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4 - Club Car Side-by-Sides & Utility Vehicles

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1. NOT APPLICABLE TO TRANSPORTER VEHICLES NOT APPLICABLE TO FOUR PASSENGER VILLAGER VEHICLES Figure 10 Lubrication Points Page 28 2003 Transportation Electric Vehicle Owner s Manual Vehicle Controller VEHICLE CONTROLLER Electric vehicles are equipped with solid state speed controllers In order to properly service and maintain the solid state speed controller vehicle it is necessary to understand the electrical circuitry and the functions of all components in the system Therefore if any repair or service is required Club Car recommends that it be per formed by an authorized Club Car distributor dealer using Club Car OEM parts BATTERIES A DANGER Battery Explosive gases Do not smoke Keep sparks and flames away from vehicle and service area Tools wires and metal objects can cause sparks when shorted across a battery Follow all instructions carefully when dealing with batteries Charge batteries in a well ventilated area only Batteries emit hydrogen while being charged Hydrogen is an explosive gas and must never exceed a level of 2 of the air Battery Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes External Flush with water for 15 minutes Call a physician immediately Internal Drink large quantities of milk or water followed with milk of magnesia or vegetable oil Call a
2. 28 Vehicle Controller 2 1 0 0 h rere rer 29 Batterles ves rev aed RW RUD DLE UE Cb NEC Db or br E vs 29 Battery Charger EE wA d tte Do eh ea Ea 30 Cleaning the Vehicle 34 ACCOSSOL OS 2 2 Iu a eran at a PR ERE ue t ri a o eet 34 Subsequent Owner 35 Vehicle Specifications 0 0 0 0 hr 36 Club Car Limited Two Year Warranty for 2003 Transportation And Utility Vehicles 38 2003 Transportation Electric Vehicle Owner s Manual Page 5 Safety Details SAFETY DETAILS A WARNING This owner s manual should be read completely before attempting to drive or service the vehicle Failure to follow the instructions in this manual could result in property damage severe personal injury or death It is important to note that some vital statements throughout this manual and on the decals affixed to the vehi cle are preceded by the words DANGER WARNING or CAUTION For your protection we recommend that you take special notice of these safety precautions Safety precautions are essential and must be followed If any of the operation or safety decals on the vehicle become damaged have been removed or cannot be easily read they should be replaced immediately to avo
3. Remain seated with entire body inside vehicle and hold on to seat handle or handrail at all times ne BED BOLT No more than two persons per seat WARNING DECAL A WARNING Do not leave children unattended vehicle at anytime Never stand in front of or behind FAILURE TO FOLLOW THESE INSTRUCTIONS vehicle STAY CLEAR CAN CAUSE SEVERE INJURY OR DEATH CCI 101609401 Bed can tip up unexpectedly Bed hold down 1017057 01 bolts must be fastened CCI 101707801 Page 14 2003 Transportation Electric Vehicle Owner s Manual General Information GENERAL INFORMATION There are two electric Transportation models the Villager and the TransPorter The four passenger Villager vehicle uses the IQ System electrical system six and eight passenger Villager and Transporter vehicles use the PowerDrive System 48 electrical system Throughout this manual important features unique to each model are highlighted We urge the owner operator to read and understand this manual and to pay special attention to the features specific to their vehicle s MODEL IDENTIFICATION The serial number of your Club Car vehicle is printed on a bar code decal mounted on the frame directly above the accelerator pedal Example T0301 123456 Figure 2 There is also a second serial number decal mounted on the front body frame behind the center dash panel The center dash panel must be removed to view this decal See following NOT
4. or IQ System purchased from CLUB CAR or an authorized distributor or dealer will be free from defects in material and workmanship and will provide 36 hole performance 60 minute discharge capacity for a period of four years or 800 rounds whichever first occurs from the date of purchase subject to the terms and conditions contained herein This limited warranty only covers defects in material and workmanship for a period of four years or 800 golf car rounds from date of purchase The terms of this four year or 800 round limited warranty shall be as follows Vehicles used for golf free replacement with respect to parts and labor within four years or 800 rounds whichever first occurs from date of purchase Vehicles used for purposes other than golf free replacement with respect to parts and labor within four years or 16 000 energy units as recorded by the Onboard Computer whichever first occurs from the date of purchase The battery should be returned to an authorized CLUB CAR distributor or dealer with evidence of proof of purchase date and number of rounds freight prepaid CLUB CAR reserves the right to test and recharge any battery returned for adjustment and to verify number of rounds played by accessing information contained in the PowerDrive System 48 PowerDrive Plus or IQ System Onboard Computer LIMITED WARRANTY EXCLUSIONS THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOT APPLY TO FAILURE DUE TO 1 Abuse such as overchargi
5. Do not leave children unattended on vehicle at anytime BRAKE PEDAL Never stand in front of or behind vehicle CCI 1017057 01 Page 10 2003 Transportation Electric Vehicle Owner s Manual Vehicle Feature Identification SIX PASSENGER VILLAGER VEHICLE REAR A WARNING Failure to follow these instructions can cause severe injury or death Remain seated with entire body inside vehicle and hold on to seat handle or handrail at all times No more than two persons per seat Do not leave children unattended on vehicle at anytime Never stand in front of or behind vehicle CCI 1017057 01 PASSENGER WARNING DECAL DANGER POISON i SULFURIC IMMEDIATELY NO ACID WITH WATER SHIELD SPARKS S D CAN CAUSE GET ExPLosve EYES FLAMES BLINDNESS OR MEDICAL GASES CAN CAUSE SMOKING SEVERE BURNS HELP BLINDNESS OR INJURY H KEEP OUT OF THE REACH OF CHILDREN DO NOT TIP KEEP VENT CAPS TIGHT AND LEVEL BATTERY DANGER MOLDED ON BATTERY CAPS di CHARGER RECEPTACLE AND FUSE LINK 9 FORWARD REVERSE HANDLE o 2003 Transportation Electric Vehicle Owner s Manual Page 11 Vehicle Feature Identification EIGHT PASSENGER VILLAGER VEHICLE REAR CHARGER RECEPTACLE PASSENGER WARNING DECAL FORWARD REVERSE Z WARNING HANDLE Failure to follow these instructions can cause severe injury or death Remain seated with entire body
6. 16 000 energy units for use other than golf whichever first occurs except for transportation expenses All parts and components replaced under this limited warranty become the property of CLUB CAR THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REPLACEMENT OR REPAIR OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE 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 This computer or controller is intended to be used only in CLUB CAR PowerDrive System 48 PowerDrive Plus and IQ System electric vehicles Any other use renders the Limited Warranties expressed herein and all implied warranties null and void and same are hereby excluded ALSO EXCLUDED FROM THIS LIMITED WARRANTY ARE ANY AND ALL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE OR REVENUE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Damage not resulting from a defect in material or workmanship o
7. BURNS HELP BLINDNESS OR INJURY KEEP OUT OF THE REACH OF CHILDREN DO NOT TIP KEEP VENT CAPS TIGHT AND LEVEL BATTERY DANGER MOLDED ON BATTERY CAPS 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 manual before servicing CCI 101931501 ELECTRICAL COMPONENT DECAL ON SPEED CONTROLLER COVER CHARGER RECEPTACLE AND FUSE LINK A WARNING Place Tow Run switch in TOW position before FAILURE TO HEED THIS Disconnecting or connecting batteries WARNING COULD RESULT IN Towing A BATTERY EXPLOSION OR Extended storage SEVERE PERSONAL INJURY Servicing CCI 101908601 FORWARD REVERSE TOW SWITCH WARNING DECAL SWITCH ON TOW SWITCH BRACKET UNDER SEAT 2003 Transportation Electric Vehicle Owner s Manual Page 9 Vehicle Feature Identification SIX AND EIGHT PASSENGER VILLAGER FRONT OPERATING INSTRUCTIONS A WARN NG e Read Owner s Manual and safety warnings located on dash panel prior to driving Study and understand controls ROLLOVER OR FALLING OFF MAY CAUSE DEATH Make sure wheels are turned in desired direction Before using vehicle read operating instructions e Turn key to ON position and be sure nothing is in your path Remain seated and hold on to seat handle while moving While vehicle is stopped select direction by placing Do not start vehicle unt
8. inside vehicle and hold on to seat handle or handrail at all times No more than two persons per seat Do not leave children unattended on vehicle at anytime Never stand in front of or behind vehicle 1017057 01 BATTERY DANGER MOLDED ON BATTERY CAPS _ DANGER POISON FLUSH EYES SULFURIC IMMEDIATELY ACID WITH WATER ae E v NO i E Sy mam can cause BLINDNESS oR SMOKING SEVERE BURNS uc BLINDNESS OR INJURY KEEP OUT OF THE REACH OF CHILDREN DO NOT KEEP VENT CAPS TIGHT AND LEVEL Page 12 2003 Transportation Electric Vehicle Owner s Manual Vehicle Feature Identification TRANSPORTER VEHICLES OPERATING INSTRUCTIONS A WARNING ROLLOVER OR FALLING OFF MAY CAUSE DEATH Before using vehicle read operating instructions Remain seated and hold on to seat handle while moving Do not start vehicle until all occupants are seated Two 2 persons per seat maximum e Read Owner s Manual and safety warnings located on dash panel prior to driving Study and understand controls Make sure wheels are turned in desired direction e Turn key to ON position and be sure nothing is in your path While vehicle is stopped select direction by placing shift lever or switch in desired position F Forward N Neutral Reverse Buzzer will sound Operate from driver side only and not on public roads Keep ent
9. is in REVERSE 7 Slowly depress accelerator pedal The park brake will release automatically and the vehicle will start to move As the accelerator pedal is depressed speed will increase until full speed is reached A WARNING Operator must control speed when going downhill IQ System vehicles only Pedal down or pedal up motor braking may be used to help control speed when going downhill however steep terrain or other conditions may require that pedal braking be used in conjunction with motor braking STOPPING THE VEHICLE A WARNING Driving through water may affect the brakes After driving through water check effectiveness of the brakes by gently depressing the brake pedal If the vehicle does not slow down at the normal rate continue to depress the brake pedal until the brakes dry out and normal performance returns Page 22 2003 Transportation Electric Vehicle Owner s Manual Loading and Unloading A CAUTION When stopped on a hill use the brake pedal to hold your position Do not use the accelerator pedal To stop the vehicle release the accelerator pedal and depress the brake pedal until the vehicle comes to a complete stop PARKING AND LEAVING THE VEHICLE 1 After coming to a complete stop firmly depress the park brake pedal until it locks This will prevent the vehicle from rolling 2 Turn the key switch to OFF and place the Forward Reverse handle or switch in the NEUTRAL position
