Club Car ONWARD 4 PASSENGER GASOLINE Operator'S Manual Download Page 54

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Page 52

ONWARD 4 PASSENGER GASOLINE

Operators Manual

TPCC01BS00EN019 (Edition B)

Release the latch (1).

Remove the air cleaner cover (2).

Remove the air filter (3).

AIR FILTER INSTALLATION

Use a wet lint-free cloth to clean the inside of the air filter container.

Install the air filter (3).

Install the air cleaner cover (2).

Engage the latch (1).

ENGINE OIL

ENGINE OIL VISCOSITY

Select the engine oil viscosity for your environmental conditions.

Vehicle Maintenance

Maintenance Tasks

Summary of Contents for ONWARD 4 PASSENGER GASOLINE

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

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

Page 4: ...dealer com Scan the dealer locator Quick Response QR code COMPANY CONTACT INFORMATION Send written correspondence to Club Car LLC Attention Marketing Services P O Box 204658 Augusta Georgia 30917 4658...

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

Page 6: ...AL AND INDUSTRY STANDARDS AMERICAN NATIONAL STANDARDS INSTITUTES ANSI Z135 The configuration of this vehicle complies with American National Standards Institutes ANSI Z135 Safety Standards for Persona...

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

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

Page 9: ...Warranty Claim 75 Federal Emissions Component Defect Warranty 75 Warranty Coverage 75 Warranty Period 75 Parts Covered 75 Distribution Center 76 Warranty Service 76 What Is Not Covered 77 Owner s Resp...

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Page 11: ...1 SAFETY INFORMATION ONWARD 4 PASSENGER GASOLINE Operators Manual TPCC01BS00EN019 Edition B Page 9 Safety Information Notices 1...

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

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

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

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

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

Page 17: ...nor adjustment 9 Rotating Parts Hot Manifold Warning Decal 10 Gas Governor Warning Decal MAXIMUM TONGUE WEIGHT 150 lb 68 kg NOTICE 101155301 WARNING ROTATING PARTS AND BURN RISK Rotating parts can cau...

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

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

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Page 21: ...2 INDICATORS GAUGES AND DISPLAYS ONWARD 4 PASSENGER GASOLINE Operators Manual TPCC01BS00EN019 Edition B Page 19 Indicators Gauges And Displays Battery Safety Information 2...

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

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

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Page 25: ...3 VEHICLE CONTROLS ONWARD 4 PASSENGER GASOLINE Operators Manual TPCC01BS00EN019 Edition B Page 23 Vehicle Controls Malfunction Indicator Light 3...

Page 26: ...Page 24 ONWARD 4 PASSENGER GASOLINE Operators Manual TPCC01BS00EN019 Edition B VEHICLE CONTROLS LOCATOR 3 Vehicle Controls Vehicle Controls Locator...

Page 27: ...elerator pedal controls the operation of the engine start or stop The accelerator pedal is used to increase and maintain the speed of the vehicle BRAKE PEDAL The brake pedal is used to decrease speed...

Page 28: ...operation of the hazard lights Move the turn signal switch up or down to turn off the hazard lights POSITION FUNCTION Out On In Off HEADLIGHT SWITCH The headlight switch controls the operation of the...

Page 29: ...ependently of the key switch ON Normal position when the vehicle is in use Electrical power from the battery is available to power the engine engine starter and electrical systems MAINTENANCE OPERATE...

Page 30: ...AKE WILL RELEASE AUTOMATICALLY WHEN THE ACCELERATOR OR BRAKE PEDAL IS PUSHED PREVENT ACCIDENTAL ACCELERATOR OR BRAKE PEDAL ACTUATION The park brake is a variable position control that is used to make...

Page 31: ...4 VEHICLE FEATURES ONWARD 4 PASSENGER GASOLINE Operators Manual TPCC01BS00EN019 Edition B Page 29 Vehicle Features Turn Signal Lever 4...

