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103897209 0412B0412A

1. Ciub Car J DS Gold Standard Remanufactured Vehicle Owner s Manual Electric and Gasoline Refer to back cover for applicable build code range am Ingersoll Rand Industrial Technologies NOTICE This manual is valid for vehicles manufactured in the build code range provided on the back cover of this manual If the vehicle build code is different from that shown on the back cover of this manual please contact your nearest dealer or go to www clubcar com to retrieve the proper owner s manual for the vehicle See also Model Identification in this manual Warranty information appears at the end of this manual No other warranties express or implied are contained herein Your authorized representative checked the vehicle before it was delivered to you and will provide you a copy of the completed vehicle warranty registration form Club Car is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual This manual contains proprietary information that is protected by copyright All rights are reserved No part of this manual may be photocopied reproduced or translated to another language without the written consent of Club Car The information contained in this document is subject to change without notice Club Car reserves the right to make design changes to vehicles without obligation to make these changes on units previously sold These vehicles do
2. Electric Vehicles At one hour and at two hours into the charge cycle the charger will shut off in order to run a self diagnostic program ammeter will drop to zero Charging will resume in a few moments ammeter returns to previous rate of charge 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 15 amperes minimum per charger To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord having an equipment grounding conductor and a grounding type plug The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electrical Code and all local codes and ordinances See the owner s manual supplied with the charger for specific operating instructions before using the charger The use of an extension cord with the charger should be avoided If an extension cord must be used use a three conductor no 12 AWG American Wire Gauge or no 14 SWG British Standard Wire Gauge heavy duty cord with ground properly wired and in good electrical condition Keep it as short as possible no more than 12 feet 3 7 m Place all cords so they will not be stepped on tripped over or otherwise subject to damage or stress Ensure that the charger ventilation slots are unobstructed and that there is adequa
3. Page 16 DS Gold Standard Remanufactured Vehicle Owner s Manual Controls and Indicators Figure 8 Forward Reverse Handle Figure 9 Forward Reverse Rocker Switch 77 Figure 10 Accelerator and Brake Pedals ACCELERATOR PEDAL The accelerator pedal is the pedal on the right with the word GO molded into it Figure 10 The operation of the accelerator pedal differs from that of an automobile When the key switch is in the ON position and the Forward Reverse handle or switch is in either in the FORWARD or REVERSE position pressing the accelerator pedal will automatically release the park brake and start the vehicle moving in the direction selected forward or reverse As the accelerator pedal is pressed speed will increase until full speed is reached When the accelerator is released power will be cut off and the motor or engine will stop running DS Gold Standard Remanufactured Vehicle Owner s Manual Page 17 Controls and Indicators IQ System vehicles use a special electrical system which employs motor braking in some modes of operation In those modes the vehicle operates as follows Walk Away Braking This prevents the vehicle from rolling away uncontrolled should the driver park on a slope and leave the vehicle without locking the park brake The vehicle will roll at about 1 mph 1 6 km h If the walk away braking function remains engaged for two seconds or more a warning buzzer will sound to alert the driver that motor
4. vehicle Do not wash engine when hot Clean terminals and wash dirt from casing Battery check electrolyte level See Battery Gasoline Vehicles on page 43 Check and adjust if necessary See Steering Front wheel alignment and camber and Front Suspension in the maintenance and service manual Semiannual service by trained technician Electrical wiring and connections Check for tightness and damage only every 50 hours of operation or eve y every bs P dr Check brake shoes replace if necessary 100 rounds for golf cars Lubricate brake slides See Periodic Lubrication Schedules on page 35 Brake system Check brake cables for damage replace if necessary Check brake cable equalizer adjustment adjust if necessary 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 if Annual service by trained technician only x wA necessary Engine air intake system every 100 hours of operation or every 200 Check clamps for tightness check hose for rounds for golf cars cracks i Check for loose hardware and tighten if General vehicle necessary Check safety decals Replace if damaged or Safety decals EE illegible Two year service by trained technician only every 200 hours of operation or every 400 Fuel filters Replace Dispose of used filters properly rounds for golf cars Page 34 DS Gold Standard Remanufactured Vehicle O
5. A garden hose at normal residential water pressure is adequate The manufacturer does not recommend any type of pressure washing or steam cleaning Such a process especially if the vehicle has an ArmorFlex rear body that is removed will expose electrical components to moisture Moisture entering electrical components can result in water damage and subsequent component failure Use non abrasive wax products Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible stains The seats of the vehicle will last longer with proper cleaning Use a solution of 1096 liquid soap and warm water applied with a soft cloth For imbedded dirt a soft bristle brush may be used For heavy soiling difficult stains or scratches blemishes or other body damage see the appropriate maintenance and service manual NOTE Dispose of waste water properly ACCESSORIES There is a complete line of accessory equipment available from Club Car and our dealers distributors You can obtain the name and phone number of your closest Club Car contact by visiting our web site at www clubcar com and clicking the Dealer Locator link Care should be taken that these accessories are properly installed by trained technicians and that they are used in the manner for which they were designed See following WARNING WARNING Tinted windshields and weather proof enclosures will not protect occupants from
