Club Car Resort Villager 1998 Owner'S Manual Download Page 7 | Manualshive

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SAFETY DETAILS

It is important to note that some vital statements throughout this manual and on the decals affixed to the
vehicle are preceded by the words

DANGER, WARNING, CAUTION,

or

NOTE.

For your protection, we rec-

ommend that you take special notice of these safety procedures. Safety procedures are essential and must
be followed.

Any operating or warning decals on the vehicle that are damaged, have been removed or cannot be easily
read should be replaced immediately to avoid possible personal injury, property damage, or death. Contact
your CLUB CAR distributor/dealer.

•

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.

• A DANGER INDICATES AN IMMEDIATE HAZARD WHICH WILL RESULT IN SEVERE PER-

SONAL INJURY OR DEATH.

•

A WARNING INDICATES AN IMMEDIATE HAZARD WHICH COULD RESULT IN SEVERE PER-
SONAL INJURY OR DEATH.

•

A CAUTION INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN PROD-
UCT OR PROPERTY DAMAGE OR MINOR PERSONAL INJURY.

•

A NOTE PROVIDES KEY INFORMATION TO MAKE PROCEDURES MORE EASILY UNDER-
STOOD.

WARNING

DANGER

WARNING

CAUTION

NOTE

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Summary of Contents for Resort Villager 1998

Page 1: ...1019682 03 ual Number 1019682 03 Print Code 0897B1297A Print Code 0897B1297A 1998 1998 T Trans P rans Por orter ter T Trans Sender rans Sender Resort V Resort Villager illager and and T Tourall ourall V Vehic ehicles les ...

Page 2: ...WARNING THE ENGINE EXHAUST FROM THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM ...

Page 3: ...ed 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 either gasoline or electric vehicles without obligation to make these changes on units previously sold These vehicles are designed and manufactured for off road use only They ...

Page 4: ...f 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 vehicle needs repairs or service we recommend that your local authorized Club Car rep resentative perform them For the name...

Page 5: ... 22 Controls Trans Porter Trans Sender Gasoline and Resort Villager Gasoline Vehicles 24 Driving Instructions Trans Porter Trans Sender Gasoline and Resort Villager Gasoline Vehicles 28 Loading and Unloading 30 Transporting on a Trailer 31 Storage Gasoline Vehicle 32 Storage Electric Vehicle 33 Maintenance 34 Periodic Service Schedule Gasoline Vehicle 37 Periodic Service Schedule Electric Vehicle ...

Page 6: ...faction are of the utmost importance to Club Car That is why we urge you to study this owner s manual and to read understand and heed the warnings in this manual as well as the safety decals on your vehicle before operat ing the vehicle Take time to understand the language of safety It is a language that can save your life WARNING Moving Parts Practice Safety ...

Page 7: ...ury property damage or death Contact your CLUB CAR distributor dealer 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 A DANGER INDICATES AN IMMEDIATE HAZARD WHICH WILL RESULT IN SEVERE PER SONAL INJURY OR DEATH A WARNING INDICATES AN IMME...

Page 8: ...L AS WELL AS THOSE AFFIXED TO THE VEHICLE ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN SERVICING THE VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL CONNECTIONS IMPROPER MAINTENANCE OR USE OF THE VEHICLE COULD RESULT IN DECREASED VEHI CLE PERFORMANCE OR SEVERE PERSONAL INJURY ANY MODIFICATION OR CHANGE...

Page 9: ... UNTIL THE REVERSE WARNING BUZZER CAN NO LONGER BE HEARD WHEN THE BUZZER STOPS SOUNDING THE CONTROLLER IS DISCHARGED TOURALL POWERDRIVE PLUS VEHICLE BEFORE DISCONNECTING BATTERIES PLACE TOW RUN SWITCH IN THE TOW POSITION FIGURE 1 FIGURE 2 WARNING POS NEG POS NEG POS NEG POS NEG POS NEG POS NEG 1 2 5 4 3 FRONT OF VEHICLE TRANS PORTER TRANS SENDER AND RESORT VILLAGER VEHICLES DISCONNECT HERE 6 POS N...

Page 10: ...BRAKE PEDAL OIL WARNING LIGHT PARK BRAKE PEDAL ARM RESTS HAND RAIL ACCELERATOR PEDAL PASSENGER WARNING LABEL ON REAR HANDRAIL FACING SEAT DRIVER PASSENGER WARNING LABEL OPERATING INSTRUCTIONS LABEL OFF ON TOURALL GASOLINE VEHICLE ...

