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1. Figure 19 Lubrication Points Gasoline Vehicles 2005 DS Golf Car Owner s Manual Page 31 Vehicle Controller Electric Vehicles VEHICLE CONTROLLER ELECTRIC VEHICLES The Club Car electric vehicle is equipped with a solid state speed controller In order to properly service and maintain the solid state controller vehicle it is necessary to understand the electrical circuitry and the func tions of all components in both systems Therefore if any repair or servicing needs to be performed we rec ommend that it be performed by an authorized Club Car distributor dealer using Club Car OEM parts BATTERIES ELECTRIC VEHICLES See General Warnings on page 9 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 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 Call a physician immediately Internal Drink large quantities of milk o
2. rw e ee e rep Rd e ge ol ale eid e 11 Safety Committee educ ER Red xax eR LER ENS AS eeu HE E 12 Controls and Indicators liliis hh herren 12 Pre Operation and Daily Safety Checklist 18 Driving Instructlons seas ke teak td SPUR ele eee ote Fn 20 TOWING eee ee he a ee ae 22 Transporting ona Trailer zu rue EDO doled ah hd eae E GR PUERO REN EU RR eee dvs 23 Storage Electri Vehicles 2 eka ete RUE Ebr uu eae Mie Abie pe eee da 24 Storage Gasoline Vehicles 0 25 Maintenance emat peel pu Ce x at s NER ope Mie an eu oed e wee d dep ae belie es 27 Periodic Service Schedules 28 Periodic Lubrication Schedules 30 Vehicle Controller Electric Vehicles 32 Batteries Electric Vehicles illii ae 32 Battery Charger Electric Vehicles 34 Battery Gasoline Vehicles 37 Engine Oil Gasoline 39 Fueling Instructions Gasoline Vehicles 40 Cleaning the Vehicle lili
3. SPECIFICATIONS GASOLINE LIQUID CAPACITIES Transaxle 22 oz 0 67 L Engine crankcase without filter 32 oz 0 95 L Engine crankcase with filter 38 oz 1 12 L Unitized transaxle 27 oz 0 8 L Fuel tank 7 gallons 26 5 L TIRE PRESSURE Front and rear 1 241 38 Bars 0 88 0 9 Bars 2005 DS Golf Car Owner s Manual Page 43 CLUB CAR LIMITED THREE YEAR WARRANTY FOR 2005 INDIVIDUAL GOLF CARS 1 WARRANTY CLUB CAR INC CLUB CAR hereby warrants to the Original Retail Purchaser that its new 2005 Model DS golf car purchased from CLUB CAR or an authorized distributor or dealer shall be free from defects in material and workmanship under normal use and service as a golf car for the periods stated below subject to the provisions limitations and exclusions contained in this limited warranty LIMITED THREE YEAR WARRANTY The golf car frame excluding the front and rear bumper mounts rack and pinion steering gearbox unit suspension system defined as the shock absorbers shock mounts A plate leaf springs shackles and associated hardware gasoline engine unitized transaxle torque converters drive and driven starter generator transaxle electric vehicle and electric motor are warranted with respect to parts and labor for a period of three years from the date of purchase LIMITED TWO YEAR WARRANTY All remaining components of the golf car not specified otherwise except options and accessories are war
4. Reverse Buzzer will sound Vehicle will start moving when accelerator pedal is depressed KEY SWITCH 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 the vehicle Firmly depress park brake until it locks Place Forward Reverse switch in NEUTRAL position Turn key OFF and remove key when not in use ci 101621601 OPERATING INSTRUCTIONS BATTERY DECAL WARNING LIGHT SERIAL NUMBER PRIVATE SPEED DECAL IQ VEHICLES WITH PRIVATE SPEED OPTION PARK BRAKE PEDAL This vehicle does not conform to ANSI 2130 1 Standard for Golf Cars Safety and Performance Requirements because it is capable of speeds in excess of 15 miles per hour Exercise caution 102228701 Maximum vehicle speed is limited by motor braking during downhill operation with accelerator pedal depressed If motor brake enabled vehicle motor will brake when accelerator pedal is released Beeping alarm indicates reduction in motor braking Apply brakes to reduce speed System is activated only when tow switch he RUN position When towing vehicle tow switch must he TOW position 101959902 A LE R AT R MOTOR BRAKING DECAL PEDAL BRAKE PEDAL Page 4 2005 DS Golf Car Owner s Manual Vehicle Feature Identification DS ELECTRIC VEHICLE ELECTRICAL COMPONENT DECAL
5. 2005 DS Golf Car Owner s Manual Page 23 Storage Electric Vehicles If the vehicle must be transported over long distances or on public highways it should be transported on an approved trailer that has the approved load rating of 1200 Ib 544 kg per vehicle being transported NOTE A two car trailer should be rated at 2 x 1200 2400 Ib 2 x 544 1088 kg STORAGE ELECTRIC VEHICLES See General Warnings on page 9 A WARNING Turn the key switch to the OFF position remove the key and leave the Forward Reverse handle or switch in the NEUTRAL position during storage This is to prevent unintentionally 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 To avoid exposing electrical components to moisture and subsequent damage do not use any type of pressure washing or steam cleaning equipment to wash the vehicle Electric vehicles only Place Tow Run switch in the TOW position PREPARING THE ELECTRIC VEHICLE FOR EXTENDED STORAGE 1 Fully charge batteries See Charging Batteries on page 35 0 029050 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
6. Batteries High capacity deep cycle Trojan PowerDrive 8 volt 117 min capacity Charger Automatic 48 volt UL and CSA listed STEERING SUSPENSION BRAKES Steering Self adjusting rack and pinion Suspension Front and rear tapered mono leaf springs with dual hydraulic shocks Brakes Dual rear wheel self adjusting brakes with cast iron drums and single brake pedal with automatic release park brake BODY CHASSIS Frame Chassis Twin welded aluminum Front and rear body ArmorFlex Body finish Matched paint finish over molded in color Tires 18 x 8 5 8 tubeless 4 ply rated DIMENSIONS WEIGHT Overall length 91 5 in 232 cm Overall width 47 25 in 120 cm Overall height with canopy 68 5 in 174 cm Overall height at steering wheel 48 in 122 cm Wheelbase 65 5 in 166 cm Ground clearance 4 5 in 11 cm Front wheel tread 34 5 in 88 cm Rear wheel tread 38 5 in 98 cm Weight vehicle with canopy without batteries 494 Ib 224 kg Weight dry without battery 619 Ib 281 kg Forward speed 12 15 mph 19 24 km h Curb clearance circle diameter 17 ft 6 in 533 cm Braking distance at 12 mph 19 km h 14 ft 427 cm Standard seating capacity 2 Page 42 2005 DS Golf Car Owner s Manual Vehicle Specifications
7. 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 be grounded to the pump before and during the fueling operation If the vehicle has an all weather enclosure installed be sure the fuel tank is properly vented as shown Figure 28 To avoid the possibility of fire clean up any spilled gasoline before operating the vehicle A CAUTION To allow for expansion do not fill higher than one inch from the top of the fuel tank Avoid fuel spillage NOTE Whenever possible avoid using oxygenated fuels and fuels that are blended with alcohol Vehicles to be stored for extended periods should be prepared for storage as instructed See Preparing the Gasoline Vehicle for Extended Storage on page 25 1 Turn the key switch to the OFF position 2 Lift and remove seat bottom 3 The fuel tank is located on passenger side of vehicle Remove fuel cap and fill the fuel tank with fresh unleaded gasoline only See preceding CAUTION 4 Replace fuel cap on tank Ensure cap is tightened securely 5 Replace seat bottom VENT SHUT OFF Figure 28 Fuel Tank Page 40 2005 DS Golf Car Owner s Manual Cleaning the Vehicle CLEANING THE VEHICLE Club Car DS vehicles are equipped with ArmorFlex front and rear bodies Use only commercially available automotive cleaners with a sponge or soft cloth for normal cleaning A garden hose at normal resi
8. 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 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 maintenanc
9. 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 illuminates 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 illuminate if the charge is 90 or more complete The onboard 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 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 man ual This indicates an abnormal charge cycle The ch
10. through the crankcase Then it is led to the air cleaner Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase and then returned back to the bottom of the crankcase 2 Exhaust Emission Control System The exhaust emission control system applied to this engine consists of a carburetor and an ignition system having optimum ignition timing characteristics The carburetors have been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system Maintenance and Warranty Proper maintenance is necessary to ensure that your engine will continue to have low emis Sion levels Those items identified by the Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards The Club Car Limited Emission Control System Warranty requires that you return your engine to an authorized Club Car Dealer for remedy under warranty Please read the warranty carefully and keep it valid by complying with the owner s obligations it contains Tampering with Emission Control System Prohibited California State law prohibits the following FUEL AND OIL RECOMMENDATIONS Fuel Use only clean fresh unleaded regular grade gasoline Octane Rating The octane rating of a gasoline is a measure of its resistance to knocking Use of a mini mum of 87 octane of the anti knock index is recommended The an
