2013 Owner’s Manual ACG 39 Roadster eGC Electric Golf Cart (eGC) This Manual is effective as of January 15, 2013
Manufactured by: American Custom Golf Cars, Inc. (ACG) 15740 El Prado Rd. Chino, CA 91710 USA (909) 597-2885 (909) 597-7183 fax www.californiaroadster.com Copyright © 2009-2013 American Custom Golf Cars, Inc. American Custom Golf Cars, Inc., ACG and California Roadster Are registered trademarks of American Custom Golf Cars, Inc. Copyright © 2009-2013 American Custom Golf Cars, Inc.
Notice The American Custom Golf Cars, Inc., herein known as ACG, “Limited Warranty” for owners of the 39 Roadster eGC is included with this manual. No other warranties, expressed or implied, are contained herein. ACG and your authorized representative checked this vehicle before it was delivered to you. This vehicle does NOT conform to Federal Motor Vehicle Safety Standard FMVSS #500 for LSV (low-speed vehicles), and is NOT equipped for operation on public streets and roads.
Table of Contents Notice…………………………………………………………………………………...... 3 Table of Contents……………………………………………………………………...... 4 Foreword……………………………………………………………………………........ 5 Introduction…………………………………………………………………………...…. 6 ABOUT THIS MANUAL……………………………………………………………....… 6 Insurance Notice…………………………………………………………………....…… 7 Warranty Registration……………………………………………………………....…… 7 General Warnings…………………………………………………………………....….. 8 SAFE OWNERSHIP OF ACG eGC………………………………………………....….
Foreword Thank you for choosing the 39 Roadster eGC for your local and community transportation needs. Please protect your investment to make sure that your 39 Roadster eGC will provide you with years of reliable performance. Your safety is important to us, so please make sure that prior to operating the vehicle you have read the following instructions and warnings. If you rent or loan your vehicle to others, please make sure that they have read this manual prior to operating this vehicle.
Introduction ABOUT THIS MANUAL Thank you for purchasing your 39 Roadster eGC vehicle manufactured by American Custom Golf Cars, Inc. (ACG) Your vehicle is designed to operate exclusively on battery power. It is a “Zero Emission Vehicle” (ZEV). The ideal application for a battery-powered Golf Cart (eGC) occurs when the daily driving pattern is predictable and the distance is relatively short. The ACG company objective includes customer safety and product satisfaction.
Insurance Notice Your Insurance may not provide coverage for accidents involving the use of this vehicle. To determine if coverage is provided you should contact your insurance company or agent. Warranty Registration The separate “Warranty” document includes a “Warranty Registration Card”. Your new 39 Roadster Limited Warranty.
General Warnings _ 1. 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. 2. When charging the vehicle, be sure that the key switch is in the “OFF” position. If the key is left in the “ON“ position, it may damage the charger or the vehicle. 3. Your vehicle is equipped with an on-board UL- listed charger.
WARNING! 1. If renting or loaning the vehicle, make sure that the driver is familiar with all controls and operating procedures before allowing the vehicle to be driven. 2. 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. 3. Do not shift the “Forward-Neutral-Reverse Switch” while the vehicle is moving.
SAFE OWNERSHIP OF ACG ELECTRIC VEHICLES ACG pure battery electric vehicles are different from vehicles you might be accustomed to owning. Special precautions should be followed when owning and operating an ACG vehicle. Please read this “Owner’s Manual” and pay particular attention to the Cautions and Warnings in this Manual, as well as those placed on the vehicle in various locations.
• The voltage in an ACG vehicle battery pack (the battery pack is what you charge and provides the “fuel” to the ACG’s electric drive system) is 48 Volt DC and is sufficient to cause death by electric shock - electrocution. For this reason, ACG owners should NEVER attempt to do any maintenance or repair work on their ACG vehicle’s electric drive system, including the battery pack, unless they have had special training.
