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1. Pps Sela a ae dead a seat 32 Subsequent Owner Registration 4 33 Fairway Viager 4 y suu et eed ee eee nt ode 33 Vehicle Specifications apy Ain wh Bare eae ees 35 ta cog ede Sea etn 36 2002 DS Golf Car Electric Vehicle Owner s Manual Page 7 Safety 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 the operation and warning 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 repre sentation is stated or implied If any of the operation or warning decals on the vehicle become damaged have been remo
2. 10 General Information Luya zn ban ee s aou Oe ea New Bae Me XA Sede BAe 12 Model Identification T u guitare ed ened eae Wheat E 12 Safety Committee a PE lea 12 Controls and Indicators 13 Pre Operation and Daily Safety 17 Driving INStructlOns s A Re et 19 TONG 21 Transporting On a Trailer dye eee whe Sa 21 Storage a debe ae 22 Maintenance o ya suyan ened ete 23 Periodic Service 4 23 Periodic Lubrication 25 Vehicle Controler ess aha a ek a Ae de ec awl 26 Batteries at eee ate Bed dl oe dati Cand ie Set te ea ae ee ee ee 26 Battery Charger sei oe a e wale ede ee RE eae ek 28 Cleaning the Vehicle 4 32 880 2
3. Attention Marketing Services P O 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 golf car If you sell the vehicle please include the manual so that the next owner will have the important operating safety and maintenance informa tion it contains 2002 DS Golf Car Electric Vehicle Owner s Manual Page 5 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 affixed to your vehicle Take time to understand the language of safety It is a language that can save your life Page 6 2002 DS Golf Car Electric Vehicle Owner s Manual TABLE OF CONTENTS Safety l he Da ee eg chee we eel a ee 8 General WarningS 9 Vehicle Feature Identification
4. 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 PowerDrive System 48 and IQ System vehicles with new batteries to 36 holes of use between charges in the first two months of operation V Glide 36 volt vehicles should be limited to 18 holes between charges in the first two months 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 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 tight Let the ter minals dry and then coat with Battery Terminal Protector Spray CCI 1014305 See following NOTE NOTE Dispose of waste water properly 2 The electrolyte level in the batteries should be checked weekly Figure 12 Page 27 Add water only after charging 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 a
5. This accessory will increase the speed of the vehicle so that it will not conform to the speed criteria of the ANSI Z130 1 Standard for Golf Cars Safety and Performance Requirements The vehicle speed will exceed 15 miles per hour 24 km h SUBSEQUENT OWNER REGISTRATION In the event a vehicle is bought as a used vehicle 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 FAIRWAY VILLAGER The electric Fairway Villager is designed to provide a smooth and comfortable ride for four passengers and is offered in the PowerDrive System 48 electric power configuration only A rack for two golf bags is also avail able Contact your nearest Club Car distributor dealer This owners manual should be read thoroughly prior to operating the vehicle The Fairway Villager should be driven and maintained as stated in this owner s manual with the following addi tions A WARNING Vehicle should be driven at slower speeds when four persons are in the vehicle Passengers should hold to seat handles or hand rails at all times Figure 17 Page 34 Driver should keep both hands on the steering wheel while vehicle is moving Do not leave children unat
6. could result in severe personal injury or death Do not shift the Forward Reverse handle 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 Release the accelerator pedal and then depress the brake pedal firmly until the vehicle stops To avoid unintentionally starting or rolling the vehicle set the park brake turn the key switch to OFF and remove the key when leaving the vehicle KEY SWITCH The key switch is mounted on the dash to the right of the steering column Figure 4 Page 13 It has two posi tions 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 Figure 4 Key Switch FORWARD REVERSE CONTROL DS V Glide and DS PowerDrive System 48 Vehicles Forward Reverse handle is located on the seat support panel below and to the right of the driver s right knee Figure 5 Page 14 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 position NEUTRAL vehicle will not operate Club Car vehicles operate at reduced speed in reverse The reverse buzzer will sound as a
7. technician only Chgckifil transaxle to plug level 2 Class SE SF or SG oil or higher every 100 hours of operation or 200 rounds Inspect front wheel bearings 8 Chassis Lube EP NLGI Grade 2 of golf Repack as necessary See Figure 11 Page 25 NOT APPLICABLE TO IQ SYSTEM VEHICLES T 36 VOLT VEHICLES ONLY Figure 11 Lubrication Points 2002 DS Golf Car Electric Vehicle Owner s Manual Page 25 Vehicle Controller VEHICLE CONTROLLER The DS electric vehicle is equipped with either a Solid State Speed Controller PowerDrive System 48 and IQ System or V Glide Speed Controller 36 Volt Vehicle In order to properly service and maintain the Solid State Controller vehicle or the V Glide Speed 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 Read DANGER and WARNING on page 9 A DANGER Battery Explosive gases Do not smoke Keep sparks and flames away from vehicle and service area Tools wires and metal objects can cause sparks when shorted across a battery Follow all instructions carefully when dealing with bat
8. Manual This warranty gives you specific legal rights and you also have other rights which vary from states to states 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 2002 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 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
9. 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 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 Page 38 2002 DS Golf Car Electric Vehicle Owner s
