RM1011169 0803A00000
Contents
1. 33 Specifications Lynx Vehicle liliis hme 34 Club Car Limited One Year Warranty for Certified Remanufactured Vehicles 35 2004 Gold Standard Electric Vehicle Owner s Manual Page 3 Vehicle Feature Identification ELECTRIC VEHICLES 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 Two 2 persons per seat maximum Operate from driver side only and not on public roads 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 Use brakes to reduce speed when coasting downhill Never stand in front of or behind vehicle 101960601 KEY SWITCH BATTERY WARNING SERIAL NUMBER PARK BRAKE PEDAL Vehicle rated capacity 550 Ibs on level surface only Weight to include passengers cargo bed load and gross trailer weight See Owner s Manual Maximum cargo load 150 Ibs Weight to include cargo VEHICLE LOADING Read Owner s Manual and warnings on dash bed load and gross trailer weight Maximum trailer hitch tongue weight 150 Ibs UNDERAGE WARNING DECAL LYNX VEHI2. belts brushes bushings engine mounts mats and pads maintenance adjustments cosmetic deterioration items which deteriorate or fail due to exposure or ordinary wear and tear and semiconductor parts such as diodes and fuses which are vulnerable to electrical overloads including lightning beyond the control of CLUB CAR Also excluded from any CLUB CAR warranty is damage to a vehicle 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 VEHICLE 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 VEHICLE TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKEWISE VOID IF THE VEHICLE INVOLVED SHOWS INDICATIONS THAT REASONABLE OR 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 whet
3. CCI 1016109 01 POTENTIOMETER DECAL ON WIPER SWITCH COVER INSIDE Z WARNING BATTERY COMPARTMENT ON WIPER SWITCH VEHICLES ONLY Place Tow Run switch in TOW position before FAILURE HEED THIS WARNING COULD RESULT IN Disconnecting or connecting batteries Towing A BATTERY EXPLOSION OR Extended storage SEVERE PERSONAL INJURY Servicing CCI 101908601 TOW SWITCH WARNING DECAL POWERDRIVE PLUS AND IQ SYSTEM VEHICLES ON TOW SWITCH BRACKET UNDER SEAT BED LOAD WARNING DECAL DS BOX BED AND LYNX VEHICLES A WARNING Riding in cargo bed can cause severe injury or death Do not ride in cargo bed A WARNING FALLING OFF COULD RESULT IN SEVERE INJURY OR DEATH CCI 101553901 Remain seated with entire body inside vehicle and hold on to seat handle or handrail at all times Two 2 persons per bench seat maximum One 1 person per bucket seat maximum Do not leave children unattended on vehicle at anytime Never stand in front of or behind vehicle CCI 101705701 REAR FACING SEAT PASSENGER WARNING DECAL FOUR PASSENGER VEHICLE ONLY 2004 Gold Standard Electric Vehicle Owner s Manual Page 5 Practice Safety IK 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 befor
4. and plug terminals should be cleaned with a good electrical contact cleaner or lightly sprayed with WD 40 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 30 2004 Gold Standard Electric Vehicle Owner s Manual Cleaning the Vehicle NOTE If the warning tag has been damaged or removed from the DC cord have it replaced immediately 48 VOLT FUSE LINK SENSE LEAD Figure 17 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 17 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 CLEANING THE VEHICLE Club Car Gold Standard 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 dential water pressure is adequate The use of any type of pressure washing or steam cleaning system is not recommended Such a process especially if the vehicle has an ArmorFlex
5. 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 Only PowerDrive System 48 PowerDrive Plus and IQ System vehicles are compatible with PowerDrive charg ers 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 or if the batteries seem weak contact your local Club Car distributor dealer Figure 15 Correct Insertion of Charger DC Plug Figure 16 Incorrect Insertion of Charger DC Plug 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
6. and abrupt turns make sure cargo is well secured The cargo s center of gravity may affect the handling steering and braking of the vehicle Avoid top heavy loads the center of gravity of a load should never exceed 15 inches 38 cm above the bottom of the cargo bed Unload cargo bed before raising vehicle with a lift hoist or jack 2004 Gold Standard Electric Vehicle Owner s Manual Towing with the Vehicle DS Golf DS Box Bed and Lynx When loading the vehicle center and secure cargo as far forward as possible in the cargo bed Do not over load the vehicle See the following chart for vehicle capacities Maximum payload capacity 150 Ib cargo bed load and gross tailer weight 68 kg Maximum vehicle capacity 550 Ib cargo bed load passengers and gross trailer weight 249 5 kg 150 Ib Trailer tongue weight 667 N TOWING WITH THE VEHICLE DS GOLF DS BOX BED AND LYNX A WARNING Do not tow a vehicle or trailer on public streets or highways Normal vehicle operating speed should be reduced when towing Extreme caution should be used when towing Total vehicle capacity including the vehicle load rating and the gross weight of the vehicle or trailer being towed should not exceed the weight previously specified Do not allow riders in the vehicle or trailer 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 hi