Controls and Indicators Key Switch The “Key Switch” is mounted on the dash to the right of the steering column. It has two positions: 1. OFF position- There is no power to vehicle. (Key is Vertical as shown in picture below) 2. ON position- vehicle is ON and can be driven. (Key is turned clockwise 45 degrees) Key is shown in OFF position WARNING! Never turn the “Key Switch” to the “OFF” position while the vehicle is in motion. This could lead to loss of speed control and loss of control of the vehicle.
Forward – Neutral - Reverse Control Switch The “Forward-Neutral-Reverse Switch” is located on the seat support panel. There are three (3) distinct positions: Forward, Neutral and Reverse. 1.) FORWARD - To operate the vehicle in the forward direction, rotate the switch towards the passenger side of the vehicle. 2.) REVERSE - To operate the vehicle in the reverse direction, rotate the switch towards the driver side of the vehicle.
Accelerator Pedal The “Accelerator Pedal” is the pedal on the right, with the word “GO” molded into it. The operation of the accelerator pedal differs from that of an Automobile. When the “Key Switch” is in the “ON” position, depressing the accelerator pedal will release the parking brake. As the accelerator pedal is depressed speed will increase until full speed is reached. When you release the accelerator pedal the power to the motor is cut OFF and the motor will stop running causing the vehicle to coast.
Brake Pedal The “Brake Pedal” is the large pedal on the left with the word “STOP” molded into it. To slow or stop the vehicle, release the “Accelerator Pedal” and then depress the brake pedal with your foot until the vehicle has come to a complete stop or the vehicle has slowed to your desired speed. Copyright © 2009-2013 American Custom Golf Cars, Inc.
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. To set the park brake, depress the “Brake Pedal” firmly and tilt the park brake portion of the pedal forward with your foot. WARNING! The “Park Brake” will release automatically when either the “Accelerator Pedal” or “Brake Pedal” is depressed.
Light Switch The “Light Switch” is located on the Dashboard to the left of the steering Column. It is identified by SAE/ISO “Lights” icon. It is a 2 position switch: 1.) OFF - When the top portion of the switch “O” is depressed the lights are “OFF”. 2.) ON - When the bottom portion of the switch “I” is depressed, the lights are “ON”. (Light switch shown in “OFF” position) Copyright © 2009-2013 American Custom Golf Cars, Inc.
Turn Signal Lever Switch The Turn Signals are activated by Lever Switch located on Left side of steering column below Steering Wheel. It is a 3 position switch. 1.) RIGHT - When the Lever is pushed UP (Clockwise) – the Right Lights Flash. 2.) OFF - When the Lever is Horizontal, the Turn Signal lights are “OFF”. 3.) LEFT – When the Lever is pushed down (Counter Clockwise) – the Left Lights Flash.
Hazard Warning Flashers The Hazard Warning Flasher Switch activates both Turn Signals to provide “Hazard Warning” by flashing both Right and Left as well as Front and Rear Turn Signals at the same time. The “Hazard” function is activated by Pull Switch located on Left side of steering column below Steering Wheel. And immediately below the Turn Signal Lever. It is a 2 position switch.
Display Panel The 39 Roadster eGC LCD display has following functions: Battery State of Charge (SoC) shown on bar graph at right of the screen and as percent % at top of the bar graph (shown above as 88%) Trip Distance Traveled in miles in NN.N format (shown above as 90.6 mi.) Odometer TOTAL Distance Traveled in miles in NNNN.N format (shown above as 231.9 mi.
Display Panel - Battery State of Charge (SoC) IMPORTANT INFORMATION Battery Percent Charge Information on SEVCON Display The Battery charge level indicates the relative state of charge of the Traction Battery and NOT the remaining driving range of the vehicle. Its algorithm is based on the PEAK Traction Battery Pack Voltage, which in turn calculates the APPROXIMATE charge of the Traction Battery.