6. It is recommended that the vehicles be plugged in and the electrolyte level maintained throughout the storage period If any of the following conditions exist however then disconnect the batteries for storage 1 The charger cannot remain plugged in 2 AC power will not be available during extended storage or 3 Electrolyte levels will not be maintained To disconnect batteries for storage go to step 12 11 To keep batteries fully charged during storage 11 1 Plug the battery charger into the car Leave battery chargers plugged in during storage The onboard computer OBC will automatically activate the charger when necessary 11 2 Check the electrolyte level and charger function monthly to ensure that proper operation is maintained To check charger function disconnect the DC cord stationary charger from the vehicle or the AC cord onboard charger from the power source wait five seconds then reconnect it The charger is functioning properly if the ammeter indicates current Page 28 DS Gold Standard Remanufactured Vehicle Owner s Manual Storage Gasoline Vehicles NOTE The OBC keeps track of the time spent in storage mode When the OBC detects that the storage charge cycles may have depleted the available electrolyte it will stop the charger from further operation Disconnecting then reconnecting the DC cord stationary charger or AC cord onboard charger indicates the electrolyte levels have been maintained and allows the OB
7. follow this maintenance program on a regular basis 1 Keep the batteries clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water 1 cup 237 mL baking soda per gallon 3 8 L of water Rinse solution off of the batteries Do not allow this solution to enter the battery Be sure terminals are tight Let the terminals dry and then coat with Battery Terminal Protector Spray CC P N 1014305 See following NOTE NOTE Dispose of waste water properly Page 38 DS Gold Standard Remanufactured Vehicle Owner s Manual Batteries Electric Vehicles 2 Checkthe electrolyte level weekly Figure 21 Add water only after charging unless the electrolyte level is below the top of the plates In this case add just enough water to cover the plates charge and then check the level again Never charge batteries if plates are exposed above electrolyte level For best battery life add only distilled water See following CAUTION and NOTE CAUTION Do not overfill the batteries NOTE A battery watering gun or bottle is available from your authorized Club Car dealer 3 The battery hold downs 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 For 8 volt batteries tighten retaining nuts on the two inner hold downs to 115 in Ib 13 N m and tighten the retaining nuts on the two outer hold downs to 55 in Ib
8. non approved alteration and acts of God Also excluded from any CLUB CAR warranty are all fuses filters decals except safety decals lubricants routine wear items such as the charger plug and receptacle engine mounts mats pads spark plugs light bulbs brake shoes belts brushes bushings drive buttons cosmetic deterioration and items that deteriorate fade or fail due to exposure or ordinary wear and tear The provisions of this limited warranty shall not apply to failure due to 1 Abuse such as overcharging undercharging improper fluid levels use of contaminated water in batteries See Water Quality in owner s manual loose wiring and fasteners or rusted or corroded hardware 2 Lack of proper maintenance such as preventive maintenance checks proper rotation of vehicles in a fleet application maintaining proper tire pressure and alignment and tightening loose wire connections as outlined in the owner s manual 3 Damages caused by improper installation of the component Neglect breakage freezing fire explosion wreckage melted terminal posts the addition of any chemical or the operation of the battery in an uncharged condition below half charge 1 200 specific gravity the installation of the batteries in reverse or recharging in reverse breakage of containers covers or terminal post or batteries used in applications for which they were not designed 5 A battery damaged by a defective charger or batteri
9. 35 Batteries Electric Vehicles 2 2 niei deer bred dd lilarddie lb nlr dii cio didi Pe dL Dd nie D Dd aa daa 37 Battery Charger Electric Vehicles 222i EE EPEA EE EAE ANNEER shed e anh b anii nnb b di inna bi en hk bodie en baba 40 Battery Gasoline Vehicles 43 Engine Oil Gasoline Vehlcles coiere ee eri ertet tint icd tice tete ces tb panier t gas 45 Fueling Instructions Gasoline Vehicles ssssssese ee mmm mme nennen n ehh nnn erre 48 Cleaning the Vehicle sarr n 49 ACCOSSOMOS 49 Subsequent Owner Registration semero raratanana eura nee ann enne da sn enne da La Pleno au one e ada Elan ka Enea nn nada nnns 50 bine eler teliteziilo other 50 Warirantles edere dg det aet do tree e virectu vi reo Givi tee Ee P Ee E Petr da 52 DS Gold Standard Remanufactured Vehicle Owner s Manual Page 3 Safety Decal and Feature Identification SAFETY DECAL AND FEATURE IDENTIFICATION The following pages contain safety decal and feature identification information For detailed information on specific features read the appropriate section in this manual ELECTRIC VEHICLE ROLLOVER OR FALLING OFF MAY CAUSE DEATH DE Before using vehicle read operating instructions Remain seated and hold on to se
10. 6 2 N m The terminal connections should be clean and tight and any worn insulation or frayed wires should be replaced Tighten battery terminals to proper torque See Connecting the Batteries Electric Vehicles on page 13 See following WARNING WARNING f battery wire terminals are damaged or corroded replace or clean them as necessary Failure to do so may cause them to overheat during operation and could result in fire property damage or personal injury 4 After use charge the batteries The batteries should never be left discharged any longer than absolutely necessary do not leave discharged overnight 1 Level Indicator 2 Cap 3 Plates Maintain electrolyte level from at least 72 inch 13 mm above plates to inch 6 mm below level indicator Figure 21 Battery Electrolyte Level DS Gold Standard Remanufactured Vehicle Owner s Manual Page 39 Battery Charger Electric Vehicles BATTERY CHARGER ELECTRIC VEHICLES DANGER The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the charging area must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being cha