10. 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 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 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 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 i
11. WARRANTY LIMITATIONS CLUB 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 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 T
12. and protect the charger from overheating Do not allow clothing blankets or other material to cover the charger Provide adequate ventilation for the charger 36 Volt Accu Power Charger Do not leave the DC cord plugged into a vehicle receptacle while unattended for more than two consecutive days Severe overheating and damage to the batteries may result if the charger does not turn off Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical electronic components in the charger and on the vehicle from all but direct or very close lightning strikes NOTE Because the PowerDrive Charger has a storage charge feature that automatically checks and recharges the batteries as necessary every 15 days it can remain plugged to a PowerDrive or 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 to a source capable of supplying 10 amperes minimum per charger The battery charger must be grounded to reduce the risk of electrical shock The charger is equipped with an AC e
13. are being charged This is to avoid the accumulation of hydrogen gas inside the enclosure The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the building must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer 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 electrical 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 d
14. expressed herein and any implied warranties null and void and same are hereby excluded 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 Ultra Power or Accu Power Charger is suitable for use in any application other than its 36 volt products As in the use of any electrical device a prudent owner will read and study the charger owner s 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 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 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
15. 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 2002 DS Golf Car Electric Vehicle Owner s Manual Page 43 Your Comments Are Appreciated Please select your category L Distributor Dealer Technician L Individual Owner Golf Course Superintendent L Other In order to help us better serve you please rate this publication in the following catesories Poor Far Average Good Excellent Ease of Understanding Ease of Finding Information Clarity of Illustrations Index Usability Troubleshooting Chart Usability WN Comments Suggestions Please fax a copy of this page to 706 228 2662 Thank You Club Car Technical Publications Department 2002 DS Golf Car Electric Vehicle Owner s Manual Manual 102252002 Edition Code 080100202 Golf Cars Electric Club Car Inc P O Box 204658 Augusta GA 30917 4658
16. 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 Batteries If batteries are not performing as expected see Section 13 Batteries 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 Page 24 2002 DS Golf Car Electric Vehicle Owner s Manual PERIODIC LUBRICATION SCHEDULE Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE REGULAR INTERVAL SERVICE PLACE RECOMMENDED LUBRICANT Semiannually by owner Brake pedal shaft bearings 1 Dry Moly Lube CCI P N 1012151 or trained technician every 50 hours of operation Brake linkage and pivots 2 Dry Moly Lube CCI P N 1012151 or 100 rounds of golf Accelerator rod pivots and mounts V Glide only Accelerator pivot rod supports 2 Dry Moly Lube CCI P N 1012151 PowerDrive and IQ System Charger receptacle all vehicles Forward Reverse switch contacts 4 WD 40 V Glide and PowerDrive only Brake slides 5 Dry Moly Lube CCI P N 1012151 Front suspension 5 fittings 6 Chassis lube EP NLGI Grade 2 Annually by trained F 22 oz 67 liters SAE 30 WT API
17. warning when the Forward Reverse handle is in REVERSE 2002 DS Golf Car Electric Vehicle Owner s Manual Page 13 Controls and Indicators Figure 5 Forward Reverse Handle Figure 6 Forward Reverse Rocker Switch DS IQ System Vehicles The Forward Reverse rocker switch is located in the same place as the Forward Reverse handle on all other DS 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 clearly marked Push down the FORWARD side of the switch to operate the vehi cle 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 depressed Figure 6 Page 14 The reverse buzzer will sound as a warning when the Forward Reverse switch is in REVERSE 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 Page 14 The operation of the accelerator pedal differs from that of an automobile When the key switch is ON and the For ward Reverse handle is in either FORWARD or REVERSE depressing the accelerator pedal will automati cally release the park brake and start the vehicle moving in the direction selected forward or reverse As the accelerator pedal is depressed speed will increase until ful
18. when ordering parts or making inquiries If the vehi cle is equipped as a Fairway Villager four passenger vehicle read the special instructions begin ning on page 33 SERIAL NUMBER T 0201 123456 tumi Figure 3 Serial Number Decal SAFETY COMMITTEE Ifthe golf car is to be rented or is part of a fleet we strongly recommend that 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 e Ensuring that proper warnings of driving hazards are displayed and visible e Who should and who should not drive golf cars Instructing first time drivers Maintaining golf cars a safe driving condition How various rules to be enforced The safety committee should include all these items and such others as the committee feels necessary or appropriate Page 12 2002 DS Golf Car Electric Vehicle Owner s Manual Controls Indicators CONTROLS AND INDICATORS Read DANGER and WARNING 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 e Any modification or change to the vehicle that affects the stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications
19. Batteries Charge batteries after each use only 4 Check electrolyte level Add water if Weekly service by owner Batteries 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 See Vehicle Specifications on page 35 Check for cracks or other damage make Wiper switch sure switch is securely fastened to frame V Glide 36 volt vehicle only 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 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 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
20. CIFIED SUCH MANUALS 4 SOLE REMEDY CLUB 95 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 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 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 2 2002 DS Golf Car Electric Vehicle Owner s Manual 5 HOW MAKE 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 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
21. DS GolfCar Electric Vehicles 2002 Owners Manual The Club Car Limited Warranty for owners of individual golf cars appears on the pages following this notice and the Limited Lifetime Fleet Warranty appears at the end of this manual along with limited warranty infor mation for 2002 T 105 6 Volt Batteries 2002 PowerDrive 8 Volt Batteries 2002 36 Volt Battery Chargers 2002 PowerDrive and IQ Battery Chargers and 2002 Onboard Computers and Solid State Speed Controllers No other warranties expressed or implied are contained herein Your authorized representative checked this 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 golf course Throughout this manual the words golf and vehicle are used interchangeably This manual contains proprietary information that is protected by copyright All rights are reserved No part of thi
22. 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 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
23. LD RESULT IN DAMAGE WIPER SWITCH VEHICLES ONLY TOWING TO VEHICLE OR BATTERY EXPLOSION EXTENDED STORAGE SERVICING DISCONNECTING OR CONNECTING BATTERIES BATTERY DANGER DECAL ON BATTERY CAPS DANGER POISON FLUSH EYES SULFURIC IMMEDIATELY a w NO WITH WATER SPARKS FD CAN CAUSE EYES BLINDNESS OR GASES CAN cause i SMOKING SEVERE BURNS Pa HELP BLINDNESS OR INJURY i KEEP OUT OF THE REACH OF CHILDREN DO NOT TIP KEEP VENT CAPS TIGHT AND LEVEL 2002 DS Golf Car Electric Vehicle Owner s Manual Page 11 General Information GENERAL INFORMATION There are three electric DS Golf Car models the DS V Glide 36 volt vehicle the DS PowerDrive System 48 48 volt vehicle and the DS IQ System 48 volt vehicle 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 your Club Car is printed on a bar code decal mounted on the frame directly above the accelerator pedal Example 00201 123456 Figure 3 Page 12 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 Always have the vehicle serial number at hand
24. 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 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 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 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 compo
25. NENT 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 specific 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 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 2002 DS Golf Car Electric Vehicle Owner s Manual Page 37 CLUB CAR LIMITED THREE YEAR WARRANTY FOR 2002 T 105 6 VOLT BATTERIES CLUB INC CLUB hereby war
26. O 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 maintenance 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 PO Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 CLUB CAR LIMITED FOUR YEAR WARRANTY FOR 2002 ONBOARD COMPUTERS AND SOLID STATE SPEED CONTROLLERS CLUB CAR INC CLUB 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 Syste
27. S Figure 10 Tow Run Switch Page 16 2002 DS Golf Car Electric Vehicle Owner s Manual Pre Operation and Daily Safety Checklist DS IQ System vehicles are equipped with a Tow Run switch located under the seat just above the Forward Reverse switch Figure 10 Page 16 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 vehi cle will not operate See following NOTE NOTE After 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 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 Attaching Battery Wires 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 wires are disconnected For Long Term Storage Place the Tow Run switch in the TOW position to turn off power to the veh
28. TORAGE Read DANGER and WARNING on page 10 A WARNING Turn the key switch OFF remove the key and leave the Forward Reverse switch handle 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 e When washing the vehicle do not direct water stream at the accelerator switch Forward Reverse switch or other electrical component IQ System vehicles only Place Tow Run switch in TOW position PREPARING THE VEHICLE FOR EXTENDED STORAGE 1 Fully charge batteries See Charging Batteries on page 29 2 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 1014305 3 Store vehicle in a cool dry place This will minimize battery self discharge 4 Adjust tires to recommended tire pressure See Vehicle Specifications on page 27 5 Lubricate front suspension and do all other semiannual periodic lubrication See Periodic Lubrication Schedul
29. Vehicle Owner s Manual Battery Charger Figure 13 Correct Insertion of Charger DC Plug Figure 14 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 and receptacle show signs of corrosion or the plug is difficult to insert and remove the receptacle con tacts 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 insertion ease of removal and good electrical contact See following NOTE NOTE If the warning tag has been damaged or removed from the DC cord have it replaced immediately 48 VOLT FUSE LINK 36 VOLT SENSE LEAD FUSE LINK Figure 15 Receptacle Fuse Link for 36 Volt Vehicle Figure 16 Receptacle Fuse Link for 48 Volt and IQ System Vehicles 2002 DS Golf Car Electric Vehicle Owner s Manual Page 31 Cleaning the Vehicle 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 15 Page 31 for V Glide 36 Volt vehicles or Figure 16 Page 31 for PowerDrive System 48 and IQ System vehicles If the charger does not come on when t