Display Screen – Other Functions Main Screen Main screen will display Direction, Speed and Battery Charge Level, it also displays Trip and Odometer (total miles) mileage traveled. If the low water battery symbol appears please check the water level in all batteries. To clear the low water battery symbol push upper arrow button [# ] 2 times; this will clear the low water level symbol.
2nd Screen VEHICLE STATUS MONITOR Section A Battery shows Battery Nominal Voltage Trac Drive Status shows current status Section B 1. Cont. Temp. (Controller Temperature) 2. 3. 4. 5. Motor Volts Motor Amps Motor RPM (Rotations Per Minute) Motor Torque in Percent (%) These values will change as soon as you start driving the vehicle. This will also let you monitor and diagnose the condition of the motor and controller . To proceed to a 3rd Screen push center arrow button [8 ] once.
3rd Screen VEHICLE INPUTS MONITOR on this screen all switch and input signal conditions are displayed: Forward FS1 Drv Select 1 Hand Brake Inch FWD sw Reverse Seat Drv Select 2 Foot Brake Inch REV sw Note: Drive profile #2 (Drv Select 2) is only used for testing Purpose to see the Range of motor on the controller. Features not used: Seat Hand Brake Inch FWD sw Inch REV sw To proceed to a 4th Screen push center arrow button [8 ] once. Copyright © 2009-2013 American Custom Golf Cars, Inc.
4th Screen TIME TO DISTANCE This screen displays the acceleration of the vehicle from 0-1000 feet and will automatically record the performance of the vehicle. It also displays the number of hours the vehicle was driven. To proceed to a 4th Screen push center arrow button [8 ] once. Copyright © 2009-2013 American Custom Golf Cars, Inc.
5th Screen FAULT LOG Log of all faults that have ever possibly occurred on the vehicle. The first 8 of the faults on the screen are fault checks which are created at the time the vehicle is the first programmed. Any fault after that might be relevant. To check new faults you need to press the upper button [# ] twice and the fault will appear (6th Screen). 6th Screen It will give you the date and time the fault first appeared and the explanation what the fault means.
Note: You will see a sequence fault if not started in neutral this code will clear as soon as you put the car in neutral. The vehicle will possibly give you a cut back code. When the vehicle gets low on power it will automatically cut back, this is a safety precaution to protect the motor and controller. In many cases the fault is just a warning. For example: Thermal cut back just means the motor is too hot and will reduce the power to protect the motor.
Locking Glove Boxes The 39 Roadster eGC is equipped with two locking glove boxes on the dashboard. Both Locking Glove Boxes use the same key as the “Key Switch” as they are keyed alike. If the keys are lost, the locks for the glove boxes as well as the ignition switch need to be changed. Front Trunk Release The “Front Trunk Release Lever” on the 39 Roadster eGC is located inside the passenger side locking glove box on the right side wall of the glove box.
Accessory Outlet The accessory outlet is located on the dash, to the right of the instrument panel. This outlet will accept a standard automotive 12-volt accessory outlet and is only intended for moderately powered accessories, such as a cellular phone, Lap top computer, etc. It is not intended to operate large current items, such as cigarette lighters. The accessory outlet is fused at 15 Amperes with fuse “F2”. WARNING! Damage to electrical components may occur from improper use.
Safety Belts Your vehicle is equipped with “Safety Belts” for both driver and passenger. Research has shown that safety belts save lives. Safety belts can reduce the seriousness of injuries in a single vehicle accident. Some of the worst injuries happen when people are thrown from the vehicle. Safety belts provide protection, and they reduce the risk of injury caused by striking the inside of the vehicle. Everyone needs to buckle up all the time, even for short trips.
Proper Use of Lap Belt 1. Enter the vehicle and sit back. 2. Grasp the safety belt buckle and slide the buckle up the webbing as far as necessary to make the belt go around your lap. 3. When the safety belt is long enough to fit, insert the buckle into the latch until you hear a click. 4. Position the lap belt across your thighs, and below your abdomen. To remove slack in the lap belt pull up on the belt. To loosen the lap belt if it is too tight, tilt the buckle and pull on the lap belt.