10. provide reasonable and necessary maintenance accident or alteration is excluded from this limited warranty Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitations of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state For further information contact WARRANTY SERVICES CLUB CAR INC Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 CLUB CAR LIMITED FOUR YEAR WARRANTY FOR 2003 POWERDRIVE BATTERY CHARGERS CLUB CAR INC CLUB CAR hereby warrants to the original retail purchaser that its new PowerDrive Chargers purchased from CLUB CAR or an authorized distributor or dealer will be free from defects in material and workmanship under normal use and service for a period of four years from the date of purchase subject to the terms provisions limitations and exclusions contained herein The limited warranty with respect to parts and labor only covers defects in material and workmanship for a period of four years from the date of purchase Such repair labor shall be performed only by CLUB CAR or by an authorized distributor or dealer Purchaser shall be responsible for all freight costs to and from CLUB facility LIMITED WARRANTY EXCLUSIONS THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOT APPLY
11. time check electrolyte to ensure it is at the proper level Figure 11 Page 30 Check battery posts Wires should be tight and free of corrosion and batteries should be fully charged Charger cord plug and receptacle Visually inspect for crack loose connections and frayed wiring See Plug and Receptacle on page 33 A WARNING Be sure the plastic has been removed from the seat bottom before operating the vehicle Failure to do so may result in fire property damage personal injury or death PERFORMANCE INSPECTION After you have familiarized yourself with the vehicle controls and have read and understood the driving instructions take the vehicle for a test drive Use the following checklist as a guide to inspect the vehicle and check daily for proper operation Any prob lems should be corrected by a Club Car distributor dealer or a trained technician All Vehicles Forward Reverse switch Check for proper operation See Controls and Indicators on page 15 Brakes Be sure the brakes function properly When brake pedal is fully depressed under moderate pressure it should not go more than halfway to the floor and vehicle should come to a smooth straight stop If the brake pedal goes more than halfway to the floor or if the vehicle swerves or fails to stop have the brake system checked and adjusted as required Brake adjustment must be maintained so that the brake pedal cannot be depressed to the floor under any circumstanc
12. to fully replenish the batteries and will complete the 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 enough power for approximately 30 minutes of operation This will alert the operator that the vehicle may be used but that it must be charged to completion as soon as possible The warning light will repeatedly illuminate for 10 seconds with 4 second intervals if the charger times out at 16 hours and the batteries are not sufficiently charged See the battery charger owner s manual This indicates an abnormal charge cycle The charger and batteries should be checked by your Club Car distributor dealer Page 18 2003 Transportation Electric Vehicle Owner s Manual Controls and Indicators The warning light will repeatedly illuminate for 10 seconds with 4 second intervals during a charge cycle DC plug is still connected if AC power to the charger is interrupted The light will go out when AC power is restored LED Light In addition to the warning light there is an infrared LED in the dash light assembly which trans mits an infrared signal from the onboard computer OBC This signal is received by the optional Communica tion Display Module which provides information on the condition of the vehicle and batteries TOW RUN SWITCH IQ System Vehicles Only A WARNING Place Tow Run s
13. 58 2227 If you would prefer to write to us direct your letter to Club Car Attention Marketing Services Box 204658 Augusta Georgia 30917 4658 USA Your local authorized Club Car representative can also provide technical advice parts and service manuals We hope you will consider this owner s manual a permanent part of your Club Car vehicle If you sell the vehi cle please include the manual so that the next owner will have the important operating safety and mainte nance information it contains 2003 Transportation Electric Vehicle Owner s Manual Page 3 Practice Safety Rotating Parts Safety signs like you see above 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 operating the vehicle we urge you to review the information in this manual Understand and become familiar with the DANGER WARNING and CAUTION state ments and procedures it contains along with the safety decals that are affixed to your vehicle Take time to understand the language of safety It is a language that can save your life PROPOSITION 65 STATE OF CALIFORNIA A WARNING This product contains or emits chemicals or substances that have been determined by the state of California to cause cancer and birth defects or other reproductive harm Page 4 2003 Transportation Electric Vehic
14. Avoid top heavy loads See Owner s Manual and gross trailer weight When driving on uneven terrain or down steep hills Maximum trailer hitch tongue weight 150 Ibs reduce speed and load CCI 101960001 Read Owner s Manual and warnings on dash 2003 Transportation Electric Vehicle Owner s Manual Page 13 Vehicle Feature Identification TRANSPORTER VEHICLES 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 manual before servicing CCI 101931501 DANG ER POISO N FLUSH EYES E SULFURIC IMMEDIATELY ELECTRICAL COMPONENT COVER CAUTION v E ACID e ON COVER ME FLAMES Pa e MEDICAL GASES CANCAUSE i SMOKING i SEVERE BURNS Ri FAST BLINDNESS OR INJURY KEEP OUT OF THE REACH OF CHILDREN DO NOT TIP KEEP VENT CAPS TIGHT AND LEVEL BATTERY DANGER MOLDED ON BATTERY CAPS NOTICE ELULE E CCI 1019646 01 ELECTRICAL COMPONENT MOUNTING PLATE NOTICE ON PLATE SIX PASSENGER F N R TRANSPORTER ED VEHICLE FORWARD REVERSE PASSENGER WARNING DECAL BED LOAD WARNING DECAL A WARNING Riding in cargo bed M can cause severe injury or death Do not ride in cargo bed CCT 1015539 01 CHARGER AC CORD REEL FOUR PASSENGER TRANSPORTER VEHICLE PASSENGER WARNING DECAL CRUSH AREA A WARNING DECAL UM M Z WARNING CRUSH AREA
15. CAL ON REAR HANDRAIL FACING SEAT A WARNING Failure to follow these instructions can cause severe injury or death Remain seated with entire body inside vehicle and hold on to seat handle or handrail at all times No more than two persons per seat Do not leave children unattended on vehicle at anytime Never stand in front of or behind vehicle 1017057 01 ROLLOVER OR FALLING OFF MAY CAUSE DEATH Before using vehicle read operating instructions Remain seated and hold on to seat handle while moving Do not start vehicle until all occupants are seated e Two 2 persons per seat maximum Operate from driver side only and not on public roads Keep entire body inside vehicle while moving Drive slowly in turns and straight and down slopes Do not leave children unattended on vehicle Never operate under the influence of alcohol or drugs Use brakes to reduce speed when coasting downhill e Never stand in front of or behind vehicle CCI 101960601 DRIVER PASSENGER WARNING DECAL BATTERY WARNING LIGHT KEY SWITCH SERIAL NUMBER ACCELERATOR PEDAL Page 8 2003 Transportation Electric Vehicle Owner s Manual Vehicle Feature Identification FOUR PASSENGER VILLAGER VEHICLE A DANGER POISON gt SULFURIC IMMEDIATELY QW NO i ACID WITH WATER SHIELD SPARKS 78 CAN CAUSE GET EXPLOSIVE GASES CAN CAUSE SMOKNG SEVERE
16. Computer LIMITED WARRANTY EXCLUSIONS THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOT APPLY TO FAILURE DUE TO 1 Abuse or neglect such as improper battery fluid levels loose wiring or rusted or corroded hardware 2 Lack of proper maintenance as outlined in the electric vehicle owners manual 3 Damages caused by improper installation of the Computer or Controller 4 Vehicles charged by systems other than the CLUB CAR PowerDrive Charger Without limiting the generality of the foregoing in any way and as part of its limited warranty exclusion CLUB CAR does not warrant that the Computer or Controller is suitable for use in any application other than its PowerDrive System 48 PowerDrive Plus and IQ System products As in the use of any battery operated device a prudent owner will read and study the charger owner s manual the electric vehicle owner s manual the operator instructions and the battery warning labels and will exercise due care in working on or around batteries Transportation expenses for warranty services are also excluded from this warranty WARRANTY LIMITATIONS CLUB liability under this limited warranty shall be to replace a defective Computer or Controller Replacement shall be furnishing a new or reconditioned Computer or Controller which is identical or reasonably equivalent to the warranted product at no cost to the purchaser during the four year or 800 round limited warranty period for golf use or 4 years or
17. E NOTE Always have the vehicle serial number at hand when ordering parts or making inquiries SERIAL NUMBER DECAL HAUNT Figure 2 Serial Number Decal CONTROLS AND INDICATORS Read DANGER and WARNING on page 6 A WARNING Before allowing anyone to drive the vehicle make sure the driver is familiar with all controls and operating procedures Any modification or change to the vehicle that affects the stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications could result in severe personal injury or death Do not shift the Forward Reverse handle or switch while the vehicle is moving To avoid injury to passenger s or damage to the vehicle always bring the vehicle to a full stop before shifting the handle or switch Release the accelerator pedal and then depress the brake pedal firmly until the vehicle stops To avoid unintentionally starting or rolling the vehicle set the park brake turn the key switch to OFF and remove the key when leaving the vehicle 2003 Transportation Electric Vehicle Owner s Manual Page 15 Controls and Indicators KEY SWITCH The key switch is mounted on the dash to the right of the steering column Figure 3 It has two positions OFF and ON which are clearly labeled See following NOTE NOTE The key can be removed only when the key switch is in the OFF position Figure Key Switch Figure 4 Forward Re