30. able from Club Car and our dealers distributors 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 e Tinted windshields weather proof enclosures will not protect occupants from flying objects golf balls etc ACCESSORY EQUIPMENT Accent striping Glove box Hour meter Custom club decals Performance grade tires Information holder Number decals Standard tread tires Beverage cooler Rear rain curtain Extra traction tires Extra two bag attachment Weather proof enclosure DC to DC converter Sand bunker rake kit Tinted split hinged windshield Chrome hub wheel covers Battery indicator Page 32 2002 DS Golf Car Electric Vehicle Owner s Manual Subsequent Owner Registration Differential guard Trailer hitch Ashtray Sand bottle divot repair kit Uncommon key switch Club protector Permanent tow bar for multiple 3 75 hp electric motor sand bucket divot ki vehicle towing factory installed PowerDrive System 48 vehicle only 3 5 hp electric motor Lighting package headlights V Glide 36 Volt vehicle only taillights brake lights and horn Onboard charger with rewind cord Fairway Villager vehicle only Turn signals for vehicles with lights Temporary tow bar for single vehicle towing Onboard tow bar Private speed mode Pear MEW mirror IQ System vehicle only NOTICE
31. and components replaced under warranty shall become the property of CLUB CAR Page 40 2002 DS Golf Car Electric Vehicle Owner s Manual THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES OTHER WARRANTY 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 maintenance 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 damag
32. anual 3 Damages caused by improper installation of the Computer or Controller 4 Vehicles charged by systems other than the CLUB CAR PowerDrive Charger Page 42 2002 DS Golf Car Electric Vehicle Owner s Manual Without limiting the generality of the foregoing way and as 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 device 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
33. are 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 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 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 2002 DS Golf Car Electric Vehicle Owner s Manual Page 39 This battery is intended t
34. bove 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 4 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 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 INDICATOR PLATES _ ELECTROLYTE LEVEL AT LEAST 1 2 INCH 13 MM ABOVE PLATES OR TO LEVEL INDICATOR Figure 12 Battery Electrolyte Level 2002 DS Golf Car Electric Vehicle Owner s Manual Page 27 Battery Charger BATTERY CHARGER A DANGER Batteries emit hydrogen while being charged Hydrogen is an explosive gas If the vehicle is equipped with a weatherproof enclosure it should be unzipped and pulled back while batteries
35. cir cumstance Park brake When latched the park brake should lock the wheels and hold the vehicle stationary on incline of 20 or less It should release when either the accelerator or brake pedal is depressed Reverse buzzer The reverse buzzer will sound as a warning when the Forward Reverse handle is in REVERSE Steering The vehicle should be easy to steer and should not have any play in the steering wheel Accelerator With the key switch ON and the Forward Reverse switch in the FORWARD position as the accelerator pedal is depressed 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 stop All DS vehicles operate at reduced speed in reverse 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 DS 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 It should resist rolling moving at no more than 1 or 2 mph 1 5 or 3 km h with the Forward Reverse switch in any position and the reverse buzzer should sound Pedal Up Motor Braking adjustable IQ System vehicles Accelerate the vehicle to full speed and then release the accel
36. 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 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 Page 36 2002 DS Golf Car Electric Vehicle Owner s Manual 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
37. e Trojan 6 volt 115 min capacity Charger Automatic 48 volt UL and CSA listed Charger Automatic 36 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 standard electric vehicle with canopy without batteries 476 Ib 216 kg 469 Ib 213 kg Weight IQ System vehicle with canopy without batteries 494 Ib 224 kg Weight Fairway Villager electric vehicle without batteries 495 Ib 225 kg N A N A Forward speed 12 15 mph 19 24 km h Curb clearance circle diameter 17 ft 6 in 533 Braking distance at 12 mph 19 k
38. e 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 battery is suitable for use in any application other than in its products As in the use 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 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 three year or 600 round 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
39. e on page 26 6 Thoroughly clean front body rear body seats battery compartment and underside of vehicle 7 Do not engage the park brake Chock the wheels to prevent the vehicle from rolling 8 Keep batteries fully charged during storage PowerDrive Chargers Leave PowerDrive Chargers 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 2 Page 8 Accu Power Chargers only Charge batteries every six to eight weeks If it is not possible to charge the batteries every six to eight weeks disconnect the batteries for storage Figure 2 Page 8 Page 22 2002 DS Golf Car Electric Vehicle Owner s Manual Maintenance RETURNING THE STORED VEHICLE TO SERVICE 1 If necessary connect batteries 2 Fully charge batteries 3 Adjust tires to recommended tire pressure See Vehicle Specifications on page 27 4 Perform the Pre Operation and Daily Safety Checklist on page 11 MAINTENANCE Read DANGER and WARNING 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 17 and the fol lowing Per