Page 32: ...and increased cargo space USB RECEPTACLE The 5 volt 2 1 amp USB receptacle supplies electricity to power and charge portable devices The USB receptacle is not for the movement of data The USB recepta...

Page 33: ...5 VEHICLE SPECIFICATIONS ONWARD 4 PASSENGER GASOLINE Operators Manual TPCC01BS00EN019 Edition B Page 31 Vehicle Specifications USB Receptacle 5...

Page 34: ...us SAE J695 Unknown At Time Of Print Intersecting Aisle Clearance Unknown At Time Of Print Curb To Curb Unknown At Time Of Print Wall To Wall Unknown At Time Of Print Outside Clearance Circle Diameter...

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

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

Page 37: ...6 VEHICLE OPERATION ONWARD 4 PASSENGER GASOLINE Operators Manual TPCC01BS00EN019 Edition B Page 35 Vehicle Operation Vehicle Weights And Load Capacities 6...

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

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

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

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

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

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

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

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

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

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

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

Page 49: ...7 VEHICLE MAINTENANCE ONWARD 4 PASSENGER GASOLINE Operators Manual TPCC01BS00EN019 Edition B Page 47 Vehicle Maintenance Driving Conditions 7...

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

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

Page 52: ...remove it from operation Removal from operation will prevent more damage to the vehicle and prevent the possible injury because of dangerous conditions Speak with your dealer or distributor for maint...

Page 53: ...ine and lubricate the brake system lubricate the shift cable pivots lubricate the front suspension 100 hours 12 months Have a trained technician examine the spark plug pedal components transaxle fluid...

Page 54: ...ve the air filter 3 AIR FILTER INSTALLATION 1 Use a wet lint free cloth to clean the inside of the air filter container 2 Install the air filter 3 3 Install the air cleaner cover 2 4 Engage the latch...

Page 55: ...ine immediately 5 Turn off the engine 6 Wait two minutes 7 Remove and clean the dipstick 8 Install the dipstick 9 Remove the dipstick 10 Make sure that the oil level is between the maximum 1 and minim...

Page 56: ...ain plug and tighten to 13 lb ft 18 N m 9 Add 39 fl oz 1 1 l of recommended engine oil 10 Install the dipstick 11 Connect the battery 12 Speak with your dealer or distributor to get more information o...

Page 57: ...SPARKS AND HEAT SOURCES FUEL IS FLAMMABLE AND EXPLOSIVE TO AVOID ELECTRIC ARC CAUSED BY STATIC ELECTRICITY THE FUEL STORAGE PUMPING DEVICE MUST BE GROUNDED IF THE PUMP IS NOT GROUNDED THE VEHICLE MUST...

Page 58: ...VEHICLE IS LIFTED Before the vehicle is lifted Disable the vehicle Disconnect the battery Use a jack and jack stands rated for the vehicle To lift the rear of the vehicle 1 Place the jack in the cent...

Page 59: ...PLUG INSTALLATION 1 Apply a thin layer of high temperature antiseize lubricant to the spark plug threads 2 Use a spark plug socket to install and tighten the spark plug to 20 lb ft 27 N m 3 Connect th...

Page 60: ...install the wheel assembly 1 Lift the vehicle to allow for installation of the wheel assembly 2 Align the wheel assembly onto the hub of the vehicle Note Make sure that the valve stem points to the ou...

Page 61: ...316V 8 BATTERY MAINTENANCE ONWARD 4 PASSENGER GASOLINE Operators Manual TPCC01BS00EN019 Edition B Page 59 Battery Maintenance Maintenance Tasks 8...

Page 62: ...e battery cables are tight If a battery cable is not tight tighten the hardware to 41 lb in 4 3 N m 6 Let the terminals dry 7 Apply battery terminal protector spray to the terminals BATTERY CHARGING J...

Page 63: ...2 Disconnect the positive cable 2 CONNECT THE BATTERY 1 Connect the positive cable 2 2 Connect the negative cable 1 WARNING LOOSE BATTERY WIRES CAN CAUSE A FIRE PROPERTY DAMAGE OR SERIOUS PERSONAL IN...