18. ND VILLAGER VEHICLES EIGHT PASSENGER VILLAGER VEHICLES Place Tow Run Io FRONT Switch D e OF VEHICLE LS FRONT OF VEHICLE Remove PLACE TOW RUN SWITCH Remove IN THE TOW POSITION BEFORE f DISCONNECT negative DISCONNECTING OR negative BATTERY CABLES HERE cable first CONNECTING BATTERY CABLES cable first Figure 1 Battery Configurations 2003 Transportation Electric Vehicle Owner s Manual Page 7 Vehicle Feature Identification FOUR PASSENGER VILLAGER VEHICLE Z WARNING OPERATING INSTRUCTIONS Read Owner s Manual and safety warnings located on dash panel prior to driving Study and understand controls Make sure wheels are turned in desired direction Turn key to ON position and be sure nothing is in your path While vehicle is stopped select direction by placing shift lever or switch in desired position F Forward N Neutral Reverse Buzzer will sound Vehicle will start moving when accelerator pedal is depressed Slowly depress accelerator pedal to increase speed Park brake will release when accelerator pedal is depressed To stop release accelerator pedal and depress brake pedal After stopping firmly depress park brake until it locks Place forward and reverse switch in neutral position Turn key OFF and remove key when not in use CCI 1016216 01 OPERATING INSTRUCTIONS DECAL PARK BRAKE PEDAL BRAKE PEDAL ARM RESTS HAND RAIL PASSENGER WARNING DE
19. Parts Fax 706 855 7413 www clubcar com Copyright 2002 Club Car Inc Club Car PowerDrive and ArmorFlex are registered trademarks of Club Car Inc This manual effective July 22 2002 2003 Transportation Electric Vehicle Owner s Manual Page 1 Page 2 2003 Transportation Electric Vehicle Owner s Manual FOREWORD Thank you for choosing Club Car You have chosen the finest utility vehicle on the market the vehicle most widely recognized as the industry leader in vehicle efficiency and long lasting value Please protect your investment and ensure that your Club Car vehicle s provides years of reliable superior performance by read ing and following the maintenance instructions in this manual Your comfort and safety are important to us so we urge you to read and follow the step by step operating instructions and safety procedures in this manual These instructions must be followed in order to avoid the risk of severe personal injury If you rent or loan your vehicle to others we recommend that you 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 vehicle needs repairs or service we recommend that your local authorized Club Car representative perform them For the name and address of the Club Car representative nearest you logon to our web site at www clubcar com or call 1 800 ClubCar 2
20. R WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE 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 7 NO CONSEQUENTIAL DAMAGES IN NO EVENT SHALL CLUB CAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS RELATED TO PROPERTY OTHER THAN THE VEHICLE LOSS OF USE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitation of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state 8 INFORMATION For further information contact WARRANTY SERVICES CLUB CAR INC P O Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 9 WARNING Any modification or alteration of any 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 WARRANTY FOR 2003 POWERDRIVE 8 VOLT BATTERIES CLUB CAR INC CLUB CAR hereby warrants to the original retail purchaser that the new PowerDrive 8 volt Battery installed in its new electric vehicle equipped with the PowerDrive System 48 PowerDrive Plus
21. REPLACEMENT OR REPAIR OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE 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 IN NO EVENT SHALL CLUB CAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS RELATED TO PROPERTY OTHER THAN THE BATTERY CHARGER LOSS OF USE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Damage not resulting from a defect that occurs due to unreasonable use abuse or neglect including failure to provide reasonable or necessary maintenance accident or alteration is excluded from the limited warranty Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitations of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state For further information contact WARRANTY SERVICES CLUB CAR INC P O Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 CLUB CAR LIMITED FOUR YEAR WARRANTY FOR 2003 ONBOARD COMPUTERS AND SOLID STATE SPEED CONTROLLERS CLUB CAR INC CLUB CAR hereby warrants to the original retail purchaser that
22. Remove the key when the vehicle is not in use 3 IQ System vehicles only When the Tow Run switch is in the RUN position with the Forward Reverse Switch or key switch in any position the zero speed detect function will prevent the vehicle from rolling at more than 1 to 3 mph 1 5 to 4 8 km h unless the accelerator is depressed This prevents the possi bility of a parked vehicle with the park brake disengaged rolling away too fast to be overtaken on foot See Zero Speed Detect on page 21 LOADING AND UNLOADING A WARNING Firmly engage the park brake before loading the vehicle Do not allow riders in the cargo bed Reduce vehicle load and speed when driving up or down slopes or on uneven terrain Do not exceed the rated capacity of the vehicle Rated capacity is for level surfaces only Overloading can affect vehicle handling or cause component failure resulting in loss of control of vehicle and possible severe personal injury or death Reduce speed and avoid sudden stops when backing up Failure to do so may cause the vehicle to overturn or flip over backwards Do not load the tailgate The tailgate should be in the upright position and latched securely while the vehicle is in motion To help avoid shifting the vehicle load and possibly overturning the vehicle avoid sudden starts sudden stops and abrupt turns The cargo s center of gravity may affect the handling steering and braking of the vehicle To help prevent cargo f
23. TO FAILURE DUE TO 1 Lack of normal maintenance services such as preventive maintenance checks and tightening loose wire connections 2 Semiconductor parts such as diodes and fuses which are vulnerable to electrical overloads including lightning beyond the control of CLUB CAR 3 Charger DC cord set with plug which is a wear item and subject to user abuse Page 40 2003 Transportation Electric Vehicle Owner s Manual Any warranty service which includes labor during the first year must be performed by CLUB CAR or by an authorized distributor or dealer For repairs made by qualified technicians other than CLUB factory technicians or an authorized distributor or dealer CLUB CAR will provide only the replacement parts or components PowerDrive Chargers are intended to be used by persons with knowledge of the chargers and proper charging practices and only on CLUB CAR PowerDrive System 48 PowerDrive Plus or IQ System vehicles Any other use renders the Limited Warranties expressed herein and any implied warranties null and void and same are hereby excluded Without limiting the generality of the foregoing in any way and as part of its limited warranty exclusion CLUB CAR does not warrant that the PowerDrive Charger is suitable for use in any application other than its PowerDrive System 48 PowerDrive Plus or IQ System products As in the use of any electrical device a prudent owner will read and study the charger owner s manua
24. Unit limited warranty period whichever first occurs All batteries which are replaced under this limited warranty become the property of CLUB CAR THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REPLACEMENT OR REPAIR OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE 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 This battery is intended to be used by persons with training and experience with batteries and only in CLUB CAR electric vehicles Any other use renders the Limited Warranties expressed herein and all implied warranties null and void and same are hereby excluded ALSO EXCLUDED FROM THIS LIMITED WARRANTY ARE ANY AND ALL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE OR REVENUE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Damage not resulting from a defect in material or workmanship or that occurs due to abuse or neglect including failure to
25. Villager TransPorter x 2005 Owners Manual Performance Utility Vehicles NOTICE The Club Car Limited Warranties for 2003 Transportation and Utility Vehicles 2003 PowerDrive 8 Volt Batter ies 2003 PowerDrive Battery Chargers and 2003 Onboard Computers and Solid State Speed Controllers appear on the last pages of this manual No other warranties express or implied are contained herein Your authorized representative checked the vehicle before it was delivered to you and will provide you a copy of the completed vehicle warranty registration form 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 This manual contains proprietary information that is protected by copyright All rights are reserved No part of this manual may be photocopied reproduced or translated to another language without the written consent of Club Car Inc The information contained in this document is subject to change without notice Club Car reserves the right to make design changes to vehicles without obligation to make these changes on units previously sold These vehicles do not conform to Federal Motor Vehicle Safety Standards for automobiles or to FMVSS 500 for low speed vehicles and are not equipped for operation on public streets roads or highways Club Car i P O Box 204658 Augusta Georgia 30917 4658 USA Telephone 706 863 3000 Service
26. able limited warranty period a new vehicle or factory reconditioned vehicle or component thereof that is identical or reasonably equivalent to the warranted product or component at no cost to the purchaser Repair shall mean remedying a defect in the vehicle or component thereof at no cost to the purchaser during the applicable limited warranty period If CLUB CAR elects to repair the vehicle it may provide factory reconditioned parts or components All parts and components replaced under warranty shall become the property of CLUB CAR 5 HOW TO MAKE A WARRANTY CLAIM To make a warranty claim under this limited warranty you must present the vehicle or defective component to an authorized CLUB CAR dealer or send the defective component freight prepaid to WARRANTY SERVICES CLUB CAR INC 4125 Washington Road Evans Georgia 30809 U S A 706 863 3000 Page 38 2003 Transportation Electric Vehicle Owner s Manual 6 DISCLAIMER THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REMEDY OF THE REPLACEMENT OR REPAIR OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER REPRESENTATION O