7. 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 NEUTRAL 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 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 accelerator pedal will automatically release the park brake and start the vehicle moving in the direction selected forward or reverse As the accelerator pedal is pressed speed will increase until full speed is reached When the accelerator is released power will be cut off and the motor will stop running PowerDrive Plus and IQ System vehicles See pedal up and pedal down motor braking on page 16 2004 Gold Standard Electric Vehicle Owner s Manual Page 11 Controls and Indicators Figure 7 Accelerator and Brake Pedals 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 the brake pedal
8. from another individual or from a distributor dealer 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 P O Box 204658 Augusta Georgia 30917 4658 Attention Vehicle Registration Page 32 2004 Gold Standard Electric Vehicle Owner s Manual Specifications DS Golf 4 Passenger DS Box Bed Vehicles SPECIFICATIONS DS GOLF 4 PASSENGER DS BOX BED VEHICLES SPECIFICATIONS POWERDRIVE SYSTEM AND 1Q SYSTEM ELECTRIC POWER SOURCE Drive motor Direct drive 48 volts DC series wound 3 1 hp Drive motor Direct drive 48 volts DC shunt wound 3 2 hp Transaxle Double reduction helical gear with 12 3 1 direct drive axle Electrical system 48 volts DC reduced speed reverse 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 A with automatic release park brake BODY CHASSIS Frame Chassis Twin l Beam welded aluminum Front and rear body ArmorFlex Body finish M
9. 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 10 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 If the pedal goes more than halfway to the floor or if the vehicle swerves or fails to stop 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 20 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 REVERSE position Steering The vehicle should be easy to steer and should not have any play in the steering wheel Accelerator With the ke
10. rear body that is removed will expose electrical components to moisture Moisture entering electrical components can result in water damage and subsequent component failure 2004 Gold Standard Electric Vehicle Owner s Manual Page 31 Accessories 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 balls etc SUBSEQUENT OWNER REGISTRATION In the event a vehicle is bought as a used vehicle
11. 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 th m e vehicle reaches maximum designed speed motor braking should engage and limit the vehicle to its aximum designed speed On very steep grades the vehicle may slightly exceed its maximum designed speed requiring use of the brake pedal DRIV ING INSTRUCTIONS A WARNING Page 16 Only licensed drivers should be allowed to drive the vehicle 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 No more than two people should be on the vehicle at one time except for the 4 passenger vehicle which can carry four people 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 vehic
12. 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 15 Page 30 Do not pull on the DC cord Figure 16 Page 30 Do not twist rock or bend the 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 f
13. tight Let the ter minals dry and then coat with Battery Terminal Protector Spray CCI P N 1014305 See following NOTE NOTE Dispose of waste water properly 2 The electrolyte level in the batteries should be checked weekly Figure 14 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 BATTERY CAP PLATES 1 LEVEL AT LEAST 1 2 INCH 13 MM ABOVE PLATES OR TO LEVEL INDICATOR ELECTROLYTE Figure 14 Electric Battery Electrolyte Level 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 corroded they should be replaced or cleaned as necessary Failure to do so may cause them to overheat during operation 4 After use the batteries s
14. with your foot Figure 8 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 Figure 8 Brake Pedal Figure 9 Park Brake Pedal Page 12 2004 Gold Standard Electric Vehicle Owner s Manual Controls and Indicators BATTERY WARNING LIGHT Electric 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 there will be enough power re