11. See General Warnings on page 9 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 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 Battery Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes DANGER CONTINUED ON NEXT PAGE 2005 DS Golf Car Owner s Manual Page 37 Battery Gasoline Vehicles A DANGER External Flush with water Call a physician immediately Internal Drink large quantities of milk or water followed with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately A WARNING Do not jump start a dead battery using another battery and jumper cables The battery in the Club Car gasoline vehicle is a 12 volt low maintenance battery that requires infrequent watering Figure 24 Any corrosion around the positive or negative terminals should be washed off with a solution of baking soda and water 1 cup 237 mL per gallon 3 8 L of water Rinse solution off the battery Do not allow this solution to enter bat
12. been removed from the seat bottom before operating the vehicle Failure to do so may result in a 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 control Check for proper operation See Controls and Indicators on page 12 Brakes Be sure the brakes function properly When brake pedal is fully pressed under moderate pres sure it should not go more than halfway to the floor and vehicle should come to a smooth straight stop within 14 feet 4 3 m If the pedal goes more than halfway to the floor or if the vehicle swerves or fails to stop within 14 feet 4 3 m have the brake system checked and adjusted as required Brake adjustment must be maintained so that the brake pedal cannot be pressed to the floor under any circumstance 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 pressed Reverse buzzer The reverse buzzer should sound as a warning when the Forward Reverse handle or switch is in the REVERS
13. dealer shall be free from defects in material and workmanship under normal use and service as a golf car for the periods stated below subject to the provisions limitations and exclusions contained in this limited warranty LIMITED LIFETIME WARRANTY The golf car frame excluding the front and rear bumper mounts rack and pinion steering gearbox unit and suspension system defined as the shock absorbers shock mounts A plates leaf springs shackles and associated hardware are warranted for the lifetime of the vehicle with respect to parts and labor against defects in material and workmanship from the date of purchase while owned by the Original Retail Fleet Purchaser or in the possession of the Original Retail Fleet Lessee LIMITED THREE YEAR WARRANTY The gasoline engine torque converter drive and driven unitized transaxle starter generator transaxle electric vehicle and electric motor are warranted for a period of three years with respect to parts and labor against defects in material and workmanship from the date of purchase while owned by the Original Retail Fleet Purchaser or in the possession of the Original Retail Fleet Lessee LIMITED TWO YEAR WARRANTY All remaining components of the golf car not specified otherwise except options and accessories are warranted for a period of two years with respect to parts and labor against defects in material and workmanship from the date of purchase while owned by the Original Retail Fleet Purc
14. grades 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 11 mph 17 7 km h Motor braking will disengage when vehicle slows to 11 mph 17 7 km h This feature is adjustable for IQ System vehicles only Contact your local Club Car dealer distrib utor to inquire about this adjustable feature Pedal Down Motor Braking Accelerate down an incline with the accelerator pedal pressed When the vehicle reaches maximum designed speed motor braking should engage and limit the vehicle to its maximum designed speed On very steep grades the vehicle may slightly exceed its maximum designed speed requiring use of the brake pedal Gasoline Vehicles Accelerator With the key switch in the ON position and the Forward Reverse switch in the FORWARD position as the accelerator pedal is pressed the engine 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 engine should stop All Club Car vehicles operate at reduced speed in reverse Governor Check maximum speed of the vehicle The vehicle should operate at 12 15 mph 19 24 km h on a level surface DRIVING INSTRUCTIONS A WARNING Only licensed drivers should be allowed to drive the vehicle f renting or loaning the vehicle ma
15. 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 that could damage the plug and receptacle and could cause batteries to explode Do not block or cover the charger ventilation slots The slots provide ventilation and protect 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 2005 DS Golf Car Owner s Manual Battery Charger Electric Vehicles NOTE Because the vehicle s onboard computer OBC has a storage charge feature that automatically checks and recharges the batteries as necessary every 15 days the charger can remain plugged to a IQ System vehicle throughout the storage period Shortly after charging begins the PowerDrive Charger 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 Each electric vehicle is supplied with a fully automatic battery charger as standard equipment The AC cord to each charger is to be connected
16. or if the batteries seem weak contact your local Club Car distributor dealer PLUG AND RECEPTACLE The charger cord plug and receptacle are wear items and should be inspected daily Visually inspect them for cracks loose connections and frayed wiring they must be replaced when worn or damaged 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 inser tion ease of removal and good electrical contact See following NOTE Page 36 2005 DS Golf Car Owner s Manual Battery Gasoline Vehicles NOTE If the warning tag has been damaged or removed from the DC cord have it replaced immediately 48 VOLT Figure 23 Receptacle Fuse Link RECEPTACLE FUSE LINK 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 23 If the charger does not come on when the vehicle is placed on charge visually inspect the fuse link See following WARNING A WARNING f the receptacle fuse link is blown determine the source of the electrical problem and correct it before replacing the fuse Contact your nearest Club Car distributor dealer BATTERY GASOLINE VEHICLES
17. run for the first time after storage 5 Adjust tires to recommended tire pressure See Vehicle Specifications on page 42 6 Perform the Pre Operation and Daily Safety Checklist on page 18 MAINTENANCE See General Warnings on page 9 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 18 and the fol lowing Periodic Service Schedules and Periodic Lubrication Schedules 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 distributor dealer to perform all repairs and semiannual and annual periodic service A WARNING If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal injury or death Hot Do not attempt to service hot engine motor resistors or exhaust system Attempting to do so could cause severe burns Gasoline vehicles only Moving parts Do not attempt to service gasoline vehicle while the engine
18. 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 Store vehicle in a cool dry place This will minimize battery self discharge Adjust tires to recommended tire pressure See Vehicle Specifications on page 42 Perform semiannual periodic lubrication See Periodic Lubrication Schedules on page 30 Thoroughly clean front body rear body seats battery compartment and underside of vehicle Do not engage the park brake Chock the wheels to prevent the vehicle from rolling Keep batteries fully charged during storage Leave PowerDrive Chargers plugged in during storage The onboard computer will automatically acti vate the charger when necessary If charger cannot remain plugged in or AC power will not be avail able during extended storage disconnect the batteries for storage Figure 2 Page 11 CAUTION Be sure to check the vehicle and charger monthly to ensure the charger is operating correctly during storage RETURNING THE STORED ELECTRIC VEHICLE TO SERVICE 1 If necessary connect batteries Page 24 2005 DS Golf Car Owner s Manual Storage Gasoline Vehicles 2 Fully charge batteries 3 Adjust tires to recommended tire pressure See Vehicle Specifications on page 42 4 Perform the Pre Operation and Daily Safety Checklist on page 18 STORAGE GASOLINE VEHICLES See
19. weight oil into the engine through the spark plug hole Rotate engine crankshaft by hand several times and then install the spark plug 6 Adjust tires to recommended tire pressure See Vehicle Specifications on page 42 7 Perform semiannual periodic lubrication See Periodic Lubrication Schedules on page 30 8 Thoroughly clean front body rear body seats engine compartment and underside of vehicle 9 Do not engage the park brake Chock the wheels to prevent the vehicle from rolling Page 26 2005 DS Golf Car Owner s Manual Maintenance RETURNING THE STORED GASOLINE VEHICLE TO SERVICE 1 Restore fuel system to operation Figure 28 Page 40 1 1 Remove plug from fuel tank vent 1 2 Connect vent tube to fuel tank vent 2 Connect battery cables positive cable first 3 Completely open the fuel shut off valve Figure 16 Make sure the valve is fully open A partially closed fuel shut off valve Figure 17 combined with the use of the choke can result in a fouled spark plug and engine failure 4 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout cam in the MAINTE NANCE position Crank the engine until fuel is pumped into the carburetor and fuel lines and the engine starts Turn the engine off and return the neutral lockout cam to the OPERATE position See following NOTE NOTE Due to the oil added to the engine in preparation for storage engine may smoke excessively for a short time when it is