Page 11: ...E FRAME NEAR FUEL TANK MOVING PARTS AND HOT MANIFOLD DECAL ON STARTER GENERATOR AND ENGINE PERIODIC SERVICE DECAL ON AIR INTAKE BOX FRAME GROUND AND GOVERNOR WARNING DECAL ON VEHICLE FRAME NEAR BATTERY CHOKE F N R FORWARD REVERSE HANDLE OIL FILL NEUTRAL LOCK OUT CAM FEATURE IDENTIFICATION ...

Page 12: ...GHT PARK BRAKE PEDAL ARM RESTS HAND RAIL ACCELERATOR PEDAL OFF ON DRIVER PASSENGER WARNING DECAL PASSENGER WARNING DECAL ON REAR HANDRAIL FACING SEAT OPERATING INSTRUCTIONS DECAL REGENERATIVE BRAKING DECAL POWERDRIVE PLUS VEHICLE ONLY TOURALL ELECTRIC VEHICLE ...

Page 13: ... BLINDNESS OR INJURY F N R FORWARD REVERSE LEVER FORWARD REVERSE HANDLE CHARGER RECEPTACLE AND FUSE LINK Club Car TOW SWITCH WARNING DECAL ON TOW SWITCH BRACKET UNDER SEAT FOR POWERDRIVE PLUS 48 VOLT VEHICLE ONLY RESISTOR WARNING DECAL ON BODY UNDER ACCESS PANEL FOR POWERDRIVE PLUS 48 VOLT VEHICLE WARNING HOT RESISTORS COILED WIRE CAN CAUSE SEVERE BURNS ELECTRICAL COMPONENT MOUNTING PLATE NOTICE O...

Page 14: ...LERATOR PEDAL BRAKE PEDAL PARK BRAKE PEDAL OIL WARNING LIGHT SERIAL NUMBER KEY SWITCH OFF ON START DRIVER PASSENGER WARNING DECAL OPERATING INSTRUCTIONS DECAL PASSENGER WARNING DECAL RESORT VILLAGER GASOLINE ...

Page 15: ... SERVICE DECAL ON AIR INTAKE BOX FRAME GROUND AND GOVERNOR WARNING DECAL ON VEHICLE FRAME NEAR BATTERY GASOLINE WARNING DECAL ON VEHICLE FRAME NEAR FUEL TANK MOVING PARTS AND HOT MANIFOLD DECAL ON STARTER GENERATOR AND ENGINE VEHICLE FEATURE IDENTIFICATION ...

Page 16: ...TING INSTRUCTIONS LABEL ACCELERATOR PEDAL PASSENGER WARNING LABEL DRIVER PASSENGER WARNING DECAL BRAKE PEDAL PARK BRAKE PEDAL BATTERY WARNING LIGHT SERIAL NUMBER OFF ON BATTERY CONDITION INDICATOR RESORT VILLAGER ELECTRIC ...

Page 17: ...G KEEP OUT OF THE REACH OF CHILDREN DO NOT TIP KEEP VENT CAPS TIGHT AND LEVEL SHIELD EYES EXPLOSIVE GASES CAN CAUSE BLINDNESS OR INJURY F N R FORWARD REVERSE LEVER FORWARD REVERSE HANDLE DANGER DECAL ON BODY CHARGER RECEPTACLE AND FUSE LINK PASSENGER WARNING LABEL ELECTRICAL COMPONENT MOUNTING PLATE NOTICE ON PLATE VEHICLE FEATURE IDENTIFICATION ...

Page 18: ...WARNING LIGHT GAS VEHICLE OFF ON START OFF ON OPERATING INSTRUCTIONS GASOLINE VEHICLE PARK BRAKE PEDAL ACCELERATOR PEDAL BATTERY WARNING LIGHT ELECTRIC VEHICLE BATTERY CONDITION INDICATOR ELECTRIC VEHICLE DRIVER PASSENGER WARNING DECAL VEHICLE LOADING DECAL COMMON FEATURES GASOLINE AND ELECTRIC VEHICLES TRANS PORTER TRANS SENDER ...

