Club Car ONWARD HP 6 PASSENGER LIFTED ELECTRIC Page 71 Operator'S Manual Download

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316V

BATTERY MAINTENANCE

ONWARD HP 6 PASSENGER LIFTED ELECTRIC
Operators Manual
TPCC01DX00EN020 (Edition A)

Page 69

Battery Maintenance

Maintenance Tasks

Summary of Contents for ONWARD HP 6 PASSENGER LIFTED ELECTRIC

Page 1: ...ONWARD HP 6 PASSENGER LIFTED ELECTRIC Operators Manual APPLICABLE TO VEHICLES WITH SERIAL PREFIX OF DX...

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

Page 4: ...cardealer 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 4...

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

Page 6: ...from the Club Car manufacturing facility EUROPEAN UNION VIBRATION AND NOISE PREN 15997 European Union specification prEN 15997 was used to measure the vibration and noise levels of the vehicle The vi...

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

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

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

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Page 11: ...1 SAFETY INFORMATION ONWARD HP 6 PASSENGER LIFTED ELECTRIC Operators Manual TPCC01DX00EN020 Edition A Page 9 Safety Information Notices 1...

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

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

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

Page 15: ...imum Load 1200 lb 544 kg Maximum Grade 20 Vehicle to be operated by licensed or authorized persons only Only operate vehicle in compliance with local and state laws Use caution when operating vehicle...

Page 16: ...Trailer Hitch Notice Decal 10 Crush Area Warning Decal Driver Side and Passenger Side WARNING RIDING IN THE CARGO BED CAN CAUSE SERIOUS INJURY OR DEATH Cargo bed has a 150 lb 68 kg load limit Do not...

Page 17: ...ttery charger and vehicle The battery charging interlock will automatically engage when the AC cord is connected to a power source The vehicle will not operate when the AC cord is connected MULTI PURP...

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

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

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Page 21: ...2 INDICATORS GAUGES AND DISPLAYS ONWARD HP 6 PASSENGER LIFTED ELECTRIC Operators Manual TPCC01DX00EN020 Edition A Page 19 Indicators Gauges And Displays Battery Safety Information 2...

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

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

Page 24: ...al TPCC01DX00EN020 Edition A DISPLAY DESCRIPTION FNR is set to F FNR is set to R Left turn signal is on Right turn signal is on Minor fault The vehicle will log the event Speak with your local dealer...

Page 25: ...Malfunction fault The vehicle may go into limp mode and operate at only 7 6 mph 12 2 kmh Speak with your local dealer or distributor Severe fault When possible all components except for the dash displ...

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Page 27: ...3 VEHICLE CONTROLS ONWARD HP 6 PASSENGER LIFTED ELECTRIC Operators Manual TPCC01DX00EN020 Edition A Page 25 Vehicle Controls Dash Display 3...

Page 28: ...020 Edition A VEHICLE CONTROLS LOCATOR 1 Accelerator Pedal 2 Brake Pedal 3 Park Brake 4 Key Switch 5 Headlight Switch 6 Turn Signal Lever 7 Hazard Lights Switch 8 Horn Button 9 Forward Neutral Reverse...

Page 29: ...RWARD NEUTRAL REVERSE CONTROL WARNING FAILURE TO STOP THE VEHICLE BEFORE SHIFTING THE FORWARD NEUTRAL REVERSE CONTROL FNR CAN CAUSE PROPERTY DAMAGE AND SERIOUS PERSONAL INJURY STOP THE VEHICLE BEFORE...

Page 30: ...utton is used to control the horn The horn button is spring loaded to stay in the off position Push and hold the horn button to operate the horn Note The horn will not operate when the key switch is O...

Page 31: ...urs the vehicle will turn off PARK BRAKE WARNING FAILURE TO ENGAGE THE PARK BRAKE CAN CAUSE PROPERTY DAMAGE AND SERIOUS PERSONAL INJURY AFTER THE VEHICLE STOPS ENGAGE THE PARK BRAKE UNTIL IT IS FULLY...

Page 32: ...is set from TOW to RUN Do not quickly operate the switch from RUN to TOW and back to RUN Wait 10 seconds to set the switch to RUN POSITION FUNCTION RUN Normal Operation TOW Connect the battery cables...

Page 33: ...4 VEHICLE FEATURES ONWARD HP 6 PASSENGER LIFTED ELECTRIC Operators Manual TPCC01DX00EN020 Edition A Page 31 Vehicle Features Turn Signal Lever 4...

Page 34: ...ngers 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 re...

Page 35: ...5 BATTERY CHARGER ONWARD HP 6 PASSENGER LIFTED ELECTRIC Operators Manual TPCC01DX00EN020 Edition A Page 33 Battery Charger USB Receptacle 5...

