Club Car Turf 1 2005, Owner'S Manual

Page 1: ...Owner s Manual 2005 Turf Vehicles Electric and Gasoline Turf 1 Turf 2 Turf 6...

Page 2: ......

Page 3: ...al or for incidental or consequential damages that result from the use of the material in this manual This manual contains proprietary information that is protected by copyright All rights are reserve...

Page 4: ...ask them to read this manual before they operate the vehicle Club Car products are backed by a customer support system designed to offer you fast courteous service In the event that your Club Car vehi...

Page 5: ...icle 30 Transporting on a Trailer 30 Storage Electric Vehicle 31 Storage Gasoline Vehicle 32 Maintenance 35 Periodic Service Schedules 36 Periodic Lubrication Schedules 38 Vehicle Controller Electric...

Page 6: ...cause severe injury or death Do not ride in cargo bed WARNING CCI 101553901 Before using vehicle read operating instructions Remain seated and hold on to seat handle while moving Do not start vehicle...

Page 7: ...storage Servicing NOTICE Do not operate vehicle without this cover properly installed Do not direct water stream in this area will cause damage to components See vehicle maintenance and service manua...

Page 8: ...ing in cargo bed can cause severe injury or death Do not ride in cargo bed WARNING CCI 101553901 Before using vehicle read operating instructions Remain seated and hold on to seat handle while moving...

Page 9: ...stment WARNING WARNING L A T C H O P E N Crush area Can cause severe injury Stay clear when closing bed WARNING Can cause severe injury or death No smoking sparks or open flame Stop engine allow to co...

Page 10: ...tating parts HOT manifold muffler CAN CAUSE SEVERE INJURY CCI 101960501 WARNING Riding in cargo bed can cause severe injury or death Do not ride in cargo bed WARNING CCI 101553901 VEHICLE LOADING Read...

Page 11: ...zerwillsound Vehiclewillstartmovingwhenacceleratorpedalisdepressed Slowlydepressacceleratorpedaltoincreasespeed Parkbrakewill releasewhenacceleratorpedalisdepressed Tostop releaseacceleratorpedalandde...

Page 12: ...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 before operat...

Page 13: ...tes an immediate hazard that could result in severe personal injury or death CAUTION A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal in...

Page 14: ...with a prop rod ensure that it is securely engaged while bed is raised Do not close bed until all persons are clear of cargo bed area Keep hands clear of all crush areas Do not drop cargo bed lower g...

Page 15: ...ing the vehicle or battery charger Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Figure 1 Gasoline Vehicle Fig...

Page 16: ...hroughout this manual important features unique to each model are highlighted We urge the owner opera tor to read and understand this manual and to pay special attention to the features specific to th...

Page 17: ...or rolling the vehicle set the park brake place the Forward Reverse handle or switch in the NEUTRAL position turn the key switch to the OFF position and remove the key when leaving the vehicle WARNIN...

Page 18: ...f the driver s knee Figure 8 The F FORWARD and R REVERSE positions are clearly marked Push down the FOR WARD side of the switch to operate the vehicle in the forward direction or push down the REVERSE...

Page 19: ...the driver that motor braking has been activated WARNING Zero speed detect will not limit vehicle speed to 1 mph 1 6 km h on very steep grades Do not operate vehicle on slopes exceeding 20 grades Peda...

Page 20: ...ke pedal firmly and tilt the park brake portion of the pedal forward with your foot Figure 10 See fol lowing WARNING WARNING The park brake will release automatically when either the accelerator or br...

Page 21: ...charge during the next charge cycle When the charger is unplugged the warning light will illuminate and remain illuminated for 10 seconds if the charge is less than 90 complete but the vehicle has en...

Page 22: ...eed Detect motor braking function is operating Before Disconnecting or Connecting Battery Cables Place the Tow Run switch in the TOW posi tion to turn off power to the vehicle electrical system thus p...

Page 23: ...he cam in the MAINTENANCE position and the engine running the vehicle may move suddenly if the Forward Reverse handle is shifted or accidentally bumped To prevent this chock the front and rear wheels...