40. e 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 2002 DS Golf Car Electric Vehicle Owner s Manual Page 19 Driving Instructions STARTING THE VEHICLE oa Study and understand controls Make sure everyone is seated and holding onto seat handles or handrails Read safety warnings located on dash and or above pedals Make sure wheels are turned in desired direction Turn key to the ON position and make sure nothing is in your path Select direction by placing Forward Reverse handle in desired position F forward or R reverse A buzzer will sound as a warning when the Forward Reverse handle is in REVERSE Slowly depress accelerator pedal The park brake will release automatically and the vehicle will start to move As the accelerator pedal is depressed speed will increase until full speed is reached See fol lowing WARNING A WARNING Operator must control vehicle speed when going downhill IQ System vehicles only Pedal down or pedal up motor braking may be used to control speed when going downhill See Performance Inspection on page 18 However terrain or other conditions may require tha
41. ecals 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 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 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 SPE
42. ed 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 is in position When towing vehicle tow switch must be in the TOW position 101959902 LE RATO R MOTOR BRAKING DECAL PEDAL IQ SYSTEM VEHICLES ONLY BRAKE PEDAL Page 10 2002 DS Golf Car Electric Vehicle Owner s Manual Vehicle Feature Identification DS ELECTRIC VEHICLE A WARNING TS NU RESISTOR WARNING DECAL ON BODY UNDER SEAT ON V GLIDE 36 VOLT VEHICLE ELECTRICAL COMPONENT DECAL ON SPEED CONTROLLER COVER IQ SYSTEM VEHICLE ONLY FORWARD REVERSE HANDLE POWERDRIVE SYSTEM 48 AND V GLIDE 36 VOLT VEHICLES 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 CCl 101931501 FORWARD REVERSE SWITCH CHARGER IQ SYSTEM RECEPTACLE VEHICLES ONLY TOW SWITCH WARNING DECAL IQ SYSTEM VEHICLES ONLY DO NOT DIRECT WATER ON TOW SWITCH BRACKET UNDER SEAT STREAM AT THIS SWITCH CCI 1016109 01 A POTENTIOMETER DECAL WARNING ON WIPER SWITCH COVER INSIDE TOW RUN BATTERY COMPARTMENT ON PLACE TOW SWITCH IN TOW POSITION BEFORE FAILURE TO DO SO COU
43. ed 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 Purchaser or in the possession of the Original Retail Fleet Lessee 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
44. elated 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 When stopping and leaving the vehicle Turn the key switch to OFF and remove the key Place the Forward Reverse handle in NEUTRAL Engage the park brake Only trained technicians should repair or service the vehicle Anyone doing even simple repairs or service should follow the procedures exactly as stated in this manual and follow all DANGER WARNING and CAUTION procedures listed in this manual as well as those affixed to the vehicle Wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shield and rubber gloves when working with batteries Use insulated tools when working around batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance or severe personal injury 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 Prior to servicing the vehicle Chock the wheels Turn the key switch to OFF and remove the key Place the Forward Reverse handle in NEUTRAL Disconnect the battery cables ne
45. erator pedal Motor braking should quickly and smoothly slow the vehicle to approximately 11 mph 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 distributor to inquire about this adjustable feature Pedal Down Motor Braking Accelerate down an incline with the accelerator pedal depressed When the vehicle reaches approximately 15 mph 24 km h motor braking should engage and moder ate vehicle speed between 15 and 16 mph 24 26 km h depending upon the grade of the hill Page 18 2002 DS Golf Car Electric Vehicle Owner s Manual Driving Instructions DRIVING INSTRUCTIONS A WARNING Only licensed drivers should be allowed to drive this 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 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 moving 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 switch Failure to do so may result in inj
46. es 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 2002 POWERDRIVE CHARGERS CLUB CAR INC CLUB hereby warrants to the original retail purchaser 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 bey
47. g straight out of the receptacle 2002 DS Golf Car Electric Vehicle Owner s Manual Page 29 Battery Charger 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 PowerDrive Chargers or blades Accu Power Chargers 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 Insert the charger DC plug into the vehicle receptacle The charger will turn on two to ten seconds later Figure 13 Page 31 When inserting the DC plug align the raised guide on the plug with the guide s
48. gative cable first IQ System vehicles Place Tow Run switch in the TOW position before disconnecting or connecting the batteries All electric vehicles To avoid unintentionally starting the vehicle disconnect the batteries as shown Figure 1 Page 8 and Figure 2 Page 8 IQ System vehicles After disconnecting the batteries wait 90 seconds for the controller capacitors to discharge PowerDrive System 48 vehicles After disconnecting the batteries discharge the controller capacitors as follows Turn the key switch to ON and place the Forward Reverse switch in the REVERSE position Slowly depress the accelerator pedal and keep it depressed until the reverse warning buzzer can no longer be heard When the buzzer stops sounding the controller capacitors are discharged 2002 DS Golf Car Electric Vehicle Owner s Manual Page 9 Vehicle Feature Identification DS ELECTRIC VEHICLE DRIVER PASSENGER WARNING DECAL N 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 alco
49. he vehicle is placed on charge visually inspect the fuse link See following WARNING A WARNING If 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 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 residential 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 avail