Page 19: ... AND REVERSE HANDLE TRANS SENDER VEHICLE PINCH POINT DECAL TRANS PORTER FRAME GROUND WARNING DECAL ON FRAME BED BOLT WARNING DECAL GASOLINE VEHICLE FEATURES CHOKE PASSENGER WARNING DECAL GASOLINE TANK DANGER DECAL ON FRAME TILT BED WARNING DECAL PASSENGER WARNING DECAL PERIODIC SERVICE SCHEDULE ON INTAKE BOX VEHICLE FEATURE IDENTIFICATION ...

Page 20: ...SES CAN CAUSE BLINDNESS OR INJURY BATTERY DANGER DECAL ON FRAME TRANS SENDER VEHICLE CHARGER AC CORD REEL ELECTRICAL COMPONENT COVER CAUTION ON COVER TILT BED WARNING DECAL PASSENGER WARNING DECAL PASSENGER WARNING DECAL TRANS PORTER VEHICLE BED BOLT WARNING DECAL PINCH POINT DECAL F N R FORWARD AND REVERSE LEVER FORWARD AND REVERSE HANDLE ELECTRICAL COMPONENT MOUNTING PLATE NOTICE ON PLATE ELECTR...

Page 21: ...ould be in place and properly installed Be sure that all nuts bolts and screws are tight On gasoline vehicles check all hose clamps for tight fit as well as the starter belt for tightness Warning Decals Check to ensure that all warning and operation decals are in place See Pages 4 through 14 Tires Check for proper tire pressure See Tire Capacities Page 44 Batteries electric vehicle Before using ve...

Page 22: ...otor should stop Both the electric and gasoline vehicles should run at a reduced speed when in reverse Gasoline powered Trans Porter Trans Sender and Resort Villager vehicles After starting the engine the vehicle should accelerate smoothly to full speed as the accelerator pedal is depressed When the accelerator pedal is released it should return to the original position and the engine should idle ...

Page 23: ...AFE SPEEDS DO NOT MODIFY OR CHANGE THE VEHICLE IN ANY WAY WHICH MIGHT AFFECT ITS STABIL ITY OR HANDLING OR INCREASE MAXIMUM VEHICLE SPEED BEYOND FACTORY SPECIFI CATIONS PROPERTY DAMAGE PERSONAL INJURY OR DEATH COULD RESULT DO NOT SHIFT THE FORWARD REVERSE HANDLE WHILE THE VEHICLE IS MOVING TO AVOID INJURY TO PASSENGER S OR DAMAGE TO THE VEHICLE ALWAYS BRING THE VEHI CLE TO A FULL STOP BEFORE SHIFT...

Page 24: ... NEUTRAL while the engine is running All Club Car transportation vehi cles operate at reduced speed in REVERSE Tourall Electric Vehicles with PowerDrive Plus Motor Braking The Forward Reverse switch shifter is located on the seat support panel below and to the right of the driver s right knee Figure 6 The FORWARD F and REVERSE R positions are clearly marked on the switch Push down the F side of th...

Page 25: ...and then shifted to NEUTRAL the engine will stop running THE OPERATION OF THE ACCELERATOR PEDAL DIFFERS FROM THAT OF AN AUTOMO BILE WHEN THE KEY SWITCH IS ON AND THE FORWARD REVERSE HANDLE 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 DE...

Page 26: ...ures activate the choke by depressing the choke cover Hold choke cover in during start up and release it after the engine starts and runs smoothly Oil Light The gasoline powered vehicle is equipped with a low oil warning light located on the dash panel just above the steering column Figure 13 If the oil warning light comes on oil should be checked and added to the engine as necessary before contin...

Page 27: ...ore complete The on board computer will retain in memory the amount of charge needed to fully replenish the batteries and will complete the charge during the next charge cycle When the charger is unplugged the warning light will come on 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 a...

Page 28: ...TOW RUN switch in the TOW position to turn off power to the vehi cle electrical system This will prevent the electrical components from discharging the batteries DRIVING INSTRUCTIONS TRANS PORTER TRANS SENDER ELEC TRIC RESORT VILLAGER ELECTRIC TOURALL GASOLINE AND TOU RALL ELECTRIC VEHICLES No one should operate the vehicle without first being instructed in the proper use of the vehicle s controls...

Page 29: ...INJURY KEEP ENTIRE BODY INSIDE VEHICLE DO NOT LEAVE CHILDREN UNATTENDED IN THE VEHICLE TO PREVENT VEHICLE FROM OVERTURNING DRIVE SLOWLY IN TURNS TO PREVENT VEHICLE FROM OVERTURNING DRIVE SLOWLY STRAIGHT UP AND DOWN SLOPES DO NOT DRIVE THE VEHICLE ON SLOPES EXCEEDING 20 INCLINE AVOID STOPPING A LOADED VEHICLE ON A HILL IF A LOADED VEHICLE MUST BE STOPPED ON A HILL AVOID SUDDEN STARTS OR ROLLING BAC...