11. Control System The exhaust emission control system applied to this engine consists of a carburetor and an ignition system having optimum ignition timing characteristics The carburetors have been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system Maintenance and Warranty Proper maintenance is necessary to ensure that your engine will continue to have low emis Sion levels Those items identified by the Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards The Club Car Limited Emission Control System Warranty requires that you return your engine to an authorized Club Car Dealer for remedy under warranty Please read the warranty carefully and keep it valid by complying with the owner s obligations it contains Tampering with Emission System Prohibited California State law prohibits the following Control FUEL AND OIL RECOMMENDATIONS Fuel Use only clean fresh unleaded regular grade gasoline Octane Rating The octane rating of a gasoline is a measure of its resistance to knocking Use of a mini mum of 87 octane of the anti knock index is recommended The anti knock index is posted on service station pumps in the U S A NOTE elf knocking or pinging occurs use a different brand of gasoline or higher octane rating 4 CAUTION Do not mix oil with gasoline Oxygenated F
12. Hold it during start up and release the choke cover after the engine starts and runs smoothly DS Gold Standard Remanufactured Vehicle Owner s Manual Page 21 Pre Operation and Daily Safety Checklist Figure 16 Choke Figure 17 Low Oil Warning Light LOW OIL WARNING LIGHT Gasoline Vehicles Only The gasoline golf car is equipped with a low oil warning light located on the dash panel just above the steering column Figure 17 If the 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 low oil warning light remaining on If the warning light goes on and off you may proceed but oil should be added at the first opportunity If the oil level is correct and the warning light stays on have a trained technician check the vehicle See following CAUTION CAUTION Failure to add oil immediately when the low oil warning light stays on may result in permanent engine damage PRE OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory however upon receiving your new vehicle s you should become familiar with its controls indicators and operation Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery Use the following checklist as a guide to inspect the vehicle This checklist should be used daily to ensure that th
13. OTHER OPERATING SYSTEMS OF THE VEHICLE TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS 4 HOW TO MAKE A WARRANTY CLAIM To make a warranty claim under this limited warranty you must present the vehicle or defective component to an authorized CLUB CAR dealer or send the defective component freight prepaid to WARRANTY SERVICES CLUB CAR LLC 4125 Washington Road Evans Georgia 30809 U S A 706 863 3000 Page 56 DS Gold Standard Remanufactured Vehicle Owner s Manual EMISSION CONTROL INFORMATION Fuel Information THIS VEHICLE IS CERTIFIED TO OPER ATE ON UNLEADED REGULAR GRADE GASOLINE ONLY A minimum of 87 octane of the anti knock index is recommended The anti knock index is posted on service station pumps in the U S A Emission Control Information To protect the environment in which we all live Club Car has incorporated crankcase emis sion 1 and exhaust emission 2 control sys tems EM in compliance with applicable regu lations of the U S Environmental Protection Agency and California Air Resources Board 1 Crankcase Emission Control System A sealed type crankcase emission control system is used to eliminate blow by gases The blow by gases are led to the breather chamber through the crankcase Then it is led to the air cleaner Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase and then returned back to the bottom of the crankcase 2 Exhaust Emission
14. 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 VEHICLE SHOWS INDICATIONS THAT REASONABLE OR NECESSARY MAINTENANCE AS OUTLINED IN THE OWNER S MANUAL AND MAINTENANCE AND SERVICE MANUAL WAS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS SOLE REMEDY CLUB CARS liability under this limited warranty or in any action whether based upon warranty contract negligence strict product liability or otherwise shall be the repair or replacement at CLUB CAR s option of the vehicle or component thereof that CLUB CAR deems to be defective Replacement shall mean furnishing during the applicable limited warranty period a new vehicle or factory reconditioned vehicle or component thereof that is identical or reasonably equivalent to the warranted product or component at no cost to the purchaser Repair shall mean remedying a defect in the vehicle or component thereof at no cost to the purchaser during the applicable limited warranty period CLUB CAR reserves the right to test and recharge any component returned for adjustment If CLUB CAR elects to repair the vehicle or component it may provide factory reconditioned parts or components All parts and components replaced under warranty shall become the property of CLUB CAR DISCLAIMER THIS LIMITED WAR
15. a small clean container then pour the fuel from the container into vehicle fuel tank Tighten the carburetor drain screw 2 3 Disconnect fuel vent line from fuel tank vent nipple 2 4 Plug the fuel tank vent nipple so that it is air tight We recommend using a slip on vinyl cap 3 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 12 4 Batteries should be clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse solution off batteries Do not allow this solution to enter the batteries Let the terminals dry and then coat them with Battery Terminal Protector Spray CC P N 1014305 1 Fuel Shut off Valve 2 Closed OFF 3 Open ON NOTE When selecting valve position ensure that it is fully opened or fully closed 449 Figure 18 Fuel Shut off Valve Page 30 DS Gold Standard Remanufactured Vehicle Owner s Manual Maintenance 5 To protect the engine remove spark plug and pour 1 2 ounce 14 2 mL of SAE 10 weight oil into the engine through the spark plug hole Rotate engine crankshaft by hand several times and then install the spark plug Adjust tires to recommended tire pressure See Vehicle Specifications on page 50 Perform semiannual periodic lubrication See Periodic Lubrication Schedules on page 35 Thoroughly clean front body rear body seats engine c