15. 2004 Owner s Manual Gold Standard Electric Vehicles Club Car e y An ingersollRand business NOTICE The Club Car Limited One Year Warranty for Certified Remanufactured Vehicles appears at the end of this manual 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 war ranty registration 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 Golf cars covered in this manual conform to the current American National Standards Institute s Z130 Safety and Performance Requirements for Golf Cars This standard which promotes safety in the design applica tion and operation of golf cars defines a golf car as vehicle used to convey a person or persons and equip ment to play the game of golf in an area designated as a golf course Throughout this manual the words golf car are used in reference to golf cars only The word vehicle is used in reference to any other vehicles cov ered in this manual or may be used when referring to all vehicles including golf cars categorically 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 l
16. 4 Gold Standard Electric Vehicle Owner s Manual Publication Part Number RM1011169 Edition Code 0803A00000 Club Car Inc Web www clubcar com P O Box 204658 Phone 1 706 863 3000 Augusta GA 30917 4658 1 800 ClubCar USA Intl 1 706 863 3000 Fax 1 706 863 5808
17. Brake slides Qv Dry Moly Lube CCI P N 1012151 Front suspension 5 fittings wy Chassis Lube EP NLGI Grade 2 Annually by trained 22 oz 0 67 liters 22 oz 0 67 liters technician only Check fill transaxle to plug level SAE 30 WT Class SE SF or SG Oil every 100 hours of or higher operation or 200 rounds of golf Repack tapered front wheel bearings Sealed bearings Qv Chassis Lube EP NLGI Grade 2 require no lubrication t Some vehicles are equipped with an MCOR throttle device Figure 13 m Tapered front wheel bearings are provided with a chrome metal bearing cap Sealed ball bearing front wheel bearings are provided with a black plastic bearing cap Page 24 2004 Gold Standard Electric Vehicle Owner s Manual Periodic Lubrication Schedule e NOT APPLICABLE TO POWERDRIVE PLUS AND IQ SYSTEM VEHICLES NOT APPLICABLE TO VEHICLES EQUIPPED WITH MCOR kee ere Figure 11 Lubrication Points Electric Vehicles LA EL FLOORBOARD REMOVED SS FOR CLARITY Figure 12 Vehicle Equipped with Figure 13 Vehicle Equipped with Multi step Potentiometer Wiper Switch Motor Controller Output Regulator MCOR 2004 Gold Standard Electric Vehicle Owner s Manual Page 25 Vehicle Controller VEHICLE CONTROLLER The electric vehicle is equipp
18. CLE ONLY A WARNING YOUNG DRIVERS INCREASE CHANCE OF DEATH Young drivers may not be able to control vehicle No drivers younger than 16 years old 102075801 Read Owner s Manual and safety warnings located on dash panel prior to driving Study and understand controls Make sure wheels are turned in desired direction 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 position 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 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 CCI 101621601 OPERATING INSTRUCTIONS DECAL PRIVATE SPEED DECAL MOTOR BRAKING DECAL POWERDRIVE PLUS AND IQ SYSTEM VEHICLES with accelerator pedal depressed System is activated only when tow switch is in the RUN position When towing vehicle tow switch must be in the TOW position ACCELERATOR PEDAL BRAKE PEDAL Cargo should be evenly spread over the floor of the cargo bed as far forward as possible and secured For vehicle stability wh
19. E PURCHASER AND CLUB CAR 2004 Gold Standard Electric Vehicle Owner s Manual Page 35 EXPRESSLY AGREE THAT THE REMEDY OF 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 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 VEHICLE 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 vehicle beyond factory specifications including those that affect the weight distribution stability or speed of the vehicle can cause serious personal injury or death Page 36 200
20. 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 See Figure 13 Page 25 to determine applicability Batteries Check for loose hardware cracks and other damage If batteries are not performing as expected see Section 13 Batteries in the appropriate maintenance and service supplement 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 2004 Gold Standard Electric Vehicle Owner s Manual Page 23 PERIODIC LUBRICATION SCHEDULE Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE 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 ion or 100 rounds Brake linkage and pivots Dry Moly Lube CCI P N 1012151 of golf Accelerator pivot rod supports Dry Moly Lube CCI P N 1012151 Spring loaded ball joint MCOR vehicles are not equipped with Dry Moly Lube P N 1012151 ball joints Charger receptacle all vehicles Forward Reverse switch contacts Qv WD 40 PowerDrive System 48 only
21. NG Operator must control vehicle speed when going downhill PowerDrive Plus and IQ System 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 STOPPING THE VEHICLE 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 2004 Gold Standard Electric Vehicle Owner s Manual Page 17 Loading and Unloading DS Box Bed and Lynx Vehicles 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 position and place the Forward Reverse handle or switch in the NEUTRAL position Remove the key when the vehicle is not in use 3 PowerDrive Plus and IQ System vehicles When the Tow Run switch is in the RUN position with the Forw