SEAT BELTS AND PREGNANT WOMEN We recommend that pregnant women use seat belts throughout their pregnancy. Keeping the mother safe is the best way to keep the baby safe. Pregnant women should wear the lap part of the belt across the thighs and as snug across the hips as possible. Keep the belt low so that it does not come across the abdomen. That way the strong bones of the hips will take the force if there is a collision.
Child Restraint Everyone in your vehicle needs to be buckled up at all times - babies and children, too. Every state in the United States and all Canadian provinces require that small children ride in proper restraint systems. This is the law, and you can be prosecuted for ignoring it. Children 12 years and under should ride properly buckled up in a rear seat, if available. According to crash statistics, children are safer when properly restrained in the rear seats, rather than in the front.
Infants and Child Restraints Safety experts recommend that children ride rearward-facing in the vehicle until they are at least one year old and weigh at least 20 lbs (9 kg). Two types of child restraints can be used rearward-facing: infant carriers and “convertible” child seats. The infant carrier is only used rearward-facing in the vehicle. It is recommended for children who weigh up to about 20 lbs (9 kg).
Children too large for booster seats Children who are large enough to wear the lap belt comfortably, and whose legs are long enough to bend over the front of the seat when their back is against the seat back, should use the lap belt. • Make sure that the child is upright in the seat. • The lap belt should be low on the hips and as snug as possible. • Check belt fit periodically. A child’s squirming or slouching can move the belt out of position.
Transporting Pets Pets should be restrained in a pet harness, or in a pet carrier that is secured by seat belt. Optional Accessories CAUTION! Use only ACG approved rear accessories. Others may cause damage to the vehicle, and will void warranty. WARNING! Any modifications or alterations to this vehicle could seriously affect its road worthiness and safety and may lead to an accident resulting in serious injury or death. Copyright © 2009-2013 American Custom Golf Cars, Inc.
Tires & Wheels Tires Proper tire inflation pressure is essential to the safe and satisfactory operation of your vehicle. Tire inflation pressures are provided on your vehicle’s “Tire Information Label” (See page 39, Figure 1). Four (4) primary areas are affected by improper tire pressure: 1. Safety Under-inflation increases tire flexing and can result in tire failure. Over-inflation causes a tire to lose its ability to cushion shock.
WARNING! Improperly inflated tires are dangerous and can cause accidents. • • • Under inflation increases tire flexing and can result in tire failure. Over inflation reduces a tire’s ability to cushion shock. Objects on the road and chuck holes can cause damage that can result in tire failure. Unequal tire pressures can cause steering problems. You could lose control of your vehicle.
WARNING! • • • Do not use a tire, wheel size or rating other than that specified for your vehicle. Some combinations of unapproved tires and wheels may change suspension dimensions and performance characteristics, resulting in changes to steering, handling, and braking of your vehicle. This can cause unpredictable handling and stress to steering and suspension components. You could lose control and have an accident resulting in serious injury or death.
Tire Changing & Jacking Points In the event of a flat tire, you need to observe the following precautions: Park the vehicle on a firm level surface; avoiding icy or slippery areas. Set the parking brake and block both the front and rear of the tire diagonally opposite the jacking position. For example, if the right front tire is being changed, block the left rear wheel. Use a small floor style jack or low profile scissors jack only.
Brakes 39 Roadster eGC has Front Disc Brakes which are self adjusting. Brake Fluid Level The Brake Fluid Reservoir is located under the hood, at the Front to the side of the hood latch mechanism. The fluid level of your brake system is a very important safety component. It should be checked according to the Monthly Vehicle Maintenance Schedule, on Page 47, by removing the Brake Fluid Reservoir Cap and observing the fluid level.
