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Manual Number 1019682-01 Print Code 0897B1297A

1. FIGURE 18 25 PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE ELECTRIC VEHICLE ace uenem REGULAR INTERVAL SERVICE PLACE Quarterly by Owner or Trained Technician Front Suspension 5 fittings Annually by Trained Check fill transaxle to plug level 22 oz 67 liter SAE 30 WT API Class SE SF or SG Oil or higher Technician Only Every 200 rounds or Repack as necessary See Figure 19 below ELECTRIC VEHICLE LUBRICATION POINTS E jm 4 M lei N m e 3 58 mml 2 60 FIGURE 19 26 VEHICLE CAPACITIES CAPACITIES GASOLINE VEHICLES ELECTRIC VEHICLES 32 oz 98 liters ee ENGINE OIL GASOLINE VEHICLE Even though the oil warning light on the dash should warn you if your oil is getting low engine oil level should be checked monthly See Figure 20 See NOTE below TO CHECK ENGINE OIL THE ENGINE MUST BE IN LEVEL POSITION REMOVE THE OIL LEVEL DIPSTICK FROM THE OIL FILLER TUBE AND WIPE OIL FROM IT WITH A CLEAN DRY CLOTH OR PAPER TOWEL CHECK OIL BY INSERTING THE DIPSTICK FULLY INTO THE OIL FILLER TUBE AND IMMEDIATELY REMOVING IT AGAIN IF THE OIL LEVEL IS AT OR BELOW THE ADD MARK ON THE DIPSTICK
2. TO CHARGE BATTERIES WARNING e BE SURE ALL WIRE CONNECTIONS AT THE RECEPTACLE AND THE FUSE LINK ARE CLEAN AND TIGHT e 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 SEE FIGURE 24 PAGE 34 e DO NOT PULL ON THE DC CORD SEE FIGURE 25 PAGE 34 DO NOT TWIST ROCK OR BEND THE PLUG TO DISCONNECT THE CHARGER PLUG FROM THE VEHICLE RECEPTACLE GRASP THE PLUG BY THE HANDLE AND PULL THE PLUG STRAIGHT OUT OF THE RECEPTA CLE 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 33 To Charge Batteries Continued WARNING 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 O 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 PERSONA
3. Club Car Owner s Manual 1998 DS Golf Car Manual Number 1019682 01 Print Code 0897B1297A A WARNING e THE ENGINE EXHAUST FROM THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM NOTICE The Club Car Limited Warranty for owners of single golf cars appears on the pages following this notice and the Limited Lifetime Fleet Warranty appears on the last pages of this manual No other warranties express or implied are contained herein Your authorized representative checked this vehicle before it was delivered to you and will provide a completed warranty registration card to you 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 Z130 Safety and Performance Requirements for Golf Cars This standard which promotes safety in the design application and operation of golf cars defines a golf car as a vehicle used to convey a person or persons and equipment to play the game of golf in an area designated as a golf course Throughout this manual the words golf car and vehi cle are used interchangeably This manual contains proprietary information that is protected by copyright All rights are reserved No part of this manual may be photocopi
4. spark plugs lubri cants 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 on board computer and solid state controller are covered by separate CLUB CAR warranties Tires are warranted by their manufacturer 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 service are also excluded from this warranty 3 VOIDING OF WARRANT Y 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 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 T
5. 36 volts DC reduced speed reverse Batteries High capacity deep cycle Trojan PowerDrive 8 volt 117 min capacity Batteries High capacity deep cycle Trojan 6 volt 115 min capacity STEERING SUSPENSION BRAKES Steering Self adjusting rack and pinion Suspension Front and rear tapered mono leaf springs with dual hydrau lic 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 Protective coat over molded in color Tires 18 00 x 8 50 8 00 tubeless 4 ply rated SEATING CAPACITY FUEL CAPACITY Standard Seating Capacity 2 persons Fairway Villager Seating Capacity 4 persons Fuel Tank 7 gallons 26 5 liters unleaded gasoline only DIMENSIONS WEIGHT 91 1 2 91 1 2 91 1 2 91 1 2 232 cm 232 cm 232 cm 232 cm 47 1 4 47 1 4 47 1 4 120 cm 120 cm 120 cm Overall Length Overall Width 47 1 id 120 cm Specifications Continued on Next Page iN 0 SPECIFICATIONS Overall Height At Steering Wheel Wheelbase Ground Clearance Front Wheel Tread Rear Wheel Tread Weight Standard electric vehicle without batteries Weight Fairway Villager electric vehicle without batteries Weight Standard gasoline powered vehicle dry without battery Weight Fairway Villager gasoline p
6. 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 RECONDI TIONED PARTS OR COMPONENTS ALL PARTS AND COMPONENTS REPLACED UNDER WARRANTY SHALL BECOME THE PROPERTY OF CLUB CAR 5 HOW TO MAKE AWARRANTY 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 WAR RANTY ADMINISTRATION CLUB CAR INC P O Box 204658 4152 Washington Road Augusta Georgia 30907 4658 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 pur pose 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 t
7. RESULT IN DECREASED VEHICLE PERFORMANCE OR SEVERE PERSONAL INJURY ANY MODIFICATION OR CHANGE TO THE VEHICLE WHICH AFFECTS THE STABILITY OR HANDLING OF THE VEHICLE OR INCREASES MAXIMUM VEHICLE SPEED BEYOND FACTORY SPECIFICATIONS COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH A or DISCONNECT HERE DISCONNECT HERE DS POWERDRIVE SYSTEM 48 AND V GLIDE 36 VOLT ELECTRIC VEHICLE POWERDRIVE PLUS WITH MOTOR BRAKING FIGURE 1 FIGURE 2 DS GASOLINE VEHICLE FEATURE IDENTIFICATION DRIVER PASSENGER OPERATING INSTRUCTIONS WARNING DECAL Read Owner s Manual and safety warnings located on dash panel prior to driving AN WARNING KEY SWITCH Study and understand controls Make sure wheels are turned in desired direction READ AND FOLLOW THESE WARNINGS AND THE OPERATING VAHP n DE INSTRUCTIONS BEFORE USING VEHICLE FAILURE TO DO SO CAN Turn key to ON position and be sure nothing is in your path iiis nid x ATTE While vehicle is stopped select direction by placing Operate from driver side by authorized persons only 3 E DC and only in designated areas not on public roads shift lever or switch in desired position DO start vehicle until all occupants two 2 per seat F Forward N Neutral R Reverse
8. 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 sys tems 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 ACCESSORIES AND OPTIONS The vehicle is available with a complete line of optional equipment items and accessories that are available from Club Car and our dealers distributors Care should be taken that these accessories and options are properly installed by trained technicians and that they are used in the manner for which they were designed OPTIONAL EQUIPMENT ALL DS GOLF CARS Accent Striping Rear View Mirror Differential Guard Custom Club Decals Glove Box Hour Meter Number Decals Performance Grade Tires Information Holder Canopy Top Premium Tread Tires Beverage Cooler Rear Rain Curtain e Extra Traction Tires e Extra Two bag Attachment Weather proof Enclosure White Wall Tires Sand Bunker Rake Kit Tinted Split Windshield Chrome Hub Wheel Covers Golf Club and Ball Cleaner Tinted Snap on Windshield Chrome Sport Wheel Covers Adjustable Seat Back Trailer Hitch Optional Equipment Continued on Next Page 36 OPTIONAL EQUIPMENT ALL DS GOLF CARS Ashtray On
9. WILL DROP TO 0 CHARGING WILL RESUME IN A FEW MOMENTS AMMETER WILL RETURN TO CURRENT STATE OF CHARGE RECYCLE OR DISPOSE OF DISCARDED BATTERIES IN ACCORDANCE WITH LOCAL STATE AND FEDERAL REGULATIONS 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 electric cord having an equipment grounding conductor and a grounding type plug and is for use on a nominal 115 Volt 60 Hertz circuit unless otherwise noted on the charger 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 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 twelve feet 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
10. crankshaft several times and then re install the spark plug 4 WARNING e TURN THE KEY SWITCH OFF REMOVE THE KEY AND LEAVE THE FORWARD AND REVERSE SWITCH IN THE NEUTRAL POSITION DURING STORAGE THIS IS TO PREVENT UNINTEN TIONAL STARTING OF THE VEHICLE 4 Increase tire pressure to 20 psi 96 kPa 5 Grease front suspension and do all quarterly periodic lubrication See Periodic Lubrication Sched ule Page 25 6 Thoroughly clean front body rear body seats engine compartment and underside of vehicle 7 Do not latch the park brake Chock wheels to prevent the vehicle from rolling TO RETURN THE STORED VEHICLE TO SERVICE 1 Restore fuel system to operation 1 1 Remove plug from the fuel tank vent nipple and connect the vent line to the nipple Open fuel shut off valve 1 2 Place the Forward and Reverse Lever in the NEUTRAL position and the neutral lock out cam in the SERVICE position Crank the engine until fuel is pumped into the carburetor and fuel lines and the engine starts Turn engine off and return neutral lock out cam to the OPERATE position 2 tire pressure to 12 14 psi 57 67 kPa Perform the Pre Operation Checklist See pages 6 and 7 DUE TO THE OIL ADDED TO THE ENGINE IN PREPARATION FOR STORAGE THE ENGINE MAY SMOKE EXCESSIVELY FOR A SHORT WHILE WHEN RUNNING IT FOR THE FIRST TIME AFTER STORAGE STORAGE ELECTRIC VEHICLE WARNING e TURN THE KEY SWITCH OFF REMOVE THE
11. manual and on the operation and warning decals affixed to the vehicle the words golf car and vehicle are used interchangeably Golf car 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 removed or cannot be easily read they should be replaced immediately to avoid possible personal injury property damage or death Contact your CLUB CAR distributor dealer DANGER DANGER INDICATES AN IMMEDIATE HAZARD WHICH WILL RESULT IN SEVERE PER SONAL INJURY OR DEATH WARNING A WARNING INDICATES AN IMMEDIATE HAZARD WHICH COULD RESULT IN SEVERE PER SONAL INJURY OR DEATH CAUTION A CAUTION INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN PROD UCT OR PROPERTY DAMAGE OR MINOR PERSONAL INJURY e A NOTE PROVIDES KEY INFORMATION TO MAKE PROCEDURES MORE EASILY UNDER STOOD GENERAL WARNINGS The safety procedures listed must be followed whenever the vehicle is being operated repaired or serviced Other specific warnings appear throughout this manual and on the vehicle DANGER GASOLINE VAPORS FLAMMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE SERVICE ONLY IN WELL VENTILATED AREAS General Warnings Continued DANGER DO NOT OPERATE GASOLINE VEHICLE IN ENCLOSED AREA WITHOUT PROPER VENTILA TION ENGI