16. allow the battery to become damaged from vibration or jarring If battery appears weak have it charged by a trained technician The battery should never be left discharged any longer than absolutely necessary do not leave discharged overnight ENGINE OIL GASOLINE VEHICLES See General Warnings on page 10 Even though the low oil warning light on the dash should illuminate if oil level becomes low engine oil level should be checked monthly Vehicle should be on a level surface when checking oil Do not overfill with oil ENGINE OIL LEVEL CHECK 1 Remove the oil level dipstick from the oil filler tube and wipe oil off dipstick 1 Figure 27 See following CAUTION CAUTION Do not remove dipstick while engine is running 2 Check oil by fully inserting the dipstick into the oil filler tube 2 and immediately removing it 3 Ifthe oil level is at or below the low level mark on the dipstick gauge add oil until the level is between low and full levels safe level 3 4 Insert the dipstick into the oil filler tube See following NOTE NOTE Properly recycle or dispose of used oil in accordance with local state and federal regulations 1 Full level 2 Safe level 3 Low level 23 Figure 27 Engine Oil Level Check DS Gold Standard Remanufactured Vehicle Owner s Manual Page 45 Engine Oil Gasoline Vehicles ENGINE OIL AND FILTER CHANGE Engine oil and oil filter should be changed after the first 100 hours
17. caution to avoid shorting of components or wiring DS Gold Standard Remanufactured Vehicle Owner s Manual Page 11 General Warnings DISABLING THE VEHICLE Set the park brake Turn the key switch OFF and remove the key Place the Forward Reverse control in the NEUTRAL position In addition chock the wheels if servicing or repairing the vehicle mo co No cm DISCONNECTING THE BATTERY GASOLINE VEHICLES 1 Disable the vehicle See Disabling the Vehicle on page 12 2 Disconnect the battery cables negative cable first as shown Figure 3 3 Disconnect the spark plug wire s from the spark plug s CONNECTING THE BATTERY GASOLINE VEHICLES Connect the battery cables positive cable first Tighten battery terminals to 80 in Ib 9 N m Coat terminals with Battery Terminal Protector Spray CC P N 1014305 to minimize corrosion Connect the spark plug wire s to the spark plug s meg So Viewed from driver side of vehicle Viewed from passenger side of vehicle 1 Place TOW RUN Switch in TOW before disconnecting or connecting 1 Remove negative battery cable battery cables 2 Remove positive battery cable 2 Remove negative battery cable Connect battery cables in reverse order 3 Remove positive battery cable Connect battery cables in reverse order 14 Figure 3 Battery Cable Removal Gasoline Vehicle 36 Figure 2 Battery Cable Removal 6x8 Volt Battery Configuration Page 12 D
18. conjunction with motor braking Gasoline vehicles only Do not shift the vehicle out of forward while going downhill If you do you will not be able to shift into reverse or back into forward until stopped Press the brake pedal as necessary and partially press the accelerator when descending a hill With the accelerator pedal partially pressed the governor will cause the engine to assist the brakes in controlling downhill speed NOTE If the Forward Reverse handle is shifted into the NEUTRAL position power will be cut off and the engine will stop running DS Gold Standard Remanufactured Vehicle Owner s Manual Page 25 Towing STOPPING THE VEHICLE WARNING Driving through water may affect the brakes After driving through water check effectiveness of the brakes by gently pressing the brake pedal If the vehicle does not slow down at the normal rate continue to press the brake pedal until the brakes dry out and normal performance returns CAUTION When stopped on a hill use the brake pedal to hold your position Do not use the accelerator pedal to hold position To stop the vehicle release the accelerator pedal and press 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 press the park brake pedal until it locks and prevents the vehicle from rolling 2 Turn the key switch to the OFF position and place th
19. connections are tight Check and adjust as required See Steering Front wheel alignment and camber and Front Suspension in the maintenance and service manual Check for loose hardware cracks and other Motor controller output regulator MCOR damage General Vehicle Check for loose hardware tighten if necessary Refer to the maintenance and service manual Annual service by tained technician only Batteries If batteries are not performing as expected every 100 hours of operation or 200 rounds see Batteries Section in the maintenance and of golf service manual Safety decals Check safety decals Replace if damaged or illegible DS Gold Standard Remanufactured Vehicle Owner s Manual Page 33 Periodic Service Schedules PERIODIC SERVICE SCHEDULE GASOLINE VEHICLES REGULAR INTERVAL SERVICE t See Pre Operation and Daily Safety Pre Operation and Daily Safety Checklist Daily service by owner Checklist on page 22 Performance Inspection See Performance Inspection on page 23 Check engine oil level change if necessary See Periodic Lubrication Schedules on page 35 Engine Check engine cooling air intake clean if necessary Visually inspect the unshrouded Monthly service by owner or trained area around engine exhaust for grass and technician debris and clean if necessary Tires Check air pressure and adjust as necessary i See Vehicle Specifications on page 50 Wash engine compartment and underside of General vehicle
20. detrimental levels of dissolved minerals and chemicals If using tap water it is important to use an in line deionizer to remove impurities that can damage batteries and significantly reduce battery life If tap water is used without a deionizer regular water analyses must be conducted to check for impurities because water companies commonly revise their additives on a periodic basis The following chart lists the maximum allowable minerals solids and contaminates in parts per million and their impact on battery performance Your local water company should be able to perform testing and compare their results to the chart If using tap water Club Car s Service Parts Department offers two different deionizer systems one for vehicles equipped with the Single Point Water System SPWS CC P N AM1240701 and the other for vehicles without SPWS CC P N AM10974 ALLOWABLE CONTENT PARTS IMPURITY PER MILLION EFFECTS OF IMPURITY Organic and volatile matter 50 0 Corrosion of positive plates Antimon Self discharge reduces life lower i d on charge voltage Loss of capacity in plates greater loss Chloride a in positive plates Increased self discharge lower on charge voltage Increased self discharge lower on charge voltage oa o o eo None allowed Intense lowering of on charge voltage 10 0 Increased sulfation of negative plate wo o BRIN e a ofj s olo o o a BATTERY CARE To keep batteries in good working condition