Pre-Operation and Daily Safety Checklist Every 39 Roadster eGC is thoroughly inspected and adjusted at the factory and again re-inspected by your ACG Dealer before it arrives at your door. However, upon receiving your new 39 Roadster eGC you should take time to become familiar with its controls and operation. The following checklist should be used daily to ensure that the vehicle is in proper working condition and in conjunction with the Periodic Service Schedule.
Performance Inspection After you have familiarized yourself with the operation of all the controls of the 39 Roadster eGC 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 problems or deficiencies you may find should be corrected at once by an authorized American Custom Golf Cars, Inc. dealer/distributor or a trained technician.
Driving Instructions WARNING! No person should be allowed to operate the vehicle without being instructed in the proper use and operation of the vehicle’s controls. Each first time driver should be accompanied by an experienced driver on a test drive before being allowed to operate the vehicle alone. 1. Only licensed drivers should be allowed to drive this vehicle. 2.
13. To prevent the vehicle from overturning, drive slowly straight up and down slopes. Slope exceeding 20% incline should be avoided. 14. Avoid sudden stops, sudden starts, and abrupt turns to prevent possible injury to an inattentive passenger or damage to the vehicle. 15. Reduce speed for adverse driving conditions such as wet grass or terrain to avoid the possibility of losing control of or overturning the vehicle. 16. Obey all the rules governing Low Speed Vehicles (LSV). 17.
Starting the Vehicle 1. Study and understand controls. 2. Make sure everyone is seated with all parts of their body inside the vehicle. 3. Make sure everyone’s “Seat Belts” are properly fastened. 4. Make sure front wheels are turned in the desired travel direction. 5. Turn “Key Switch” to the “ON” position and make sure nothing is in your path. 6. Select the travel direction using the “Forward–Neutral-Reverse Switch”. 7. Slowly depress the “Accelerator Pedal” (GO) and bring vehicle up to desired speed. 8.
Batteries Your California Roadster is operated as a 48-volt unit with eight (8) 6-Volt batteries. The batteries are Trojan® T-105 deep-cycle batteries, specially designed and produced for use in an electric vehicle. If the batteries need to be replaced at any time for any reason, do not use automotive batteries. New batteries usually will not deliver their full capabilities until they have been discharged and recharged 15 to 30 times.
Battery Inspection & Maintenance Inspection There are many tools that may help in properly caring for and maintaining batteries. Below is a list of basic items that ACG & Trojan recommends for this task: Recommended Equipment: Wrench Distilled Water Voltmeter Hydrometer Post Cleaner Baking Soda Vaseline Goggles & Gloves CAUTION! Always wear protective clothing, gloves, and goggles when handling batteries, electrolyte, and charging your battery.
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. Tighten all wiring connections to the proper specification (see below). Make certain there is good contact with the terminals.
Cleaning Batteries seem to attract dust, dirt, and grime. Keeping them clean will help one spot trouble signs if they appear and avoid problems associated with grime. 1. Check that all vent caps are tightly in place. 2. Clean the battery top with a cloth or brush and a solution of baking soda and water. When cleaning, do not allow any cleaning solution, or other foreign matter to get inside the battery. 3. Rinse with water and dry with a clean cloth. 4.
WATERING (FLOODED BATTERIES ONLY) Flooded batteries need water. More importantly, watering must be done at the right time and in the right amount or else the battery's performance and longevity suffers. Water should always be added after fully charging the battery. Prior to charging, there should be enough water to cover the plates. If the battery has been discharged (partially or fully), the water level should also be above the plates.
Step by step watering procedure: 1. Open the vent caps and look inside the fill wells. 2. Check electrolyte level; the minimum level is at the top of the plates. 3. If necessary add just enough water to cover the plates at this time. Add only water, never acid, to cells ! (distilled water is highly recommended) 4. Put batteries on a complete charge before adding any additional water (refer to the “Charging Batteries” section, on page 43). 5.