20. 2 oz 0 67 L SAE 30 every 100 hours of Check fill transaxle to plug level way WT API Class SE SF or SG Oil or operation or 200 rounds higher of golf Figure 18 Lubrication Points Electric Vehicles Page 30 2005 DS Golf Car Owner s Manual Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULE GASOLINE VEHICLES REGULAR INTERVAL SERVICE LUBRICATION RECOMMENDED LUBRICANT Semiannually by owner Brake pedal shaft bearings Oo Dry Moly Lube CCI P N 1012151 or trained technician every 50 hours of Y s operation or every 100 Brake linkage and pivots Dry Moly Lube CCI P N 1012151 rounds of golf AGER ccelerator push rod pivots mounts and shifter cable pivots 9 Dry Moly Lube P N 1012151 Front suspension 5 fittings Chassis Lube NLGI Grade 2 Brake slides Dry Moly Lube P N 1012151 Annually by trained technician only M 27 oz 0 8 L 80 90 WT API Class every 100 hours of transaxle to Qv GL 3 or 80 90 WT AGMA Class EP operation or every 200 Gear Lube rounds of golf First change 100 hours additional change every 200 hours of 22 oz 0 67 L without filter 38 oz 1 12 operation or every 400 Changsengneolandol er 7 d L with filter rounds of golf or annually whichever comes first
21. 2005 Owner s Manual p DS Golf Cars Gasoline and Electric NOTICE The Club Car Limited Warranty for owners of individual golf cars and the Limited Lifetime Fleet Warranty appear at the end of this manual along with limited warranty information for 2005 PowerDrive 8 Volt Batteries 2005 PowerDrive Battery Chargers and 2005 Onboard Computers and Solid State Speed Controllers No other warranties expressed 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 registra tion 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 vehicle conforms to the current American National Standards Institute s 2130 Safety and Performance Requirements for Golf Cars This standard which promotes safety in the design application and operation of golf cars defines a golf car as a vehicle used to convey a person or persons and equipment to play the game of golf in an area designated as a golf course Throughout this manual the words golf car and vehicle are used interchangeably 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 Ca
22. E position Steering The vehicle should be easy to steer and should not have any play in the steering wheel General Listen for any unusual noises such as squeaks or rattles Check the vehicle s ride and perfor mance Have a Club Car distributor dealer or a trained technician investigate anything unusual Electric Vehicles Accelerator With the key switch in the ON position and the Forward Reverse switch in the FORWARD position as the accelerator pedal is pressed 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 or go into motor braking mode See Pedal Up Motor Braking below All Club Car vehicles operate at reduced speed in reverse 2005 DS Golf Car Owner s Manual Page 19 Driving Instructions 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 than 1 to 3 mph 1 5 to 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 See following WARNING A WARNING Zero speed detect will not limit vehicle speed to 1 mph 1 6 km h on very steep grades Do not operate vehicle on slopes exceeding 20
23. General Warnings on page 9 A DANGER Do not attempt to drain gasoline when the engine is hot or while it is running Be sure to clean up any spilled gasoline before operating the vehicle Store gasoline in an approved gasoline container only Store in a well ventilated area away from sparks open flames heaters or heat sources Keep gasoline out of reach of children Do not siphon gasoline from the vehicle A WARNING Turn the key switch to the OFF position remove the key and leave the Forward Reverse handle in the NEUTRAL position during storage This is to prevent unintentionally starting the vehicle or a fire hazard Turn the fuel shut off valve to the closed OFF position Figure 15 A CAUTION Batteries in a low state of charge will freeze at low temperatures PREPARING THE GASOLINE VEHICLE FOR EXTENDED STORAGE 1 Store vehicle in a cool dry place This will minimize battery self discharge If the battery appears to be weak have it charged by a trained technician Use an automotive type 12 volt battery charger rated at 10 amps or less 2 Drain carburetor and seal the fuel tank 2 1 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout cam in the MAINTENANCE position Turn the fuel shut off valve to the closed OFF position Figure 15 and run the engine until fuel remaining in the carburetor and fuel lines is depleted and the engine stalls Return the neutral lock
24. HICLE A WARNING Driving through water may affect the brakes After driving through water check effectiveness of the brakes by gently pressing the brake pedal If the vehicle does not slow down at the normal rate continue to press the brake pedal until the brakes dry out and normal performance returns 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 press the brake pedal with your right foot until the vehi cle comes to a complete stop PARKING AND LEAVING THE VEHICLE 1 After stopping the vehicle firmly press the park brake pedal until it locks This will prevent the vehicle from rolling 2 Turn the key switch to the OFF postion and place the Forward Reverse handle or switch in the NEUTRAL position Remove the key when the vehicle is not in use Electric 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 roll ing at more than 1 to 3 mph 1 5 to 4 8 km h unless the accelerator is pressed This prevents the pos sibility of a parked vehicle with the park brake disengaged rolling away too fast to be overtaken on foot Gasoline vehicles only Turn the fuel shut off valve to the closed OFF position when the vehicle is not in use TOWING A WARNING Do not
25. ION 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 GOLF CAR 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 golf car beyond factory specifications including those that affect the weight distribution stability or speed of the golf car can cause serious personal injury or death CLUB CAR LIMITED LIFETIME WARRANTY FOR 2005 FLEET GOLF CARS 1 Warranty CLUB CAR INC CLUB CAR hereby warrants to the Original Retail Fleet Purchaser or Original Retail Fleet Lessee as those terms are defined herein and subject to the provisions limitations and exclusions contained in this limited warranty that its new 2005 Model DS golf car purchased from CLUB CAR or an authorized distributor or
26. MAINTENANCE position Figure 11 This will allow the technician to operate the engine in neutral for certain maintenance procedures With the cam in this position the vehicle will not operate if the Forward Reverse handle is placed in either the FORWARD or REVERSE position NEUTRAL NEUTRAL MAINTENANCE POSITION OPERATE POSITION Figure 11 Neutral Lockout Maintenance Figure 12 Neutral Lockout Operate To put the cam back into the OPERATE position pull the cam out approximately 3 8 inch 10 mm and rotate it one half turn until it snaps into place Figure 12 See following WARNING and NOTE A WARNING With the cam in the MAINTENANCE 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 firmly set the park brake before servicing or leaving the vehicle NOTE Be sure to return the cam to the OPERATE position after servicing the vehicle or it will not operate with the Forward Reverse handle in either the FORWARD or REVERSE position 2005 DS Golf Car Owner s Manual Page 17 Pre Operation and Daily Safety Checklist CHOKE Gasoline Vehicles Only The choke is located on the seat support panel below and to the left of the driver s left knee Figure 13 If the vehicle is hard to start in cool or cold temperatures simply push in the choke cover to activate it Hold it during start up and release the ch
27. ON SPEED CONTROLLER COVER 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 TOW SWITCH WARNING DECAL ON TOW SWITCH BRACKET UNDER SEAT Z WARNING Place Tow Run switch in TOW position before FAILURE TO HEED THIS Disconnecting or connecting batteries WARNING COULD RESULT IN s A BATTERY EXPLOSION OR Extended storage SEVERE PERSONAL INJURY Servicing 101908601 CHARGER RECEPTACLE FORWARD REVERSE SWITCH BATTERY DANGER DECAL ON BATTERY CAPS OR ON BODY UNDER SEAT A DANGER POISON FI SULFURIC IMMEDIATELY WITH WATER NO 1 SPARKS IP CAN CAUSE GET 5 EYES BUNC N T EN MEDICAL GASES CAN CAUSE i e SMOKING SEVERE BURNS ut FAST BLINDNESS OR INJURY Li OUT OF THE REACH OF CHILDREN DO VENT CAPS TIGHT AND LEVEL a 2005 DS Golf Car Owner s Manual Page 5 Vehicle Feature Identification DS GASOLINE VEHICLE OPERATING INSTRUCTIONS A WARNI 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 Remain seated and hold on to seat handle while moving Do
28. R 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 or 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 P O Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 Page 50 2005 DS Golf Car Owner s Manual Your Comments Are Appreciated Please select your category Distributor Dealer Individual Ow
29. RY OR DEATH NO SMOKING SPARKS OR OPEN FLAME ROTATING PARTS AND STOP ENGINE ALLOW TO COOL BEFORE REFUELING TURN FUEL VALVE ON DURING OPERATION HOT MANIFOLD DECAL ON STARTER GENERATOR x OFF DURING STORAGE OR TRANSPORT 1015476 01 GASOLINE WARNING DECAL ON VEHICLE FRAME NEAR FUEL TANK WARNING CAN CAUSE SEVERE INJURY OIL FILL Rotating parts x men manifold amp muffler FUEL SHUT OFF KEEP CLEAR 1019605 01 VALVE FORWARD REVERSE NEUTRAL LOCKOUT CAM FRAME GROUND AND GOVERNOR WARNING DECAL ON VEHICLE FRAME NEAR BATTERY A WARNING Z WARNING Negative frame ground Can cause severe injury s Excessive speed Do not contact positive battery post or cable to frame Can cause severe injury or death Disconnect negative battery lead first Do not tamper with engine governor adjust ment CCI 1019152 01 2005 DS Golf Car Owner s Manual Page 7 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 affi