22. anguage without the written consent of Club Car Inc The information contained in this document is subject to change without notice Club Car reserves the right to make design changes to 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 2003 Club Car Inc Club Car ArmorFlex and PowerDrive are registered trademarks of Club Car Inc This manual effective July 28 2003 2004 Gold Standard Electric Vehicle Owner s Manual Page 1 FOREWORD Thank you for choosing Club Car the vehicle most widely recognized as the industry leader in vehicle effi ciency and long lasting value Please protect your investment and ensure that your Club Car vehicle s pro vides 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 loan your vehicle to others we recommend that y
23. ard Reverse switch or key switch in any position the zero speed detect function will prevent the vehicle from rolling at more than 1 or 3 mph 1 5 or 4 8 km h unless the accelerator is pressed This pre vents the possibility of a parked vehicle with the park brake disengaged rolling away too fast to be over taken on foot See Zero Speed Detect on page 15 LOADING AND UNLOADING DS BOX BED AND LYNX VEHICLES A WARNING Page 18 Firmly engage the park brake before loading the vehicle Do not allow riders in the cargo bed Do not exceed the rated capacity of the vehicle Rated capacity is for level surfaces only Overloading can affect vehicle handling or cause component failure resulting in loss of control of vehicle and possible severe personal injury Reduce speed and avoid sudden stops when backing up Failure to do so may cause the vehicle to overturn or flip over backwards Avoid stopping on a hill when loaded If you must stop on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning may cause vehicle to overturn possibly resulting in severe personal injury Reduce vehicle load and speed when driving up or down slopes or on uneven terrain Do not load the tailgate The tailgate should be in the upright position and latched securely while the vehicle is in motion To help avoid shifting the vehicle load and possibly overturning the vehicle avoid sudden starts sudden stops
24. atched paint finish over molded in color Tires 18 x 8 50 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 without batteries 476 Ib 216 kg 494 Ib 224 kg Forward speed 12 15 mph 19 24 km h Curb clearance circle diameter 17 ft 6 in 533 cm Standard seating capacity DS and box bed vehicles 2 Standard seating capacity 4 passenger vehicle 4 LIQUID CAPACITIES Transaxle 22 oz 0 67 liters TIRE PRESSURE Front and rear 18 20 psi 1 24 1 38 Bars 2004 Gold Standard Electric Vehicle Owner s Manual Page 33 SPECIFICATIONS LYNX VEHICLE Specifications Lynx Vehicle SPECIFICATIONS POWERDRIVE SYS 48 ELECTRIC POWERDRIVE PLUS AND IQ SYSTEM ELECTRIC TEM POWER SOURCE Drive motor Direct drive 48 volts DC series wound 3 1 hp Drive motor Direct drive 48 volts DC shunt wound 3 2 hp Transaxle Double reduction helical gear with 12 3 1 direct drive axle Electrical system 48 volts DC reduced speed reverse Batteries High capacity de
25. ated 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 2004 Gold Standard Electric Vehicle Owner s Manual Page 7 General Warnings 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 turn the key switch to the OFF position remove the key and place the Forward Reverse handle or switch in the NEUTRAL position 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 mechanical repair The appropriate instructions must b
26. 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 The model year designation of a Gold Standard vehicle is the year that the vehicle was remanufac tured rather than the year that it was originally manufactured 2004 Gold Standard Electric Vehicle Owner s Manual Page 9 Controls and Indicators SERIAL NUMBER DECAL TUAE Figure 3 Serial Number Decal CONTROLS AND INDICATORS See General Warnings on page 7 A WARNING f loaning the vehicle make sure the driver is familiar with all controls and operating procedures before allowing the vehicle to be driven 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 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
27. cle This checklist should be used daily to ensure that the vehicle is in proper working condition and in conjunction with the Periodic Service Schedule on page 22 Any problems should be corrected by 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 Safety and information decals Check to ensure that all safety and information decals are in place See pages 4 and 5 Tires Check for proper tire pressure on your new vehicle Visually inspect tires for wear damage and proper inflation on a daily basis See Specifications DS Golf 4 Passenger DS Box Bed Vehicles on page 33 or Specifications Lynx Vehicle on page 34 Page 14 2004 Gold Standard Electric Vehicle Owner s Manual Pre Operation and Daily Safety Checklist Batteries Check electrolyte to ensure that it is at the proper level Figure 14 Page 27 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 Visually inspect for cracks loose connections and frayed wiring See Plug and Receptacle on page 30 Wiper switch Be sure wiper switch cover is properly secured prior to operating the vehicle A WARNING Be sure the plastic has been removed from the seat bottom before operating the vehicle Failure to do so may result