27. ake Chock the wheels to prevent the vehicle from rolling 9 Keep batteries fully charged during storage 10 Leave PowerDrive Chargers plugged in during storage The onboard computer will automatically activate the charger when necessary If charger cannot remain plugged in or AC power will not be available dur ing extended storage disconnect the batteries for storage Figure 1 Page 7 RETURNING THE STORED VEHICLE TO SERVICE If necessary connect batteries Fully charge batteries Adjust tires to recommended tire pressure See Vehicle Specifications on page 36 e 0v Perform the Pre Operation and Daily Safety Checklist on page 20 2003 Transportation Electric Vehicle Owner s Manual Page 25 Maintenance MAINTENANCE Read DANGER and WARNING on page 6 To ensure trouble free vehicle performance it is very important to follow an established preventive mainte nance program Regular and consistent vehicle maintenance can prevent vehicle downtime and expensive repairs that can result from neglect Use the Pre Operation and Daily Safety Checklist on page 20 and the fol lowing Periodic Service Schedule and Periodic Lubrication Schedule to keep the vehicle in proper working condition Any vehicle not functioning correctly should be removed from use until it is properly repaired This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions Contact your local Club Car d
28. an 1 to 3 mph 1 5 or 4 8 km h with the Forward Reverse switch in any position When zero speed detect motor braking is engaged the reverse buzzer should emit a distinct pattern of beeps Pedal Up Motor Braking adjustable on IQ System vehicles Accelerate the vehicle to full speed and then release the accelerator pedal Motor braking should quickly and smoothly slow the vehicle to approximately 9 mph Motor braking will disengage when vehicle slows to 9 mph 15 km h This fea ture is adjustable for IQ System vehicles only Contact your local Club Car dealer distributor to inquire about this adjustable feature Pedal Down Motor Braking Accelerate down an incline with the accelerator pedal depressed When the vehicle reaches maximum designed speed motor braking should engage and limit the vehi cle to its maximum designed speed On very steep grades the vehicle may slightly exceed its maxi mum designed speed requiring use of the brake pedal DRIVING INSTRUCTIONS A WARNING Only licensed drivers should be allowed to drive the vehicle Before allowing anyone to drive the vehicle make sure the driver is familiar with all controls and operating procedures No more than two people per seat at one time Do not allow riders in the cargo bed The vehicle is not specially equipped for handicapped persons Make sure all persons can properly operate the vehicle prior to allowing them to drive the vehicle Make sure all pass
29. ay be used For heavy soiling difficult stains or scratches blemishes or other body damage see Section 4 of the maintenance and service manual NOTE Dispose of waste water properly ACCESSORIES There is a complete line of accessory equipment available from Club Car and our distributors dealers Contact a Club Car distributor dealer for information about all of the accessories available for your vehicle Page 34 2003 Transportation Electric Vehicle Owner s Manual Care should be taken that these accessories are properly installed by trained technicians and they are used in the manner for which they were designed A WARNING Custom cab assemblies weatherproof enclosures door kits and tinted windshields will not protect occupants from flying objects golf balls etc SUBSEQUENT OWNER REGISTRATION In the event a vehicle is bought used from another individual or from a distributor dealer we strongly urge the new owner to register the vehicle with Club Car This will enable us to contact you if the need arises Please send your name address and serial number s of the vehicle s to Club Car Inc Box 204658 Augusta Georgia 30917 4658 Attention Vehicle Registration 2003 Transportation Electric Vehicle Owner s Manual Page 35 VEHICLE SPECIFICATIONS Villager TransPorter Four Six Eight Four Six S P ECI FICATIONS Passenger Passenger Passenger Passenger Passenger IQ System PowerDrive System 48 PowerD
30. bottom rem Load bed height s n 35 8 in Load bed size flat bed dimensions x 44 3 in 91 x 112 cm Vehicle rated capacity level surface only Ges ko 630 ka 680 ke 630 ka 680 0 Standard seating capacity 4 6 8 4 6 LIQUID CAPACITIES 22 oz 22 oz 22 oz 22 oz 22 oz Transaxle 67 liters 67 liters 67 liters 67 liters 67 liters TIRE PRESSURE 18 20 psi 30 34 psi 30 34 psi 30 34 psi 30 34 psi Front and rear 1 24 1 38 Bars 2 07 2 34 Bars 2 07 2 34 Bars 2 07 2 34 Bars 2 07 2 34 Bars 2003 Transportation Electric Vehicle Owner s Manual Page 37 CLUB CAR LIMITED TWO YEAR WARRANTY FOR 2003 TRANSPORTATION AND UTILITY VEHICLES 1 WARRANTY CLUB CAR INC CLUB CAR hereby warrants to the Original Retail Purchaser that its new 2002 Model Transportation and Utility Vehicles purchased from CLUB CAR or an authorized dealer shall be free from defects in material and workmanship under normal use and service as a transportation or utility vehicle for the periods stated below subject to the provisions limitations and exclusions contained in this limited warranty LIMITED TWO YEAR 2000 HOUR WARRANTY The engine assembly unitized transaxle assembly gasoline vehicle motor transaxle assembly electric vehicle main frame assembly hydraulic dump kit Custom Cab assembly and doors and Driving Range Protective Enclosure are warranted with respect to parts and labor against defects in material an
31. clean and tight Do not expose to rain or any liquid Keep the charger dry Do not use near fuels grain dust solvents thinners or other flammables Chargers can ignite flammable materials and vapors Connect the charger AC supply cord to a properly grounded three wire outlet of the proper voltage and frequency as shown on the charger Do not 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 Use only an extension cord or electrical outlet that will accept a three prong plug Extension cord should be a three wire no 12 AWG and be as short as possible The use of an improper extension cord could result in fire or an electrical shock Do not operate the charger if it has received a sharp blow was dropped or otherwise damaged in any way Never push objects of any kind into the charger through cabinet slots They may touch dangerous voltage points or cause an electrical short circuit that could result in fire or electrical shock Do not connect a stationary charger to the receptacle if the charger cord plug or the vehicle receptacle is broken damaged or does not make a good electrical connection Fire or personal injury can result Have a qualified technician repair or replace it immediately When using a stationary charger do not pull on the DC cord Figure 13 Page 33 Do not twist rock or ben
32. controller are covered under separate CLUB CAR warranties Also excluded from any CLUB CAR warranty is damage to a vehicle or component resulting from a cause other than a defect including unreasonable or unintended strain or use improper installation of accessories installation of parts or accessories that are not original equipment overloading accident alteration abuse or neglect Transportation expenses for warranty services are also excluded from this warranty 3 VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICLE IS ABUSED OR USED IN AN UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY INCLUDING BUT NOT LIMITED TO MODIFICATION OF THE SPEED GOVERNOR BRAKING SYSTEM STEERING TRANSAXLE OR OTHER OPERATING SYSTEMS OF THE VEHICLE TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKEWISE VOID IF THE VEHICLE INVOLVED SHOWS INDICATIONS THAT REASONABLE OR NECESSARY MAINTENANCE AS OUTLINED IN THE OWNER S MANUAL AND MAINTENANCE AND SERVICE MANUAL WAS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS 4 SOLE REMEDY CLUB liability under this limited warranty or in any action whether based upon warranty contract negligence strict product liability or otherwise shall be the repair or replacement at CLUB CAR s option of the vehicle or component thereof that CLUB CAR deems to be defective Replacement shall mean furnishing during the applic
33. d workmanship for a period of two years or 2000 hours of operation whichever first occurs from the date of purchase LIMITED ONE YEAR 1000 HOUR WARRANTY All remaining components of the vehicle not specified otherwise the Portable Refreshment Center and all other original equipment options and accessories supplied by CLUB CAR are warranted with respect to parts and labor against defects in material and workmanship for a period of one year or 1000 hours of operation whichever first occurs from the date of purchase This limited warranty covers material workmanship and repair labor cost as to those items specifically listed above for the periods specified Such repair labor shall be performed only by CLUB CAR its authorized dealers or a service agency approved by CLUB CAR IF THE WARRANTY REGISTRATION FORM IS NOT COMPLETED AND RETURNED TO CLUB CAR AT THE TIME OF THE ORIGINAL RETAIL SALE PURCHASER MUST PROVIDE PROOF OF DATE OF PURCHASE WITH ANY WARRANTY CLAIM 2 EXCLUSIONS Excluded from any CLUB CAR warranty are all fuses filters decals except safety decals spark plugs light bulbs lubricants trim pieces seats routine wear items such as the charger plug and 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 Batteries battery charger onboard computer and solid state speed
34. d the plug To disconnect the plug from the receptacle grasp the plug not the cord and slowly pull it straight out of the receptacle Figure 12 Page 33 When the charger is on the charger DC cord may be disconnected from the vehicle receptacle slowly Jerking or pulling the DC cord out quickly could cause arcing and burning which could damage the plug and receptacle and could cause batteries to explode Do not use a charger if The plug is too loose or does not make a good connection The plug and receptacle feel hotter than normal during charge The plug pins or contacts are bent or corroded The plug receptacle or cords are cut worn have any exposed wires or are damaged in any way Using a charger with any of the above symptoms could result in fire property damage personal injury or death 2003 Transportation Electric Vehicle Owner s Manual Page 31 Battery Charger A CAUTION Do not block or cover the charger ventilation slots The slots provide ventilation and prevent the charger from overheating Do not allow clothing blankets or other material to cover the charger Do not allow the charger to operate for more than 30 minutes at 19 or more amperes Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightning strikes Each electric vehicle is supplied with either a fully automat
35. e Park brake When latched the park brake should lock the wheels and hold the vehicle stationary on an incline of 2096 or less It should release when either the accelerator or brake pedal is depressed Reverse buzzer The reverse buzzer will sound as a warning when the Forward Reverse handle or switch is in REVERSE Steering The vehicle should be easy to steer and should not have any play in the steering wheel Accelerator As the accelerator pedal is depressed the motor should start and the vehicle should accelerate smoothly to full speed When the pedal is released it should return to the original position and the motor should rotate freely The vehicle will run at a reduced speed when in REVERSE IQ System vehicles only When the pedal is released it should return to the original position and the motor should rotate freely or go into motor braking mode See Pedal Up motor braking below Page 20 2003 Transportation Electric Vehicle Owner s Manual Driving Instructions General Listen for any unusual noises such as squeaks or rattles Check the vehicle ride and perfor mance Have a Club Car distributor dealer or a trained technician investigate anything unusual IQ System Vehicles Zero Speed Detect With the vehicle parked on level ground and the park brake disengaged place the Tow Run switch in the RUN position and attempt to push the vehicle Motor braking should engage and cause resistance to rolling moving at no more th