30. TOR 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 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 2005 POWERDRIVE CHARGERS CLUB CAR INC CLUB CAR hereby warrants to the original retail purch
31. 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 On gasoline vehicles check all hose clamps for tight fit as well as the starter belt for tightness Page 18 2005 DS Golf Car Owner s Manual Pre Operation and Daily Safety Checklist Safety and information decals Check to ensure that all safety and information decals are in place See pages 4 through 7 Tires Check for proper tire pressure Visually inspect tires for wear damage and proper inflation on a daily basis See Vehicle Specifications on page 42 Battery ies Check electrolyte to ensure that it is at its proper level Figure 20 Page 33 or Figure 25 Page 38 Check battery posts Wires should be tight and free of corrosion On electric vehicles charge batteries fully before first use of vehicle Charger cord plug and receptacle electric vehicles Visually inspect for cracks loose connec tions and frayed wiring See Plug and Receptacle on page 36 Engine gasoline vehicles Check for proper engine oil level See Engine Oil Gasoline Vehicles on page 39 Fuel gasoline vehicles Check fuel level See Fueling Instructions Gasoline Vehicles on page 40 Check fuel tank lines cap pump fuel filters and carburetor for fuel leakage Exhaust system gasoline vehicles Check for leaks A WARNING Be sure the plastic has
32. a safety committee be appointed One of the main concerns of this committee should be the safe operation of the golf cars This should include at a minimum Where golf cars should be driven Ensuring that proper warnings of driving hazards are displayed and visible Who should and who should not drive golf cars Instructing first time drivers Maintaining golf cars in a safe driving condition How various rules are to be enforced The safety committee should include all these items and such others as the committee feels necessary or appropriate Warning signs from Club Car are listed below WARNING SIGN CCI P N Sharp Left 9911211 Sharp Right 9921211 Steep Hill 9931211 CONTROLS AND INDICATORS See General Warnings on page 9 A WARNING If renting or loaning the vehicle make sure the driver is familiar with all controls and operating procedures before allowing the vehicle to be driven Do not shift the Forward Reverse handle or switch while the vehicle is moving To avoid injury to an unsuspecting passenger or damage to the vehicle always bring the vehicle to a full stop before shifting the Forward Reverse handle or switch Release the accelerator pedal and then press the brake pedal firmly until the vehicle stops To avoid unintentionally starting or rolling the vehicle set the park brake place the Forward Reverse handle or switch in the NEUTRAL position turn the key switch to the OFF positi
33. acement 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 Computer 2005 DS Golf Car Owner s Manual Page 49 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 owner s 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 devic
34. alls etc SUBSEQUENT OWNER REGISTRATION In the event a vehicle is bought as a used vehicle 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 Vehi cle Registration 2005 DS Golf Car Owner s Manual Page 41 VEHICLE SPECIFICATIONS Vehicle Specifications SPECIFICATIONS IQ SYSTEM ELECTRIC GASOLINE POWER SOURCE Drive motor Direct drive 48 volts DC shunt wound 3 2 hp Engine 4 cycle OHV 286 cc 9 0 hp rated single cylinder air cooled with pressure lubrication System Fuel system Side draft carburetor with float bowl fixed jets fuel filters and impulse fuel pump Governor Automatic ground speed sensing internally geared in unitized transaxle Ignition Transistor electronic ignition with electronic RPM limiter Transaxle Double reduction helical gear with 12 3 1 direct drive axle Unitized transaxle Fully synchronized forward and reverse with neutral and reduced speed reverse 11 8 1 forward 17 1 1 reverse Torque converter Automatic variable speed dry type Electrical system 48 volts DC reduced speed reverse Electrical system 12 volt 500 cca at 0 F 17 8 C 650 at 32 F 0 C 105 minute reserve capacity and 35 amp charging capacity
35. and overflow through the vent in the fuel tank acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replace ment of any device or element of design incor porated into any new engine for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the engine after such device or element of design has been removed or rendered inopera tive by any person Among those acts presumed to constitute tampering are the acts listed below Do not tamper with the original emission relat ed parts Carburetor and internal parts Spark plugs Magneto or electronic ignition system Fuel filter element Air cleaner element Crankcase Cylinder head Breather chamber and internal parts Intake pipe and tube WARNING After refueling make sure the tank cap is closed securely f gasoline is spilled on the fuel tank wipe it off immediately Cil Viscosity Choose the viscosity according to the tem perature as follows 20 10 C 0 C RE TI y 40 C Jes lt SAE10W 30 SAE gt 10W 30 SAE 10W 40 ccc 14 F 32 F 50 F 68 F 86 F 104 F NOTE Engine Oil The following engine oils are recommended API Service Classification SC SD SE SF SG or SH 2005 DS Golf Car Owner s Manual e Using m
36. arger and batteries should be checked by your Club Car distributor dealer 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 CCI P N 101831801 which provides information on the condition of the vehicle and batteries 2005 DS Golf Car Owner s Manual Page 15 Controls and Indicators TOW RUN SWITCH IQ System Electric Vehicles Only A WARNING 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 When the Tow Run switch is in the TOW position all motor braking functions including zero speed detect are disabled IQ System vehicles are equipped with a Tow Run switch located under the seat just above the Forward Reverse switch Figure 10 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 sw
37. aser 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 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 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 CAR s factory technicians or an authorized distributor or dealer CLUB CAR will provide only the replacement parts or components PowerDrive Chargers are intended to be us
38. caution to avoid shorting of components or wiring DISCONNECT BATTERY CABLES BEFORE WORKING ON VEHICLE AS SEEN FROM PASSENGER SIDE OF VEHICLE negative cable first 6 PLACE TOW RUN SWITCH Remove negative IN THE TOW POSITION BEFORE DISCONNECTING OR cable first CONNECTING BATTERY CABLES Figure 1 Gasoline Vehicle Figure 2 IQ System Electric Vehicle GENERAL INFORMATION This manual features two DS Golf Car models the IQ System 48 volt electric vehicle and the gasoline vehi cle 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 his her vehicle s MODEL IDENTIFICATION The serial number of the vehicle is printed on a bar code decal mounted on the frame directly above the accel erator pedal Example AQ0501 123456 Figure 3 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 NOTE NOTE Have the vehicle serial number available when ordering parts or making inquiries EJ SERIAL NUMBER DECAL SEED AQ0501 123456 Figure 3 Serial Number Decal 2005 DS Golf Car Owner s Manual Page 11 Safely Committee SAFETY COMMITTEE If the golf car is to be rented or is part of a fleet we strongly recommend that
39. chanical repair The appropriate instructions must be used when performing maintenance service or accessory installation Gasoline vehicles To avoid unintentionally starting the vehicle Disconnect battery cables negative cable first Figure 1 Disconnect the spark plug wire from the spark plug Frame ground Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wiring Do not allow a positive wire to touch the vehicle frame engine or any other metal component Electric 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 To avoid unintentionally starting the vehicle disconnect the batteries as shown Figure 2 After disconnecting the batteries wait 90 seconds for the controller capacitors to discharge All vehicles 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 WARNING CONTINUED ON NEXT PAGE Page 10 2005 DS Golf Car Owner s Manual A WARNING General Information Use insulated tools when working near batteries or electrical connections Use extreme
40. dential water pressure is adequate 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 is removed will expose electrical components to moisture 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 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 may be used For heavy soiling difficult stains or scratches blemishes or other body damage see Section 4 of the appropriate maintenance and ser vice manual NOTE Dispose of waste water properly ACCESSORIES There is a complete line of accessory equipment available from Club Car and our dealers distributors You can obtain the name and phone number of your closest Club Car contact by visiting our web site at www clubcar com and clicking the Find a Dealer link Care should be taken that these accessories are properly installed by trained technicians and that they are used in the manner for which they were designed See following WARNING A WARNING Tinted windshields and weather proof enclosures will not protect occupants from flying objects golf b