Page 24: ...UTION Failure to add oil immediately when the low oil warning light stays on may result in permanent engine damage Figure 14 Button Choke Figure 15 Cable Choke Figure 16 Fuel Gauge Hour Meter and Low...

Page 25: ...d information decals Check to ensure that all safety and information decals are in place See pages 4 through 9 Tires Check for proper tire pressure Visually inspect for wear damage and proper inflatio...

Page 26: ...e freely Club Car vehicles should run at reduced speed in reverse IQ System and IQ Plus vehicles only When the pedal is released it should return to the original position and the motor should rotate f...

Page 27: ...ights and reflectors Stop the vehicle before shifting the Forward Reverse handle or switch Failure to do so may result in injury to inattentive passengers and or damage to the vehicle Do not leave chi...

Page 28: ...Forward Reverse handle or switch in the desired position F for ward or R reverse A buzzer will sound as a warning when the Forward Reverse handle or switch is in the REVERSE position 4 3 Slowly press...

Page 29: ...Forward Reverse handle or switch in the NEU TRAL position Remove the key IQ System vehicles only When the Tow Run switch is in the RUN position with the Forward Reverse switch or key switch in any pos...

Page 30: ...rop rod DANGER Use caution when working under bed Be sure prop rod is secure Otherwise the bed will fall resulting in severe personal injury or death WARNING Do not disengage prop rod until all person...

Page 31: ...stops and abrupt turns The cargo s center of gravity may affect the handling steering and braking of the vehicle When the vehicle is loaded reduce speed and drive slowly in turns To help prevent carg...

Page 32: ...park brake TRANSPORTING ON A TRAILER WARNING Do not allow riders in the trailer being towed Avoid sudden starts sudden stops and tight turns when towing Avoid stopping on a hill when towing If you mus...

Page 33: ...cle 2 Fully charge batteries See Charging Batteries on page 37 3 Batteries should be clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water 1 cup 237...

Page 34: ...tion during storage This is to prevent unintentionally starting the vehicle or a fire hazard Turn the fuel shut off valve to the closed OFF position Figure 19 Page 26 Do not attempt to charge frozen b...

Page 35: ...CCI P N 1014305 6 To protect the engine remove spark plug and pour 1 2 ounce 14 2 mL of SAE 10 weight oil into the engine through the spark plug hole Rotate engine crankshaft by hand several times and...

Page 36: ...llow ing NOTE NOTE Due to the oil added to the engine in preparation for storage engine may smoke excessively for a short time when it is run for the first time after storage 5 Adjust tires to recomme...

Page 37: ...could cause severe burns Do not work on vehicle powertrain or under the cargo bed when it is loaded Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle T...

Page 38: ...ecifications Electric Vehicles on page 44 General vehicle Wash battery compartment and underside of vehicle Semiannual service by trained technician only or every 50 hours of operation whichever comes...

Page 39: ...ean terminals and wash dirt from casing check electrolyte level See Figure 29 Front wheel alignment and camber Check and adjust if necessary See Section 7 Steering and Front Suspension in the appropri...

Page 40: ...ube CCI P N 1012151 Charger receptacle all vehicles Forward Reverse switch contacts PowerDrive vehicles only WD 40 Brake slides Dry Moly Lube CCI P N 1012151 Front suspension 5 fittings Chassis Lube E...

Page 41: ...P NLGI Grade 2 Brake slides Dry Moly Lube CCI P N 1012151 Annually by trained technician only or every 100 hours of operation whichever comes first Check fill unitized transaxle to plug level 27 oz 8...

Page 42: ...milk or water followed with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately WARNING Wear safety glasses or approved ey...

Page 43: ...atteries if plates are exposed above electrolyte level For best battery life use only distilled water NOTE A battery watering gun or bottle is available at many auto parts dealers 3 The hold down stra...

Page 44: ...ot use an adapter to plug the charger with a three prong plug into a two prong outlet Improper connection of the equipment grounding conductor can result in a fire or an electrical shock An extension...