50. he vehicle Be sure the AC cord is properly wound up on the reel before driving the vehicle e Study all general information and WARNING CAUTION and NOTE statements in the Battery Charger section on page 28 Information pertaining specifically to the 36 volt charger does not apply to the onboard charger ARM REST Failure to follow these instructions can cause severe injury or death Remain seated with entire body inside vehicle and hold on to seat handle or handrail at all times No more than two persons per seat PASSENGER Do not leave children unattended on WARNING DECAL vehicle at anytime ON REAR HANDRAIL EROALE CUER T K K FACING SEAT vehicle CCI 1017057 01 FOOT REST Figure 17 Fairway Villager Page 34 2002 DS Golf Car Electric Vehicle Owner s Manual VEHICLE SPECIFICATIONS Vehicle Specifications SPECIFICATIONS POWERDRIVE SYSTEM 48 IQ SYSTEM 36 VOLT 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 Drive motor Direct drive 36 volts DC series wound 2 97 hp Transaxle Double reduction helical gear with 12 28 1 direct drive axle Electrical system 48 volts DC reduced speed reverse Electrical system 36 volts DC reduced speed reverse Batteries High capacity deep cycle Trojan PowerDrive 8 volt 117 min capacity Batteries High capacity deep cycl
51. hol or drugs Use brakes to reduce speed when coasting downhill Never stand in front of or behind vehicle 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 firmly depress park brake until it locks Place forward and reverse switch in neutral position Turn key OFF and remove key when not in use CCI 1016216 01 OPERATING INSTRUCTIONS DECAL CCI 1019606 01 KEY SWITCH BATTERY 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 depress
52. icle 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 vehicle 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 23 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 Warning decals Check to ensure that all warning and operation decals are in place See pages 10 and 11 Tires Check for proper tire pressure on your new vehicle See Vehicle Specifications on page 35 Visually inspect tires for wear damage and proper inflation on a daily basis Batteries Check electrolyte to ensure that it is at its proper level Figure 12 Page 27 Check battery posts Wires should be tight and free of corrosion Charge batteries fully before first use of vehicle Charger cord plug and receptacle Visually inspect for cracks loose connectio
53. ing 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 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 2002 DS Golf Car Electric Vehicle Owner s Manual Page 15 Controls and Indicators 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
54. iodic 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 possibility 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 Hot Do not attempt to service hot motor or resistors Attempting to do so could cause severe burns PERIODIC SERVICE SCHEDULE A WARNING Service repairs and adjustments must be made per instructions in the maintenance and service manual 2002 DS Golf Car Electric Vehicle Owner s Manual Page 23 Periodic Service Schedule 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 service 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 REGULAR INTERVAL SERVICE Daily service by owner
55. l speed is reached When the accelerator is released power will be cut off and the motor will stop running IQ System vehicles only See pedal up and pedal down motor braking on page 18 Page 14 2002 DS Golf Car Electric Vehicle Owner s Manual Controls and Indicators BRAKE PEDAL The brake pedal is the large pedal on the left with the word STOP molded into it Figure 7 Page 14 To slow or stop the vehicle depress the brake pedal with your foot Figure 8 Page 15 Figure 8 Brake Pedal 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 Page 15 To set the park brake depress the brake pedal firmly and tilt the park brake portion of the pedal forward with your foot Figure 9 Page 15 See following WARNING A WARNING The park brake will release automatically when either the accelerator or brake pedal is depressed The park brake has multiple locking positions and should be firmly pressed and locked to prevent the vehicle from rolling BATTERY WARNING LIGHT PowerDrive System 48 and IQ System Electric Vehicles Only PowerDrive System 48 and 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 indi cates a charg
56. lectric cord having an equipment grounding conductor and a grounding type plug The plug must be grounded to an appropriate dedicated receptacle that is properly installed and grounded in accordance with the National Electrical Code ANSI NFPA 70 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 a three conductor No 12 AWG heavy duty cord with a ground conductor in good electrical condition must be used Keep it as short as possible no more than 12 feet 3 7 meters Locate all cords so that they will not be stepped on tripped over or otherwise subject to damage or stress Ventilation fans should be located at the highest point in the room and must be capable of changing the total volume of air in the room five times per hour Consult a local HVAC engineer 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 13 Page 31 Do not pull on the DC cord Figure 14 Page 31 Do not twist rock or bend the plug disconnect the charger plug from the vehicle receptacle grasp the plug by the handle and pull the plu
57. lot in the receptacle and push straight in slowly The PowerDrive Charger interacts with an onboard computer on PowerDrive System 48 and IQ System vehi cles 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 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 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 or if the batteries seem weak contact your local Club Car distributor dealer Page 30 2002 DS Golf Car Electric
58. m 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 replacement 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 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 m
59. m h 14 ft 427 cm Standard seating capacity 2 2 2 Fairway Villager seating capacity 4 Specifications continued on next page 2002 DS Golf Car Electric Vehicle Owner s Manual Page 35 SPECIFICATIONS IQ SYSTEM 36 VOLT LIQUID CAPACITIES Transaxle 22 oz 67 liters TIRE PRESSURE Front and rear 18 20 psi 1 24 1 38 Bars CLUB CAR LIMITED LIFETIME WARRANTY FOR 2002 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 2002 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 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 own