21. inch 10 mm and then rotated Page 20 DS Gold Standard Remanufactured Vehicle Owner s Manual Controls and Indicators one half turn until it snaps into place the cam will be in the MAINTENANCE position Figure 14 This will allow the technician to operate the engine in neutral for certain maintenance procedures With the cam in this position the vehicle will not operate if the Forward Reverse handle is placed in either the FORWARD or REVERSE position Figure 14 Neutral Lockout Maintenance Figure 15 Neutral Lockout Operate To put the cam back into the OPERATE position pull the cam out approximately 3 8 inch 10 mm and rotate it one half turn until it snaps into place Figure 15 See following WARNING and NOTE A WARNING With the cam in the MAINTENANCE position and the engine running the vehicle may move suddenly if the Forward Reverse handle is shifted or accidentally bumped To prevent this chock the front and rear wheels and firmly set the park brake before servicing or leaving the vehicle NOTE Be sure to return the cam to the OPERATE position after servicing the vehicle or it will not operate with the Forward Reverse handle in either the FORWARD or REVERSE position CHOKE Gasoline Vehicles Only The choke is located on the seat support panel below and to the left of the driver s left knee Figure 16 If the vehicle is hard to start in cool or cold temperatures simply push in the choke cover to activate it
22. listed STEERING SUSPENSION BRAKES Steering Self adjusting rack and pinion Suspension Front and rear tapered mono leaf springs with dual hydraulic shocks Brakes Dual rear wheel self adjusting brakes with cast iron drums and single brake pedal with automatic release park brake BODY CHASSIS Frame Chassis Twin l Beam welded aluminum Front and rear body ArmorFlex Page 50 DS Gold Standard Remanufactured Vehicle Owner s Manual Vehicle Specifications GASOLINE ELECTRIC SPECIFICATIONS EIE GASOLINE FOUR FOUR PASSENGER PASSENGER Tires 18 x 8 5 8 tubeless 4 ply rated DIMENSIONS WEIGHT Wheelbase 0000000000000 65 5 in o0 655m o OE cm Ground clearance 4 5 in 11 cm Front wheel tead wheel tread 34 5 in 88 fh in Bem int tees e ees o omen emere OCC 0 ams RemMEN wewem LIQUID CAPACITIES meme o o 1 seu eranen oran 5es Ename caress nme i ws funtion ree we dC mam ooo Ll e TIRE PRESSURE 18 20 psi 18 20 psi Front and rear 12 14 psi 0 83 0 96 Bars 1 24 1 38 Bars 1 24 1 38 Bars NOISE AND VIBRATION 68 dBA 70 7dBA Drive by noise level to operator Test method EN 12053 2001 Uncertainty 2 Uncertainty 2 dBA dBA 0 7 m s 0 8 m s Vibration at driver s seat Test method EN 13059 2002 Uncertainty Uncertainty 0 12 m s2 0 020 m s DS Gold Standard Remanufactured Vehicle Owner s Man
23. must be towed an adequately powered vehicle tractor or full sized truck properly fitted with a tow hitch height of 11 inches 28 cm should be used Only heavy duty tow bars should be used for multi vehicle towing Never tow more than five vehicles at one time WARNING CONTINUED ON NEXT PAGE Page 26 DS Gold Standard Remanufactured Vehicle Owner s Manual Transporting on a Trailer WARNING Electric vehicles only Place the Tow Run switch in TOW position otherwise the vehicle will not roll while being towed Gasoline vehicles only Turn the fuel shut off valve to the closed OFF position Figure 18 Page 30 All vehicles are equipped with both front and rear tow bar attaching points A light duty tow bar is available for break down towing and single vehicle towing A heavy duty tow bar and an onboard tow bar are available for multi vehicle towing Observe all of the previous WARNING statements when towing TRANSPORTING ON A TRAILER WARNING For use on public roads the trailer must meet all federal state and local requirements such as taillights brake lights etc Do not tow a Club Car vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer The vehicle to be towed should be tied securely to the trailer with the Forward Reverse handle or switch in the NEUTRAL position the key switch in the OFF position and the park brake firmly pressed and locked to prevent mo
24. not conform to US Federal Motor Vehicle Safety Standards for automobiles or to FMVSS 500 for low speed vehicles and are not equipped for operation on public streets roads or highways If in English this manual is the Original Instructions provided by the manufacturer If in any language other than English this manual is a translation of the Original Instructions Club Car i P O Box 204658 Augusta Georgia 30917 4658 USA Telephone 706 863 3000 Service Parts Fax 706 855 7413 www clubcar com Copyright 2012 Club Car LLC Club Car Tranquility and ArmorFlex are registered trademarks of Club Car LLC This manual effective April 25 2012 DS Gold Standard Remanufactured Vehicle Owner s Manual Page 1 FOREWORD Thank you for choosing Club Car the name most widely recognized as the industry leader in vehicle efficiency and long lasting value You have chosen the finest golf car on the market Please protect your investment and ensure that your Club Car vehicle s provides years of reliable superior performance by reading and following the maintenance instructions in this manual Your comfort and safety are important to us so we urge you to read and follow the step by step operating instructions and safety procedures in this manual These instructions must be followed in order to avoid the risk of severe personal injury If you rent or loan your vehicle to others we recommend that you ask them to read this manual before they o
25. of operation After that they should be changed every 200 hours of operation or annually whichever comes first 1 Turn the key switch to the OFF position then remove the key Place the Forward Reverse handle in the neutral POSITION Chock the front wheels Access the engine compartment Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 12 Position a pan designed for oil changes under the front drain plug Figure 28 e O N 1 Drain pan 2 Drain plug 3 Oil filter 25 Figure 28 Engine Oil Drain Plug and Pan 5 Use a 14 mm socket or wrench to remove the drain plug turning it counterclockwise and allow the engine oil to drain into the pan See following WARNING WARNING Do not attempt to change engine oil when the engine is hot or even warm Engine oil can cause skin burns Wear safety glasses or approved eye protection when servicing the vehicle Wear rubber gloves when handling oil drain plug oil filter and oil drain pan 6 Clean the oil drain plug threads with solvent to remove oil and oil residue Make sure that the compression washer remains on the drain plug 7 Usea 14 mm socket or wrench and replace the front oil drain plug turning it clockwise and tighten to 18 ft lb 24 4 N m 8 Relocate the oil drain pan to a position under the engine oil filter Figure 28 9 Remove the engine oil filter 1 turning it counterclockwise allow