12. the PowerDrive Charger neither vehicles made by other manufacturers nor other Club Car models are 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 PLUG AND RECEPTACLE If the charger plug becomes difficult to insert or disconnect the receptacle contacts should be 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 NOTE IF THE WARNING TAG HAS BEEN DAMAGED OR REMOVED FROM THE DC CORD HAVE IT REPLACED IMMEDIATELY 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 26 V Glide 36 volt vehicle or Figure 27 PowerDrive System 48 vehicle If the portable charger does not come on when the vehicle is placed on charge visually inspect the fuse link WARNING e IF THE RECEPTACLE FUSE LINK IS BLOWN DETERMINE THE SOURCE OF THE ELECTRICAL
13. AND PLACE THE FORWARD AND REVERSE SWITCH IN NEU TRAL BEFORE TOWING THE VEHICLE EXTREME CAUTION SHOULD BE USED WHEN TOWING ANY VEHICLE DO NOT EXCEED 5 MPH 8 KPH TOWING SPEED DO NOT ALLOW PEOPLE IN THE VEHICLES BEING TOWED AVOID SUDDEN STARTS SUDDEN STOPS AND TIGHT TURNS WHEN TOWING 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 TRAC TOR OR FULL SIZED TRUCK PROPERLY FITTED WITH A TOW HITCH HEIGHT OF 11 INCHES SHOULD BE USED ONLY HEAVY DUTY TOW BARS SHOULD BE USED FOR MULTI VEHICLE TOWING NEVER TOW MORE THAN FIVE VEHICLES AT ONE TIME POWERDRIVE PLUS VEHICLE WITH MOTOR BRAKING ONLY PLACE THE TOW RUN SWITCH IN TOW POSITION THE VEHICLE WILL NOT ROLL OTHERWISE 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 on board tow bar are avail able for multi vehicle towing Observe all of the above warnings when towing TRANSPORTING ON A TRAILER If your vehicle must be transported over long distances or on public highways it should be done on an approved trailer and all the following WARNINGS below and at the top page 16 should be heeded WARNING FOR USE ON PUBLIC ROADS THE TRAILER MUST MEET ALL FEDERAL STATE AND LOCAL REQUIREMENTS SUCH AS TAILLIGHTS BRAKE LIGHTS ETC ALWAYS U
14. ARKS expose YS o 9 FLAMES BLINDNESS OR MEDICAL A WARNING sta ere B2 6 AV GASES SMOKING SEVERE BURNS k HELP RESISTOR WARNING DECAL ON BODY UNDER SEAT ON V GLIDE 36 VOLT VEHICLE FORWARD REVERSE ON BODY UNDER ACCESS PANEL HANDLE ON POWERDRIVE PLUS 48 VOLT VEHICLE SS POWERDRIVE SYSTEM 48 AND 36 VOLT VEHICLES SS ae CHARGER TOW SWITCH WARNING DECAL RECEPTACLE FORWARD REVERSE POWERDRIVE PLUS VEHICLES ONLY SWITCH ON TOW SWITCH BRACKET UNDER SEAT POWERDRIVE PLUS VEHICLES ONLY A WARNING TOW PLACE TOW SWITCH IN TOW POSITION BEFORE DO NOT OPERATE VEHICLE NOTICE WITHOUT COVER IN PLACE DO NOT DIRECT WATER STREAM AT THIS SWITCH 1016109 01 eTOWING TO VEHICLE OR BATTERY EXPLOSION ENG b POTENTIOMETER CAUTION DECAL DISCONNECTING BATTERIES ON WIPER SWITCH COVER INSIDE BATTERY COMPARTMENT FAILURE TO DO SO COULD RESULT IN DAMAGE GENERAL INFORMATION There are four DS Golf Car models the DS gasoline powered vehicle the DS V Glide 36 volt electric pow ered vehicle the DS PowerDrive System 48 48 volt electric vehicle and the DS PowerDrive Plus 48 volt electric vehicle with motor braking 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 vehicl
15. Buzzer will sound maximum are seated e Remain seated with entire body inside vehicle and hold Vehicle will start moving when accelerator pedal is depressed on to seat handle or handrail at all Slowly depress accelerator pedal to increase speed Park brake will slowly in Owm Stopes release when accelerator pedal is depressed DO NOT operate while under the influence of alcohol or To stop release accelerator pedal and depress brake pedal rugs TN on DO NOT leave children unattended on vehicle at any time After stopping firmly depress park brake until it locks CCI 1019606 01 Place forward and reverse switch in neutral position Turn key OFF and remove key when not in use 1016216 01 OPERATING INSTRUCTIONS DECAL SERIAL NUMBER ACCELERATOR PEDAL BRAKE PEDAL WW FRAME GROUND AND LIGHT GOVERNOR WARNING DECAL ON VEHICLE FRAME NEAR BATTERY PARK BRAKE PEDAL N WARNING N WARNING GASOLINE WARNING DECAL MOVING PARTS AND ON VEHICLE FRAME NEAR FUEL TANK HOT MANIFOLD DECAL ON STARTER GENERATOR AND ENGINE A WARNING GASOLINE EXPLOSION FIRE N WARNING CAN CAUSE SEVERE INJURY OR DEATH NO SMOKING SPARKS OR OPEN FLAME CAN CAUSE SEVERE INJURY STOP ENGINE ALLOW TO COOL BEFORE Moving parts REFUELING 1015476 01 4 HOT manifold amp muffler OIL FILL KEEP CLEAR cci 1019605 01 FORWARD REVER
16. E PROPERTY DAM AGE SEVERE PERSONAL INJURY OR DEATH e SERVICE REPAIRS AND ADJUSTMENTS MUST BE MADE PER INSTRUCTIONS IN THE 1998 DS GOLF CAR MAINTENANCE amp SERVICE MAUAL PERIODIC SERVICE SCHEDULE ELECTRIC VEHICLE REGULAR INTERVAL SERVICE Check for proper operation See Performance Inspec Daily Service by Owner Accelerator pedal rod tion Page 6 Adjust as necessary Periodic Service Schedule Continued on Next Page 22 PERIODIC SERVICE SCHEDULE ELECTRIC VEHICLE REGULAR INTERVAL SERVICE Multi Step Potentiometer 48 volt or V Check for proper operation See DS Maintenance and Glide Wiper Switch 36 volt Service Manual Batteries Charge batteries Check for proper operation See Performance Inspec Brake System tion Page 6 Adjust as necessary Charger and Receptacle Check for damage and snug fit Daily Service by Owner Check for proper operation See Performance Inspec Park Brake tion Page 6 Adjust as necessary Continued Check for proper operation See Performance Inspec Reverse Warning Buzzer tion Page 6 Steering and linkages Check for proper operation Tires Check for wear and damage Make sure all are in place See Electric Vehicle Fea Vehicle warning decals ture Identification Page 4 Clean terminals and wash dirt from case check elec Batteries trolyte level See Page 29 Dispose of waste water properly Electrical wiring and connections C
17. E 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 PULL ING THE DC CORD OUT QUICKLY COULD CAUSE ARCING AND BURNING THAT COULD DAM AGE THE PLUG AND RECEPTACLE AND COULD CAUSE BATTERIES TO EXPLODE CAUTION DO NOT BLOCK OR COVER SLOTS AND OPENINGS IN THE BACK AND BOTTOM OF CHARGER CABINET THEY PROVIDE VENTILATION 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 VEHI CLE RECEPTACLE WHILE UNATTENDED FOR MORE THAN TWO DAYS IN A ROW SEVERE OVERHEATING AND DAMAGE TO THE BATTERIES MAY RESULT IF THE CHARGER DOES NOT TURN OFF 32 CAUTION e INSTALL SURGE ARRESTORS ON INCOMING 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 BECAUSE THE POWERDRIVE CHARGER HAS A STORAGE CHARGE FEATURE THAT AUTO MATICALLY CHECKS AND RECHARGES THE BATTERIES AS NECESSARY EVERY 15 DAYS IT CAN REMAIN PLUGGED TO A POWERDRIVE VEHICLE THROUGHOUT THE STORAGE PERIOD SHORTLY AFTER CHARGING HAS BEGUN THE POWERDRIVE CHARGER WILL SHUT OFF IN ORDER TO RUN A SELF DIAGNOSTIC PROGRAM AMMETER
18. EATH e ALL SERVICE REPAIRS AND ADJUSTMENTS MUST BE MADE PER INSTRUCTIONS IN THE 1998 DS GOLF CAR MAINTENANCE AND SERVICE MANUAL 24 PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE GASOLINE VEHICLE REGULAR INTERVAL SERVICE PLACE RECOMMENDED LUBRICANT Brake shaft bearings Dry Moly Lube Club Car Part No 1012151 or Trained Technician Accelerator push rod pivots and shifter cable pivots Brake Linkage and Pivots Dry Moly Lube Club Car Part No 1012151 Quarterly by Owner 7 1 3 4 Dry Moly Lube Club Car Part No 1012151 4 Chassis Lube EP NLGI 2 Check fill unitized transaxle to plug 5 27 oz 8 liter 80 90 WT API Class GL 5 or ned d A ua level l 80 90 WT AGMA Class EP Gear Lube 7 Front Suspension 5 fittings Inspect front wheel bearings Repack as necessary Technician Only Chassis Lube EP NLGI 2 Every 200 rounds or 100 hours of operation First Change 100 Hours Change engine oil and oil filter 32 oz 97 liter without filter 38 oz 1 16 Additional Change Every Dispose of used oil properly liters with filter 10W30 above 32 F 0 C 400 Rounds or Every 200 or SAE 5W20 below 32 F 0 C API Class Hours of Operation SE SF or SG Oil or higher or Annually Whichever Comes First See Figure 18 below DS GASOLINE VEHICLE LUBRICATION POINTS
19. EL TANK AVOID SPILLING FUEL 3 Replace fuel cap on tank being sure cap is tightened securely 4 Replace seat bottom BATTERY GASOLINE VEHICLE The battery in the DS Gasoline Vehicle is a 12 volt low maintenance battery that requires infrequent water ing Figure 22 DANGER BATTERY EXPLOSIVE GASES DO NOT SMOKE KEEP SPARKS AND FLAMES A SAFE DISTANCE FROM THE VEHICLE TOOLS WIRES AND METAL OBJECTS CAN CAUSE SPARKS WHEN SHORTED ACROSS A BATTERY FOLLOW ALL INSTRUCTIONS CAREFULLY WHEN WORKING WITH BATTERIES CHARGE BATTERY IN A WELL VENTILATED AREA ONLY 28 DANGER 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 WARNING e DO NOT JUMP START THE VEHICLE TO CHARGE THE BATTERY USE AN AUTOMOTIVE TYPE 12 VOLT CHARGER RATED AT 10 AMPS OR LESS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN SERVICING THE VEHICLE e ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL CONNECTIONS Any corrosion around the positive or negative terminals should be washed off with a solution of baking soda and water 1 cup per gallon of water R
20. G 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 See Figure 4 Page 8 It has two positions OFF and ON which are clearly labeled NOTE e THE KEY CAN BE REMOVED WHEN THE KEY SWITCH IS IN THE OFF POSITION ONLY FIGURE 4 FIGURE 5 FORWARD REVERSE CONTROL DS Gasoline DS V Glide Electric and DS PowerDrive System 48 The forward reverse shift handle is located on the seat support panel below and to the right of the driver s right knee See Figure 5 The lever has three distinct positions F forward N neutral and R reverse Rotate the lever towards the driver F forward to run the vehicle in the forward direction or towards the pas senger R reverse to run the vehicle in reverse When the lever is in the straight up or N neutral position the vehicle will not run The engine on the DS gasoline vehicle will stop if it is shifted to this position while running DS electric and gasoline vehicles operate at reduced speed in reverse When the vehicle is in reverse the reverse warning buzzer will sound DS PowerDrive Plus With Motor Braking The forward reverse shift switch is located in the same place as the forward reverse shift lever on all other DS models on the seat support panel below and to the right of the driver s right knee The Forward F and Reverse R po