28. e 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 affixed 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 6 2004 Gold Standard Electric Vehicle 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 are used in reference to golf cars only The word vehicle is used in reference to any other vehicles covered in this manual or may be used when ref
29. e used when performing maintenance service or accessory installation PowerDrive Plus and IQ System 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 All electric vehicles To avoid unintentionally starting the vehicle disconnect the batteries as shown Figure 1 or Figure 2 IQ System vehicles After disconnecting the batteries wait 90 seconds for the controller capacitors to discharge PowerDrive System 48 and PowerDrive Plus vehicles After disconnecting the batteries discharge the controller capacitors as follows Turn key switch to the ON position and place the Forward Reverse handle in the REVERSE position Slowly press the accelerator pedal and keep it pressed until the reverse warning buzzer can no longer be heard When the buzzer stops sounding the controller capacitors are discharged All electric 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 Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Page 8 2004 Gold Standa
30. ed 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 This signal is received by the optional Communication Dis play Module CCI P N 101831801 which provides information on the condition of the vehicle and batteries TOW RUN SWITCH PowerDrive Plus and IQ System Vehicles 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 PowerDrive Plus and 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 2004 Gold Standard Electric Vehicle Owner s Manual Page 13 Pre Operation and Daily Safety Checklist 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
31. ed 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 functions of all components in both systems Therefore if any repair or servicing needs to be performed we recommend that it be performed by an authorized Club Car distributor dealer using Club Car OEM parts BATTERIES See General Warnings on page 7 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 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 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 whe
32. en fully loaded drive slowly and avoid stopping on or backing down steep hills Avoid top heavy loads See Owner s Manual When driving on uneven terrain or down steep hills reduce speed and load diui VEHICLE LOADING DECAL DS BOX BED AND LYNX VEHICLES Page 4 2004 Gold Standard Electric Vehicle Owner s Manual IQ VEHICLES WITH PRIVATE SPEED OPTION This vehicle does not conform to ANSI Z130 1 Standard for Golf Cars Safety and Performance Requirements because it is capable of speeds in excess of 15 miles per hour Exercise caution CCI 102228701 Maximum vehicle speed is limited by motor braking during downhill operation 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 101959902 Vehicle Feature Identification ELECTRIC VEHICLES ELECTRICAL COMPONENT DECAL ON SPEED CONTROLLER COVER FORWARD REVERSE HANDLE POWERDRIVE PLUS AND IQ SYSTEM VEHICLES POWERDRIVE SYSTEM 48 VEHICLE 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 CHARGER RECEPTACLE FORWARD REVERSE SWITCH AND IQ SYSTEM VEHICLES DO NOT OPERATE VEHICLE NOTICE WITHOUT COVER IN PLACE DO NOT DIRECT WATER STREAM AT THIS SWITCH
33. ep 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 Front Suspension Tapered mono leaf springs with dual hydraulic shocks Rear Suspension Heavy duty multi 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 I Beam welded aluminum Front and rear body ArmorFlex Body finish Matched paint finish over molded in color Tires 22 x 11 00 10 6 ply rated DIMENSIONS WEIGHT Overall length 9 1 5 in 232 cm Overall width 5 0 5 in 128 cm Overall height with canopy 70 in 178 cm Overall height at steering wheel 4 9 5 in 126 cm Wheelbase 66 38 in 169 cm Ground clearance 6 0 in 15 cm Front wheel tread 34 5 in 88 cm Rear wheel tread 38 5 in 98 cm Weight without batteries 587 lb 266 kg 605 Ib 275 kg Forward speed 12 15 mph 19 24 km h Curb clearance circle diameter 17 ft 6 in 533 cm Standard seating capacity 2 LIQUID CAPACITIES 22 oz Transaxle 0 67 liters TIRE PRESSURE Front and rear Off road tread 14 18 psi 96 1 24 Bars Page 34 2004 Gold Standard Elect
34. erring to all vehicles including golf cars categorically 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 dealer 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 A CAUTION indicates a hazard or unsafe practice that could result in minor personal injury or product or property damage CAUTION A CAUTION without the safety alert symbol indicates a situation that could potentially 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 and 5 Other specific safety state ments 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 A Club Car vehicle will not provide protection from lightning flying objects or other storm rel