60. ncluding those that affect the weight distribution stability or speed of the golf car can cause serious personal injury or death 2002 DS Golf Car Electric Vehicle Owner s Manual Page 3 Page 4 2002 DS Golf Car Electric Vehicle Owner s Manual FOREWORD Thank you for choosing Club Car the golf car most widely recognized as the industry leader in vehicle effi ciency and long lasting value You have chosen the finest golf car on the market Please protect your invest ment and ensure that your Club Car provides years of reliable superior performance by reading and following the maintenance instructions in this manual Your comfort and safety are important to us as well so we urge you to read and follow the step by step oper ating instructions and safety precautions 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 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 golf car needs repairs or service we recommend that your local authorized Club Car rep resentative 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
61. nent 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 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 then 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 CAR OR COMPO
62. ner s Manual Towing TOWING A WARNING Never tow the vehicle on public streets or highways Use only approved Club Car tow bars Turn the key switch to OFF and place the Forward Reverse handle in NEUTRAL 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 IQ System vehicles only Place the Tow Run switch in TOW position otherwise the vehicle will not roll while being towed All vehicles are equipped with both front and rear tow bar attaching points 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
63. nion 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 warranted 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 d
64. ns and frayed wiring See Plug and Receptacle on page 31 Wiper switch for V Glide 36 volt vehicles 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 in a fire property damage personal injury or death 2002 DS Golf Car Electric Vehicle Owner s Manual Page 17 Pre Operation and Daily Safety Checklist 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 problems should be corrected by a Club Car distributor dealer or a trained technician All Vehicles Forward Reverse switch Check for proper operation See Controls and Indicators on page 13 Brakes Be sure the brakes function properly When brake pedal is fully depressed under moderate pressure 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 depressed to the floor under any
65. o be used by persons with training and experience with batteries and only 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 THREE YEAR WARRANTY FOR 2002 36 VOLT BATTERY CHARGERS CLUB CAR INC CLUB hereby warrants to the original retail purchaser that its new Ultra Power II or Accu Power Charger purchased from CLUB CAR or an authorized distributor or dealer will be free from defects in material and workmanshi
66. 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 use of any battery a prudent owner will read and study the charger owner s manual the electric vehicle owners manual the operator instructions and the battery warning labels and will exercise due c
67. ond 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 used by persons with knowledge of the chargers and proper charging practices and only 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 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 2002 DS Golf Car Electric Vehicle Owner s Manual Page 41
68. p under normal use and service for a period of three 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 three 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 This charger is intended to be used by persons with knowledge of the charger and proper charging practices and only on CLUB CAR 36 Volt vehicles Any other use renders the Limited Warranties
69. rants to the original retail purchaser that the new Trojan T 105 6 Volt Battery installed in its new electric vehicle 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 three years or 600 rounds from the date of purchase whichever first occurs subject to the terms and conditions contained herein This limited warranty only covers defects in material and workmanship for a period of three years or 600 golf car rounds from date of purchase The terms of this three year or 600 round limited warranty shall be as follows Free replacement with respect to parts and labor within three years or 600 rounds whichever first occurs from 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 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 wreckag
70. 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 PowerDrive Owner s Manual This indicates an abnormal charge cycle The charger 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 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 which provides information on the condition of the vehicle and batteries TOW RUN SWITCH IQ System Vehicles Only A WARNING To avoid possible battery explosion the Tow Run switch must be in the TOW position before disconnecting or connecting battery wires When the Tow Run switch is in the TOW position all motor braking functions including zero speed detect are disabled O
71. s manual may be photocopied reproduced or translated to another language without the written consent of Club Car Inc The information contained in this document is subject to change without notice Club Car reserves the right to make design changes to 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 2001 Club Car Inc Club Car ArmorFlex and PowerDrive are registered trademarks of Club Car Inc This manual effective July 23 2001 2002 DS Golf Car Electric Vehicle Owner s Manual Page 1 CLUB CAR LIMITED THREE YEAR WARRANTY FOR 2002 INDIVIDUAL GOLF CARS 1 WARRANTY CLUB CAR INC CLUB hereby warrants to the Original Retail Purchaser that its new 2002 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 pi
