Page 18: ...for more information WALK AWAY BRAKING WARNING WALK AWAY BRAKING WILL NOT LIMIT VEHICLE SPEED TO 3 MPH 4 8 KM H ON STEEP SLOPES DO NOT OPERATE THE VEHICLE ON SLOPES THAT ARE MORE THAN A 20 GRADE Walk...

Page 19: ...en flames No sparks Keep away from children Battery acid hazard Explosive gas hazard LITHIUM ION BATTERY RECYCLING Lithium Ion batteries must be collected and recycled separately from other waste Do n...

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Page 21: ...2 INDICATORS GAUGES AND DISPLAYS ONWARD HP 4 PASSENGER LITHIUM ION Operators Manual TPCC01DL00EN019 Edition A Page 19 Indicators Gauges And Displays Battery Safety Information 2...

Page 22: ...sh 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 switch i...

Page 23: ...of charge SOC Battery SOC is 10 or less Charge the battery as quickly as possible Battery SOC is 3 or less The multi purpose buzzer and headlights if equipped will operate three times Charge the batt...

Page 24: ...SENGER LITHIUM ION Operators Manual TPCC01DL00EN019 Edition A DISPLAY DESCRIPTION FNR is set to N FNR is set to F FNR is set to R Left turn signal is on Right turn signal is on 2 Indicators Gauges And...

Page 25: ...will log the event Speak with your local dealer or distributor 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 Seve...

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Page 27: ...3 VEHICLE CONTROLS ONWARD HP 4 PASSENGER LITHIUM ION Operators Manual TPCC01DL00EN019 Edition A Page 25 Vehicle Controls Dash Display 3...

Page 28: ...Page 26 ONWARD HP 4 PASSENGER LITHIUM ION Operators Manual TPCC01DL00EN019 Edition A VEHICLE CONTROLS LOCATOR 3 Vehicle Controls Vehicle Controls Locator...

Page 29: ...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 R...

Page 30: ...azard 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 control...

Page 31: ...urn the key to OFF then ON ACC Electrical power from the battery is available to power some electrical components No electrical power is available to power the motor After 15 minutes the vehicle will...

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

Page 33: ...4 VEHICLE FEATURES ONWARD HP 4 PASSENGER LITHIUM ION Operators Manual TPCC01DL00EN019 Edition A Page 31 Vehicle Features Turn Signal Lever 4...

Page 34: ...charging will operate when the key switch is set to OFF or ON If the key switch is set to ACC the battery will charge Note When the DC cord is connected the battery will charge for 20 to 30 seconds t...

Page 35: ...5 BATTERY CHARGER ONWARD HP 4 PASSENGER LITHIUM ION Operators Manual TPCC01DL00EN019 Edition A Page 33 Battery Charger USB Receptacle 5...

Page 36: ...MAGE SERIOUS PERSONAL INJURY OR DEATH CONNECT THE AC CORD TO AN APPROVED POWER SOURCE AND RECEPTACLE LIQUID ON THE BATTERY CHARGER CAN CAUSE PROPERTY DAMAGE ELECTRICAL SHOCK SERIOUS PERSONAL INJURY OR...

Page 37: ...DIMENSION AND WEIGHT Dimension 9 9 in 25 1 cm length 7 3 in 18 5 cm width 3 1 in 7 9 cm height Weight 5 3 lb 2 4 kg OPERATIONAL TEMPERATURE Temperature Range 40 F to 149 F 40 C to 65 C AC INPUT Volta...

Page 38: ...inimum maximum 100 to 240 VAC maximum efficiency range Current 10 5 A maximum Frequency 50 to 60 Hz DC OUTPUT Voltage 48 VDC nominal 72 VDC maximum Current 20 0 A maximum GOVERNMENTAL AND INDUSTRY CER...

Page 39: ...International Protection Marking IP certification of IP20 Note The AC supply connector is applicable for indoor use only Keep all AC connections clean and dry UNDERWRITERS LABORATORIES AND CANADIAN S...

Page 40: ...xternal fault condition See the display panel for more information 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 G...

Page 41: ...e BATTERY CHARGING INTERLOCK EXTERNAL BATTERY CHARGER MOUNTING CAUTION IF THE BATTERY CHARGER IS NOT CORRECTLY ATTACHED IT CAN FALL AND CAUSE PROPERTY DAMAGE AND SERIOUS PERSONAL INJURY DO NOT HANG TH...

Page 42: ...ace electrical cords for Cracks Cuts Frayed wiring Insulation damage Loose connections Splices Make sure that the DC electrical cord has the warning tag attached and that the warning tag is readable R...

Page 43: ...the manufacturer instructions 5 Clean the electrical plugs and receptacles 6 Lightly lubricate the electrical plugs and receptacles with WD 40 BATTERY CHARGER USB RECEPTACLE The USB receptacle can hav...