35. g electrical components to moisture and subsequent damage do not use any type of pressure washing or steam cleaning equipment to wash the vehicle PowerDrive Plus and IQ System vehicles only Place Tow Run switch in the TOW position PREPARING THE ELECTRIC VEHICLE FOR EXTENDED STORAGE 1 Unload the vehicle so that the tires are supporting only the weight of the vehicle 2 Fully charge batteries See Charging Batteries on page 29 3 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 4 Store vehicle in a cool dry place This will minimize battery self discharge 5 Adjust tires to recommended tire pressure See Specifications DS Golf 4 Passenger DS Box Bed D OL O Vehicles on page 33 or Specifications Lynx Vehicle on page 34 Perform semiannual periodic lubrication See Periodic Lubrication Schedule on page 24 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 PowerDrive Chargers Leave PowerDrive Charger
36. harger 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 2004 Gold Standard Electric Vehicle Owner s Manual Battery Charger NOTE Because the vehicle 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 the 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 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
37. her based upon warranty contract negligence strict product liability or otherwise shall be the repair or replacement at CLUB CAR s option of the vehicle or component thereof that CLUB CAR deems to be defective Replacement shall mean furnishing during the applicable limited warranty period a factory reconditioned 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 vehicle or component thereof at no cost to the purchaser during the applicable limited warranty period If CLUB CAR elects to repair the vehicle 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 vehicle 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 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 TH
38. hould be placed on charge The batteries should never be left discharged any longer than absolutely necessary do not leave discharged overnight 2004 Gold Standard Electric Vehicle Owner s Manual Page 27 Battery Charger BATTERY CHARGER 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 28 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 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 elect
39. ice Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Daily service by owner Batteries Charge batteries after each use only Weekly service by owner Batteries Check electrolyte level Add water if necessary See page 27 Monthly service by owner Batteries Wash battery tops and clean terminals or trained technician with baking soda water solution Check air pressure and adjust if Tires necessary Wiper switch Check for cracks or other damage make See Figure 12 Page 25 to determine applicability sure switch is securely fastened to frame Check moveable contact for correct operation 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 Annual service by trained technician only every 100 hours of operation or 200 rounds of golf Brake system Check brake shoes replace if necessary See Section 6 Wheel Brake Assemblies in the appropriate maintenance and service manual Lubricate brake slides per Lubrication Schedule See Section 6 Wheel Brake Assemblies in the appropriate maintenance and service manual Check brake cables for damage replace if 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
40. 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 before transporting on a trailer 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 Page 20 2004 Gold Standard Electric Vehicle Owner s Manual Storage STORAGE See General Warnings on page 7 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 exposin
41. ity of injury due to unsafe conditions Contact your local Club Car distributor dealer to perform all repairs and semiannual and annual periodic ser vice 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 Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle Turn key switch to the OFF position remove the key place the Forward Reverse handle in the NEUTRAL position and chock wheels prior to servicing Hot Do not attempt to service hot motor or resistors Attempting to do so could cause severe burns Do not work on the vehicle powertrain or under the cargo bed when it is loaded PERIODIC SERVICE SCHEDULE See General Warnings on page 7 A WARNING 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 Page 22 2004 Gold Standard Electric Vehicle Owner s Manual Periodic Serv
42. le drive slowly in turns Use brakes to reduce speed when coasting downhill 2004 Gold Standard Electric Vehicle Owner s Manual Driving Instructions 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 1 Wong OF E GM Study and understand controls Read safety warnings located on dash and above pedals For vehicles with cargo beds Make sure load is secure Make sure everyone is seated and holding onto seat hand holds or handrails Make sure wheels are turned in desired direction and that nothing is in your path Turn key to the ON position 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 8 Place both hands on the steering wheel 9 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 WARNI