26. should be placed on charge as soon as possible after use Batteries are warmest immediately after use and cold batteries require more time to fully charge Insert the charger DC plug into the vehicle receptacle The charger will turn on two to ten seconds later Figure 22 When inserting the DC plug align the raised guide on the plug with the guide slot in the receptacle and push straight in slowly Club Car battery chargers interact with the vehicle onboard computer The computer records the amount of energy consumed during vehicle use While the charger is plugged in the vehicle s control circuit is locked out preventing operation of the vehicle as well as the possibility of consequent damage to the charger and the vehicle DS Gold Standard Remanufactured Vehicle Owner s Manual Page 41 Battery Charger Electric Vehicles Once the lockout is actuated the charger turns on The onboard computer then records the amount of energy being returned to the batteries When the optimum amount of energy needed to replenish the batteries is returned the charger will shut off The control circuit lockout remains activated until the charger plug is disconnected from the vehicle Figure 22 Correct Insertion of Charger DC Plug Figure 23 Incorrect Insertion of Charger DC Plug Only PowerDrive System 48 and IQ System vehicles are compatible with PowerDrive chargers Other Club Car models or vehicles made by other manufacturers are not compatible A
27. the emission control system on the vehicle engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your small off road engine Your emission control system may include parts such as the carburetor or fuel injection system the ignition system the catalytic converter and related hoses belts connectors and other emission assemblies or components Where a warrantable condition exists as defined herein CLUB CAR will repair your vehicle engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE This emission control system is warranted for two years from the vehicles date of purchase If any emission related part on your CLUB CAR SORE is defective the part will be repaired or replaced by CLUB CAR OWNER S WARRANTY RESPONSIBILITIES As the vehicle engine owner you are responsible for the performance of the required maintenance listed in your owner s manual CLUB CAR recommends that you retain all receipts covering maintenance on your vehicle engine but CLUB CAR cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the vehicle engine owner you should however be aware that CLUB CAR may deny you warranty coverage if vehicle engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting vehicle e
28. working condition the purity of water used is very important Distilled water is quite pure and is the most common type of water used in batteries Other acceptable types are deionized water and water from reverse osmosis Ordinary tap water should not be used because it contains an excessive amount of impurities that will degrade battery performance Distilled water is produced by distillation a process in which water is boiled the steam is collected and then condensed back into water This process creates a finished product free of minerals having left all the impurities in the original water sample Club Car along with our battery manufacturers highly recommends that distilled water be used in electric vehicle batteries Deionized water is the purest form of water Deionization removes all ionizable particles organic and inorganic from water through ion exchange Positively and negatively charged ions are removed from the water and replaced with H and OH ions When these two ions are combined they form H2O or purified water DS Gold Standard Remanufactured Vehicle Owner s Manual Page 37 Batteries Electric Vehicles Reverse osmosis is a method of removing solids from water by forcing it through a membrane The membrane rejects all solids while allowing purified water to pass through The choice of membrane determines the amount of impurities that the water may contain Water from municipal supplies ponds and wells usually contain
29. 101960601 Before using vehicle read owner s manual and vehicle safety warnings Study and understand controls TO OPERATE Ensure wheels are turned in desired direction and path is clear Turnkey to ON position Select FORWARD or REVERSE only when stopped Release park brake fully Vehicle will start moving when accelerator pedal is pressed Slowly press accelerator pedal to increase speed Tostop release accelerator pedal and press brake pedal Unintended vehicle movement may cause severe injury or death Before leaving vehicle Engage park brake to lock wheels Place vehicle in NEUTRAL Turn key to OFF and remove key 103783002 F Park Brake Pedal Fs Accelerator Pedal 1 sereosnr Decat Roter warina on mauent pane 5 laf Low Oil Warning Light 8 Serial Number Brake Pedal Page 6 DS Gold Standard Remanufactured Vehicle Owner s Manual Safety Decal and Feature Identification GASOLINE VEHICLE GASOLINE EXPLOSION FIRE Can cause severe injury or death No smoking sparks or open flame Stop engine allow to cool before refueling Turn fuel valve 4 on during operation off during storage or transport CCI 101547601 CAN CAUSE SEVERE INJURY Rotating parts a men manifold amp muffler KEEP CLEAR cci 1019605 01 y Negative frame ground Can cause severe injury 3 Excessive speed T ee Ba nat tannar anh ads aerarii Decal Gasoline Fuel Warning at fuel fill or
30. 897209 Edition Code 0412B0412A This manual is valid for vehicles with build codes between 55775 and the one indicated at the top of this page aa Club Car LLC P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Intl 1 706 863 3000 Fax 1 706 863 5808