Charging Batteries CAUTION! Be sure that the “Key Switch” is in the “OFF” position prior to charging. 1. Your vehicle is equipped with an on board charger. To begin charging the batteries, insert a UL approved 3 prong extension cord into any 110volt outlet and plug the other end into the charging cord receptacle located below the “Forward – Neutral - Reverse Switch”. (Refer to supplied “Battery Charger Manual” and “Charging Procedures Manual” for further information regarding the operation of the charger.
Battery Replacement CAUTION! If the batteries are replaced, make sure they are the exact type and make originally supplied with the vehicle. Failure to follow this caution can result in damage to the vehicle’s electrical system. CAUTION! Each vehicle is programmed at the factory for a particular battery type. Switching battery types can only be done by ACG certified technician.
Additional Battery Service Warnings & Cautions WARNING! Always wear safety glasses or approved eye protection when servicing the vehicle. Wear a full-face shield and gloves when working with or around batteries and electrical connectors. Always use insulated tools when working with or near batteries. WARNING! Battery fluid is a corrosive acid solution and can burn or blind you. Do not allow battery fluid to contact eyes, skin or clothing.
Periodic Maintenance DAILY TASKS 1. Charge Batteries fully before first use of vehicle. 2. Check battery terminals for tight connections. 3. Visually inspect the tires for wear, damage, and proper inflation. 4. Check for proper operation of parking brake. 5. Check seat belts for proper operation. Copyright © 2009-2013 American Custom Golf Cars, Inc.
Periodic Maintenance MONTHLY TASKS 1. Check all eight (6 Volt) Flooded batteries for proper water level. Use only Distilled Water for addition. (Not necessary if vehicle is equipped with Sealed or maintenance free Gel batteries). 2. Check battery terminals for tight connections. 3. Check tires for correct air pressure and wear. 4. Check for proper operation of parking brake. 5. Check brake fluid reservoir for proper brake fluid level. 6. Check brake lines for leaks. 7.
Cleaning CARE AND CLEANING Cleaning the Windshield Please be extremely careful when cleaning the Windshield on your 39 Roadster eGC as it is made from acrylic plastic. ACG recommends using Windshield Washer Fluid to remove normal dust and dirt. A liquid household glass cleaner can also be used. Do not use abrasive cleaners on the windshield, as they will cause scratches. CAUTION! Be very careful when cleaning the acrylic glazing as it can be scratched or damaged.
Cleaning the Seats To clean the seats of your ACG vehicle, use water or mild liquid detergent. Rubbing seats with warm water and a clean, damp cloth will also remove dirt. Substances such as tar, asphalt, and other soils will stain if not removed quickly. Use a clean cloth and solvent type vinyl cleaner and then wash the area thoroughly with a damp cloth and mild liquid detergent. Finish by rinsing with cool water. Dry with a soft, clean chamois or towel to avoid surface scratches or water spotting.
Transport or Towing Transporting Your Vehicle The best way to transport your vehicle is in an enclosed trailer. If it is necessary to transport your vehicle on an open trailer, follow these guidelines: 1. Never transport your vehicle while the vehicle is facing rearward on the trailer. 2. With the vehicle facing forward, pull the trailer at speeds of 55 MPH or less. 3. Secure any items that could be affected by airflow through the vehicle. 4.
Specifications Overall Length Overall Width Height to top of Windshield Wheelbase Ground Clearance Weight (standard golf cart no batteries) Weight (Curb, with Batteries) Weight (GVWR) Front Wheels Rear Wheels Front Tire Size Rear Tire Size 123 Inches 51 Inches 45 Inches 85 Inches 5.5 Inches 738 lb. 1,262 lb. 2,000 lb.
2013 ACG 39 Roadster eGC Manufactured by: American Custom Golf Cars, Inc. (ACG) 15740 El Prado Rd. Chino, CA 91710 USA (909) 597-2885 (909) 597-7183 fax www.californiaroadster.com Copyright © 2009-2013 American Custom Golf Cars, Inc. ACG logo and California Roadster Are registered trademarks of American Custom Golf Cars, Inc.