43. le 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 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 possible 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 Where applicable obey all local rules concerning golf cars and off road vehicles 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 vehic
44. ll avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning could cause vehicle to overturn possibly resulting in severe personal injury Because towing a vehicle or trailer can have adverse effects on vehicle handling be especially cautious when towing with a Club Car vehicle See the preceding chart for vehicle capacities Parking the vehicle with a trailer on a hill should be avoided If you must park on a hill apply the brakes and have someone chock the tires of the trailer Brakes should be released to allow the chocks to absorb the load of the trailer After the tires have been chocked engage the park brake TOWING THE VEHICLE A WARNING Do not tow the vehicle on public streets or highways 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 2004 Gold Standard Electric Vehicle Owner s Manual Page 19 DS golf Transporting on a Trailer 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 resulti
45. maining 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 charger and batteries should be check
46. n working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring CAUTION On all 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 all electric vehicles are 8 volts each 8 volt batteries are deep cycle batteries specially built for electric vehicle 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 vehicles with new batteries to 36 holes of use or 60 minutes of actual vehicle operation between charges in the first two months of operation Batter ies 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 26 2004 Gold Standard Electric Vehicle Owner s Manual Batteries 1 The batteries should be kept 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 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
47. ng 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 PowerDrive Plus and IQ System vehicles only Place the Tow Run switch in TOW position otherwise the vehicle will not roll while being towed cars and DS box bed vehicles are equipped with both front and rear tow bar attaching points A heavy duty tow bar and an onboard tow bar are available for multi vehicle towing The four passenger vehicle is equipped with a front tow bar attaching point A light duty tow bar is available for break down towing and single 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
48. ollow 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 2004 Gold Standard Electric Vehicle Owner s Manual Page 29 Battery Charger Insert the charger DC plug into the vehicle receptacle The charger will turn on two to ten seconds later Figure 15 When inserting the DC plug align 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 electric vehicles The computer records the amount of energy consumed during vehicle use While the charger is plugged in the vehicle s control circuit is locked out preventing operation of the vehicle as well as the possibility of consequent damage to the charger and the vehicle
49. ou ask them to read this manual before they operate the vehicle Club Car products are backed by a customer support system designed to offer you fast courteous service In the event that your 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 P O Box 204658 Augusta Ga 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 2004 Gold Standard Electric Vehicle Owner s Manual TABLE OF CONTENTS Vehicle Feature Identification Electric Vehicles 4 Safety Details bue uds MA ieee BUA Ooi neh Ex ERAS 7 amp hh hr eher 7 General Information Aceon gie tee ideo tete uter Sl a e BAR Rcs 9 Model IdentifiCation 5 gr ey RA ESL LANES ARES 9 Controls and Indica
50. placing the Tow Run switch 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 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 vehi
51. position and remove the key when leaving the vehicle Figure 4 Key Switch Page 10 2004 Gold Standard Electric Vehicle Owner s Manual Controls and Indicators 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 NOTE The key can be removed only when the key switch is in the OFF position FORWARD REVERSE CONTROL PowerDrive System 48 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 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 posi tion 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 PowerDrive Plus and IQ System Vehicles The Forward Reverse rocker switch is located in the same place as the Forward Reverse handle on all other models on the seat support panel below and to the right of the driver s right knee The F FORWARD and R REVERSE positions are