21. GAUGE ADD OIL UNTIL THE LEVEL IS BETWEEN ADD AND FULL SAFE LEVEL DO NOT OVERFILL REINSERT DIPSTICK INTO THE OIL FILLER TUBE PROPERLY RECYCLE OR DISPOSE OF USED OIL IN ACCORDANCE WITH LOCAL STATE AND FEDERAL REGULATIONS FIGURE 20 FIGURE 21 27 FUELING INSTRUCTIONS GASOLINE VEHICLE DANGER e GASOLINE FLAMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE VEHICLE FUELING OR SERVICE AREA SERVICE OR REPAIR IN WELL VENTILATED AREA ONLY NEVER ATTEMPT TO POUR GASOLINE INTO THE FUEL TANK WHEN THE ENGINE IS HOT OR WHILE IT IS RUNNING e TO AVOID ELECTRIC ARC CAUSED BY STATIC ELECTRICITY THE FUEL STORAGE PUMP ING DEVICE MUST BE GROUNDED IF THE PUMP IS NOT GROUNDED THE VEHICLE MUST BE GROUNDED TO THE PUMP BEFORE AND DURING THE FUELING OPERATION IF THE VEHICLE HAS AN ALL WEATHER ENCLOSURE INSTALLED THE GAS TANK MUST BE PROPERLY VENTED AS SHOWN FIGURE 21 e TO AVOID THE POSSIBILITY OF FIRE BE SURE TO CLEAN UP ANY SPILLED GASOLINE BEFORE OPERATING THE VEHICLE e WHENEVER POSSIBLE AVOID USING OXYGENATED FUELS AND FUELS THAT ARE BLENDED WITH ALCOHOL VEHICLES TO BE STORED FOR EXTENDED PERIODS SHOULD BE PREPARED FOR STORAGE AS INSTRUCTED ON PAGE 16 OF THIS MANUAL 1 Lift and remove seat bottom 2 The fuel tank is located on passenger side of vehicle Remove fuel cap and fill the fuel tank with fresh unleaded gasoline only CAUTION DO OVERFILL THE FU
22. HE MANNER SPECIFIED IN SUCH MANUALS 4 SOLE REMEDY CLUB CAR S ONLY LIABILITY UNDER THIS LIMITED WARRANTY OR IN ANY ACTION WHETHER BASED UPON WARRANTY CONTRACT NEGLIGENCE STRICT PRODUCT LIABILITY OR OTHER WISE IS LIMITED TO THE REPAIR OR REPLACEMENT AT CLUB CAR S OPTION OF A 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 FAC TORY RECONDITIONED VEHICLE OR COMPONENT THEREOF WHICH IS IDENTICAL OR REASON ABLY 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 RECONDI TIONED PARTS OR COMPONENTS ALL PARTS AND COMPONENTS REPLACED UNDER WARRANTY SHALL BECOME THE PROPERTY OF CLUB CAR 5 HOW TO MAKE AWARRANTY 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 WAR RANTY ADMINISTRATION CLUB CAR INC P O Box 204658 4152 Washington Road Augusta Georgia 30907 4658 6 DISCLAIMER THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESS OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABI
23. IGURE 3 PRE OPERATION CHECKLIST Your CLUB CAR has been thoroughly inspected and adjusted at the factory and also by your CLUB CAR distributor dealer However upon arrival of your new CLUB CAR s you should become familiar with its con trols and operation and carefully inspect each vehicle to be satisfied that it is in proper working condition before accepting delivery Use the following checklist as a guide to inspect your new vehicle and in conjunction with the Periodic Ser vice Schedules pages 20 through 24 Any problems should be corrected only by your CLUB CAR distribu tor dealer or a trained mechanic General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tight On the DS Gasoline vehicle check all hose clamps for tight fit as well as the starter belt for tightness Warning Decals Check to ensure that all warning and operation decals are in place See Pages 3 and 4 Tires Check for proper tire pressure See Vehicle Capacities Page 27 Batteries electric vehicles Check electrolyte to ensure that it is at its proper level See Figure 23 Page 29 Check battery posts Wires should be tight and free of corrosion Charge batteries fully before first use of vehicle Multi Step Potentiometer 48 volt electric vehicles and V Glide Wiper Switch 36 volt electric vehicles Be sure accelerator switch cover is properly secured prior to operating the vehicle Engine gasoli
24. ITCH OPERATING INSTRUCTIONS 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 BATTERY WARNING LIGHT SERIAL NUMBER ACCELERATOR PEDAL Maximum vehicle speed is limited during downhill operation NN with accelerator pedal depressed Vehicle will brake gently when accelerator pedal is released System is activated only when tow switch is the RUN Men tow switch must be in the TOW position PARK BRAKE PEDAL 1019599 01 MOTOR BRAKING DECAL POWERDRIVE PLUS VEHICLES ONLY DANGER DECAL ON BODY UNDER SEAT DANGER POISON o suLFuRic IMMEDIATELY WITH WATER SHIELD SP
25. KEY AND LEAVE THE FORWARD AND REVERSE SWITCH IN THE NEUTRAL POSITION DURING STORAGE THIS IS TO PREVENT UNINTEN TIONAL STARTING OF THE VEHICLE e POWERDRIVE PLUS VEHICLES WITH MOTOR BRAKING ONLY PLACE THE TOW RUN SWITCH IN THE TOW POSITION DO NOT ATTEMPT TO CHARGE FROZEN BATTERIES OR BATTERIES WITH BULGED CASES DISCARD THE BATTERY FROZEN BATTERIES CAN EXPLODE CAUTION BATTERIES IN LOW STATE OF CHARGE WILL FREEZE LOW TEMPERATURES 17 Storage Electric Vehicle Continued CAUTION WHEN WASHING THE VEHICLE DO NOT DIRECT WATER STREAM AT THE MULTI STEP POTENTIOMETER 48 VOLT VEHICLES OR V GLIDE SPEED SWITCH 86 VOLT VEHICLE FORWARD AND REVERSE SWITCH OR OTHER ELECTRICAL COMPONENT e IF BATTERY WIRE TERMINALS ARE DAMAGED CORRODED THEY SHOULD REPLACED OR CLEANED AS NECESSARY FAILURE TO DO SO MAY CAUSE THEM TO OVER HEAT DURING OPERATION e POWERDRIVE PLUS VEHICLES ONLY PLACE TOW RUN SWITCH IN THE TOW POSITION 1 Fully charge batteries See Batteries Electric Vehicle Page 30 2 Wash off any corrosion around the terminals with a solution of baking soda and water one cup per gal lon of water then rinse solution from the batteries do not allow this solution to enter the batteries Let the terminals dry and coat them with CLUB CAR battery terminal spray Part No 1014305 3 Store in a cool dry place This will prevent self discharge of the batteries 4 Adjust tire pressu
26. L INJURY OR DEATH e THE DC CHARGER CORD AND PLUG ARE WEAR ITEMS AND MUST BE REPLACED WHEN WORN OR DAMAGED WHEN TEMPERATURES FALL BELOW 65 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 FIGURE 24 FIGURE 25 Insert the charger DC plug into the vehicle receptacle The charger will turn on two to ten seconds later Fig ure 24 e When inserting the PowerDrive System 48 DC plug align the raised guide on the plug with the guide slot in the receptacle and push straight in slowly e The PowerDrive Charger interacts with an on board computer on the PowerDrive System 48 Golf Car The computer records the amount of energy consumed during vehicle use While the charger is plugged in the golf car 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 34 Once the lock out is actuated the charger turns on The on board computer then records the amount of energy being returned to the batteries When the optimum amount of energy needed to replenish the batteries is returned the charger will shut off The control circuit lock out remains activated until the charger plug is disconnected from the vehicle Because of these unique features only PowerDrive System 48 vehicles are compatible with
27. LITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WAR RANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REMEDY OF REPLACEMENT OR REPAIR OF THE DEFECTIVE GOLF CAR OR COMPONENT THEREOF IS THE EXCLUSIVE AND 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 DAM AGES 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 inci dental 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 ADMINISTRATION CLUB CAR INC P O Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 9 WARNING Any modification or alteration of any golf car beyond factory specifications includi
28. NE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POISON BATTERY VAPORS FLAMMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE SERVICE ONLY IN WELL VENTILATED AREAS A GOLF CAR WILL NOT PROVIDE PROTECTION FROM LIGHTNING FLYING OBJECTS OR OTHER STORM RELATED HAZARDS IF CAUGHT IN A STORM WHILE DRIVING A GOLF CAR EXIT THE VEHICLE AND SEEK SHELTER IN ACCORDANCE WITH APPLICABLE SAFETY GUIDELINES FOR YOUR LOCATION WARNING ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THE VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD FOLLOW THE PROCEDURES EXACTLY AS STATED IN THIS MANUAL AND OBEY ALL DANGERS WARNINGS AND CAUTIONS LISTED IN THIS MANUAL AS WELL AS THOSE AFFIXED TO THE VEHICLE ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN SERVICING THE VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES TURN THE KEY SWITCH TO OFF REMOVE THE KEY CHOCK THE WHEELS PLACE THE FOR WARD AND REVERSE SWITCH IN NEUTRAL AND DISCONNECT BATTERY IES PRIOR TO SERVICING THE VEHICLE ON GASOLINE VEHICLES DISCONNECT THE NEGATIVE BATTERY LEAD FIRST ON POWERDRIVE PLUS VEHICLES PLACE TOW SWITCH IN THE TOW POSITION BEFORE DISCONNECTING BATTERIES FOR ELECTRIC VEHICLE BATTERY DISCONNECT SEE FIGURES 1 AND 2 ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL CONNECTIONS IMPROPER USE OF THE VEHICLE OR FAILURE TO PROPERLY MAINTAIN IT COULD
29. OW POSITION BEFORE DISCONNECTING BATTERIES 19 Maintenance Continued 4 FRONT OF CAR FRONT OF CAR 0 i DISCONNECT HERE DISCONNECT HERE DS POWERDRIVE SYSTEM 48 AND V GLIDE 36 VOLT ELECTRIC VEHICLE POWERDRIVE PLUS WITH MOTOR BRAKING FIGURE 16 FIGURE 17 PERIODIC SERVICE SCHEDULES WARNING e F ANY PROBLEMS ARE FOUND DO NOT OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE FAILURE TO MAKE NECESSARY REPAIRS COULD RESULT IN FIRE PROPERTY DAM AGE SEVERE PERSONAL INJURY OR DEATH e SERVICE REPAIRS AND ADJUSTMENTS MUST BE MADE PER INSTRUCTIONS IN THE 1998 DS GOLF CAR MAINTENANCE amp SERVICE MANUAL PERIODIC SERVICE SCHEDULE GASOLINE VEHICLE REGULAR INTERVAL Check for proper operation See Performance Inspection Page 6 Adjust as necessary Check for proper operation See Performance Inspec tion Page 6 Adjust as necessary Check for proper operation See Performance Inspec tion Page 6 Adjust as necessary Daily Service by Owner Check fuel tank lines cap pump and carburetor for fuel leakage Check for proper operation See Performance Inspection Page 6 Check for proper operation See Performance Inspec tion Page 6 Check for proper operation See Performance Inspec tion Page 6 C