31. C to resume operation 11 3 If AC power is off for 7 days or longer the OBC will not function or charge the vehicle again until it has been restarted To restart the computer make sure AC power has been restored disconnect the DC cord stationary charger from the vehicle or the AC cord onboard charger from the power source wait five seconds then reconnect it CAUTION Be sure to check the batteries and charger monthly to maintain correct battery water level and to ensure the charger is operating correctly during storage 12 To disconnect the batteries for storage 12 1 Disconnect B battery cable that comes from the OBC and secure it in a way that ensures the cable will not come into contact with battery terminal RETURNING THE STORED ELECTRIC VEHICLE TO SERVICE 1 If necessary connect batteries See Connecting the Batteries Electric Vehicles on page 13 2 Fully charge batteries WARNING Do not attempt to charge frozen batteries or batteries with bulged cases Discard the battery Frozen batteries can explode 3 Adjust tires to recommended tire pressure See Vehicle Specifications on page 50 4 Perform the Pre Operation and Daily Safety Checklist on page 22 STORAGE GASOLINE VEHICLES See General Warnings on page 10 DANGER Do not attempt to drain fuel when the engine is hot or while it is running Besure to clean up any spilled gasoline before operating the vehicle Store fuel in
32. CLUB CAR according to subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the original warranty period 2 Any warranted part that is scheduled only for regular inspection in the written instructions supplied is warranted for the warranty period stated above Any such part repaired or replaced under warranty will be warranted for the remaining original warranty period 3 Any warranted part that is scheduled for replacement as required maintenance in the written instructions supplied is warranted for the period of time before the first scheduled replacement date for that part If the part fails before the first scheduled replacement the part will be repaired or replaced by CLUB CAR according to subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the period prior to the first scheduled replacement point for the part 4 Repair or replacement of any warranted part under the warranty provisions herein must be performed at a warranty station at no charge to the owner 5 Notwithstanding the provisions herein warranty services or repairs will be provided at all of our distribution centers that are franchised to service the subject engines or equipment DS Gold Standard Remanufactured Vehicle Owner s Manual Page 55 Warranties 6 The engine or equipment owner will not be charged for diagnostic labor that is directly associated wi
33. RANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANT Y THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE SOLE REMEDY OF THE REPLACEMENT OR REPAIR OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE DISTRIBUTOR OR DEALER OF CLUB CAR HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY In the event that another pre printed warranty document certificate or both offered by or through Club Car at the time of sale of this vehicle each an Additional Warranty Document is deemed to conflict with the limitations or exclusions contained herein the limitations and exclusions contained herein shall continue to apply to both this limited warranty statement and to the maximum extent permitted by law to each Additional Warranty Document NO CONSEQUENTIAL DAMAGES IN NO EVENT SHALL CLUB CAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS RELATED TO PROPERTY OTHER THAN THE VEHICLE LOSS OF USE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Some states allow neither limitation on the duration of an implied warranty nor exclusions or l
34. S Gold Standard Remanufactured Vehicle Owner s Manual General Warnings DISCONNECTING THE BATTERIES ELECTRIC VEHICLES 1 Disable the vehicle See Disabling the Vehicle on page 12 2 Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning could result in a battery explosion or severe personal injury 3 Disconnect the batteries negative cable first as shown Figure 2 4 After disconnecting the batteries wait 90 seconds for the controller capacitors to discharge CONNECTING THE BATTERIES ELECTRIC VEHICLES Ensure the Tow Run switch is in the TOW position Connect the battery cables positive cable first Tighten battery terminals to 110 in Ib 12 4 N m Coat terminals with Battery Terminal Protector Spray CC P N 1014305 to minimize corrosion meo c RECYCLING LEAD ACID BATTERIES WARNING Lead acid batteries contain lead Pb other metals acids and other compounds If improperly handled they can contaminate both water and soil causing environmental damage and personal injury Lead acid batteries are identified by the symbol shown below and should be properly recycled Figure 4 They cannot be disposed as municipal waste and must be collected separately Responsibility for environmental protection must be shared not only by the manufacturers of the batteries but by people who use the batteries as well Please contact your nearest Club C
35. UTRAL position during storage If so installed turn off all accessories including GPS units fans etc 3 Place the tow run switch in the TOW position Because the battery warning light does not illuminate with the key in the OFF position and the tow switch in TOW do not use the warning light as an indication of the batteries state of charge NOTE If Visage or Guardian units are installed on vehicles and remote monitoring will be used during the storage period make sure the Tow Run Switch remains in the RUN position rather than in the TOW position required for all other vehicles 4 Batteries should be clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse solution off batteries Do not allow this solution to enter the batteries Let the terminals dry and then coat them with Battery Terminal Protector Spray CC P N 1014305 Tighten all battery cable connections to 110 in Ib Store vehicle in a cool dry place This will minimize battery self discharge Adjust tires to recommended tire pressure See Vehicle Specifications on page 50 Perform semiannual periodic lubrication See Periodic Lubrication Schedules on page 35 Thoroughly clean front body rear body seats battery compartment and underside of vehicle Do not engage the park brake Chock the wheels to prevent the vehicle from rolling COND e NOTE