52. rd Electric Vehicle Owner s Manual General Information GENERAL INFORMATION This manual features the following Gold Standard electric vehicles DS golf car 4 passenger vehicle DS box bed vehicle see following NOTE Lynx vehicle The electric vehicles have one of several possible powertrain configurations PowerDrive System 48 Power Drive Plus and IQ System It is important that you know which powertrain your vehicle has NOTE Throughout this manual the term DS box bed vehicle is used when referring to the DS vehicle equipped with a box bed The Lynx also has a box bed but it has larger tires a lifted chassis and a brush guard 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 Place Tow Run LS FRONT OF VEHICLE Bier ey Canoe Be 6 PLACE TOW RUN SWITCH WORKING ON VEHICLE Remove negative IN THE TOW POSITION BEFORE DISCONNECTING OR cable first CONNECTING BATTERY CABLES Figure 1 PowerDrive System 48 Vehicle Figure 2 PowerDrive Plus and IQ System Vehicle 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 2A0401 123456 Figure 3 There is also a second serial number decal mounted on the front body frame behind the center dash panel The
53. ric Vehicle Owner s Manual CLUB CAR LIMITED ONE YEAR WARRANTY FOR CERTIFIED REMANUFACTURED VEHICLES 1 WARRANTY CLUB CAR INC CLUB CAR hereby warrants to the Purchaser that its Certified Remanufactured Vehicle purchased from CLUB CAR or an authorized agent shall be free from defects in material and workmanship under normal use and service for the periods stated below subject to the provisions limitations and exclusions contained in this limited warranty LIMITED ONE YEAR WARRANTY All original equipment including batteries battery charger onboard computer and solid state speed controller 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 listed above for the period 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 DC cord set with plug and receptacle brake shoes
54. rical outlet must accept a three prong plug Extension cord should be a three wire No 12 AWG 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 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 c
55. s plugged in during storage The onboard computer will automatically activate the charger when necessary If charger cannot remain plugged in or AC power will not be available during extended storage disconnect the batteries for storage Figure 1 Page 9 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 2 If necessary connect batteries Fully charge batteries 2004 Gold Standard Electric Vehicle Owner s Manual Page 21 Maintenance 3 Adjust tires to recommended tire pressure See Specifications DS Golf 4 Passenger DS Box Bed Vehicles on page 33 or Specifications Lynx Vehicle on page 34 4 Perform the Pre Operation and Daily Safety Checklist on page 14 MAINTENANCE See General Warnings on page 7 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 14 and the fol lowing Periodic Service Schedule and Periodic Lubrication Schedule 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 possibil
56. tors e hr ra 10 Pre Operation and Daily Safety Checklist 14 DFiVINGHINStrUCtlIONS 2 2 sacked ENE EUR RUNI ekle qe V fica noes bara ERU RR AR UE eee S 16 Loading and Unloading DS Box Bed and Lynx Vehicles 18 Towing with the Vehicle DS Golf DS Box Bed and Lynx 19 Towing the Vehicle ed AES e AR ag ee ae DAR Ron EE ae 19 Transporting onia Traller e he Rae eee bee eee eee dens 20 Storage su etos vx eot o tte De esatta 21 Maintenances pt etes er eee ee ie e ade 22 Periodic Service Schedule 2 doa cea deere re RR dob XI OS RE ere wad e SIRE 22 Periodic Lubrication Schedule ene 24 Vehicle Controller SaaS dee sedem dot n ane ee AUREUS DEREN Rankine 26 Batteries oss eR RE RPM Qt ae uo P um Mte ty area RS 26 Battery Charger zx I DREAM EE Mua pic NS eee NE 28 Cleaning the Vehicle ees eves ea ae eae uus 31 ACCeSSOL IOS ths ais oes eed oae x VP ER PLA We eA CI e NSS fede sux eA hs 32 Subsequent Owner 32 Specifications DS Golf 4 Passenger DS Box Bed Vehicles
57. y 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 come up smoothly to full speed When the pedal is released it should return to the original position and the motor should rotate freely All Club Car vehicles operate at reduced speed in reverse PowerDrive Plus and IQ System vehicles 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 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 PowerDrive Plus and IQ System Vehicles 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 or 4 8 km h with the Forward Reverse switch in any position IQ System vehicles When zero speed detect motor braking is engaged the reverse buzzer should emit a distinct pattern of beeps 2004 Gold Standard Electric Vehicle Owner s Manual Page 15 Driving Instructions Pedal Up Motor Braking adjustable on IQ System vehicles Accelerate the vehicle to full speed and then
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