30. PROBLEM AND CORRECT IT BEFORE REPLACING THE FUSE CONTACT YOUR NEAREST CLUB CAR DISTRIBUTOR DEALER 36 VOLT FUSE LINK FIGURE 26 FIGURE 27 35 CLEANING THE VEHICLE The vehicle is equipped with an Armorflex front body and rear body Use only mild dishwashing liquid soap with a sponge or soft cloth for normal cleaning See CAUTION and NOTE below e IF A PRESSURE WASHER IS USED DO NOT EXCEED 500 PSI 3448 KPA NOZZLE SHOULD BE SET TO WIDE ANGLE SPRAY NOTE DISPOSE OF WASTE WATER PROPERLY Minor scratches or blemishes in the front body or the rear body can be buffed out using most commercially available polishing compounds and polishes The seats of the vehicle will last longer with proper cleaning Mild soap or detergent with a sponge or soft cloth for normal cleaning is recommended For stubborn or imbedded dirt a soft bristle brush may be used Do not use harsh detergents or cleaning solvents on the front body the rear body or the seat Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to pre vent possible stains Use commercial automotive products because the finish on the vehicle is the same as the finish on today s automobiles VEHICLE CONTROLLER ELECTRIC VEHICLE The DS Electric vehicle is equipped with either a Solid State Speed Controller PowerDrive System 48 and PowerDrive Plus with Motor Braking or a V Glide Speed Controller 36
31. Regular and consistent vehicle maintenance can prevent vehicle down time and expensive repairs that result from neglect Any vehicle not functioning correctly should be removed from use until it is properly repaired This will prevent fur ther damage to the vehicle and avoid the possibility of injury due to unsafe conditions 18 Contact your local Club Car distributor dealer to perform all repairs and semi annual and annual periodic ser vice See Page 20 for Gasoline Vehicle Periodic Service Schedule e See Page 22 for Electric Vehicle Periodic Service Schedule See 25 for Gasoline Vehicle Periodic Lubrication Schedule See 26 for Electric Vehicle Periodic Lubrication Schedule e See 27 for Vehicle Capacities all DS vehicles WARNING ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THE VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD FOLLOW THE PROCEDURES EXACTLY AS STATED IN THIS MANUAL AND OBEY THE DANGERS WARNINGS AND CAUTIONS LISTED IN THIS MANUAL AS WELL AS THOSE AFFIXED TO THE VEHICLE e IF PROBLEMS ARE FOUND DURING SCHEDULED INSPECTION OR SERVICE DO NOT OPER ATE THE VEHICLE UNTIL REPAIRS ARE MADE FAILURE TO MAKE NECESSARY REPAIRS COULD RESULT IN FIRE PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN SERVICING THE VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES ALWAYS USE INSULATED TOOLS
32. S 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 WARNING ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN SERVICING THE VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL CONNECTIONS CAUTION e ON ALL VEHICLES TURN OFF ALL ACCESSORIES BEFORE CHARGING BATTERIES NOTE RECYCLE OR DISPOSE OF DISCARDED BATTERIES IN ACCORDANCE WITH LOCAL STATE AND FEDERAL REGULATIONS The batteries in DS V Glide 36 Volt Electric Vehicles are 6 volts each The batteries in PowerDrive System 48 and PowerDrive Plus Electric Vehicles are 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 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 vehicles with new batteries to 36 holes of use between charges in the first two months of operation V Glide 36 volt vehi cles should be limited to 18 holes between charges in the first two months Batteries should be fully charged before first use of new vehicle b
33. SE LEVER Periodic Service Schedule Service Regular Interval 1 Check Engine Oil Level Monthly 2 Change Engine Oil and First 100 Hours Then Filter One Year or 200 hours 3 Check and Clean One Year Under Normal Use Air Filter Element Six Months Under Dusty Conditions 4 Change Air Filter Two Years or 300 Hours 5 Check Tire Pressure Monthly See Manual 6 Replace Fuel Filters Two Years or 300 Hours 7 Check Fill Transaxle One Year or 150 Hours Whichever comes first For easy access to air filter housing remove the intake hose from the front of the housing PERIODIC SERVICE DECAL ON AIR INTAKE BOX NEUTRAL CHOKE LOCK OUT CAM DS ELECTRIC VEHICLE FEATURE IDENTIFICATION DRIVER PASSENGER WARNING DECAL WARNING READ AND FOLLOW THESE WARNINGS AND THE OPERATING INSTRUCTIONS BEFORE USING VEHICLE FAILURE TO DO SO CAN CAUSE SEVERE INJURY OR DEATH Operate from driver side by authorized persons only and only in designated areas not on public roads DO NOT start vehicle until all occupants two 2 per seat maximum are seated Remain seated with entire body inside vehicle and hold on to seat handle or handrail at all times Drive slowly in turns and straight up and down slopes Never stand in front of or behind vehicle DO NOT operate while under the influence of alcohol rugs DO NOT leave children unattended on vehicle at any time 1019606 01 KEY SW
34. SE AN APPROVED TRAILER THAT HAS A LOAD RATING OF 1200 LBS 544 KG PER VEHICLE TO BE TOWED EXAMPLE A TWO CAR TRAILER SHOULD BE RATED AT 2 X 1200 2400 LBS 2 X 544 1088 KG NEVER TOW A CLUB CAR VEHICLE BEHIND A PASSENGER VEHICLE OR TRUCK ON A PUB LIC ROAD UNLESS IT IS ON AN APPROVED TRAILER e THE VEHICLE TO BE TOWED SHOULD BE TIED SECURELY TO THE TRAILER WITH THE FOR WARD AND REVERSE SWITCH IN NEUTRAL THE KEY SWITCH OFF AND THE PARK BRAKE FIRMLY DEPRESSED AND LOCKED WHEN TOWING ON A TRAILER NORMAL ROAD SPEED OF THE TOW VEHICLE SHOULD BE REDUCED 15 Transporting on a Trailer Continued WARNING e 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 GASOLINE VEHICLE ONLY TURN FUEL SHUT OFF VALVE TO OFF FIGURE 15 PAGE 12 STORAGE GASOLINE VEHICLE To prepare your vehicle for extended off season storage 1 Store vehicle in a cool place This will prevent self discharge of the battery If the battery appears to be weak have it charged using an automotive type 12 volt battery charger rated 10 amps or less DANGER GASOLINE FLAMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE NEVER ATTEMPT TO DRAIN GASOLINE WHEN THE ENGINE IS HOT OR WHILE IT IS RUN NING BE SURE TO CLEAN UP ANY SPILLED GASOLINE BEFORE OPERATING THE VEHICLE STORE GA
35. SOLINE IN AN APPROVED GASOLINE CONTAINER ONLY STORE IN A WELL VEN TILATED AREA AWAY FROM SPARKS OPEN FLAMES HEATERS OR HEAT SOURCES DO NOT SERVICE REPAIR OR OPERATE IN AN ENCLOSED AREA WITHOUT PROPER VEN TILATION THE ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POISON KEEP GASOLINE OUT OF THE REACH OF CHILDREN DO NOT SIPHON GASOLINE FROM THE VEHICLE WARNING DO NOT ATTEMPT TO CHARGE A BATTERY IF IT IS FROZEN OR IF THE CASE IS BULGED DISCARD THE BATTERY FROZEN BATTERIES CAN EXPLODE CAUTION BATTERIES IN ALOW STATE OF CHARGE WILL FREEZE AT LOW TEMPERATURES 2 Drain carburetor 2 1 Place the Foward and Reverse handle in the NEUTRAL position and the neutral lock out cam in the SERVICE position Turn the fuel shut off valve to the OFF position and run the engine until fuel remaining in the carburetor and fuel lines is used up and the engine stalls Return the neutral lock out cam to OPERATE position 2 2 Loosen do not remove the carburetor drain screw and drain fuel remaining in bowl into a small container then pour the fuel from the container into vehicle fuel tank 2 3 Disconnect fuel vent line from fuel tank vent nipple 2 4 Plug the fuel tank vent nipple so that it is air tight We recommend using a slip on vinyl cap 16 3 To protect the engine remove the spark plug and pour 1 2 ounce of SAE 10 weight oil into the engine through the spark plug hole Rotate the engine
36. THE TOW POSITION BEFORE DISCONNECTING OR CONNECTIING BATTERY WIRES WHEN THE TOW RUN SWITCH IS IN THE TOW POSITION ALL MOTOR BRAKING FUNCTIONS INCLUDING ZERO SPEED DECTECT ARE DISABLED VENT SHUT OFF VALVE GAS TANK 0 S Su gt 2719 a FIGURE 14 FIGURE 15 All 1998 DS PowerDrive Plus vehicles with motor braking are equipped with TOW RUN switch located under the seat just above the forward and reverse switch Figure 14 The tow run 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 electri cal components is turned off and the vehicle will not operate AFTER PLACING THE SWITCH IN TOW POSITION ALLOW 10 SECONDS BEFORE SWITCHING BACK TO RUN AFTER PLACING THE SWITCH IN RUN POSITION ALLOW 10 SECONDS 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 arci
37. TURNING OF THE VEHICLE DRIVE SLOWLY IN TURNS e TO PREVENT OVERTURNING OF THE VEHICLE DRIVE SLOWLY STRAIGHT UP AND DOWN SLOPES DO NOT DRIVE THE VEHICLE ON SLOPES EXCEEDING 20 INCLINE TO AVOID POSSIBLE INJURY TO AN UNSUSPECTING PASSENGER AND OR DAMAGE TO THE VEHICLE AVOID SUDDEN STARTS SUDDEN STOPS AND ABRUPT TURNS e 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 IS NOT DESIGNED OR INTENDED FOR STREET USE AND SHOULD NOT BE LICENSED FOR USE ON PUBLIC ROADS e OBEY ALL LOCAL RULES CONCERNING GOLF CARS e THE VEHICLE SHOULD BE DRIVEN IN ONLY SPECIFIED AREAS BY TRAINED DRIVERS TO AVOID BEING STRUCK DO NOT STAND IN FRONT OF OR BEHIND THE VEHICLE DO NOT DRIVE WHILE UNDER THE INFLUENCE OF ALCOHOL DRUGS OR MEDICATIONS No one should drive the vehicle without first being instructed in the proper operation and use of the vehicle s controls An experienced operator should accompany each first time driver on a test drive before allowing him her to operate the vehicle alone Only licensed drivers should be allowed to drive this vehicle To ensure safe operation of the vehicle follow exactly and in order all of the following procedures Read and understand all instructions prior to driving the vehicle 13 Driving Instructions Continued STARTING THE VEHICLE 1 Ent
38. UGH 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 CAUTION e WHEN STOPPED ON A HILL USE THE BRAKE PEDAL TO HOLD YOUR POSITION DO 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 2 urn the key switch to OFF and place the shift handle in the NEUTRAL position Remove the key when the vehicle is not in use 14 PowerDrive Plus Vehicles Motor Braking Only When the vehicle tow run switch is in the RUN posi tion with the forward and 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 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 Zero Speed Detect on 7 TOWING WARNING NEVER TOW THE VEHICLE ON PUBLIC STREETS OR HIGHWAYS USE ONLY APPROVED CLUB CAR TOW BARS TURN THE KEY SWITCH TO OFF