41. e 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 2005 ONBOARD COMPUTERS AND SOLID STATE SPEED CONTROLLERS CLUB CAR INC CLUB CAR hereby warrants to the original retail purchaser that 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 IQ 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 Vehicles used for golf free repl
42. e 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 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 DISTRIBUTO
43. e 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 2005 DS Golf Car Owner s Manual Page 47 WARRANTY LIMITATIONS CLUB 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 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 DISTRIBU
44. ecking oil Do not overfill with oil ENGINE OIL LEVEL CHECK 1 Remove the oil level dipstick from the oil filler tube and wipe oil from dipstick Figure 26 See following CAUTION A CAUTION Do not remove dipstick while engine is running 2 Check oil by fully inserting the dipstick into the oil filler tube and immediately removing it 3 Ifthe oil level is at or below the low level mark on the dipstick gauge add oil until the level is between low and full levels safe level 4 Reinsert dipstick into the oil filler tube NOTE Properly recycle or dispose of used oil in accordance with local state and federal regulations 20 C 10 0 C RE 20 30 40 pu lt _ SAE10W 30 SAE 0W 40 gt 10W 30 SAE 10W 40 14 F lt 50 F 68 F 86 F 104 F Figure 26 Engine Oil Level Check Figure 27 Oil Viscosity OIL VISCOSITY Choose the viscosity according to the temperature as indicated by the oil viscosity chart Figure 27 See fol lowing NOTE NOTE Using multi grade oils 5W 20 10W 30 and 10W 40 will increase oil consumption Check oil level more frequently when using them 2005 DS Golf Car Owner s Manual Page 39 Fueling Instructions Gasoline Vehicles FUELING INSTRUCTIONS GASOLINE VEHICLES See General Warnings on page 9 A DANGER Turn the key switch to the OFF position before fueling Do not pour gasoline into the fuel tank when the engine is hot or while it is running
45. ed 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 placed on charge The batteries should never be left discharged any longer than absolutely necessary do not leave discharged overnight LEVEL BATTERY CAP INDICATOR PLATES ELECTROLYTE LEVEL AT LEAST 1 2 INCH 13 MM ABOVE PLATES OR TO LEVEL INDICATOR Figure 20 Electric Battery Electrolyte Level 2005 DS Golf Car Owner s Manual Page 33 Battery Charger Electric Vehicles BATTERY CHARGER ELECTRIC VEHICLES 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 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 Page 34 Only trained technicians should repair or service the charger Contact your nearest 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
46. ed by persons with knowledge of the chargers and proper charging practices and only on CLUB CAR PowerDrive System 48 PowerDrive Plus and IQ System vehicles Any other use renders the Limited Warranties expressed herein and any implied warranties null and void and same are hereby excluded Page 48 2005 DS Golf Car Owner s Manual 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 and IQ System products As in the use of any electrical device a prudent owner will read and study the charger owners manual the electric vehicle owners 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
47. er A DANGER ADANGER indicates an immediate hazard that will result in severe personal injury or death A WARNING A WARNING indicates an immediate hazard that could result in severe personal injury or death A CAUTION ACAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury CAUTION A CAUTION without the safety alert symbol indicates a situation that potentially could result in 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 on pages 4 through 7 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 DANGER CONTINUED ON NEXT PAGE 2005 DS Golf Car Owner s Manual Page 9 General Warnings A DANGER Gasoline Flammable Explosive Do not smoke Keep sparks and flames away from the vehicle and service area Service only in a well ventilated area Do not operate gasoline vehicle in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadl
48. fill plugs etc Inspect clean and regap spark plug replace if necessary Engine air intake system Check air filter element clean or replace if necessary Check clamps for tightness check hose for cracks General vehicle Check for loose hardware and tighten if necessary Two year service by trained technician only every 200 hours of operation or every 400 rounds for golf cars Fuel filters Replace Dispose of used filters properly A WARNING If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal injury or death 2005 DS Golf Car Owner s Manual Page 29 Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE ELECTRIC VEHICLES REGULARINTERVAL SERVICE LUBRICATION RECOMMENDED LUBRICANT Semiannually by owner Brake pedal shaft bearings Dry Moly Lube P N 1012151 or trained technician every 50 hours of E or 100 rounds Brake linkage and pivots Dry Moly Lube CCI P N 1012151 of golf Accelerator pivot rod supports Qv Dry Moly Lube CCI P N 1012151 Charger receptacle Qv WD 40 Brake slides Qv Dry Moly Lube CCI P N 1012151 Front suspension 5 fittings Qv Chassis Lube EP NLGI Grade 2 Annually by trained technician only 22 oz 0 67 L 2
49. handle has three distinct positions F FORWARD R REVERSE and N NEUTRAL Rotate the handle towards the driver FORWARD to operate the vehicle in the forward direction or towards the passenger REVERSE to operate vehicle in reverse When the handle is in the straight up position NEUTRAL the vehicle will not operate Club Car vehicles operate at reduced speed in reverse The reverse buzzer will sound as a warning when the Forward Reverse handle is in the REVERSE position Figure 5 Forward Reverse Handle Figure 6 Forward Reverse Rocker Switch 2005 DS Golf Car Owner s Manual Page 13 Controls and Indicators Figure 7 Accelerator and Brake Pedals ACCELERATOR PEDAL The accelerator pedal is the pedal on the right with the word GO molded into it Figure 7 The operation of the accelerator pedal differs from that of an automobile When the key switch is in the ON position and the Forward Reverse handle or switch is in either the FORWARD or REVERSE position pressing the acceler ator pedal will automatically release the park brake and start the vehicle moving in the direction selected for ward or reverse As the accelerator pedal is pressed speed will increase until full speed is reached When the accelerator is released power will be cut off and the motor or engine will stop running BRAKE PEDAL The brake pedal is the large pedal on the left with the word STOP molded into it Figure 7 To slow or stop the vehicle press
50. haser or in the possession of the Original Retail Fleet Lessee 2005 DS Golf Car Owner s Manual Page 45 LIMITED ONE YEAR WARRANTY All 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 from the date of purchase while owned by the Original Retail Fleet Purchaser or in the possession of the Original Retail Fleet Lessee 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 distributors or 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 controller are covered under separate CLUB CAR warranties Al
51. he plug To disconnect the charger plug from the vehicle receptacle grasp the plug by the handle and pull the plug straight out of the receptacle Do not connect a charger to the receptacle if the charger cord plug or the vehicle receptacle is broken damaged in any manner or does not make a good electrical connection Fire or personal injury can result Have it replaced by a qualified service person immediately Failure to follow these instructions could result in damage to the charger cord the plug and or the vehicle receptacle 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 receptacle contacts are bent or corroded The plug receptacle or cords are cut worn have any exposed wires or are damaged in any way Using the charger with any of the above symptoms could result in a fire property damage personal injury or death 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 and cold batteries require more time to fully charge 2005 DS Golf Car Owner s Manual Page 35 Battery Charger Electric Vehicles Insert the charger DC plug into the vehicle receptacle The charger will turn on two to ten seconds later Figure 21 When inserting the DC plug align
52. hen this limited warranty shall extend only to the first Original Retail Fleet Lessee and not to such entity or to any subsequent lessee of the golf car 7 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 SOLE REMEDY OF THE REPLACEMENT OR REPAIR OF THE DEFECTIVE GOLF Page 46 2005 DS Golf Car Owner s Manual CAR 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 8 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 GOLF CAR 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 spec
53. ific legal rights and you may also have other rights which vary from state to state 9 INFORMATION For further information contact WARRANTY SERVICES CLUB CAR INC P O Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 10 WARNING Any modification or alteration of any golf car beyond factory specifications including those that affect the weight distribution stability or speed of the golf car can cause serious personal injury or death CLUB CAR LIMITED FOUR YEAR WARRANTY FOR 2005 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 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