72. 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 Never 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 in NEUTRAL the key switch OFF and the park brake firmly depressed 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 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 2002 DS Golf Car Electric Vehicle Owner s Manual Page 21 Storage S
73. t 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 depressing the brake pedal If the vehicle does not slow down at the normal rate continue to depress the brake pedal until the brakes dry out and normal performance returns A CAUTION When stopped on hill use the brake pedal to hold your position Do not use the accelerator pedal To stop the vehicle release the accelerator pedal and depress the brake pedal with your right foot until the vehicle comes to a complete stop PARKING AND LEAVING THE VEHICLE 1 After stopping the vehicle firmly depress the park brake pedal until it locks This will prevent the vehicle from rolling Turn the key switch to OFF and place the Forward Reverse handle in the NEUTRAL position Remove the key when the vehicle is not in use IQ System 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 rolling at more than 1 or 2 mph 1 5 or 3 km h unless the accelerator is depressed This prevents the possibility of a parked vehicle with the park brake disengaged rolling away too fast to be overtaken on foot See DS IQ System Vehicles on page 18 Page 20 2002 DS Golf Car Electric Vehicle Ow
74. tended on the rear seat while vehicle is moving No more than four persons should be on the vehicle at one time MAINTENANCE Refer to pages 23 through 25 for Periodic Service and Lubrication Schedules See following NOTE NOTE If the vehicle is constantly hauling heavy loads the preventive maintenance procedures should be performed more often than recommended in the service and lubrication schedules 2002 DS Golf Car Electric Vehicle Owner s Manual Page 33 Fairway Villager ACCESSORY ONBOARD CHARGER An onboard charger which is installed under the rear seat is available for the Fairway Villager electric vehicle The charger should be plugged into a properly grounded outlet The AC line to which the charger is to be con nected must be capable of supplying 15 amperes minimum to the charger The rear seat should be propped open while charging the batteries See the owner s manual supplied with the battery charger for specific oper ating instructions before using the charger See following WARNING and CAUTION A WARNING Each charger should its own dedicated 15 20 ampere separately protected circuit breaker or fuse single phase branch circuit in accordance with all applicable electrical codes for the location A CAUTION Before charging batteries turn off all accessories on all vehicles If using an onboard charger be sure the AC plug is unplugged from the outlet before attempting to drive t
75. teries 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 Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes External Flush with water for 15 minutes 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 Wear a full face shield and rubber gloves when working with batteries Use insulated tools when working around batteries or electrical connections Use extreme caution to avoid shorting of components or wiring A 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 DS V Glide 36 Volt electric vehicles are 6 volts each The batteries PowerDrive System 48 and IQ System electric vehicles 8 volts each Both the 6 and 8 volt batteries are deep cycle batteries specially built for electric vehicle application Auto motive batteries should never be used Page 26 2002 DS Golf Car Electric Vehicle Owner s Manual Batteries
76. ury to an unsuspecting passenger and or damage to the vehicle To avoid being struck do not stand in front of or behind the vehicle Operate the vehicle from the driver seat only To prevent falls from the vehicle remain seated in a moving vehicle and hold on to seat handles or handrails at all times Driver should keep both hands on the steering wheel when the vehicle is in motion To prevent the possibility of serious injury keep your entire body inside the vehicle Do not leave children unattended on vehicle To prevent overturning the vehicle drive slowly straight up and down slopes Avoid driving the vehicle on slopes exceeding 20 incline To avoid possible injury to an inattentive passenger and or damage to the vehicle avoid sudden starts sudden stops and abrupt turns To 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 th
77. ust 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 36 Volt Accu Power Charger Do not disconnect the DC output plug from the vehicle receptacle when the charger is on The resulting arcing and burning could damage the plug and receptacle and could cause batteries to explode If the charger must be stopped disconnect the AC supply plug from the wall outlet before disconnecting the charger DC cord from the vehicle receptacle 48 Volt PowerDrive Charger 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 2002 DS Golf Car Electric Vehicle Owner s Manual Battery Charger A CAUTION Do not block or cover slots and openings in the back and bottom of charger cabinet They provide ventilation
78. ved 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 A DANGER 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 OF VEHICLE FRONT e REMOVE NEGATIVE OF VEHICLE gt lt gt CABLE FIRST DISCONNECT THESE DISCONNECT THESE BATTERY CABLES BEFORE BATTERY CABLES BEFORE WORKING ON VEHICLE WORKING ON VEHICLE Figure 1 V Glide 36 Volt Vehicle Figure 2 PowerDrive System 48 and IQ System Vehicles Page 8 2002 DS Golf Car Electric Vehicle Owner s Manual General Warnings 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 page 10 Other specific safety statements appear throughout this manual and on the vehicle A DANGER Battery vapors Flammable Explosive Do not smoke Keep sparks and flames away from vehicle and service area Service only in well ventilated areas A Club Car vehicle will not provide protection from lightning flying objects or other storm r

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