39. UTOMATICALLY 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 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 See Figure 8 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 FIGURE 8 GASOLINE VEHICLES ONLY Neutral Lock out The vehicle has a neutral lock out circuit that prevents the driver from starting the vehicle in NEUTRAL If the vehicle is started in forward or reverse and then shifted to neutral the engine will stop running Neutral Lock out Continued For the convenience of the trained mechanic there is a neutral lock out cam located on the back of the for ward reverse lever If the neutral lock out cam is pulled out approximately 3 8 inch 10 millimeters and then rotated one half turn until it snaps into place the cam will be in the SERVICE position See Figure 10 This will allow the mechanic to run the engine in NEUTRAL for certain maintenance procedures With the cam in this position the vehicle will not operate if the forward reverse lever is placed in either the forward or reverse position To put the cam back into the OPERATE position pull the cam out approxi
40. WHEN WORKING AROUND BATTERIES OR ELECTRICAL CONNECTIONS e TURN KEY SWITCH TO OFF REMOVE THE KEY PLACE THE FORWARD AND REVERSE SWITCH IN THE NEUTRAL POSITION AND CHOCK WHEELS PRIOR TO SERVICING MOVING PARTS DO NOT ATTEMPT TO SERVICE GASOLINE VEHICLE WHILE THE ENGINE IS RUNNING HOT DO NOT ATTEMPT TO SERVICE HOT ENGINE MOTOR RESISTORS OR EXHAUST SYS TEM ATTEMPTING TO DO SO COULD CAUSE SEVERE BURNS GASOLINE VEHICLES ONLY TURN FUEL SHUT OFF VALVE TO OFF TO AVOID UNINTENTIONALLY STARTING THE VEHICLE BEFORE SERVICING ALWAYS DISCONNECT THE BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG e FRAME GROUND DO NOT ALLOW TOOLS OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERIES OR OTHER ELECTRICAL WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE OR OTHER METAL COMPONENT ELECTRIC VEHICLES ONLY TO AVOID UNINTENTIONALLY STARTING THE VEHICLE DISCONNECT THE BATTERIES AS SHOWN SEE FIGURES 16 AND 17 PAGE 20 ON POWERDRIVE SYSTEM 48 AND POWER DRIVE PLUS VEHICLES ALSO DISCHARGE THE CONTROLLER AS FOLLOWS TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD AND 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 IS DISCHARGED POWERDRIVE PLUS VEHICLES ONLY PLACE TOW RUN SWITCH IN THE T
41. Wheel Alignment and Camber amp Service Manual Trained Mechanic Only Every 100 rounds or 50 hours of operation Continued Check for cracks wear and glazing replace if neces sary Torque Converter Check for proper operation Starter Generator Belt Check belt tension adjust as required Lubricate per Gas Vehicle Lubrication Chart on Page General Vehicle 25 Check all daily weekly monthly and quarterly items listed above Check for leaks around gaskets fill plugs etc Engine Inspect clean and regap spark plug replace if necessary Check air filter element clean or replace Dispose of Engine Air Intake used filter element properly Fuel Filters Replace Dispose of used filters properly Annual Service by Trained Mechanic Only Front Wheel Bearings Every 200 rounds or 100 hours of operation Inspect and check for free play repack with chassis lube and adjust as necessary Check brush length remove excess carbon dust Starter Generator replace as necessary Check fill transaxle to plug level See Gas Vehicle Unitized Transaxle Lubrication Chart on Page 25 Lubricate per Gas Vehicle Lubrication Chart General Vehicle on Page 25 Check all daily weekly monthly quarterly and semi annual items listed above PERIODIC SERVICE SCHEDULES WARNING e IF ANY PROBLEMS ARE FOUND DO NOT OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE FAILURE TO MAKE NECESSARY REPAIRS COULD RESULT IN FIR
42. absorbers shock mounts A plate leaf springs shackles and associ ated 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 against defects in materials and workmanship for a period of three years from the date of purchase LIMITED TWO YEAR WARRANTY All remaining components of the golf car not specified otherwise except options and accessories are war ranted with respect to parts and labor against defects in materials 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 materials 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 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 PUR CHASE WITH ANY WARRANTY CLAIM 2 EXCLUSIONS Excluded from any CLUB CAR warranty are all fuses filters decals except safety decals
43. ail 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 This limited warranty covers materials 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 dis tributors 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 PUR CHASE WITH ANY WARRANTY CLAIM 2 EXCLUSIONS Excluded from any CLUB CAR warranty are all fuses filters decals except safety decals spark plugs lubri cants and 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 the battery charger on board computer and solid state speed controller are covered under separate CLUB CAR warranties Tires are warranted by their manufacturer Also excluded from any CLUB CAR warranty is damage to a golf car or component resulting f
44. aphite See DS Mainte nance amp Service Manual Semi annual Service by Electrical Wiring Check for cracked or worn insulation Trained Mechanic Only l Every 100 rounds or Eonward and Revere Switch Check condition of contacts and wire connections 50 hours of operation Make sure connections are tight Check and adjust as required See DS Maintenance amp Service Manual General Vehicle Lubricate per Electric Vehicle Lubrication Chart on Page 26 Check all daily weekly monthly and quarterly items listed above Batteries Brake System Front Wheel Alignment and Camber Remove cover and check for wear and damage See Multi Step Potentiomer 48 volt or Maintenance amp Service Manual Check contacts for V Glide Wiper Switch 36 volt burns excessive heat or arcing check brush for wear Annual Service by Check motor brushes replace as necessary Trained Mechanic Only Inspect and check for free play repack with chassis bia en MAREM lube and adjust as necessary Check fill transaxle to plug level see Electric Vehicle General venice Lubricate per Electric Vehicle Lubrication Chart on Page 26 Check all daily weekly monthly quarterly and semi annual items listed above WARNING e IF ANY PROBLEMS ARE FOUND DO NOT OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE FAILURE TO MAKE NECESSARY REPAIRS COULD RESULT IN FIRE PROPERTY DAM AGE SEVERE PERSONAL INJURY OR D
45. ate to state 9 INFORMATION For further information contact WARRANTY ADMINISTRATION CLUB CAR INC PO 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 44 CLUB CAR Golf Cars NEQUIT Club Car Inc INGERSOLL RAND PO Box 204658 Augusta GA 30917 4658
46. board Tow Bar Sand Bottle Divot Sand Basket and Divot Repair Kit Bucket Repair Kit e Lighting Package high low beam head Temporary Tow Bar for Single Vehi lights taillights brake lights and horn cle Towing Deluxe Lighting Package with Turn Permanent Tow Bar for Multiple Signals Vehicle Towing factory installed OPTIONAL EQUIPMENT ELECTRIC VEHICLES ONLY 3 75 hp Electric Motor PowerDrive Sys Battery Indicator tem 48 vehicle only e 3 5 hp Electric Motor V Glide 36 volt On board Charger with Rewind vehicle only Cord OPTIONAL EQUIPMENT GASOLINE VEHICLES ONLY Fuel Gauge Spark Arrestor Kit WARNING e TINTED WINDSHIELDS AND WEATHER PROOF ENCLOSURES WILL NOT PROTECT OCCU PANTS FROM FLYING OBJECTS GOLF BALLS ETC 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 re 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 GA 30917 4658 ATTN Vehicle Registration FAIRWAY VILLAGER The Fairway Villager is designed to provide a smooth and comfortable ride for four passengers and is offered in both gasoline and PowerDrive System 48 electric power configurations An optional rack for two golf bags is also available Co
47. d as a warning when the vehicle 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 and reverse switch in the FORWARD position as the accelerator pedal is depressed the engine or motor should start and the vehicle should come up smoothly to full soeed When the pedal is released it should return to the original position and the engine or motor should stop All DS gasoline and electric vehicles run at reduced speed in reverse Governor gasoline vehicles Check maximum speed of the vehicle The vehicle should run at 12 15 MPH 19 24 KPH on a level surface General Listen for any unusual noises such as squeaks rattles Check the vehicle ride and perfor mance Have a CLUB CAR distributor dealer or a trained mechanic investigate anything unusual DS PowerDrive Plus Vehicles with Motor Braking Zero Speed Detect With the vehicle parked on level ground and the park brake disengaged place the tow switch in the RUN position and attempt to push the vehicle It should resist rolling moving at no more than 1 or 2 mph with the forward and reverse switch in any position e Pedal Up Motor Braking Accelerate the vehicle to full speed and then release the accelerator pedal Motor braking should quickly and smoothly slow the vehicle to approximately 9 mph Motor brak ing will disengage when vehicle slows to 9 mph e Pedal D
48. d from CLUB CAR or an authorized distributor or dealer for use in the United States or Canada shall be free from defects in materials and workmanship under normal use and service as a golf car for the periods stated below LIMITED LIFETIME WARRANT Y The golf car frame excluding the front and rear bumper mounts the rack and pinion steering gearbox unit and the suspension system defined as the shock absorbers shock mounts A plates leaf springs shackles and associated hardware are warranted with respect to parts and labor against defects in materials and workmanship for the lifetime of the vehicle while owned by the Original Retail Fleet Purchaser or in the pos session of the Original Retail Fleet Lessee LIMITED THREE YEAR WARRANT Y The gasoline engine transmission torque converter drive and driven unitized transaxle starter generator transaxle electric vehicle and electric motor are warranted with respect to parts and labor against defects in materials and workmanship for a period of three years from the date of purchase while owned by the Orig inal 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 war ranted with respect to parts and labor against defects in materials and workmanship for a period of two years from the date of purchase while owned by the Original Ret