54. in your path Qt B oc s c Select direction by placing the 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 is in the REVERSE position 7 Slowly press accelerator pedal The park brake will release automatically and the vehicle will start to move As the accelerator pedal is pressed speed will increase until full speed is reached See following WARNING and NOTE A WARNING Operator must control vehicle speed when going downhill Electric 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 WARNING CONTINUED ON NEXT PAGE 2005 DS Golf Car Owner s Manual Page 21 Towing A WARNING Gasoline vehicles only Do not shift the vehicle out of forward while going downhill If you do you will not be able to shift into reverse or back into forward until stopped Press the brake pedal as necessary and partially press the accelerator when descending a hill With the accelerator pedal partially pressed the governor will cause the engine to assist the brakes in controlling downhill speed NOTE the Forward Reverse handle is shifted into the NEUTRAL position power will be cut off and the engine will stop running STOPPING THE VE
55. is eee 41 ACCOSSOTL OS de Baden yes ic Sade UU TERN acd RD pala ey Ee PH etos Rea OU Er TN e Rae 41 Subsequent Owner eee 41 Vehicle Specifications 0 6 hm rere 42 Warranties OP ERR RR RU ae R e veu dde 44 2005 DS Golf Car Owner s Manual Page 3 Vehicle Feature Identification DS ELECTRIC VEHICLE DRIVER PASSENGER WARNING DECAL 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 e Two 2 persons per seat maximum Operate from driver side only and not on public roads Keep entire body inside vehicle while moving OP C INSTRUC IONS Drive slowly in turns and straight up and down slopes Do not leave children unattended on vehicle Read Owner s Manual and safety warnings located on dash panel prior to driving Never operate under the influence of alcohol or drugs Study and understand controls Use brakes to reduce speed when coasting downhill Make sure wheels are turned in desired direction s Never stand in front of or behind vehicle Turn key to position and be sure nothing is in your path CCI 101960601 While vehicle is stopped select direction by placing shift lever or switch in desired position F Forward N Neutral
56. is running Turn the fuel shut off valve to the closed OFF position Figure 15 Page 26 To avoid unintentionally starting the vehicle before servicing always disconnect the battery negative cable first Figure 1 Page 11 and disconnect the spark plug wire from the spark plug Frame ground Do not allow tools or other metal objects to contact frame when disconnecting batteries or other electrical wiring Never allow a positive wire to touch the vehicle frame engine or other metal component 2005 DS Golf Car Owner s Manual Page 27 PERIODIC SERVICE SCHEDULES See General Warnings on page 9 A WARNING Periodic Service Schedules 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 procedure 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 PERIODIC SERVICE SCHEDULE ELECTRIC VEHICLES REGULAR INTERVAL SERVICE Daily service by owner Batteries Charge batteries after each use only Check electrolyte level Add water if Weekly service by owner Batteries necessary See page 33 Monthly service by owner Batteries Wash battery tops and clean termi
57. itch in the TOW position allow 10 seconds to elapse before switching back to the RUN position After placing the Tow Run switch in the 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 arcing 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 Figure 10 Tow Run Switch Page 16 2005 DS Golf Car Owner s Manual Controls and Indicators NEUTRAL LOCKOUT Gasoline Vehicles Only For the convenience of the trained technician there is a neutral lockout cam located on the back of the For ward Reverse shifter If the neutral lockout cam is pulled out approximately 3 8 inch 10 mm and then rotated one half turn until it snaps into place the cam will be in the
58. ke sure the driver is familiar with all controls and operating procedures before allowing the vehicle to be driven No more than two people should be on the vehicle at one time The vehicle is not specially equipped for handicapped persons Be sure all persons can properly operate the vehicle prior to allowing them to drive the vehicle Be sure all passengers are capable of securing themselves in a vehicle before allowing them to ride in one For night use the vehicle must be equipped with headlights taillights and reflectors Stop the vehicle before shifting the Forward Reverse handle Failure to do so may result in injury to an unsuspecting passenger and or damage to the vehicle To help avoid being struck do not stand in front of or behind the vehicle Operate the vehicle from the driver seat only WARNING CONTINUED ON NEXT PAGE Page 20 2005 DS Golf Car Owner s Manual Driving Instructions A WARNING To help prevent falls from the vehicle remain seated in a moving vehicle and hold on to hand holds 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 your entire body inside the vehicle Do not leave children unattended on vehicle To help prevent overturning the vehicle drive slowly straight up and down slopes Avoid driving the vehicle on slopes exceeding 20 incline To help avoid p
59. location 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 An extension cord or electrical outlet must accept a three prong plug Extension cord should be a three wire No 12 AWG American Wire Gauge or No 14 SWG British Standard Wire Gauge and be as short as possible The use of 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 Have worn cut or damaged power cords or wires replaced immediately Do not use near fuels grain dust solvents thinners or other flammables Chargers can ignite flammable materials and vapors Do not expose to rain or any liquid Keep the charger dry 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 replace the parts When the charger
60. nals or trained technician with baking soda water solution Check air pressure and adjust if Tires necessary See Vehicle Specifications on page 42 General vehicle Wash battery compartment and underside of vehicle Semiannual service by trained technician only every 50 hours of operation or 100 rounds of golf Brake system Check brake shoes replace if necessary See Section 6 Wheel Brake Assemblies in the appropriate maintenance and service manual Check brake cables for damage replace if Lubricate brake slides per Lubrication Schedule See Section 6 Wheel Brake Assemblies in the appropriate maintenance and service manual necessary Electrical wiring and connections Check for tightness and damage Forward Reverse switch Check condition of contacts and wire connections Make sure connections are tight Front wheel alignment and camber Check and adjust as 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 and other damage Annual service by trained technician only every 100 hours of operation or 200 rounds of golf Page 28 Batteries 2005 DS Golf Car Owner s Manual If batteries are not performing as expected see Section 13 Batteries in the appropriate maintenance and service supplement Periodic Se
61. ned 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 golf car or component thereof at no cost to the purchaser during the applicable limited warranty period If CLUB CAR elects to repair the golf car 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 golf car or defective component to an authorized CLUB CAR distributor or dealer or send the defective component freight prepaid to WARRANTY SERVICES CLUB CAR INC 4125 Washington Road Evans Georgia 308089 U S A 706 863 3000 6 DEFINITIONS For the purpose of this warranty an Original Retail Fleet Purchaser is the original purchaser of the golf car who is in the business of owning or operating golf courses and who purchases such golf car for the purpose of renting it to golf players for use on such courses An Original Retail Fleet Lessee is the first end user of the golf car who is in the business of owning and operating golf courses and who leases such golf car for the purpose of renting it to golf players for use on such golf courses In the event the golf car is purchased or leased by any entity for the purpose of leasing it to an Original Retail Fleet Lessee t
62. ner Club Car Associate Representative Other Technician Golf Course Superintendent In order to help us better serve you please rate this publication in the following catgories 1 Ease of Understanding 2 Ease of Finding Information 3 Clarity of Illustrations 4 Periodic Service and Poor Fair Average Good Excellent Periodic Lubrication Schedules Comments Suggestions Please fax a copy of this page to 706 228 2662 Thank You Club Car Technical Publication Department 2005 DS Golf Car Owner s Manual EMISSION CONTROL INFORMATION Fuel Information THIS VEHICLE IS CERTIFIED TO OPER ATE ON UNLEADED REGULAR GRADE GASOLINE ONLY A minimum of 87 octane of the anti knock index is recommended The anti knock index is posted on service station pumps in the U S A Emission Control Information To protect the environment in which we all live Club Car has incorporated crankcase emis sion 1 and exhaust emission 2 control sys tems EM in compliance with applicable regu lations of the U S Environmental Protection Agency and California Air Resources Board 1 Crankcase Emission Control System A sealed type crankcase emission control System is used to eliminate blow by gases The blow by gases are led to the breather chamber