Page 30: ... See Zero Speed Detect Page 16 CONTROLS TRANS PORTER TRANS SENDER GASOLINE AND RESORT VILLAGER GASOLINE VEHICLES VEHICLE OPERATOR MUST CONTROL SPEED WHEN GOING DOWNHILL GASOLINE VEHICLES ONLY DEPRESS THE BRAKE PEDAL AS NECESSARY AND PARTIALLY DEPRESS THE ACCELERATOR WHEN DESCENDING A HILL WITH THE ACCELERATOR PEDAL PARTIALLY DEPRESSED THE GOVERNOR WILL CAUSE THE ENGINE TO ASSIST THE BRAKES IN CONT...

Page 31: ...E OR SHE IS FAMILIAR WITH ALL CONTROLS AND OPERATING PROCEDURES DO NOT TAMPER WITH THE GASOLINE VEHICLE GOVERNOR DOING SO WILL VOID THE WARRANTY AS WELL AS DAMAGE THE ENGINE AND OTHER COMPONENTS AND COULD RESULT IN PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO UNSAFE SPEEDS DO NOT MODIFY OR CHANGE THE VEHICLE IN ANY WAY WHICH MIGHT AFFECT ITS STABIL ITY OR HANDLING OR INCREASE MAXIMUM VEHICLE SP...

Page 32: ... neutral lock out cam is pulled out approximately 3 8 inch 10 millimeters and then rotated one half turn until it snaps into place the cam will be in the SERVICE position Figure 20 Page 28 This will allow the mechanic to run the engine for certain maintenance procedures With the cam in this position the vehicle will not operate if the Forward Reverse THE OPERATION OF THE ACCELERATOR PEDAL DIFFERS ...

Page 33: ...ate the choke Pull out the choke handle to activate it Push the handle back in when the engine begins to run smoothly Figure 22 Page 28 FIGURE 17 FIGURE 18 FIGURE 19 WITH THE CAM IN THE SERVICE POSITION AND THE ENGINE RUNNING THE VEHICLE MAY MOVE SUDDENLY IF THE FORWARD REVERSE HANDLE IS SHIFTED OR ACCIDENTALLY BUMPED TO PREVENT THIS CHOCK THE FRONT AND REAR WHEELS AND ALWAYS FIRMLY SET THE PARK B...

Page 34: ...OLINE AND RESORT VILLAGER GASOLINE VEHICLES 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 Only licensed drivers should be allowed to drive this vehicle To ensure safe operation of the vehicle ...

Page 35: ...ICLE DO NOT LEAVE CHILDREN UNATTENDED IN THE VEHICLE TO PREVENT VEHICLE FROM OVERTURNING DRIVE SLOWLY AROUND TURNS TO PREVENT VEHICLE FROM OVERTURNING DRIVE SLOWLY STRAIGHT UP AND DOWN SLOPES DO NOT DRIVE THE VEHICLE ON SLOPES EXCEEDING 20 GRADE 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 FAI...

Page 36: ...ling 2 Turn the key switch to OFF and place the shift handle in the NEUTRAL position Remove the key when the vehicle is not in use LOADING AND UNLOADING Center and secure cargo as far forward as possible in the cargo bed See WARNING below IF THE ACCELERATOR PEDAL IS DEPRESSED WHILE THE FORWARD REVERSE HANDLE IS IN NEUTRAL OR IF YOU TRY TO SHIFT FROM FORWARD TO REVERSE WHILE THE ACCEL ERATOR PEDAL ...

Page 37: ...E VEHICLE LOAD AND POSSIBLY OVERTURNING THE VEHICLE AVOID SUDDEN STARTS SUDDEN STOPS AND ABRUPT TURNS THE CARGO S CENTER OF GRAV ITY MAY AFFECT THE HANDLING STEERING AND BRAKING OF THE VEHICLE TO PREVENT CARGO FROM SHIFTING AND POSSIBLY INJURING A PASSENGER OR AFFECT ING THE VEHICLE S HANDLING MAKE SURE CARGO IS WELL SECURED AVOID TOP HEAVY LOADS THE CENTER OF GRAVITY OF A LOAD SHOULD NEVER EXCEED...