36. ed on charge The batteries should never be left discharged any longer than absolutely necessary do not leave batteries discharged overnight LEVEL BATTERY INDICATOR J CAP PLATES ELECTROLYTE LEVEL AT LEAST 1 2 INCH 13 MM ABOVE PLATES OR TO LEVEL INDICATOR Figure 11 Battery Electrolyte Level BATTERY CHARGER Read DANGER and WARNING on page 6 A DANGER The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the charging area must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Page 30 2003 Transportation Electric Vehicle Owner s Manual Battery Charger Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosion A WARNING Only trained technicians should repair or service the charger Contact a Club Car distributor dealer Each charger should have its own dedicated 15 or 20 ampere separately protected circuit breaker or fuse single phase branch circuit in accordance with all applicable electrical codes for the location Have worn cut or damaged power cords or wires replaced immediately Be sure that all wire connections at the receptacle and fuse link are
37. edal differs from that of an automobile When the key switch is ON and the Forward Reverse handle or switch is in either FORWARD or REVERSE depressing the accelerator pedal will automatically release the park brake and start the vehicle moving in the direction selected forward or reverse As the accelerator pedal is depressed speed will increase until full speed is reached When the accelerator pedal is released power will be cut off and the motor will stop running NOTE IQ System vehicles only See pedal up and pedal down motor braking on page 21 Page 16 2003 Transportation Electric Vehicle Owner s Manual Controls and Indicators Figure 5 Forward Reverse Rocker Switch Figure 6 Accelerator and Brake Pedals Figure 7 Brake Pedal Figure 8 Park Brake Pedal BRAKE PEDAL The brake pedal is the large pedal on the left with the word STOP molded into it Figure 6 To slow or stop the vehicle depress the brake pedal with your foot Figure 7 PARK BRAKE PEDAL The park brake pedal is the small raised portion in the upper left corner of the brake pedal It has the word PARK molded into it and the words PARK BRAKE marked on top Figure 7 To set the park brake depress the brake pedal firmly and tilt the park brake portion of the pedal forward Figure 8 See following WARN ING A WARNING The park brake will release automatically when either the accelerator or brake pedal is depressed The park brake has multiple locking p
38. electrical and mechanical repair The appropriate instructions must be used when performing maintenance Service or accessory installation IQ System vehicles Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning could result in a battery explosion or severe personal injury All electric vehicles To avoid unintentionally starting the vehicle disconnect the batteries as shown Figure 1 IQ System vehicles After disconnecting the batteries wait 90 seconds for the controller capacitors to discharge PowerDrive System 48 vehicles After disconnecting the batteries discharge the controller capacitors as follows Turn key switch to ON and place the Forward Reverse handle in REVERSE Slowly depress the accelerator pedal and keep it depressed until the reverse warning buzzer can no longer be heard When the buzzer stops sounding the controller capacitors are discharged Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing 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 BATTERY BANK FOR FOUR PASSENGER BATTERY BANK FOR TRANSPORTER AND SIX A
39. engers are capable of securing themselves in a vehicle before allowing them to ride in one For night use vehicle must be equipped with headlights taillights and reflectors Stop vehicle before shifting Forward Reverse handle or switch Failure to do so may result in injury to inattentive passengers and or damage to the vehicle To help avoid being struck do not stand in front of or behind the vehicle Do not leave children unattended on vehicle Operate the vehicle from the driver seat only To help prevent falls from the vehicle remain seated and hold on to seat handles or handrails at all times Driver should keep both hands on the steering wheel when the vehicle is in motion To help prevent the possibility of serious injury keep entire body inside vehicle To help prevent vehicle from overturning drive slowly in turns To help prevent vehicle from overturning drive slowly straight up and down slopes Avoid driving the vehicle on slopes exceeding 20 incline 2003 Transportation Electric Vehicle Owner s Manual Page 21 Driving Instructions Avoid stopping a loaded vehicle on a hill If a loaded vehicle must be stopped on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning could result in the vehicle overturning To help avoid possible injury to inattentive passengers and or damage to the vehicle avoid sudden starts sudden stops and abrupt turns To help avo
40. es of six and eight passenger Villager vehicles are ABS DR acrylic material Use only commercially available automotive cleaner with a sponge or soft cloth for normal cleaning A garden hose at normal residential water pressure is adequate To remove oxidation or discoloration from aluminum use a commercially available aluminum cleaner paste and fine grade No 00 steel wool Club Car does not recommend any type of pressure washing or steam cleaning Such a process especially if the vehicle has an ArmorFlex rear body that has been removed will expose electrical components to mois ture Moisture entering electrical components can result in water damage and subsequent component failure Use non abrasive wax products Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible stains The center bodies of six and eight passenger Villager vehicles are made of an ABS DR acrylic material similar to the material used to manufacture hot tubs and shower tub units Cleaning and repair techniques for the center body are the same as those used on conventional acrylic sheet Repair kits cleaning and polishing products may be purchased at any hardware store where ABS DR acrylic hot tubs and shower tub units are sold The seats of the vehicle will last longer with proper cleaning Use a solution of 10 liquid soap and warm water applied with a soft cloth For imbedded dirt a soft bristle brush m
41. ian BATTERY WARNING LIGHT PowerDrive System 48 and IQ System vehicles feature a dash mounted warning light above steering column that when the vehicle is in operation indicates low battery voltage or when the vehicle is being charged indi cates a charging problem The battery warning light is controlled by the onboard computer When the vehicle is in operation the warning light will illuminate and remain illuminated if Batteries voltage drops below 48 volts when there is no load on the batteries the vehicle is stopped and there are no accessories on Batteries have discharged to less than 25 of rated capacity If the warning light comes on when the vehicle is operating there will be enough power remaining to drive the vehicle for approximately 30 minutes However the vehicle should be charged at the first opportunity If the warning light comes on and the vehicle is unable to operate for 30 minutes have your Club Car distributor dealer check the vehicle for a possible battery or electrical system problem When the batteries receive an incomplete charge because 1 the DC power cord is disconnected 2 AC power to the charger is interrupted 3 automatic charger shut off occurs after 16 hours of operation or 4 the charger malfunctions the warning light will indicate as follows The warning light will not come on if the charge is 90 or more complete The onboard computer will retain in memory the amount of charge needed
42. ic stationary battery charger Villager vehicles or fully automatic onboard charger TransPorter as standard equipment The AC cord from the charger should be connected to a source capable of supplying 10 amperes minimum per charger To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord having an equipment grounding conductor and a grounding type plug The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electrical Code and all local codes and ordinances See the owner s manual supplied with the battery charger for specific operating instructions before using the charger NOTE Because the PowerDrive Chargers have a storage charge feature that automatically checks and recharges the batteries as necessary every 15 days either charger can remain plugged to a Pow erDrive vehicle throughout the storage period Shortly after charging begins PowerDrive Chargers will shut off in order to run a self diagnostic program ammeter 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 The use of an extension cord with the charger should be avoided If an extension cord must be used use a three conductor no 12 AWG American Wire Gauge or no 14 SWG British Standard Wire Gauge heavy du
43. id possible property damage personal injury or death Contact your Club Car distributor dealer A DANGER A DANGER indicates an immediate hazard that will result in severe personal injury or death A WARNING AWARNING indicates an immediate hazard that could result in severe personal injury or death A CAUTION A CAUTION indicates a hazard or unsafe practice that could result in minor personal injury or product or property damage GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated repaired or ser viced Vehicle feature identification information is also included beginning on page 8 Other specific safety statements appear throughout this manual and on the vehicle A DANGER Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries A Club Car vehicle will not provide protection from lightning flying objects or other storm related hazards If caught in a storm while driving a Club Car vehicle exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location A WARNING Follow the procedures exactly as stated in this manual and heed all DANGER WARNING and CAUTION statements in this manual as well as those on the vehicle and batter