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Page 65: ...9 TRANSPORT AND TOW ONWARD 4 PASSENGER GASOLINE Operators Manual TPCC01BS00EN019 Edition B Page 63 Transport And Tow Battery Electrical Connection 9...

Page 66: ...LIGHTS PREPARE THE VEHICLE TO BE TOWED 1 Turn the key to OFF 2 Remove the key Keep the key in a safe area 3 Set the Forward Neutral Reverse control FNR to N TOWING A TRAILER OR VEHICLE CAUTION USE EX...

Page 67: ...ed to be towed at speeds over 5 mph If movement over long distances or on public roads is necessary transport the vehicle on a trailer Use a trailer with appropriate load rating 1 Set the park brake 2...

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Page 69: ...10 EXTENDED STORAGE ONWARD 4 PASSENGER GASOLINE Operators Manual TPCC01BS00EN019 Edition B Page 67 Extended Storage Vehicle Transport Recovery 10...

Page 70: ...EMPERATURES KEEP THE BATTERIES IN A HIGH STATE OF CHARGE UNINTENDED VEHICLE OPERATION CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH BEFORE LEAVING THE VEHICLE OR DURING VEHICLE MAINTENANCE DISABLE THE VE...

Page 71: ...4 D Turn the engine crankshaft by hand several times 14 E Apply a thin layer of high temperature anti seize lubricant to the spark plug threads 14 F Use a spark plug socket to install and tighten the...

Page 72: ...battery 5 Set the Maintenance Operate switch to MAINTENANCE 6 Start and run the engine Note The engine exhaust may smoke for a short time after returning to service 7 Turn the key to OFF 8 Set the Mai...

Page 73: ...11 WARRANTIES ONWARD 4 PASSENGER GASOLINE Operators Manual TPCC01BS00EN019 Edition B Page 71 Warranties Return To Service From Extended Storage 11...

Page 74: ...ved by Club Car For repairs made by qualified technicians other than Club Car s factory technicians or an Authorized Dealer or Distributor Club Car will provide only the replacement parts or component...

Page 75: ...not apply to failure due to the following conditions Batteries Improper charging of a vehicle due to the use of a battery charger model not approved by Club Car for use with the vehicle Use of any ac...

Page 76: ...mean remedying a defect in the vehicle or component thereof at no cost to the purchaser during the applicable limited warranty period Club Car reserves the right to test and recharge any component re...

Page 77: ...Of America Environmental Protection Agency EPA and that the engine is free of defects in materials and workmanship which would cause this engine to fail to conform with EPA regulations during its warr...

Page 78: ...Fittings Clamps Fuel Tank Fuel Cap Vapor Hoses Carbon Canister Carbon Canister Mounting Brackets Air Cleaner Purge Port Connector DISTRIBUTION CENTER Replacement parts are provided to the market upon...

Page 79: ...nsible for the performance of the required maintenance listed in your operator s manual Club Car recommends that you retain all receipts covering maintenance on your engine but Club Car cannot deny wa...

Page 80: ...SORE must be designed built and equipped to meet the State s stringent anti smog standards Club Car must warrant the evaporative emission control system on your vehicle engine for the period listed be...

Page 81: ...written instructions supplied is warranted for the warranty period stated above Any such part repaired or replaced under warranty will be warranted for the remaining original warranty period 3 Any wa...

Page 82: ...ected or improperly maintained and that such abuse neglect or improper maintenance was the direct cause of the need for repair or replacement of the part That notwithstanding any adjustment of a compo...

Page 83: ...Manual TPCC01BS00EN019 Edition B Page 81 Valves hosing tubing fittings seals gaskets clamps and fittings as they relate to the evaporative emissions control system Warranties California Evaporative E...

Page 84: ...Publication Part Number TPCC01BS00EN019 Edition Code B Club Car LLC P O Box 204658 Augusta GA 30917 4658 USA Web Phone Fax www clubcar com 1 706 258 2225 1 800 ClubCar 1 706 863 5858...

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