63. not start vehicle until all occupants are seated Two 2 persons per seat maximum Operate from driver side only and not on public roads 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 posi F Forward N Neutral R 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 Use brakes to reduce speed when coasting downhill After stopping the vehicle Never stand in front of or behind vehicle KEY SWITCH depress park brake itlocks 101960601 Place Forward Reverse switch NEUTRAL position Turn key OFF and remove key when not in use DRIVER PASSENGER WARNING DECAL Keep entire body inside vehicle while moving Drive slowly in turns and straight up and down slopes Do not leave children unattended on vehicle Never operate under the influence of alcohol or drugs CCI 101621601 OPERATING INSTRUCTIONS DECAL LOW OIL WARNING LIGHT PARK BRAKE PEDAL ACCELERATOR PEDAL BRAKE PEDAL SERIAL NUMBER Page 6 2005 DS Golf Car Owner s Manual Vehicle Feature Identification DS GASOLINE VEHICLE A WARNING GASOLINE EXPLOSION FIRE CAN CAUSE SEVERE INJU
64. o 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 258 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 Page 2 2005 DS Golf Car Owner s Manual TABLE OF CONTENTS Vehicle Feature Identification DS Electric Vehicle 4 Vehicle Feature Identification DS Gasoline Vehicle 6 Safety Details Aion beate et eb Ue deni Mu uU Ed da 9 General Warnings scm er MES E tue gua edel VIR AO wee EE PERPE 9 General Information pee deeds one bed ew ned APER nee 11 Model Identification irosun
65. 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 overcharging 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 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 us
66. oke cover after the engine starts and runs smoothly Figure 13 Choke Figure 14 Low Oil Warning Light LOW OIL WARNING LIGHT Gasoline Vehicles Only The gasoline golf car is equipped with a low oil warning light located on the dash panel just above the steer ing column Figure 14 If the warning light comes on oil should be checked and added to the engine as nec essary before continuing to use the vehicle The vehicle should never be driven with the low oil warning light remaining on If the warning light goes on and off you may proceed but oil should be added at the first oppor tunity If the oil level is correct and the warning light stays on have a trained technician check the vehicle See following CAUTION CAUTION Failure to add oil immediately when the low oil warning light stays on may result in permanent engine damage 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 Schedules on page 28 Any problems should be corrected by
67. on and remove the key when leaving the vehicle Gasoline vehices only Do not tamper with the 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 KEY SWITCH The key switch is mounted on the dash to the right of the steering column Figure 4 It has two positions OFF and ON which are clearly labeled See following NOTE Page 12 2005 DS Golf Car Owner s Manual Controls and Indicators NOTE The key can be removed only when the key switch is in the OFF position Figure 4 Key Switch FORWARD REVERSE CONTROL IQ System Electric Vehicles The Forward Reverse rocker switch is located 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 the NEUTRAL position with neither side down the vehicle will not operate if the accelerator pedal is pressed Figure 6 The reverse buzzer will sound as a warning when the Forward Reverse switch is in the REVERSE position Gasoline Vehicles The Forward Reverse handle is located on the seat support panel below and to the right of the driver s right knee Figure 5 The Forward Reverse
68. ossible injury to an inattentive passenger and or damage to the vehicle avoid sudden starts sudden stops and abrupt turns To help avoid 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 not designed or intended for street use and should not be licensed for use on public roads Obey all local rules concerning golf cars The vehicle should be driven in only specified areas by trained drivers Do not drive while under the influence of alcohol drugs or medications To prevent overturning the vehicle drive slowly in turns 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 exactly and in order all of the following procedures Read and understand all instructions prior to driving the vehicle STARTING THE VEHICLE Study and understand controls Make sure everyone is seated and holding onto seat hand holds or handrails Read safety warnings located on dash and or above pedals Make sure wheels are turned in desired direction Turn the key to the ON position and make sure nothing is
69. out cam to the OPERATE position 2 2 Loosen but do not remove the carburetor drain screw and drain fuel remaining in bowl into a small clean container then pour the fuel from the container into vehicle fuel tank Tighten the carburetor drain screw 2 3 Disconnect fuel vent line from fuel tank vent nipple 2 4 Plug the fuel tank vent nipple so that it is air tight We recommend using a slip on vinyl cap 3 Disconnect the battery cables negative cable first 2005 DS Golf Car Owner s Manual Page 25 Storage Gasoline Vehicles 4 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 CLOSED OFF POSITION SELECTOR IS ALIGNED WITH OFF MARKINGS ON THE SIDES OF VALVE VIEWED FROM SELECTOR SIDE OF VALVE Figure 15 Fuel Shut off Valve Closed Position PARTIALLY CLOSED FULL OPEN ON POSITION POSITION gt VIEWED FROM SELECTOR VIEWED FROM SELECTOR SIDE OF VALVE SIDE OF VALVE Figure 16 Fuel Shut off Valve Open Position Figure 17 Fuel Shut off Valve Partially Closed Position 5 To protect the engine remove spark plug and pour 1 2 ounce 14 2 mL of SAE 10
70. r 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 Parts Fax 706 855 7413 www clubcar com Copyright 2004 Club Car Inc Club Car ArmorFlex and PowerDrive are registered trademarks of Club Car Inc This manual effective August 2 2004 2005 DS Golf Car Owner s Manual Page 1 FOREWORD Thank you for choosing Club Car the name most widely recognized as the industry leader in vehicle efficiency and long lasting value You have chosen the finest golf car on the market Please protect your investment and ensure that your Club Car vehicle s provides years of reliable superior performance by reading 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 t
71. r water followed with milk of magnesia or vegetable oil Call a 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 or battery charger Wear a full face shield and rubber gloves when working on or near batteries Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring CAUTION all electric 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 the IQ System electric vehicles are 8 volt deep cycle batteries specially built for electric vehi cle 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 IQ System vehicles with new batteries to 36 holes of use between charges in the first two months of operation 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 Page 32 2005 DS Golf Car Owner s Man
72. ranted with respect to parts and labor against defects in material and workmanship for a period of two years from the date of purchase LIMITED ONE YEAR WARRANTY All 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 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 distributors or 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 controller are covered under separate CLUB CAR warranties Also excluded from any CLUB CAR warranty is damage to a golf car or component re
73. rvice Schedules PERIODIC SERVICE SCHEDULE GASOLINE VEHICLES REGULAR INTERVAL SERVICE Monthly service by owner or trained technician Semiannual service by trained technician only every 50 hours of operation or every 100 rounds for golf cars Engine Check engine oil level change if necessary See Periodic Lubrication Schedules on page 30 Check engine cooling air intake clean if necessary Visually inspect the unshrouded area around engine exhaust for grass and debris and clean if necessary Tires Check air pressure and adjust as necessary See Vehicle Specifications on page 42 General vehicle Battery Wash engine compartment and underside of vehicle Do not wash engine when hot Clean terminals and wash dirt from casing check electrolyte level See Battery Gasoline Vehicles on page 37 Front wheel alignment and camber Check and adjust if necessary See Section 7 Steering and Front Suspension in the appropriate maintenance and service manual Electrical wiring and connections Check for tightness and damage Brake system Check brake shoes replace if necessary Lubricate brake slides See Periodic Lubrication Schedules on page 30 Check brake cables for damage replace if necessary Annual service by trained technician only every 100 hours of operation or every 200 rounds for golf cars Engine Check for leaks around gaskets
74. s A light duty tow bar is available for break down towing and single vehicle towing A heavy duty tow bar and an onboard tow bar are available for multi vehicle towing Observe all of the previous WARNING statements when towing TRANSPORTING ON A TRAILER A WARNING For use on public roads the trailer must meet all federal state and local requirements such as 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 the NEUTRAL position the key switch in the OFF position and the park brake firmly pressed and locked Do not allow people in the trailer or vehicle 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 When towing on a trailer normal road speed of the tow vehicle should be reduced Because of the added length of the trailer caution should be used when turning a corner Remove the vehicle windshield and secure the seat bottom before transporting on a trailer Gasoline vehicles only Turn the fuel shut off valve to the closed OFF position Figure 15 Page 26