Page 38: ...G ON A TRAILER GASOLINE VEHICLES ONLY TURN FUEL SHUT OFF VALVE TO OFF GASOLINE FLAMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE NEVER ATTEMPT TO DRAIN GASOLINE WHEN THE ENGINE IS HOT OR WHILE IT IS RUN NING BE SURE TO CLEAN UP ANY SPILLED GASOLINE BEFORE OPERATING THE VEHICLE STORE GASOLINE IN AN APPROVED GASOLINE CONTAINER ONLY STORE IN A WELL VEN TILATED ...

Page 39: ...argo bed engine compartment and underside of vehicle 8 Do not latch the park brake Chock wheels to prevent the vehicle from rolling TO RETURN THE STORED VEHICLE TO SERVICE 1 Restore fuel system to operation 1 1 Remove plug from the fuel tank vent nipple and reconnect fuel vent line to nipple Open the fuel shut off valve 1 2 Place the Forward Reverse handle in the NEUTRAL position and the neutral l...

Page 40: ...ETURN THE STORED VEHICLE TO SERVICE 1 Fully charge batteries See Batteries Electric Vehicle Page 47 2 Readjust tire pressure to rated capacities See Tire Capacities Page 44 3 Perform the Pre Operation Checklist See pages 15 and 16 MAINTENANCE GENERAL INFORMATION To ensure trouble free vehicle performance it is very important to follow an established preventive mainte nance program Regular and cons...

Page 41: ...WHEN WORKING WITH BATTERIES DO NOT WEAR LOOSE CLOTHING OR JEWELRY SUCH AS RINGS WATCHES CHAINS ETC WHEN SERVICING THE VEHICLE ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL CONNECTIONS TURN KEY SWITCH TO OFF REMOVE THE KEY PLACE THE FORWARD REVERSE HANDLE IN THE NEUTRAL POSITION AND CHOCK WHEELS PRIOR TO SERVICING MOVING PARTS DO NOT ATTEMPT TO SERVICE GASOLINE VEHICLE WHIL...

Page 42: ...S OR HAULING A TRAILER THESE PREVENTIVE MAINTENANCE PROCEDURES SHOULD BE PERFORMED MORE OFTEN THAN RECOMMENDED IN THE PERIODIC SERVICE SCHEDULE FIGURE 24 FIGURE 25 IF ANY PROBLEMS ARE FOUND DO NOT OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE FAILURE TO MAKE NECESSARY REPAIRS COULD RESULT IN FIRE PROPERTY DAM AGE SEVERE PERSONAL INJURY OR DEATH ALL SERVICE REPAIRS AND ADJUSTMENTS MUST BE MADE PER INS...

Page 43: ...eration Vehicle warning decals Make sure all are in place See Gasoline Vehicle Fea ture Identification Pages 4 5 8 9 and 12 13 Weekly Service by Owner Battery Clean terminals and wash dirt from case check elec trolyte level See page 47 Electrical wiring and connections Check for tightness and damage Torque Converter Rinse with water General Vehicle Check for loose hardware and tighten as required ...

Page 44: ...ice by Trained Mechanic Only Every 50 hours of operation Brake System Check for proper operation See Performance Inspec tion Page 16 Check brake pedal free play Clean and adjust as necessary See Maintenance Service Manual Check brake shoes and drums replace if necessary Lubricate slide plates with graphite See Maintenance Service Manual Electrical Wiring Check for cracked or worn insulation Engine...

Page 45: ...MS ARE FOUND DO NOT OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE FAILURE TO MAKE NECESSARY REPAIRS COULD RESULT IN FIRE PROPERTY DAM AGE SEVERE PERSONAL INJURY OR DEATH ALL SERVICE REPAIRS AND ADJUSTMENTS MUST BE MADE PER INSTRUCTIONS IN THE TRANSPORTATION MAINTENANCE AND SERVICE MANUAL PUBLICATION PART NO 1019051 03 PERIODIC SERVICE SCHEDULE ELECTRIC VEHICLE REGULAR INTERVAL SERVICE Daily Service b...

Page 46: ...ontinuously Variable Potentiometer Multi step for Tourall only Check for cracks or other damage make sure switch is securely fastened to frame Check moveable con tact for correct operation Check all daily and weekly items listed above Quarterly Service by Owner or Trained Mechanic Accelerator pedal rod Check for proper operation adjust as necessary See NOTE Page 19 Front Suspension Lubricate per E...