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Page 45: ...6 VEHICLE SPECIFICATIONS ONWARD HP 4 PASSENGER LITHIUM ION Operators Manual TPCC01DL00EN019 Edition A Page 43 Vehicle Specifications Inspection And Maintenance 6...

Page 46: ...ORMANCE Forward Speed On Level Ground 19 mph 30 6 km h Turning Radius SAE J695 9 ft 3 in 2 81 m Intersecting Aisle Clearance Unknown At Time Of Print Curb To Curb 9 ft 7 in 2 92 m Wall To Wall 9 ft 7...

Page 47: ...ACITY IS FOR LEVEL SURFACES ONLY TOO MUCH WEIGHT 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 E...

Page 48: ...tow with a Club Car approved tow kit Trailer Tongue Weight The trailer tongue weight is the maximum permitted weight applied by the trailer tongue onto the trailer hitch Gross Trailer Weight The gross...

Page 49: ...7 VEHICLE OPERATION ONWARD HP 4 PASSENGER LITHIUM ION Operators Manual TPCC01DL00EN019 Edition A Page 47 Vehicle Operation Vehicle Weights And Load Capacities 7...

Page 50: ...PASSENGERS CAN SECURE THEMSELVES IN THE VEHICLE BEFORE VEHICLE OPERATION TO PREVENT SERIOUS PERSONAL INJURY KEEP ENTIRE BODY IN THE VEHICLE DURING OPERATION THE VEHICLE IS NOT SPECIALLY EQUIPPED FOR H...

Page 51: ...OR ON UNIMPROVED SURFACES DAILY PRE OPERATIONAL SAFETY AND PERFORMANCE CHECKS OVERVIEW Use the daily pre operational checklist and vehicle performance inspection to inspect the operational condition a...

Page 52: ...ecals and 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 Front wheels are...

Page 53: ...unctions normally 12 Slowly push the brake pedal Stop the vehicle 13 Park the vehicle on a level surface 14 Disengage the park brake 15 Try to push the vehicle to engage the walk away braking Walk awa...

Page 54: ...op To start the motor 1 Put the key into the key switch 2 Turn the key to ON Push the accelerator pedal to start the motor TURN OFF MOTOR 1 Release the accelerator pedal 2 Stop the vehicle 3 Push and...

Page 55: ...E AND PREVENT SUDDEN STOPS Before reverse movement Read and obey all safety decals and information located on the vehicle Understand how to operate the vehicle correctly and safely Understand the func...

Page 56: ...STRAIGHT UP AND DOWN SLOPES DO NOT OPERATE THE VEHICLE ON SLOPES THAT ARE MORE THAN A 20 GRADE VEHICLE ROLLBACK WHEN STARTING ON AN INCLINE CAN CAUSE PROPERTY DAMAGE SERIOUS PERSONAL INJURY OR DEATH...

Page 57: ...E ROLL OVER CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH PREVENT STOPPING ON A HILL WHEN TOWING OR WITH A LOADED VEHICLE IF A VEHICLE WITH A LOAD IS STOPPED ON A HILL PREVENT SUDDEN STARTS ROLLING BACKW...

Page 58: ...E THE VEHICLE BELOW OBJECTS WITH A HEIGHT THAT IS LESS THAN THE HEIGHT OF THE VEHICLE Driving below obstacles is not recommended Precautions if operation below obstacles is unavoidable Always examine...

Page 59: ...E BRAKE PERFORMANCE AFTER DRIVING THROUGH WATER LIGHTLY PUSH THE BRAKE PEDAL TO CHECK THE BRAKE PERFORMANCE IF THE VEHICLE SPEED DOES NOT DECREASE AT A NORMAL RATE CONTINUE TO PUSH THE BRAKE PEDAL UNT...

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Page 61: ...8 VEHICLE MAINTENANCE ONWARD HP 4 PASSENGER LITHIUM ION Operators Manual TPCC01DL00EN019 Edition A Page 59 Vehicle Maintenance Driving Conditions 8...

Page 62: ...EHICLE POWERTRAIN WHEN THE VEHICLE IS LOADED DO NOT WEAR LOOSE CLOTHING OR JEWELRY SUCH AS RINGS WATCHES CHAINS ETC WHEN SERVICING THE VEHICLE OR BATTERY CHARGER LIFT ONLY ONE END OF THE VEHICLE AT A...

Page 63: ...removed immediately to prevent possible stains Discard the waste water correctly CLEANING THE VEHICLE INTERIOR NOTICE MOISTURE CAN CAUSE ELECTRICAL COMPONENT DAMAGE DO NOT USE A PRESSURE WASHER OR STE...

Page 64: ...er receptacle Have a trained technician examine and lubricate the brake system examine the electrical system examine the front wheel alignment lubricate the front suspension examine the Motor Controll...