44. id the possibility of losing control of or overturning the vehicle reduce speed for adverse driving conditions such as wet grass or rough terrain Do not use the vehicle on public roads It is neither designed nor intended for street use and should not be licensed for use on public roads The vehicle should be driven in only specified areas by trained operators Do not drive while under the influence of alcohol drugs or medications Use brakes to reduce speed when coasting downhill No one should drive the vehicle without first being instructed in the proper operation and use of the vehicle s controls An experienced operator should accompany each first time driver on a test drive before allowing him her to operate the vehicle alone To ensure safe operation of the vehicle follow all procedures exactly as written Read and understand all instructions prior to driving the vehicle STARTING THE VEHICLE 1 Make sure load is secure 2 Make sure everyone is seated and holding onto seat handles or handrails Driver should have both hands on the steering wheel Read safety warnings located on dash and or above pedals Make sure wheels are turned in desired direction Turn key to the ON position and make sure nothing is in your path oa gt Select direction by placing Forward Reverse handle or switch in desired position F forward or R reverse A buzzer will sound as a warning when the Forward Reverse handle or switch
45. il all occupants are seated shift lever or switch in desired position e Two 2 persons per seat maximum F Forward N Neutral Reverse Buzzer will sound Operate Tom driver side only and not on public roads Vehicle will start moving when accelerator pedal is depressed Keep entire body inside vehicle while moving Slowly depress accelerator pedal to increase speed Park brake will Drive slowly in turns and straight up and down slopes not leave children unattended on vehicle release when accelerator pedal is depressed To stop release accelerator pedal and depress brake pedal Never operate under the influence of alcohol or drugs MTS e to reduce speed when coasting KEY SWITCH After stopping firmly depress park brake until it locks Place forward and reverse switch in neutral position Never stand in front of or behind vehicle Turn key OFF and remove key when not in use DRIVER PASSENGER CCI 1016216 01 WARNING DECAL OPERATING INSTRUCTIONS DECAL CCI 101960601 BATTERY WARNING LIGHT ACCELERATOR PEDAL BATTERY CONDITION INDICATOR LIGHT SWITCH SERIAL NUMBER PASSENGER WARNING DECAL A WARNING Failure to follow these instructions can cause severe injury or death PARK BRAKE PEDAL Remain seated with entire body inside vehicle and hold on to seat handle or handrail at all times No more than two persons per seat
46. ilure to make necessary repairs could result in fire property damage severe personal injury or death 2003 Transportation Electric Vehicle Owner s Manual Page 27 PERIODIC LUBRICATION SCHEDULE Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE REGULARINTERVAL SERVICE LUBRICATION RECOMMENDED LUBRICANT Semiannually by owner Brake pedal shaft bearings Dry Moly Lube P N 1012151 or trained technician 50h f al es e Brake linkage and pivots oa Dry Moly Lube CCI P N 1012151 Accelerator pivot rod supports 3 Dry Moly Lube CCI P N 1012151 Charger receptacle Villager vehicles only N Forward Reverse switch contacts 4 4 MEER PowerDrive vehicles only Brake slides Qv Dry Moly Lube CCI P N 1012151 Front suspension 5 fittings Qv Chassis Lube EP NLGI Grade 2 Annually by trained 22 oz 0 67 liters SAE 30 WT API technician only Check fill transaxle to plug level Class SE SF or SG Oil or higher every 100 hours of Operation nspect front wheel bearings _ Repack if necessary Gv Chassis Lube EP NLGI Grade 2 FLOORBOARD
47. ing they must be replaced when worn or dam aged If charger plug or receptacle show signs of corrosion or the plug is difficult to insert or remove the receptacle contacts and plug terminals should be cleaned with a good electrical contact cleaner or lightly sprayed with WD 409 brand spray lubricant The plug should then be inserted and removed several times to ensure ease of insertion ease of removal and good electrical contact See following NOTE NOTE If the warning tag has been damaged or removed from the DC cord have it replaced immediately RECEPTACLE FUSE LINK Villager vehicles As an additional feature to protect the batteries and charging circuit from an overload the electric vehicle is equipped with a receptacle fuse link Figure 14 If the charger does not come on when the vehicle is placed on charge visually inspect the fuse link See following WARNING A WARNING If the receptacle fuse link is blown determine the source of the problem and correct it before replacing the fuse Never modify wiring to bypass the gray sense lead fuse Figure 14 2003 Transportation Electric Vehicle Owner s Manual Page 33 Cleaning the Vehicle 48 VOLT FUSE LINK SENSE LEAD Figure 14 Receptacle Fuse Link CLEANING THE VEHICLE Transportation vehicles are equipped with ArmorFlex front bodies and either ArmorFlex or all aluminum rear bodies The four passenger TransPorter vehicle has an aluminum cargo bed The center bodi
48. ire body inside vehicle while moving Drive slowly in turns and straight and down slopes Do not leave children unattended on vehicle Never operate under the influence of alcohol or drugs Use brakes to reduce speed when coasting downhill Never stand in front of or behind vehicle e Vehicle will start moving when accelerator pedal is depressed Slowly depress accelerator pedal to increase speed Park brake will release when accelerator pedal is depressed To stop release accelerator pedal and depress brake pedal 101960601 After stopping firmly depress park brake until it locks Place forward and reverse switch in neutral position DRIVER PASSENGER Turn key OFF and remove key when not in use WARNING DECAL CCI 1016216 01 CUD OPERATING INSTRUCTIONS KEY SWITCH DECAL BATTERY WARNING LIGHT BATTERY CONDITION INDICATOR LIGHT SWITCH SERIAL NUMBER ACCELERATOR PEDAL VEHICLE LOADING DECAL Vehicle rated capacity 1500 Ibs on level surface only Cargo should be evenly spread over the floor of the VEHICLE Weight to include passengers cargo bed load and cargo bed as far forward as possible and secured LOADING gross trailer weight See Owner s Manual For vehicle stability when fully loaded drive slowly Maximum cargo load CARRYALL 6 and TURF 6 1000 Ibs and avoid stopping on or backing down steep hills TRANSPORTER 300 LBS Weight to include cargo bed load
49. istributor dealer to perform all repairs and semiannual and annual periodic ser vice A WARNING f any problems are found during scheduled inspection or service do not operate vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal injury or death Do not work on vehicle powertrain or under cargo bed when it is loaded Hot Do not attempt to service hot motor Attempting to do so can cause severe burns PERIODIC SERVICE SCHEDULE A WARNING Service repairs and adjustments must be made per instructions in the maintenance and service manual NOTE If the vehicle is constantly subjected to heavy use or severe operating conditions the preventive maintenance procedures should be performed more often than recommended in the periodic ser vice and lubrication schedules Both the Periodic Service Schedule and Periodic Lubrication Schedule must be followed to keep vehicle in optimum operating condition Page 26 2003 Transportation Electric Vehicle Owner s Manual Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Daily service by owner Batteries Charge batteries after each use only Weekly service by owner Check electrolyte level Add water if Batteries necessary per Section 13 Batteries in the maintenance and service supplement Monthly service by owner Batteries Wash battery tops and clean terminals o
50. l the electric vehicle owner s manual the operator instructions and the battery warning labels and will exercise due care in working on or around electrical devices Transportation expenses for warranty services are also excluded from this warranty WARRANTY LIMITATIONS CLUB CARS liability under this limited warranty or in any action whether based upon warranty contract negligence strict product liability or otherwise shall be the replacement or repair of a charger or component thereof that CLUB CAR deems to be defective Replacement shall mean furnishing during the applicable limited warranty period a new charger or component thereof that is identical or reasonably 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 during the applicable limited warranty period If CLUB CAR elects to repair the charger it may provide factory reconditioned parts or components All parts and components replaced under warranty shall become the property of CLUB CAR THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE
51. le Owner s Manual TABLE OF CONTENTS Safety Details tke eda egt osea iota EHE SER e ep eria eR e pore te iR reta te sa 6 General Warnings eie 54 dap Dha ad e xb ie eee Bee ed eee NERA REA ee EE 6 Vehicle Feature Identification Four Passenger Villager Vehicle 8 Vehicle Feature Identification Six and Eight Passenger Villager 10 Vehicle Feature Identification Six Passenger Villager Vehicle 11 Vehicle Feature Identification Eight Passenger Villager Vehicle 12 Vehicle Feature Identification Transporter Vehicles 13 General 8 3 15 Model Identification eee eee 15 Controls and Indicators Pad ea dad nist Geen ere ees 15 Pre Operation and Daily Safety Checklist 20 Driving lristr ctlorns s 22e zer ELE ian tees O ee aed de deus 21 Loading and Unloading reve URS RORIS rub Rte RR IEEE PETERS 23 Transporting ona Trailer oi oessa saia a a OE TR AA A rs 24 Storage nean n tae gu pre ni iv bM ed ag deere 25 Maintenance tene Bee ee Bie ed er ee Pg E oe eds 26 Periodic Service Schedule hh 26 Periodic Lubrication 5
52. minals of batteries with a solution of baking soda and water 1 cup 237 mL baking soda per gallon 3 8 L of water Rinse solution off bat teries Do not allow this solution to enter the batteries Be sure terminals are tight Let the terminals dry and then spray them with Battery Terminal Protector Spray CCI P N 1014305 NOTE Dispose of waste water properly 2 The electrolyte level in the batteries should be checked weekly Figure 11 Add water only after charg ing unless the electrolyte level is below the top of the plates In this case add just enough water to cover the plates charge and then check the level again Never charge batteries 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 straps should be tight enough so that the batteries do not move while the vehicle is in motion but not so tight as to crack or buckle the battery case Tighten hold down retaining nuts to 40 in Ib 4 5 N m The terminal connections should be clean and tight and any worn insulation or frayed wires should be replaced Tighten battery terminals to 110 in Ib 12 4 N m See following CAUTION A CAUTION If battery wire terminals are damaged or corroded they should be replaced or cleaned as necessary Failure to do so may cause them to overheat during operation 4 After use the batteries should be plac