Page 47: ...oper operation Batteries Perform discharge test Motor Check motor brushes replace as necessary Front Wheel Bearings Inspect and check for free play repack with chassis lube and adjust as necessary Transaxle Check fill transaxle to plug level See Electric Vehicle Lubrication Chart on Page 43 General Vehicle Lubricate per Electric Vehicle Lubrication Chart on Page 43 Check all daily weekly monthly q...

Page 48: ...ssis Lube NLGI Grade 2 Annually by Trained Technician Only Every 100 hours of operation Check fill unitized transaxle to plug level 5 27 oz 8 liter 80 90 WT API Class GL 3 or 80 90 WT AGMA Class EP Gear Lube Inspect front wheel bearings Repack as necessary 6 Chassis Lube NLGI Grade 2 First Change 100 Hours Additional Change Every 200 Hours of Operation or Annually Whichever Comes First Change engi...

Page 49: ...1 Brake Linkage and Pivots 2 Dry Moly Lube Club Car Part No 1012151 Accelerator pivots 3 Dry Moly Lube Club Car Part No 1012151 Forward Reverse switch contacts and charger receptacle 4 WD 40 Front Suspension 5 fittings 5 Chassis Lube NLGI Grade 2 Annually by Trained Technician Only Every 100 hours of operation Check fill transaxle to plug level 6 22 oz 67 liter SAE 30 WT API Class SE SF or SG Oil ...

Page 50: ...soline Tank 7 gallons 26 5 liters TIRE CAPACITIES GASOLINE VEHICLES ELECTRIC VEHICLES Tourall 12 14 psi 83 96 kPa 18 20 psi 124 138 kPa Resort Villager 30 34 psi 207 234 kPa 30 34 psi 207 234 kPa Trans Porter 30 34 psi 207 234 kPa 30 34 psi 207 234 kPa Trans Sender 30 34 psi 207 234 kPa 30 34 psi 207 234 kPa 1 6 3 3 4 1 4 5 5 7 7 2 5 5 2 FLOORBOARD TRANS PORTER TRANS SENDER AND RESORT VILLAGER ELE...

Page 51: ...OLINE FLAMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE SERVICE OR REPAIR IN WELL VENTILATED AREA ONLY NEVER ATTEMPT TO POUR GASOLINE INTO THE FUEL TANK WHEN THE ENGINE IS HOT OR WHILE IT IS RUNNING TO AVOID ELECTRIC ARC CAUSED BY STATIC ELECTRICITY THE FUEL STORAGE PUMP ING DEVICE MUST BE GROUNDED IF THE PUMP IS NOT GROUNDED THE VEHICLE MUST BE GROUNDED TO ...

Page 52: ...S MANUAL BATTERY EXPLOSIVE GASES DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE TOOLS WIRES AND METAL OBJECTS CAN CAUSE SPARKS WHEN SHORTED ACROSS A BATTERY FOLLOW ALL INSTRUCTIONS CAREFULLY WHEN WORKING WITH BATTERIES CHARGE BATTERY IN A WELL VENTILATED AREA ONLY POISON CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING ANTIDOTES EXTERNAL FLUSH WITH ...

Page 53: ...e it charged by a trained mechanic The battery should never be left discharged any longer than absolutely necessary do not leave battery discharged overnight BATTERIES ELECTRIC VEHICLE FIGURE 31 FIGURE 32 DO NOT ALLOW BAKING SODA SOLUTION TO ENTER THE BATTERIES IF BATTERY WIRE TERMINALS ARE DAMAGED OR CORRODED THEY SHOULD BE REPLACED OR CLEANED AS NECESSARY FAILURE TO DO SO MAY CAUSE THEM TO OVER ...

Page 54: ...ter only after charging unless the water 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 water level For best battery life use only distilled water 3 The hold down straps should be tight enough so that the batteries do not move while the vehicle is in motion but not ...

Page 55: ...CHARGER SHOULD HAVE ITS OWN DEDICATED 15 OR 20 AMPERE SEPARATELY PRO TECTED CIRCUIT BREAKER OR FUSE SINGLE PHASE BRANCH CIRCUIT IN ACCORDANCE WITH ALL APPLICABLE ELECTRICAL CODES FOR THE LOCATION ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THE CHARGER CONTACT YOUR NEAREST CLUB CAR DISTRIBUTOR DEALER HAVE WORN CUT OR DAMAGED POWER CORDS OR WIRES REPLACED IMMEDIATELY BE SURE THAT ALL WIRE CONN...