75. so excluded from any CLUB CAR warranty is damage to a golf car 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 GOLF CAR 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 CAR TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKEWISE VOID IF THE CAR INVOLVED SHOWS INDICATIONS THAT REASONABLE 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 golf car or component thereof that CLUB CAR deems to be defective Replacement shall mean furnishing during the applicable limited warranty period a new golf car or factory reconditio
76. sulting 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 GOLF CAR 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 CAR TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKEWISE VOID IF THE CAR INVOLVED SHOWS INDICATIONS THAT REASONABLE 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 CARS 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 golf car or component thereof that CLUB CAR deems to be defective Replacement shall mean furnishing during the applicable limited warranty period a new golf car or factory reconditioned vehicle or component thereof that is identical or reasonably equivalent
77. tery Be sure terminals are tight battery terminals should be tightened to 20 ft lb 27 1 N m Let the terminals dry and then spray them with Battery Terminal Protector Spray CCI P N 1014305 See preceding WARNING and 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 BATTERY CAP LEVEL pes PLATES X ELECTROLYTE LEVEL AT LEAST 1 2 INCH 13 MM ABOVE PLATES OR TO LEVEL INDICATOR Figure 24 Battery Gasoline Vehicle Figure 25 Gasoline Battery Electrolyte Level Be sure battery clamp is properly tightened Tighten to 12 ft Ib 16 3 N m A loose battery clamp may allow the battery to become damaged from vibration or jarring If battery appears weak have it charged by a trained technician The battery should never be left discharged any longer than absolutely necessary do not leave discharged overnight Page 38 2005 DS Golf Car Owner s Manual Engine Oil Gasoline Vehicles ENGINE OIL GASOLINE VEHICLES See General Warnings on page 9 Even though the low oil warning light on the dash should illuminate if oil level becomes low engine oil level should be checked monthly Vehicle should be on a level surface when ch
78. the brake pedal with your foot Figure 8 Figure 8 Brake Pedal Figure 9 Park Brake Pedal Page 14 2005 DS Golf Car Owner s Manual Controls and Indicators 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 of it Figure 8 To set the park brake press the brake pedal firmly and tilt the park brake portion of the pedal forward with your foot Figure 9 See fol lowing WARNING A WARNING The park brake will release automatically when either the accelerator or brake pedal is pressed The park brake has multiple locking positions and should be firmly pressed and locked to prevent the vehicle from rolling BATTERY WARNING LIGHT IQ System Electric Vehicles Only 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 indicates 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 illuminates when the vehicle is operating
79. the raised guide on the plug with the guide slot in the receptacle and push straight in slowly The PowerDrive Charger interacts with an onboard computer on IQ System vehicles The computer records the amount of energy consumed during vehicle use While the charger is plugged in the vehicle s control cir cuit is locked out preventing operation of the vehicle as well as the possibility of consequent damage to the charger and the vehicle 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 shut off The control circuit lockout remains activated until the charger plug is dis connected from the vehicle Figure 21 Correct Insertion of Charger DC Plug Figure 22 Incorrect Insertion of Charger DC Plug 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 period 9 holes of golf or 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
80. ti knock index is posted on service station pumps in the U S A NOTE If knocking or pinging occurs use a different brand of gasoline or higher octane rating CAUTION Do not mix oil with gasoline Oxygenated Fuel If you use oxygenated fuel either ethanol or MTBE added to gasoline be sure it is unleaded and meets the minimum octane rating require ment The following are the EPA approved percent ages of fuel oxygenates ETHANOL Ethyl or Grain Alcohol You may use gasoline containing up to 10 ethanol by volume Page 52 MTBE Methyl Tertiary Butyl Ether You may use gasoline containing up to 15 MTBE by volume METHANOL Methanol or Wood Alcohol 5 by volume You may use gasoline containing up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may also dam age metal rubber and plastic parts of your fuel system WARNING Gasoline is extremely flammable and can be explosive under certain con ditions Turn the engine switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Never fill the tank so the fuel level rises into the filler neck If the tank is overfilled heat may cause the fuel to expand
81. 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 charger for specific operating instructions before using the charger 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 duty 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 A WARNING Be sure all wire connections at the receptacle and the fuse link are clean and tight Do not rock or bend the plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 21 Page 36 Do not pull on the DC cord Figure 22 Page 36 Do not twist rock or bend t
82. to the warranted product or component at no cost to the purchaser Repair shall mean remedying a defect in the golf car or component thereof at no cost to the purchaser during the applicable limited warranty period If CLUB CAR elects to repair the golf car it may provide factory reconditioned parts or components All parts and components replaced under warranty shall become the property of CLUB CAR Page 44 2005 DS Golf Car Owner s Manual 5 HOW TO MAKE A WARRANTY CLAIM To make a warranty claim under this limited warranty you must present the golf car or defective component to an authorized CLUB CAR distributor or 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 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 GOLF CAR 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 REPRESENTAT
83. tow the vehicle on public streets or highways WARNING CONTINUED ON NEXT PAGE Page 22 2005 DS Golf Car Owner s Manual Transporting on a Trailer A WARNING Use only approved Club Car tow bars Turn the key switch to the OFF position and place the Forward Reverse handle or switch in the NEUTRAL position before towing the vehicle Extreme caution should be used when towing any vehicle Do not exceed 5 mph 8 km h towing speed Do not allow people in the vehicles 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 Do not tow more than one Club Car vehicle with another Club Car vehicle If more than one vehicle must be towed an adequately powered vehicle tractor or full sized truck properly fitted with a tow hitch height of 11 inches 28 cm should be used Only heavy duty tow bars should be used for multi vehicle towing Never tow more than five vehicles at one time Electric vehicles only Place the Tow Run switch in TOW position otherwise the vehicle will not roll while being towed Gasoline vehicles only Turn the fuel shut off valve to the closed OFF position Figure 15 Page 26 All vehicles are equipped with both front and rear tow bar attaching point
84. ual Batteries Electric Vehicles 1 The batteries should be kept clean and free of corrosion Wash tops and terminals of batteries with a solu tion of baking soda and water 1 cup 237 mL baking soda per gallon 3 8 L of water Rinse solution off of the batteries Do not allow this solution to enter the battery Be sure terminals are tight Let the terminals dry and then coat with Battery Terminal Protector Spray 1 P N 1014305 See following NOTE NOTE Dispose of waste water properly 2 The electrolyte level in the batteries should be checked weekly Figure 20 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 add only distilled water See following NOTE 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 corrod
85. ulti grade oils 5W 20 10W 30 and 10W 40 will increase oil consumption Check oil level more frequently when using them Publication Part Number 102680202 Edition Code 0704A00000 Club Car Inc Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Intl 1 706 863 3000 Fax 1 706 863 5808
86. xed 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 8 2005 DS Golf Car Owner s Manual Safely 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 Throughout this manual and on the operation and safety decals affixed to the vehicle the words golf car and vehicle are used interchangeably Golf is defined in the Notice of this manual and no other representa tion is stated or implied 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 avoid possible property damage personal injury or death Contact your Club Car distributor deal
87. y poison 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 battery charger Do not leave children unattended on vehicle Prior to leaving the vehicle unattended or servicing the vehicle set the park brake place the Forward Reverse handle or switch in the NEUTRAL position turn the key switch to the OFF position and remove the key 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 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 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 electrical and me

102680202 0704A00000

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