Page 45: ...ter will drop to zero Charging will resume in a few moments ammeter returns to previous rate of charge This will be repeated at one hour and at two hours into the charge cycle Each Club Car electric v...

Page 46: ...t of energy being returned to the batteries When the optimum amount of energy needed to replenish the batteries is returned the charger will turn off The control circuit lockout remains activated unti...

Page 47: ...charging circuit from an overload Turf 1 and Turf 2 elec tric vehicles are equipped with a receptacle fuse link Figure 27 If the charger does not turn on when the vehicle is placed on charge inspect t...

Page 48: ...watering Figure 28 Any corrosion around the positive or negative terminals should be washed off with a solution of baking soda and water 1 cup 237 mL per gallon 3 8 L of water Rinse solution off the...

Page 49: ...ly tightened Tighten to 12 ft Ib 16 N m A loose clamp may allow the battery to become damaged from vibration or jarring If battery appears weak have it charged by a trained technician The battery shou...

Page 50: ...he dipstick into the oil filler tube and immediately removing it 3 If the oil level is at or below the low level mark on the dipstick gauge add oil until the level is between low and full levels safe...

Page 51: ...e before operating the vehicle CAUTION To allow for expansion do not fill higher than one inch from top of the fuel tank Avoid spilling fuel NOTE Whenever possible avoid using oxygenated fuels and fue...

Page 52: ...soap and warm water applied with a soft cloth For imbedded dirt a soft bristle brush may be used For heavy soiling difficult stains or scratches blemishes or other body damage see Section 4 of the Tur...

Page 53: ...rings with dual hydraulic shocks Brakes Mechanical brake cable system to self adjusting drum brakes on each rear wheel Park brake is automatically released Self adjusting multi latch ratchet and pawl...

Page 54: ...ESSURE Front and rear 18 20 psi 1 24 1 38 Bars 30 34 psi 2 07 2 34 Bars SPECIFICATIONS Turf 1 Gasoline Turf 2 Gasoline Turf 6 Gasoline POWER SOURCE Engine 4 cycle OHV 286 cc 9 hp rated single cylinder...

Page 55: ...in 122 cm Wheelbase 65 5 in 166 cm 77 5 in 197 cm 98 5 in 250 cm Ground clearance 4 5 in 11 cm 4 5 in 11 cm 4 5 in 11 cm Front wheel tread 34 5 in 88 cm 34 5 in 88 cm 34 5 in 88 cm Rear wheel tread 3...

Page 56: ...iters 32 oz 95 liters 32 oz 95 liters Engine crankcase with filter 38 oz 1 12 liters 38 oz 1 12 liters 38 oz 1 12 liters Unitized transaxle 27 oz 8 liters 27 oz 8 liters 27 oz 8 liters Fuel tank 7 gal...

Page 57: ...Vehicle Specifications Gasoline Vehicles Page 48 2005 Turf Vehicle Owner s Manual...

Page 58: ...receptacle brake shoes belts brushes bushings engine mounts mats and pads maintenance adjustments cosmetic deterioration and items which deteriorate or fail due to exposure or ordinary wear and tear...

Page 59: ...vehicle beyond factory specifications including those that affect the weight distribution stability or speed of the vehicle can cause serious personal injury or death CLUB CAR LIMITED FOUR YEAR WARRA...

Page 60: ...Y 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 Th...

Page 61: ...sonably equivalent to the warranted product or defective component at no cost to the purchaser Repair shall mean remedying a defect in the charger or component thereof at no cost to the purchaser duri...

Page 62: ...s are also excluded from this warranty WARRANTY LIMITATIONS CLUB CAR s liability under this limited warranty shall be to replace a defective Computer or Controller Replacement shall be furnishing a ne...

Page 63: ...g optimum ignition timing characteristics The carburetors have been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system...

Page 64: ...3 Clarity of Illustrations 4 Periodic Service and Periodic Lubrication Schedules Poor Fair Average Good Excellent Comments Suggestions In order to help us better serve you please rate this publicatio...

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Page 68: ...Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Intl l 1 706 863 3000 Fax 1 706 863 5808 Publication Part Number 102680226 Edition Code 0505A00...