Page 65: ...ICLE LIFT THE FRONT 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 BEFORE THE VEHICLE IS LIFTED Be...

Page 66: ...oltage interlock fuse 1 A Disconnect the fuse holder 1 from the red cover 2 1 B Remove the 10A fuse 3 2 Place the jack in the center of the lift point 3 Lift the front of the vehicle 4 Put jack stands...

Page 67: ...DAMAGE SERIOUS PERSONAL INJURY OR DEATH REMOVE ALL CARGO FROM THE CARGO BED BEFORE THE VEHICLE IS LIFTED Before the vehicle is lifted Disable the vehicle Use a jack and jack stands rated for the vehi...

Page 68: ...rails 5 Lower the vehicle onto the jack stands LOWER THE VEHICLE LOWER THE FRONT OF THE VEHICLE Before the front of the vehicle is lowered Use a jack rated for the vehicle To lower the front of the v...

Page 69: ...oval of the high voltage interlock fuse will cause a fault code 5 C Turn the key switch to ON then OFF to clear the fault code 6 Set the Run Tow Stow switch to RUN LOWER THE REAR OF THE VEHICLE Before...

Page 70: ...fault code 6 Set the Run Tow Stow switch to RUN TIRE PRESSURE MEASUREMENT Before the tire pressure measurement Disable the vehicle To measure the tire pressure 1 Remove the valve stem cap 2 Use a pres...

Page 71: ...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 Make sure that the tire tread...

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Page 73: ...316V 9 BATTERY MAINTENANCE ONWARD HP 4 PASSENGER LITHIUM ION Operators Manual TPCC01DL00EN019 Edition A Page 71 Battery Maintenance Maintenance Tasks 9...

Page 74: ...ES WITH ACCESSORIES ON CAN CAUSE A FIRE AND SERIOUS PERSONAL INJURY TURN OFF ALL ACCESSORIES BEFORE CHARGING THE BATTERIES WARNING THE BATTERY CHARGER BECOMES HOT WHEN IT IS ON AND CAN CAUSE A FIRE PR...

Page 75: ...ghts will flash Note When the battery is fully charged CHARGD will show on the dash display DANGER IF THE DC CORD IS REMOVED TOO FAST ARCING AND BURNING CAN CAUSE DAMAGE TO THE PLUG RECEPTACLE AND CAU...

Page 76: ...2 to 10 seconds When the vehicle starts to charge ON CHG will show on the dash display The multi purpose buzzer will operate 3 times If equipped the headlights will operate 2 times Note When the batt...

Page 77: ...10 TRANSPORT AND TOW ONWARD HP 4 PASSENGER LITHIUM ION Operators Manual TPCC01DL00EN019 Edition A Page 75 Transport And Tow Battery Charging 10...

Page 78: ...ON A PUBLIC ROAD THE TRAILER MUST MEET ALL FEDERAL STATE AND LOCAL REQUIREMENTS SUCH AS TAILLIGHTS AND BRAKE LIGHTS PREPARE THE VEHICLE TO BE TOWED 1 Turn the key to OFF 2 Remove the key Keep the key...

Page 79: ...ON CAUTION USE EXTREME CAUTION WHEN TRANSPORTING THE VEHICLE ON A TRAILER REFER TO THE TOW VEHICLE OPERATOR MANUAL The vehicle is not designed to be towed at speeds over 5 mph If movement over long di...

Page 80: ...Page 78 ONWARD HP 4 PASSENGER LITHIUM ION Operators Manual TPCC01DL00EN019 Edition A 4 Install the windshield 10 Transport And Tow Vehicle Transport Recovery...

Page 81: ...11 EXTENDED STORAGE ONWARD HP 4 PASSENGER LITHIUM ION Operators Manual TPCC01DL00EN019 Edition A Page 79 Extended Storage Vehicle Transport Recovery 11...

Page 82: ...rage temperature range is from 4 F 20 C to 113 F 45 C To prepare your vehicle for extended storage 1 Turn off all electronic accessories 2 Set the Forward Neutral Reverse control FNR to N 3 Turn the k...

Page 83: ...itch to RUN 2 Fully charge the battery 3 Set the Forward Neutral Reverse control FNR to N 4 Adjust the pressure in each tire to the recommended tire pressure 5 Have a trained technician lubricate the...

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Page 85: ...12 WARRANTIES ONWARD HP 4 PASSENGER LITHIUM ION Operators Manual TPCC01DL00EN019 Edition A Page 83 Warranties Return To Service From Extended Storage 12...

Page 86: ...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 components If...

Page 87: ...his limited warranty shall not apply to failure due to the following conditions Batteries Tampering with or opening of the battery case Intentional overcharging or undercharging of a vehicle Improper...

Page 88: ...mponent 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...

Page 89: ...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 with...

Page 90: ...Publication Part Number TPCC01DL00EN019 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...