49. e 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 A9801 123456 for Electric or AG9801 123456 for Gasoline See Figure 3 There is also a second serial number decal mounted on the front body frame behind the center dash panel The center dash panel must be removed to access it ALWAYS HAVE THE VEHICLE SERIAL NUMBER AT HAND WHEN ORDERING PARTS OR MAK ING INQUIRIES IF THE VEHICLE IS EQUIPPED AS A FAIRWAY VILLAGER FOUR PASSENGER VEHICLE READ THE SPECIAL INSTRUCTIONS ON PAGES 37 AND 38 SAFETY COMMITTEE If the 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 Who should and who should not drive golf cars Instructing first time drivers e Maintaining golf cars in a safe driving condition How various rules are to be enforced The safety committee should include all these items and such others as the committee feels necessary or appropriate 5 leave children unattended on vehicle at any time CCI 1019606 01 SERIAL NUMBER BOX 2 i A9801 123456 F
50. ecessary Tires See Vehicle Capacities Chart on Page 27 Check all daily and weekly items listed above Check engine oil level change as required See Gas Vehicle Lubrication Chart Page 25 Engine Dispose of used oil properly Engine air intake hose Check clamps for tightness check hose for cracks ee ee Check for proper operation adjust as necessary and cables Front Suspension Lubricate per Gas Vehicle Lubrication Chart 25 General Vehicle Lubricate per Gas Vehicle Lubrication Chart on Page 25 Check all daily weekly and monthly items listed above Check brake shoes replace if necessary Lubricate slide plates with graphite See DS Mainte nance amp Service Manual Quarterly Service by Owner or Trained Mechanic Brake System Semi annual Service by Trained Mechanic Only Every 100 rounds or 50 hours of operation Check for cracks wear or glazing replace if neces sary Electrical Wiring Check for cracked or worn insulation Periodic Service Schedule Continued on Next Page 2 Drive Belt PERIODIC SERVICE SCHEDULE GASOLINE VEHICLE REGULAR INTERVAL SERVICE Check spark plug wire and boot for damage and proper routing Check engine oil level Check head and exhaust header pipe flange connec Exhaust System tion gasket for leaks Check muffler condition Check and adjust as required See DS Maintenance Semi annual Service b i y Front
51. ed reproduced or translated to another language without the written consent of Club Car Inc The information contained in this document is subject to change without notice Club Car reserves the right to make design changes to either gasoline or electric vehicles without obligation to make these changes on units previously sold These vehicles are designed and manufactured for off road use only They do not conform to Federal Motor Vehicle Safety Standards or EPA regulations and are not equipped for operation on public streets roads or highways 1997 Club Car Inc Club Car Armorflex PowerDrive PowerDrive Plus and Tranquility are registered trademarks of Club Car Inc This manual effective August 18 1997 CLUB CAR LIMITED THREE 3 YEAR WARRANTY FOR SINGLE 1998 GOLF CARS IN THE UNITED STATES AND CANADA 1 WARRANTY CLUB CAR INC CLUB CAR hereby warrants to the original retail purchaser that its new 1998 Model DS golf car purchased from CLUB CAR or an authorized distributor or dealer for use in the United States or Can ada shall be free from defects in materials 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 war ranty LIMITED THREE YEAR WARRANTY The golf car frame excluding the front and rear bumper mounts rack and pinion steering gearbox unit sus pension system defined as the shock
52. edi eh ee 15 Storage Gasoline Vehicle 16 Storage Electric Vehicle x sek sd needs gene eS Ra diea we ba ee eR e 17 18 Periodic Service Schedule Gasoline Vehicle 20 Periodic Service Schedule Electric Vehicle 22 Periodic Lubrication Schedule Gasoline Vehicle 25 Periodic Lubrication Schedule Electric 26 Vehicle CapacileS TP 27 Engine Oil Gasoline Vehicle 27 Fueling Instructions Gasoline 28 Battery Gasoline Vehicle 123135 m teca bred a ace os m XE PUR De pacc BC aO trs 28 Batteries Electric Vehicle Adc es S E do NICE E ie a abes piu eb ecd A mE a 30 Battery Charger Electric Vehicle 31 Cleaning The Vehicle Berg sia o e Ee t Ce Pu TESS TAS wee Ed de EORR CEDE 36 Vehicle Controller Electric 36 Accessories and eR RON EOS Ed Pc Kum ema ede ud iu n dts 36 Subsequ
53. efore 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 baking soda per gallon of water once per week Rinse solution off batteries See NOTE at top of page 31 30 NOTE DO NOT ALLOW THIS SOLUTION TO ENTER THE BATTERY DISPOSE OF WASTE WATER PROPERLY Be sure terminals are tight Let the terminals dry and then spray them with CLUB CAR battery protec tor spray Part No 1014305 2 The water level in the batteries should be checked weekly See Figure 23 Page 29 for proper level Add water only after charging unless the water level is below the top of the plates In this case add just enough water to cover the plates charge and then check the level again Never charge batteries if plates are exposed above water level For best battery life add only distilled water NOTE ABATTERY 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 Torque hold down retaining nuts to 35 45 in lbs 4 0 5 1 N m The terminal connections should be clean and tight and any w
54. ent Owner Registration 37 Villager Ben cnet dala iut BSS sane eae et tania 37 Vehicle Specifications ew se ed wah Rr A we oet au det 40 Practice Safety IK Moving 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 we urge you to study this owner s manual and to read understand and heed the warnings in this manual as well as the safety decals on your vehicle before operat ing the vehicle Take time to understand the language of safety It is a language that can save your life SAFETY DETAILS WARNING e 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 is important to note that some vital statements throughout this manual and on the decals affixed to the vehicle are preceded by the words DANGER WARNING CAUTION or NOTE For your protection we rec ommend that you take special notice of these safety procedures Safety procedures are essential and must be followed Throughout this
55. er the vehicle Study and understand controls Be 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 be sure nothing is in your path Select direction by placing shift handle in desired position forward or R 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 WARNING e VEHICLE OPERATOR MUST CONTROL SPEED WHEN GOING DOWNHILL GASOLINE VEHICLE ONLY e NEVER SHIFT THE VEHICLE OUT OF FORWARD WHILE GOING DOWNHILL IF YOU DO YOU WILL NOT BE ABLE TO SHIFT INTO REVERSE OR BACK INTO FORWARD UNTIL STOPPED e DEPRESS THE BRAKE PEDAL AS NECESSARY AND PARTIALLY DEPRESS THE ACCELERA TOR WHEN DESCENDING A HILL WITH THE ACCELERATOR PEDAL PARTIALLY DEPRESSED THE GOVERNOR WILL CAUSE THE ENGINE TO ASSIST THE BRAKES IN CON TROLLING DOWNHILL SPEED POWERDRIVE PLUS VEHICLE WITH MOTOR BRAKING ONLY e PEDAL DOWN OR PEDAL UP MOTOR BRAKING MAY BE USED TO CONTROL SPEED WHEN GOING DOWNHILL SEE PERFORMANCE INSPECTION ON PAGE 7 HOWEVER TERRAIN OR OTHER CONDITIONS MAY REQUIRE THAT PEDAL BRAKING BE USED IN CONJUNCTION WITH MOTOR BRAKING STOPPING THE VEHICLE WARNING e DRIVING THRO
56. he 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 EXPRESS OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WAR RANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REMEDY OF REPAIR OR REPLACE MENT OF THE DEFECTIVE GOLF CAR OR COMPONENT THEREOF IS THE EXCLUSIVE AND 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 43 8 NO CONSEQUENTIAL DAMAGES IN NO EVENT SHALL CLUB CAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAM AGES 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 inci dental 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 st
57. heck for tightness and damage Check for loose hardware and tighten as required Weekly Service by Owner General Vehicle Check maximum speed of vehicle Maximum vehicle speed should be 12 15 mph 19 24 kph Check all daily items listed above Batteries Wash battery tops and terminals with baking soda water solution Dispose of waste water properly Check for proper operation See Performance Inspec tion Page 6 Check brake pedal free play Adjust as Brake System necessary See DS Maintenance amp Service Manual Monthly Service by Owner required or Trained Mechanic Tires Check air pressure and adjust as necessary See Vehicle Capacities Chart on Page 27 Check for cracks or other damage make sure switch Multi Step Potentiomer 48 volt or is securely fastened to frame Check movable contact V Glide Wiper Switch 36 volt for correct operation Check all daily and weekly items listed above Front Suspension Lubricate per Electric Vehicle Lubrication Chart on R Page 26 General Vehicle Lubricate per Electric Vehicle Lubrication Chart on Page 26 Check all daily weekly and monthly items listed above Periodic Service Schedule Continued on Next Page Quarterly Service by Owner or Trained Mechanic PERIODIC SERVICE SCHEDULE ELECTRIC VEHICLE Check specific gravity electrolyte level and on charge voltage Check brake shoes replace if necessary Lubricate slide plates with gr
58. heck for wear and damage Check shift linkage for proper operation Make sure all are in place See Gasoline Vehicle Fea ture Identification Page 3 20 PERIODIC SERVICE SCHEDULE GASOLINE VEHICLE REGULAR INTERVAL SERVICE Battery Clean terminals and wash dirt from case check elec trolyte level See Pages 28 and 29 Electrical wiring and connections Check for tightness and damage Torque Converter Rinse with water Dispose of waste water properly Check for loose hardware and tighten Weekly Service by Owner as required Check maximum speed of vehicle Maximum vehicle General Vehicle speed should be 12 15 mph 19 24 kph Wash engine compartment and underside of vehicle Dispose of waste water properly Check all daily items listed above Wash battery and terminals with baking soda water solution See Page 28 Dispose of waste water Battery properly Check brake cables for damage replace as required Check for proper operation See Performance Inspec tion Page 6 Check brake pedal free play Adjust as necessary See DS Maintenance amp Service Manual Make sure that both ground wires are tight and properly connected Check engine oil level change as required See Gas Vehicle Lubrication Chart Page 25 Brake System Monthly Service by Owner or Trained Mechanic Engine Dispose of used oil properly Exhaust System Check for leaks Check air pressure and adjust as n