Page 56: ...AL INJURY CAN RESULT HAVE A QUALIFIED TECHNICIAN REPAIR OR REPLACE DEFECTIVE PARTS IMMEDIATELY WHEN USING AN EXTERNAL STATIONARY CHARGER DO NOT PULL ON THE DC CORD FIG URE 34 PAGE 52 DO NOT TWIST ROCK OR BEND THE PLUG TO DISCONNECT THE PLUG FROM THE RECEPTACLE GRASP THE PLUG NOT THE CORD AND PULL IT SLOWLY STRAIGHT OUT OF THE RECEPTACLE FIGURE 33 PAGE 52 WHEN THE CHARGER IS ON THE CHARGER DC CORD ...

Page 57: ... 48 vehicle 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 preventing operation as well as subsequent damage to the charger and the vehicle Once the lock out is actuated the charger turns on The on board computer then records the amount of energy being returned to the batteries When the amount of ene...

Page 58: ...th a receptacle fuse link Figure 35 If the charger does not come on when the vehicle is placed on charge visually inspect the fuse link See WARNING below CLEANING THE VEHICLE The vehicle is equipped with an Armorflex front body and either an Amorflex or all aluminum rear body Some models also have aluminum cargo beds Use only mild dishwashing liquid soap with a sponge or soft cloth for normal clea...

Page 59: ... be performed by an authorized Club Car distributor dealer using CLUB CAR OEM parts ACCESSORIES AND OPTIONS A complete line of optional equipment items and accessories is available Contact your distributor dealer for an Optional Equipment book Care should be taken that these accessories and options are properly installed by trained technicians and that they are used in the manner for which they we...

Page 60: ...chronized Forward Reverse with neutral 11 8 1 forward 17 1 1 reverse Transaxle Double reduction helical gear with 12 28 1 direct drive axle Electrical System 12 volt 500 cca at 0 650 at 32 85 minute reserve capacity and 35 amp charging capacity Electrical System 48 volts DC reduced speed reverse Batteries High capacity deep cycle Trojan PowerDrive 8 volt 117 min capacity Charger Automatic 17 amp P...

Page 61: ...ound Clearance 4 1 2 11 cm 4 1 2 11 cm 4 1 2 11 cm 4 1 2 11 cm 4 1 2 11 cm 4 1 2 11 cm 4 1 2 11 cm 4 1 2 11 cm 4 1 2 11 cm Front Wheel Tread 34 1 2 88 cm 34 1 2 88 cm 34 1 2 88 cm 34 1 2 88 cm 34 1 2 88 cm 34 1 2 88 cm 34 1 2 88 cm 34 1 2 88 cm 34 1 2 88 cm Rear Wheel Tread 38 1 2 98 cm 38 1 2 98 cm 38 1 2 98 cm 38 1 2 98 cm 38 1 2 98 cm 38 1 2 98 cm 38 1 2 98 cm 38 1 2 98 cm 38 1 2 98 cm Weight S...

Page 62: ... cm 11 3 4 30 cm 11 3 4 30 cm 11 3 4 30 cm 11 3 4 30 cm 11 3 4 30 cm 11 3 4 30 cm 11 3 4 30 cm 11 3 4 30 cm Seat Height 29 1 2 75 cm 29 1 2 75 cm 29 1 2 75 cm 30 76 cm 30 76 cm 30 76 cm 30 76 cm 30 76 cm 30 76 cm Load Bed Height Box bed inside dimensions 27 69 cm 27 69 cm Load Bed Size Flat bed inside dimensions 35 3 4 x 44 1 4 91 x 112 cm 35 3 4 x 44 1 4 91 x 112 cm Vehicle rated capacity Level s...

Page 63: ... 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 PUR CHASE WITH ANY WARRANTY CLAIM 2 EXCLUSIONS Excluded from any Transportation Utility vehicle warranty are all fuses filters decals except safety decals spark plugs lubricants trim pieces seats routine w...

Page 64: ...RANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WAR RANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REMEDY OF REPAIR OR REPLACE MENT OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE EXCLUSIVE AND SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTH...

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Page 68: ...Transportation and Utility Vehicles Club Car Inc P O Box 204658 Augusta GA 30917 4658 ...

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