53. nally starting the vehicle or a fire hazard Do not attempt to charge frozen batteries or batteries with bulged cases Discard the battery Frozen batteries can explode A CAUTION Batteries in a low state of charge will freeze at low temperatures When washing the vehicle do not direct water stream at the MCOR Forward Reverse switch or other electronic component Q System vehicles only Place Tow Run switch in TOW position PREPARING THE VEHICLE FOR EXTENDED STORAGE 1 Unload the vehicle so that tires are supporting only the weight of the vehicle 2 Fully charge batteries See Charging Batteries on page 32 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 mL baking soda per 1 gallon 3 8 L of water Rinse solution off bat teries Do not allow this solution to enter the batteries Be sure terminals are tight Let the terminals dry and then coat them with Battery Terminal Protector Spray CCI P N 1014305 4 Store vehicle in a cool dry place This will minimize battery self discharge 5 Adjust tires to recommended tire pressure See Vehicle Specifications on page 36 6 Lubricate front suspension and do all other semiannual periodic lubrication See Periodic Lubrication Schedule on page 28 7 Thoroughly clean front body rear body seats cargo bed battery compartment and underside of vehicle 8 Do not engage the park br
54. ng undercharging improper fluid levels loose wiring or rusted or corroded hardware 2 Lack of proper maintenance as outlined in the electric vehicle owner s manual 3 Damages caused by improper installation of the battery 4 Neglect breakage freezing fire explosion wreckage the addition of any chemical or the operation of the battery in an uncharged condition below half charge 1 200 specific gravity 5 A battery damaged by a defective charger 2003 Transportation Electric Vehicle Owner s Manual Page 39 Without limiting the generality of the foregoing in any way and as part of its limited warranty exclusion CLUB CAR does not warrant that its PowerDrive battery is suitable for use in any application other than in its products As in the use of any battery a prudent owner will read and study the charger owner s manual the electric vehicle owner s manual the operator instructions and the battery warning labels and will exercise due care in working on or around batteries Transportation expenses for warranty services are also excluded from this warranty WARRANTY LIMITATIONS CLUB CARS liability under this limited warranty shall be to replace a defective battery Replacement shall be furnishing a new or used battery with sufficient life to complete the remainder of the warranty term which is identical or reasonably equivalent to the warranted product at no cost to the purchaser during the four year 800 round or 16 000 Energy
55. ng and possible battery explosion as the battery cables are disconnected For Long Term Storage Place the Tow Run switch in the TOW position to turn off power to the vehicle electrical system thus preventing vehicle electrical components from discharging the batteries 2003 Transportation Electric Vehicle Owner s Manual Page 19 Pre Operation and Daily Safety Checklist PRE OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory however upon receiving your new vehicle s you should become familiar with its controls indicators and operation Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery Use the following checklist as a guide to inspect the vehicle This checklist should be used daily to ensure that the vehicle is in proper working condition and in conjunction with the Periodic Service Schedule on page 27 Any problems should be corrected by a Club Car distributor dealer or a trained technician General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tight Safety and information decals Check to ensure that all safety and information decals are in place See pages 8 through 14 Tires Check for proper tire pressure See Vehicle Specifications on page 36 Visually inspect for wear damage and proper inflation Batteries Before using vehicle for the first
56. ositions and should be firmly pressed and locked to prevent the vehicle from rolling 2003 Transportation Electric Vehicle Owner s Manual Page 17 Controls and Indicators HEADLIGHT CONTROL TransPorter Six and Eight passenger Villager Vehicles Only The headlight control is located on the front dash between the battery condition indicator and steering col umn Pull the headlight control knob out to turn headlights on and push the knob in to turn headlights off BATTERY CONDITION INDICATOR TransPorter Six and Eight passenger Villager Vehicles Only The battery condition indicator features a 10 bar LED display that when the vehicle is in operation displays the level of battery capacity measuring battery voltage over a period of time When batteries are fully charged all indicator lights will be on When battery voltage drops below 75 of full discharge the last two indicator lights will flash alternately Continued use of vehicle after indicator lights begin flashing without recharging could result in decreased vehicle performance A CAUTION f the battery condition indicator moves rapidly approximately 45 minutes from full charge to empty there may be a problem with the wiring or with a battery cell If indicator display does not reset back to full after recharging there may be a problem with the battery charger or with one of the batteries In either case the vehicle should be checked by a Club Car dealer or a trained technic
57. physician immediately Eyes Flush with water for 15 minutes Call a physician immediately A WARNING Wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shield and rubber gloves when working with batteries Use insulated tools when working around batteries or electrical connections A CAUTION On all vehicles turn off all accessories before charging batteries NOTE Recycle or dispose of discarded batteries in accordance with local state and federal regulations The batteries in PowerDrive System 48 and IQ System electric vehicles are 8 volt deep cycle batteries spe cially built for electric vehicle application Automotive batteries should never be used New batteries will not deliver their full capabilities until they have been discharged and recharged 20 to 50 times To obtain the maximum service life from new batteries restrict the use of vehicles with new batteries to one hour of operation between charges for the first two months the vehicle is in service Batteries should be fully charged before first use of new vehicle before first use of a vehicle after storage and before releasing vehicle for use each day BATTERY CARE To keep batteries in good working condition follow this maintenance program on a regular basis 2003 Transportation Electric Vehicle Owner s Manual Page 29 Battery Charger 1 Batteries should be kept clean and free of corrosion Wash tops and ter
58. r that occurs due to abuse or neglect including failure to provide reasonable and necessary maintenance accident or alteration is excluded from this limited warranty Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitations of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state For further information contact WARRANTY SERVICES CLUB CAR INC Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 Page 42 2003 Transportation Electric Vehicle Owner s Manual Your Comments Are Appreciated Please select your category Distributor Dealer Technician Individual Owner Golf Course Superintendent Other In order to help us better serve you please rate this publication in the following categories Poor Fair Average Good Excellent 1 Ease of Understanding 2 Ease of Finding Information 3 Clarity of Illustrations Comments Suggestions Please fax a copy of this page to 706 228 2662 Thank You Club Car Technical Publications Department 2003 Transportation Electric Vehicle Owner s Manual Manual No 102318606 Edition Code 0802C00000 Tran
59. r trained technician with baking soda water solution Check air pressure and adjust if Tires necessary See Vehicle Specifications General vehicle on page 36 Wash battery compartment and underside of vehicle Semiannual service by trained technician only every 50 hours of operation Brake system Check brake shoes replace if necessary See Section 6 Wheel Brake Assemblies in the appropriate maintenance and service manual Lubricate brake slides per Lubrication Schedule See Section 6 Wheel Brake Assemblies in the appropriate maintenance and service manual Check brake cables for damage replace if necessary Electrical wiring and connections Check for tightness and damage Forward Reverse switch Front wheel alignment and camber Check condition of contacts and wire connections make sure connections are tight Check and adjust if required See Section 7 Steering and Front Suspension in the appropriate maintenance and service manual Motor controller output regulator MCOR Check for loose hardware cracks or other damage Annual service by trained technician only every 100 hours of operation A WARNING Batteries If batteries are not performing as expected see Section 13 Batteries in the maintenance and service supplement If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Fa
60. reventing operation of the vehicle as well as the possibility of sub sequent damage to the charger and the vehicle Page 32 2003 Transportation Electric Vehicle Owner s Manual Battery Charger Once the lockout is actuated the charger turns on The onboard computer then records the amount 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 until the charger plug is discon nected from the vehicle Only PowerDrive System 48 and IQ System vehicles are compatible with PowerDrive chargers Other Club Car models or vehicles made by other manufacturers are not compatible As long as the charger is allowed to shut off by itself the batteries will be fully charged Overcharging and undercharging will normally be prevented Batteries should be put on charge even if they have been used for only a short time 10 minutes The charger is automatic and will turn off when batteries are fully charged If the charger does not seem to be operating properly or if the batteries seem weak contact a Club Car distributor dealer Figure 12 Correct Insertion of Charger DC Plug Figure 13 Incorrect Insertion of Charger DC Plug PLUG AND RECEPTACLE Villager vehicles The charger cord plug and receptacle are wear items and should be inspected daily Visu ally inspect them for cracks loose connections and frayed wir
61. rive System 48 POWER SOURCE Drive motor Direct drive 48 volt DC series wound 3 1 hp Drive motor Direct drive 48 volt DC shunt wound 3 2 hp Transaxle Double reduction helical gear with 12 3 1 direct drive axle Electrical system 48 volt DC reduced speed reverse Batteries High capacity deep cycle Trojan Power Drive 8 Volt 117 min capacity Charger Automatic 48 volt 17 amp PowerDrive UL and CSA listed STEERING SUSPENSION BRAKES Steering Self adjusting rack and pinion Suspension Front mono leaf and rear multi leaf springs with dual hydraulic shocks Suspension Front and rear multi leaf springs with dual hydraulic shocks Brakes Mechanical brake cable system to self adjusting drum brakes on each rear wheel and single e brake pedal with automatic release park brake Brakes Mechanical brake cable system to manually adjusted drum brakes on all four wheels and single brake pedal with automatic release park brake BODY CHASSIS Frame Chassis Twin Beam welded aluminum e Side and rear body All aluminum Front body ArmorFlex Front body finish Matched paint finish over molded in color E Center body ABS DR acrylic cap Tires 18 x 8 50 8 tubeless 4 ply rated load range front and rear Tires 18 x 8 50 8 tubeless 6 ply rated load range 2 fron