59. inse solution off the battery Be sure terminals are tight Let the terminals dry and then spray them with CLUB CAR battery terminal spray Club Car Part 1014305 CAUTION e IF BATTERY WIRE TERMINALS ARE DAMAGED OR CORRODED THEY SHOULD REPLACED OR CLEANED AS NECESSARY FAILURE TO DO SO MAY CAUSE THEM TO OVER HEAT DURING OPERATION BATTERY CAP PLATES WATER LEVEL AT LEAST 1 2 ABOVE PLATES OR TO LEVEL INDICATOR FIGURE 22 FIGURE 23 Be sure battery clamp is properly tightened Torque to 10 13 in Ibs 13 5 17 6 N m A loose battery clamp may allow the battery to become damaged from vibration or jarring If battery appears weak have it charged by a trained mechanic The battery should never be left discharged any longer than absolutely necessary do not leave discharged overnight 29 BATTERIES ELECTRIC VEHICLE DANGER BATTERY EXPLOSIVE GASES DO NOT SMOKE KEEP SPARKS AND FLAMES SAFE DISTANCE FROM THE VEHICLE TOOLS WIRES AND METAL OBJECTS CAN CAUSE SPARKS WHEN SHORTED ACROSS A BATTERY FOLLOW ALL INSTRUCTIONS CAREFULLY WHEN DEALING WITH BATTERIES CHARGE BATTERIES IN A WELL VENTILATED AREA ONLY BATTERIES EMIT HYDROGEN WHILE BEING CHARGED HYDROGEN IS AN EXPLOSIVE GAS AND MUST NEVER EXCEED A LEVEL OF 2 OF THE AIR POISON CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING ANTIDOTES EXTERNAL FLUSH WITH WATER FOR 15 MINUTE
60. lectric Vehicle Continued WARNING e 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 CON DUCTOR 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 POSSI BLE THE USE OF IMPROPER EXTENSION CORD COULD RESULT IN FIRE OR AN ELECTRI CAL SHOCK ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THE CHARGER CONTACT YOUR NEAREST CLUB CAR DISTRIBUTOR DEALER DO NOT OPERATE THE CHARGER IF IT HAS RECEIVED A SHARP BLOW WAS DROPPED OR OTHERWISE DAMAGED IN ANY WAY HAVE WORN CUT OR DAMAGED POWER CORDS OR WIRES REPLACED IMMEDIATELY DO NOT USE NEAR FUELS GRAIN DUST SOLVENTS THINNERS OR OTHER FLAMMABLES CHARGERS CAN IGNITE FLAMMABLE MATERIALS AND VAPORS DO NOT EXPOSE TO RAIN OR ANY LIQUID KEEP THE CHARGER DRY NEVER PUSH OBJECTS OF ANY KIND INTO THE CHARGER THROUGH CABINET SLOTS THEY MAY TOUCH DANGEROUS VOLTAGE POINTS OR CAUSE AN ELECTRICAL SHORT CIR CUIT THAT COULD RESULT IN FIRE OR ELECTRICAL SHOCK 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 BEFOR
61. mately 3 8 inch 10 milli meters and rotate it one half turn until it snaps into place See Figure 11 See WARNING and NOTE below WARNING WITH THE CAM IN THE SERVICE POSITION AND THE ENGINE RUNNING THE VEHICLE MAY MOVE SUDDENLY IF THE FORWARD REVERSE HANDLE IS SHIFTED OR ACCIDENTALLY BUMPED TO PREVENT THIS CHOCK THE FRONT AND REAR WHEELS AND ALWAYS FIRMLY SET THE PARK BRAKE BEFORE SERVICING OR LEAVING THE VEHICLE e BE SURE TO RETURN THE CAM TO THE OPERATE POSITION AFTER SERVICING THE VEHI CLE OR IT WILL NOT RUN WITH THE FORWARD AND REVERSE SWITCH IN EITHER THE FORWARD OR REVERSE POSITION Choke The choke is located on the seat support panel below and to the left of the driver s left knee See Figure 12 If the vehicle is hard to start in cool or cold temperatures simply push in the choke cover with your left hand to activate it Hold it during start up and release the choke cover after the engine starts and runs smoothly Oil Light The DS Gasoline golf car is equipped with a low oil warning light located on the dash panel just above the steering column See Figure 13 If the oil warning light comes on oil should be checked and added to the engine as necessary before continuing to use the vehicle The vehicle should never be driven with the oil warning light remaining on If the oil warning light goes on and off you may proceed but oil should be added at the first opportunity If the oil level is correct and the ligh
62. ment by lifting the rear seat ELECTRIC FAIRWAY VILLAGER An optional on board charger which is installed under the rear seat is available for the Fairway Villager elec tric vehicle The charger should be plugged into a properly grounded nominal 115 Volts AC 60 Hertz outlet The AC line to which the charger is to be connected must be capable of supplying 15 amperes minimum to the charger The rear seat should be propped open while charging the batteries WARNING EACH CHARGER SHOULD HAVE ITS OWN DEDICATED 15 OR 20 AMPERE SEPARATELY PRO TECTED CIRCUIT BREAKER OR FUSE SINGLE PHASE BRANCH CIRCUIT IN ACCORDANCE WITH ALL APPLICABLE ELECTRICAL CODES FOR THE LOCATION CAUTION e BEFORE CHARGING BATTERIES TURN OFF ALL ACCESSORIES ON ALL VEHICLES IF USING AN ON BOARD CHARGER BE SURE THE AC PLUG IS UNPLUGGED FROM THE OUT LET BEFORE ATTEMPTING TO DRIVE THE VEHICLE CHARGER AND AC OUTLET WILL BE DAMAGED IF THE CHARGER IS NOT UNPLUGGED BEFORE DRIVING BE SURE THE AC CORD IS PROPERLY WOUND UP ON THE REEL BEFORE DRIVING THE VEHICLE STUDY ALL GENERAL INFORMATION NOTES CAUTIONS AND WARNINGS AS WELL AS ALL INFORMA TION NOTES CAUTIONS AND WARNINGS SPECIFIC TO THE POWERDRIVE CHARGER AND POWERDRIVE SYSTEM 48 IN THE BATTERY CHARGER SECTION OF THIS OWNER S MANUAL PAGE 31 38 FAIRWAY VILLAGER SEAT HANDLE PASSENGER WARNING HAND RAIL DECAL ON HAND RAIL WARNING Failure to follow these instructions can cause
63. ne vehicles Check for proper engine oil level See Engine Oil Page 27 Fuel gasoline vehicles Check fuel level See Fueling Instructions Page 28 WARNING e BE SURE THE PLASTIC HAS BEEN REMOVED FROM THE SEAT BOTTOM BEFORE OPERAT ING THE VEHICLE FAILURE TO DO SO MAY RESULT IN A FIRE PROPERTY DAMAGE PER SONAL INJURY OR DEATH PERFORMANCE INSPECTION After you have familiarized yourself with the vehicle s 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 your new vehi cle Any problems should be corrected only by your CLUB CAR distributor dealer or a trained technician All vehicles 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 If the pedal goes more than halfway to the floor or if the vehicle swerves or fails to stop within 14 feet 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 circumstances 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 should soun
64. nected 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 come on if the charge is 90 or more complete The on board computer will retain in memory the amount of charge needed to fully replenish the batteries and will complete the charge during the next charge cycle When the charger is unplugged the warning light will come on and remain illuminated for 10 seconds if the charge is less than 90 complete but the car has enough power to complete 36 holes of golf This will alert the fleet operator that the car 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 see charger manual and the batteries are not sufficiently charged This indicates an abnormal charge cycle Charger and batteries should be checked by your Club Car distributor dealer e 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 11 Controls Continued POWERDRIVE PLUS ELECTRIC VEHICLES ONLY Tow Run Switch WARNING TO AVOID POSSIBLE BATTERY EXPLOSION THE TOW RUN SWITCH MUST BE IN
65. ng 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 vehicle electrical system thus preventing vehicle electrical components from discharging the batteries 12 DRIVING INSTRUCTIONS e 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 e 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 FOR NIGHT USE THE VEHICLE MUST BE EQUIPPED WITH HEADLIGHTS TAILLIGHTS AND REFLECTORS e STOP THE VEHICLE BEFORE SHIFTING THE FORWARD AND REVERSE SWITCH FAILURE TO DO SO MAY RESULT IN INJURY TO AN UNSUSPECTING PASSENGER AND OR DAMAGE TO THE VEHICLE A BUZZER WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE WHEN DRIVING THE VEHICLE e OPERATE THE VEHICLE FROM THE DRIVER S SEAT ONLY e 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 INCLUDING HEAD HANDS ARMS LEGS AND FEET INSIDE THE VEHICLE PREVENT OVER
66. ng those that affect the weight distribution stability or speed of the golf car can cause serious personal injury or death lii 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 Whether you have chosen the DS Gasoline or DS Electric you have chosen the finest golf car on the market Please protect your investment and ensure that your Club Car provides years of reliable superior performance by returning your Warranty Registration provided by your distributor dealer and 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 procedures in this manual These instructions must be followed in order to avoid the risk of severe personal injury If you rent or loan your vehicle to others we recommend that you ask them 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 call 706 863 3000 Ext 2601 If you would prefer to write to us direct your letter to Club Car Attention Product Develo
67. ntact your nearest Club Car distributor dealer This Owner s Manual should be read thor oughly prior to operating the vehicle The Fairway Villager should be driven and maintained as stated in this Owner s Manual with the following exceptions WARNING e TO PREVENT POSSIBLE INJURY AN UNSUSPECTING PASSENGER OR DAMAGE TO THE VEHICLE AVOID SUDDEN STARTS SUDDEN STOPS AND ABRUPT TURNS e VEHICLE SHOULD BE DRIVEN AT SLOWER SPEEDS WHEN FOUR PERSONS ARE IN THE VEHICLE PASSENGERS SHOULD HOLD ON TO SEAT HANDLES OR HAND RAILS AT ALL TIMES SEE FIGURE 28 DRIVER SHOULD KEEP BOTH HANDS ON THE STEERING WHEEL WHILE VEHI CLE IS MOVING 37 Fairway Villager Continued WARNING DO NOT LEAVE CHILDREN UNATTENDED ON THE REAR SEAT WHILE VEHICLE IS MOVING NO MORE THAN FOUR PERSONS SHOULD BE ON THE VEHICLE AT ONE TIME TO PREVENT THE POSSIBILITY OF SERIOUS INJURY KEEP YOUR ENTIRE BODY INCLUDING HEAD HANDS ARMS LEGS AND FEET INSIDE THE VEHICLE MAINTENANCE Refer to Pages 20 through 26 for periodic service schedules and periodic lubrication schedules See NOTE below IF THE VEHICLE IS CONSTANTLY HAULING HEAVY LOADS THE PREVENTIVE MAINTENANCE PROCEDURES SHOULD BE PERFORMED MORE OFTEN THAN RECOMMENDED IN THE SER VICE AND LUBRICATION SCHEDULES STORAGE COMPARTMENT There is an enclosed storage compartment underneath the rear seat with 2 cu ft 6 cu m of storage area Access the storage compart