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

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

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

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

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

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

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

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

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Page 45: ...6 VEHICLE SPECIFICATIONS ONWARD HP 6 PASSENGER LIFTED ELECTRIC Operators Manual TPCC01DX00EN020 Edition A Page 43 Vehicle Specifications Inspection And Maintenance 6...

Page 46: ...19 mph 30 km h maximum Turning Radius SAE J695 13 ft 11 in 4 25 m Intersecting Aisle Clearance 9 ft 3 in 2 83 m Curb To Curb 14 ft 3 in 4 36 m Wall To Wall 14 ft 3 in 4 36 m Outside Clearance Circle D...

Page 47: ...S ONLY TOO MUCH WEIGHT IN THE VEHICLE CAN AFFECT THE VEHICLES HANDLING OR CAUSE COMPONENT FAILURE RESULTING IN LOSS OF CONTROL OF VEHICLE AND SERIOUS PERSONAL INJURY DO NOT EXCEED THE VEHICLE LOAD CAP...

Page 48: ...gue 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 trailer weight is the trailer weight pl...

Page 49: ...7 VEHICLE OPERATION ONWARD HP 6 PASSENGER LIFTED ELECTRIC Operators Manual TPCC01DX00EN020 Edition A Page 47 Vehicle Operation Vehicle Weights And Load Capacities 7...

Page 50: ...E PROPERTY DAMAGE SERIOUS PERSONAL INJURY OR DEATH IF PROBLEMS ARE FOUND DURING SCHEDULED INSPECTION OR SERVICE OPERATE THE VEHICLE ONLY WHEN REPAIRS ARE MADE MAKE SURE THAT ALL PASSENGERS CAN SECURE...

Page 51: ...ICLE 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...

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

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

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

Page 55: ...t all passengers are seated with seat belts fastened if equipped and use the hand holds or handrails The operator must have both hands on the steering wheel Make sure that the front wheels are turned...

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

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

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

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

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

Page 61: ...8 VEHICLE MAINTENANCE ONWARD HP 6 PASSENGER LIFTED ELECTRIC Operators Manual TPCC01DX00EN020 Edition A Page 59 Vehicle Maintenance Driving Conditions 8...

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

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

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

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

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

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

Page 68: ...front of the vehicle 1 Place the jack in the center of the lift point 2 Lift the vehicle off of the jack stands 3 Remove the jack stands 4 Lower the vehicle LOWER THE REAR OF THE VEHICLE Before the re...

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

Page 70: ...the vehicle to allow for installation of the wheel assembly 2 Align the wheel assembly onto the hub of the vehicle Note Make sure that the valve stem points to the outer side of the vehicle Note Make...

Page 71: ...316V 9 BATTERY MAINTENANCE ONWARD HP 6 PASSENGER LIFTED ELECTRIC Operators Manual TPCC01DX00EN020 Edition A Page 69 Battery Maintenance Maintenance Tasks 9...

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

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

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

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

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

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

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

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

Page 80: ...y determines the quantity of solids or impurities which get caught and hence the purity quality of the filtered water Because of the variance in water quality consistency Club Car recommends the use o...

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

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Page 83: ...10 TRANSPORT AND TOW ONWARD HP 6 PASSENGER LIFTED ELECTRIC Operators Manual TPCC01DX00EN020 Edition A Page 81 Transport And Tow Water Quality 10...

Page 84: ...BE TOWED 1 Turn the key to OFF 2 Remove the key Keep the key in a safe area 3 Set the Forward Neutral Reverse control FNR to N 4 Set the Run Tow switch to TOW TOWING A TRAILER OR VEHICLE CAUTION USE...

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

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Page 87: ...11 EXTENDED STORAGE ONWARD HP 6 PASSENGER LIFTED ELECTRIC Operators Manual TPCC01DX00EN020 Edition A Page 85 Extended Storage Vehicle Transport Recovery 11...

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

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

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Page 91: ...12 WARRANTIES ONWARD HP 6 PASSENGER LIFTED ELECTRIC Operators Manual TPCC01DX00EN020 Edition A Page 89 Warranties Return To Service From Extended Storage 12...

Page 92: ...uthorized Dealer or Distributor Club Car will provide only the replacement parts or components If the warranty registration form is not completed and returned to Club Car at the time of the original r...

Page 93: ...conditions Batteries Improper charging of a vehicle due to the use of a battery charger model not approved by Club Car for use with the vehicle Use of water in batteries including tap water that cont...

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

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

Page 96: ...Publication Part Number TPCC01DX00EN020 Edition Code A Club Car LLC P O Box 204658 Augusta GA 30917 4658 USA Web Phone Fax www clubcar com 1 706 258 2225 1 800 ClubCar 1 706 863 5858...

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