62. rom shifting and possibly injuring a passenger or affecting the vehicle s handling make sure cargo is well secured Avoid top heavy loads The center of gravity of a load should never exceed 15 inches 38 cm above the bottom of the cargo bed Unload cargo bed before raising vehicle with hoist jack or other lifting device Center and secure cargo as far forward as possible in the cargo bed Do not overload the vehicle See the fol lowing chart for vehicle capacities 2003 Transportation Electric Vehicle Owner s Manual Page 23 Transporting on a Trailer Four Passenger Six and Eight Passenger Transporter Villager Villager 300 Ib Maximum payload capacity n a n a 136 kg Cargo bed load and gross trailer weight four passenger only Maximum vehicle capacity 800 Ib 1500 Ib 1500 Ib Cargo bed load passengers and gross trailer weight 363 kg 680 kg 680 kg TRANSPORTING ON A TRAILER A 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 must stop on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning could cause the vehicle to overturn possibly resulting in severe personal injury Reduce normal driving speed when towing a Club Car vehicle on a trailer For use on public roads the trailer must meet all federal state and local requirements such as
63. sportation and Utility Vehicles Electric Club Car Inc P O Box 204658 Augusta GA 30917 4658 am
64. t and rear DIMENSIONS WEIGHT 100 in 124 in 157 in 134 in 133 in Overall length 254 cm 315 cm 398 cm 340 cm 338 cm i 47 3 in 47 3 in 47 3 in 49 3 in 49 3 in Overall width 120 cm 120 cm 120 cm 125 cm 125 cm i 48 in 48 in 48 in 48 in 48 in Overall height at steering wheel 122 cm 122 cm 122 cm 122 cm 122 cm 65 5 in 98 5 in 131 5 in 98 5 in 98 5 in Wheelbase 166 cm 250 cm 334 cm 250 cm 250 cm Specifications continued on next page Page 36 2003 Transportation Electric Vehicle Owner s Manual Villager TransPorter S PECI FICATIONS Four Six Eight Four Six Passenger Passenger Passenger Passenger Passenger IQ System PowerDrive System 48 PowerDrive System 48 4 5 in 4 5 in 4 5 in 4 5 in 4 5 in Ground clearance 11 11 11 11 11 Front wheel tread 6 em Rear wheel tread iom Weight without batteries 38 Ka 12 15 mph 12 15 mph 12 15 mph 12 15 mph 12 15 mph Forward speed 19 24 km h 19 24 km h 19 24 km h 19 24 km h 19 24 km h n 17 ft 6 in 24 ft 8 in 32 ft 7 in 24 ft 8 in 24 ft 8 in Curb clearance circle diameter 533 cm 752 cm 993 cm 752 cm 752 cm i i 68 in 129 in 191 in 129 in 129 in Turning radius per SAE J 695 173 cm 328 cm 485 cm 328 cm 328 cm Intersecting aisle clearance 183 G Floorboard height Q0 em Seat height at seat
65. taillights brake lights etc Do not tow a Club Car vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer The vehicle to be towed should be tied securely to the trailer with the Forward Reverse handle or switch in NEUTRAL the key switch OFF and the park brake firmly depressed and locked Because of the added length of the trailer use caution when making turns Do not transport the vehicle on a trailer with a load in the vehicle cargo bed If vehicle is equipped with a windshield remove the windshield before transporting on a trailer If the vehicle must be transported over long distances or on public highways it should be transported on an approved trailer that has the following approved load rating per vehicle being transported Four passenger Villager 800 Ib 363 kg Six passenger Villager 1600 Ib 727 kg Eight passenger Villager 2000 Ib 909 kg TransPorter 2000 Ib 909 kg NOTE A two car trailer should be rated at 2 x 1600 Ib 3200 Ib 2 x 727 kg 1454 kg for six passenger Villager or 2 x 2000 Ib 4000 Ib 2 x 909 kg 1818 kg for eight passenger Villager or TransPorter vehicles Page 24 2003 Transportation Electric Vehicle Owner s Manual Storage STORAGE Read DANGER and WARNING on page 6 A WARNING Turn the key switch OFF remove the key and leave the Forward Reverse handle or switch in the NEUTRAL position during storage This is to prevent unintentio
66. the new Onboard Computer and the Solid State Speed Controller hereinafter called Computer and Controller respectively installed in its new electric vehicle equipped with the PowerDrive System 48 PowerDrive Plus or 1Q System purchased from CLUB CAR or an authorized distributor or dealer will be free from defects in material and workmanship for a period of four years or 800 rounds whichever first occurs from the date of purchase subject to the terms and conditions contained herein This limited warranty only covers defects in material and workmanship for a period of four years or 800 golf car rounds from date of purchase The terms of this four year or 800 round limited warranty shall be as follows 2003 Transportation Electric Vehicle Owner s Manual Page 41 Vehicles used for golf free replacement with respect to parts and labor within four years or 800 rounds whichever first occurs from date of purchase Vehicles used for purposes other than golf free replacement with respect to parts and labor within four years or 16 000 energy units as recorded by the Computer whichever first occurs from date of purchase The Computer or Controller should be returned to an authorized CLUB CAR distributor or dealer with evidence of proof of purchase date and number of rounds freight prepaid CLUB CAR reserves the right to test any Computer returned for warranty and to verify number of rounds played by accessing information contained in the
67. ty cord with ground properly wired and in good electrical condition Keep it as short as possible no more than 12 feet 3 7 m Place all cords so they will not be stepped on tripped over or otherwise subject to dam age or stress Ensure that the charger ventilation slots are unobstructed and that there is adequate ventilation CHARGING BATTERIES NOTE When temperatures fall below 65 F 18 3 C batteries charged in unheated areas should be placed on charge as soon as possible after use Batteries are warmest immediately after use while cold batteries require more time to fully charge Villager stationary charger Insert the charger AC plug into a dedicated AC receptacle that is properly grounded and wired in accor dance with the National Electric Code and all local codes and ordinances Then insert the charger DC plug into the vehicle receptacle The charger will turn on two to ten seconds later Figure 12 Page 33 TransPorter onboard charger Insert the onboard charger AC plug into a dedicated AC receptacle that is properly grounded and wired in accordance with the National Electric Code and all local codes and ordinances The charger will turn on two to ten seconds later PowerDrive Chargers interact with an onboard computer on the PowerDrive System 48 and IQ System vehi cle The computer records the amount of energy consumed during vehicle use While the charger is plugged in the vehicle s control circuit is locked out p
68. verse Handle FORWARD REVERSE CONTROLS PowerDrive System 48 Vehicles The Forward Reverse handle is located on the seat support panel Figure 4 The handle has three distinct positions F FORWARD N NEUTRAL and R REVERSE Rotate the handle towards the driver FOR WARD to operate the vehicle in the forward direction or towards the passenger REVERSE to operate the vehicle in reverse When the handle is in the straight up position NEUTRAL the vehicle will not operate Club Car transportation vehicles operate at reduced speed in reverse The reverse buzzer will sound as a warning when the Forward Reverse handle is in REVERSE IQ System Vehicles The Forward Reverse rocker switch is located in the same place as the Forward Reverse handle on other models on the seat support panel below and to the right of the driver s right knee The F FORWARD and R REVERSE positions are clearly marked Push down the FORWARD side of the switch to operate the vehicle in the forward direction or push down the REVERSE side of the switch to operate the vehicle in reverse When the rocker switch is positioned in NEUTRAL with neither side down the vehicle will not operate if the accelerator pedal is depressed Figure 5 The reverse buzzer will sound as a warning when the Forward Reverse switch is in REVERSE ACCELERATOR PEDAL The accelerator pedal is the pedal on the right with the word GO molded into it Figure 6 The operation of the accelerator p
69. witch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning could result in a battery explosion or severe personal injury When the Tow Run switch is in the TOW position all motor braking functions including zero speed detect are disabled Figure 9 Tow Run Switch IQ System vehicles are equipped with a Tow Run switch located under the seat just above the Forward Reverse switch Figure 9 The switch must be in the RUN position in order to operate the vehicle When the switch is in the TOW position power to the vehicle electrical components is turned off and the vehicle will not operate See following NOTE NOTE After placing the Tow Run switch in the TOW position allow 10 seconds to elapse before switching back to the RUN position After placing the Tow Run switch in RUN position allow 10 seconds to elapse before operating the vehicle The Tow Run switch should be placed in the TOW position under the following conditions Before Towing the Vehicle Place the Tow Run switch in the TOW position to disable all motor braking functions thus preventing possible damage that could occur to the vehicle or electrical components if the vehicle is towed while the Zero Speed Detect motor braking function is operating Before Disconnecting or Connecting Battery Cables Place the Tow Run switch in the TOW position to turn off power to the vehicle electrical system thus preventing severe arci
70. y charger Do not leave children unattended on vehicle Prior to leaving the vehicle unattended or servicing the vehicle turn the key switch OFF remove the key and place the Forward Reverse handle or switch in the NEUTRAL position Chock the wheels when servicing the vehicle Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance severe personal injury or death Page 6 2003 Transportation Electric Vehicle Owner s Manual General Warnings Any modification or change to the vehicle that affects the stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications could result in severe personal injury or death Check the vehicle for proper location of all vehicle safety and operation decals and make sure they are in place and are easy to read For vehicles with cargo beds remove all cargo before raising the bed or servicing the vehicle If the vehicle is equipped 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 gently and keep entire body clear Failure to heed this warning could result in severe personal injury or death Only trained technicians should service or repair the vehicle or battery charger Anyone doing even simple repairs or service should have knowledge and experience in

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