68. orn insulation or frayed wires should be replaced Torque battery terminals to 125 145 in lbs 14 1 16 4 N m CAUTION e F BATTERY WIRE TERMINALS ARE DAMAGED OR CORRODED THEY SHOULD REPLACED OR CLEANED AS NECESSARY FAILURE TO DO SO MAY CAUSE THEM TO OVER HEAT DURING OPERATION 4 After use the batteries should be placed on charge The batteries should never be left discharged any longer than absolutely necessary do not leave discharged overnight BATTERY CHARGER ELECTRIC VEHICLE 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 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 WARNING EACH CHARGER SHOULD HAVE ITS OWN DEDICATED 15 OR 20 AMPERE SEPARATELY PRO TECTED CIRCUIT BREAKER OR FUSE SINGLE PHASE BRANCH CIRCUIT IN ACCORDANCE WITH ALL APPLICABLE ELECTRICAL CODES FOR THE LOCATION CONNECT THE CHARGER AC SUPPLY CORD TO A PROPERLY GROUNDED THREE WIRE OUTLET OF THE PROPER VOLTAGE AND FREQUENCY AS SHOWN ON THE CHARGER 31 Battery Charger E
69. owered vehicle dry DS GASOLINE 48 122 cm 65 1 2 166 cm 4 1 2 11 cm 34 1 2 88 cm 38 1 2 98 cm 598 Ibs 271 kg 638 Ibs 289 kg POWERDRIVE SYSTEM 48 ELECTRIC 48 122 cm 65 1 2 166 cm 4 1 2 11 cm 34 1 2 88 cm 38 1 2 98 cm 455 Ibs 206 kg 495 lbs 225 kg POWERDRIVE PLUS ELECTRIC 48 122 cm 65 1 2 166 cm 4 1 2 11 cm 34 1 2 88 cm 38 1 2 98 cm 477 Ibs 216 kg 517 Ibs 235 kg DS 36 VOLT ELECTRIC 48 122 cm 65 1 2 166 cm 4 1 2 11 cm 34 1 2 88 cm 38 1 2 98 cm 448 lbs 203 kg 12 15 mph 19 24 kph 12 15 mph 19 24 kph 12 15 mph 19 24 kph 12 15 mph Forward Speed At 2700 rpm 19 24 kph 17 6 17 6 17 6 17 6 Clearance Circle diameter 533 cm 533 cm 533 cm 533 cm Braking Distance At 12 mph 19 kph 14 427 14 427 14 427 cm 14 427 41 CLUB CAR LIMITED LIFETIME WARRANTY FOR 1998 FLEET GOLF CARS IN THE UNITED STATES AND CANADA 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 1998 Model DS golf car purchase
70. own Motor Braking Accelerate down an incline with the accelerator pedal depressed When the vehicle reaches approximately 15 mph motor braking should engage and moderate vehicle speed between 15 and 16 mph depending upon the grade of the hill CONTROLS DANGER DO NOT OPERATE GASOLINE VEHICLE AN ENCLOSED AREA WITHOUT PROPER VENTI LATION GASOLINE ENGINES PRODUCE CARBON MONOXIDE GAS WHICH IS AN ODOR LESS DEADLY POISION WARNING e IF RENTING OR LOANING THE VEHICLE MAKE SURE THE DRIVER IS FAMILIAR WITH ALL CONTROLS AND OPERATING PROCEDURES BEFORE ALLOWING THE VEHICLE TO BE DRIVEN DO NOT TAMPER WITH THE GASOLINE VEHICLE GOVERNOR DOING SO WILL VOID THE WARRANTY AS WELL AS DAMAGE THE ENGINE AND OTHER COMPONENTS AND COULD RESULT IN PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO ACCIDENT AT UNSAFE SPEED DO NOT MODIFY OR CHANGE THE VEHICLE IN ANY WAY WHICH MIGHT AFFECT ITS STABIL ITY OR HANDLING OR INCREASE MAXIMUM SPEED BEYOND FACTORY SPECIFICATIONS PROPERTY DAMAGE PERSONAL INJURY OR DEATH COULD RESULT DO NOT SHIFT THE FORWARD REVERSE SWITCH WHILE THE VEHICLE IS MOVING TO AVOID INJURY TO AN UNSUSPECTING PASSENGER OR DAMAGE TO THE VEHICLE ALWAYS BRING THE VEHICLE TO A FULL STOP BEFORE SHIFTING THE SWITCH A BUZZER WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE RELEASE THE ACCELERATOR PEDAL AND THEN DEPRESS THE BRAKE PEDAL FIRMLY UNTIL THE VEHICLE STOPS TO AVOID UNINTENTIONALLY STARTING OR ROLLIN
71. pment Department P O Box 204658 Augusta Ga 30917 4658 USA Your local authorized Club Car representative can also provide technical advice parts and service manuals We hope you will consider this owners 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 information it contains IV TABLE OF CONTENTS oal Deals siendo vae Fon tenes rade v MV ed c pe vd dr EY a ed andes 1 General VAT I AEN Sh PTT c pr 1 Feature Identification Gasoline Vehicle 3 Feature Identification Electric 4 General INiOnnaliOn deed eee 5 siu ok wed Feste eee Re 5 Salely COMMINGS anata 5 Checklist 6 Sou M EET 7 Biden OTI eae as 13 s Mata aes 15 Trensportng ona Maler He p ehe atis pU a
72. re to 20 psi 96 kPa 5 Grease front suspension and do all quarterly periodic lubrication See Periodic Lubrication Sched ule Page 26 6 Thoroughly clean front body rear body seats battery compartment and underside of vehicle 7 Do not latch the park brake Chock wheels to prevent the vehicle from rolling 8 Keep batteries fully charged during storage See Batteries Electric Vehicle Page 30 If possible charge 36 volt vehicles with Accu Power battery chargers every 6 8 weeks as necessary If it is not possible or practical to charge the batteries leave them disconnected while the vehicle is in storage Leave PowerDrive System 48 and PowerDrive Plus vehicles with PowerDrive chargers plugged in dur ing storage The PowerDrive storage charge feature will automatically charge the batteries as needed throughout storage period See Batteries Electric Vehicle Page 30 POWERDRIVE SYSTEM 48 OR POWERDRIVE PLUS VEHICLE WILL NOT OPERATE WHILE PLUGGED TO A CHARGER TO RETURN THE STORED VEHICLE TO SERVICE 1 Fully charge batteries See Batteries Electric Vehicle Page 30 2 tire pressure to 18 20 psi 86 96 kPa 3 Perform the Pre Operation Checklist See pages 6 and 7 MAINTENANCE GENERAL INFORMATION To ensure trouble free vehicle performance it is very important to follow an established preventive mainte nance program regularly scheduled service even though the vehicle is functional
73. rom 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 service are also excluded from this warranty 42 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 INCLUD ING BUT NOT LIMITED TO MODIFICATION OF THE SPEED GOVERNOR BRAKING SYSTEM STEER ING TRANSAXLE OR OTHER OPERATING SYSTEMS OF THE CAR TO CAUSE IT PERFORM OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKEWISE VOID IF THE CAR SHOWS INDI CATIONS 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 CAR S ONLY LIABILITY UNDER THIS LIMITED WARRANTY OR IN ANY ACTION WHETHER BASED UPON WARRANTY CONTRACT NEGLIGENCE STRICT PRODUCT LIABILITY OR OTHER WISE IS LIMITED TO THE REPAIR OR REPLACEMENT AT CLUB CAR S OPTION OF A 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 FAC TORY RECONDITIONED VEHICLE OR COMPONENT THEREOF WHICH IS IDENTICAL OR REASON ABLY
74. severe injury or death FOOT REST Remain seated with entire body inside vehicle and hold onto seat handle or handrail at all times No more than two persons per seat Do not leave children unattended on vehicle at anytime Never stand in front of or behind vehicle 1017057 01 FIGURE 28 39 VEHICLE SPECIFICATIONS POWERDRIVE POWERDRIVE DS SPECIFICATIONS SYSTEM 48 PLUS 36 VOLT ELECTRIC ELECTRIC ELECTRIC POWER SOURCE Engine 4 cycle OHV 286 cc 9 0 hp rated single cylinder air cooled with pressure lubrication system Drive Motor Direct drive 48 volts DC shunt wound 3 2 hp Drive Motor Direct drive 36 volts DC series wound 2 97 hp Fuel System Side draft carburetor with float bowl fixed jets fuel filter and impulse fuel pump Governor Automatic ground speed sensing internally geared in unitized transaxle Drive Motor Direct drive 48 volts DC series wound 3 1 hp SF Ignition Transistor electronic ignition with electronic RPM limiter Unitized Transaxle Fully synchronized forward and reverse with neutral and reduced speed reverse 11 8 1 forward 17 1 1 reverse Transaxle Double reduction helical gear with 12 28 1 direct drive axle Electrical System Battery 12 volt 500 cold cranking amps at 0 650 cranking amps at 32 85 minute reserve and 35 amp charging capacity Electrical System 48 volts DC reduced speed reverse Electrical System
75. sitions are clearly marked on the switch Push down the F forward side of the switch to run the vehicle in the forward direction or push down the R reverse side of the switch to run the vehicle in reverse When the switch is positioned with neither side down the vehicle is in the NEUTRAL position and the vehicle will not run if the accelerator pedal is depressed See Figure 6 NOTE e THE REVERSE BUZZER WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE ACCELERATOR PEDAL The accelerator pedal is the pedal on the right with the word GO molded into it See Figure 7 THE OPERATION OF THE ACCELERATOR PEDAL DIFFERS FROM THAT OF AN AUTOMO BILE WHEN THE KEY SWITCH IS ON AND THE SHIFT LEVER IS IN EITHER FORWARD OR REVERSE DEPRESSING THE ACCELERATOR PEDAL WILL AUTOMATICALLY RELEASE THE PARK BRAKE AND START THE VEHICLE MOVING IN THE DIRECTION SELECTED FORWARD OR REVERSE AS THE ACCELERATOR PEDAL IS DEPRESSED SPEED WILL INCREASE UNTIL FULL SPEED IS REACHED WHEN THE ACCELERATOR IS RELEASED POWER WILL BE CUT OFF AND THE ENGINE OR MOTOR WILL STOP RUNNING POWERDRIVE PLUS VEHICLES ONLY SEE PEDAL UP AND PEDAL DOWN MOTOR BRAK ING ON PAGE 7 FIGURE 6 FIGURE 7 BRAKE PEDAL The brake pedal is the large pedal on the left with the word STOP molded into it See Figure 7 To slow or stop the vehicle depress the brake pedal with your right foot See Figure 8 WARNING e THE PARK BRAKE WILL RELEASE A
76. t stays on have a trained mechanic check the vehicle CAUTION e FAILURE TO ADD OIL IMMEDIATELY WHEN THE OIL WARNING LIGHT STAYS ON MAY RESULT IN PERMANENT ENGINE DAMAGE POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS ELECTRIC VEHICLES ONLY Battery Warning Light PowerDrive System 48 and PowerDrive Plus vehicles feature a dash mounted warning light above steering column that when the vehicle is in operation indicates low battery voltage or when the vehicle is being charged indicates a charging problem The battery warning light is controlled by the PowerDrive on board computer 10 NEUTRAL FORWARD NEUTRAL FORWARD SERVICE POSITION OPERATE POSITION FIGURE 10 FIGURE 11 E TQ Dos FIGURE 12 FIGURE 13 When the vehicle is in operation the warning light will come on and remain illuminated if Batteries voltage drops below 48 when there is no load on the batteries the vehicle is stopped and there are no accessories on e Batteries have discharged to less than 25 of their capacity If the warning light comes on during a round of golf there is enough power remaining to finish the round but the car should be charged before being used again If the warning light comes on and the vehicle is unable to finish the round have your Club Car distributor dealer check the vehicle for a possible battery or electrical system problem When the batteries receive an incomplete charge because 1 the DC power cord is discon

Manual Number 1019682-01 Print Code 0897B1297A

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