36. ake pedal cannot be pressed to the floor under any circumstance Park brake When latched the park brake should lock the wheels and hold the vehicle stationary on an incline of 209 or less It should release when either the accelerator or brake pedal is pressed Reverse buzzer The reverse buzzer should sound as a warning when the Forward Reverse handle or switch is in the REVERSE position Steering The vehicle should be easy to steer and should not have any play in the steering wheel General Listen for any unusual noises such as squeaks or rattles Check the vehicle s ride and performance Have a Club Car distributor dealer or a trained technician investigate anything unusual Electric Vehicles Accelerator With the key switch in the ON position and the Forward Reverse switch in the FORWARD position as the accelerator pedal is pressed the motor should start and the vehicle should accelerate smoothly to full speed When the pedal is released it should return to the original position and the motor should rotate freely or go into motor braking mode See Pedal Up Motor Braking below All Club Car vehicles operate at reduced speed in reverse Walk Away Braking With the vehicle parked on level ground and the park brake disengaged place the Tow Run Switch in the RUN position and attempt to push the vehicle Motor braking should engage and cause resistance to rolling moving at no more than 1 to 3 mph 1 5 to 4 8 km h with the Fo
37. an approved fuel container only Store in a well ventilated area away from sparks open flames heaters or heat sources Keep fuel out of the reach of children Do not siphon fuel from the vehicle WARNING Turn the key switch to the OFF position remove the key and leave the Forward Reverse handle in the NEUTRAL position during storage This is to prevent unintentionally starting the vehicle or a fire hazard Turn the fuel shut off valve to the closed OFF position Figure 18 DS Gold Standard Remanufactured Vehicle Owner s Manual Page 29 Storage Gasoline Vehicles CAUTION Batteries in a low state of charge will freeze at low temperatures PREPARING THE GASOLINE VEHICLE FOR EXTENDED STORAGE 1 Store vehicle in a cool dry place This will minimize battery self discharge If the battery appears to be weak have it charged by a trained technician Use an automotive type 12 volt battery charger rated at 10 amps or less 2 Drain carburetor and seal the fuel tank 2 1 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout cam in the MAINTENANCE position Turn the fuel shut off valve to the closed OFF position Figure 18 and run the engine until fuel remaining in the carburetor and fuel lines is depleted and the engine stalls Return the neutral lockout cam to the OPERATE position 2 2 Loosen but do not remove the carburetor drain screw and drain fuel remaining in bowl into
38. ar dealer or distributor for information on how to properly recycle your batteries 1403 Figure 4 Dispose of Lead acid Batteries Properly INTERNATIONAL SAFETY SYMBOLS ON BATTERIES Anyone using repairing or servicing the vehicle must understand and heed the safety symbols on the vehicle battery or batteries DS Gold Standard Remanufactured Vehicle Owner s Manual Page 13 General Information Q d 9 amp A o 000 1 Shield eyes 3 No smoking no open flames no sparks 5 Battery acid hazard 2 Read and follow operating instructions 4 Keep away from children 6 Explosive gas hazard Refer to General Warnings for more information 1642 Figure 5 International Safety Symbols on Batteries GENERAL INFORMATION This manual features two remanufactured DS Golf Car models the IQ System 48 volt electric vehicle and the gasoline vehicle Throughout this manual important features unique to each model are highlighted We urge the owner operator to read and understand this manual and to pay special attention to the features specific to his her vehicle s MODEL IDENTIFICATION The serial number of each remanufactured vehicle is printed on a bar code decal mounted either below the passenger side cup holder or above the accelerator or brake pedal Example PH0901 583947 Figure 6 The two letters 1 at the beginning of the serial number indicate the vehicle model The following four digits 2 indicate the model year a
39. at handle while moving Do not start vehicle until all occupants are seated Two 2 persons per seat maximum Operate from driver side only and not on public roads Keep entire body inside vehicle while moving Drive slowly in turns and straight up and down slopes Do not leave children unattended on vehicle Never operate under the influence of alcohol or drugs Use brakes to reduce speed when coasting downhill Never stand in front of or behind vehicle CCI 101960601 OPERATING INSTRUCTIONS Before using vehicle read owner s manual and vehicle safety warnings Study and understand controls TO OPERATE Ensure wheels are turned in desired direction and path is clear Turnkey to ON position Select FORWARD or REVERSE only when stopped Release park brake fully Vehicle will start moving when accelerator pedal is pressed Slowly press accelerator pedal to increase speed During operation beeping alarm indicates reduction in motor braking Tostop release accelerator pedal and press brake pedal Unintended vehicle movement may cause severe injury or death Before leaving vehicle Engage park brake to lock wheels Place vehicle in NEUTRAL Turn key to OFF and remove key 103783001 101960601 Decal Rollover Warning on instrument panel 103783001 Decal Operating Instructions on steering wheel Page 4 DS Gold Standard Remanufactured Vehicle Owner s Manual Safety Decal and Feature Identi
40. bled The key switch may be used as an emergency stop The key can be removed only when the key switch is in the OFF position Figure7 Key Switch FORWARD REVERSE CONTROL IQ System Electric Vehicles The Forward Reverse rocker switch is located on the seat support panel below and to the right of the driver s right knee The F FORWARD and R REVERSE positions are clearly marked Push down the FORWARD side of the switch to operate the vehicle in the forward direction or push down the REVERSE side of the switch to operate the vehicle in reverse When the rocker switch is positioned in the NEUTRAL position with neither side down the vehicle will not operate if the accelerator pedal is pressed Figure 9 The reverse buzzer will sound as a warning when the Forward Reverse switch is in the REVERSE position Gasoline Vehicles The Forward Reverse handle is located on the seat support panel below and to the right of the driver s right knee Figure 8 The Forward Reverse handle has three distinct positions F FORWARD R REVERSE and N NEUTRAL Rotate the handle towards the driver FORWARD to operate the vehicle in the forward direction or towards the passenger REVERSE to operate vehicle in reverse When the handle is in the straight up position NEUTRAL the vehicle will not operate Club Car vehicles operate at reduced speed in reverse The reverse buzzer will sound as a warning when the Forward Reverse handle is in the REVERSE position
41. braking has been activated See following WARNING WARNING Walk Away braking will not limit vehicle speed to 1 mph 1 6 km h on very steep grades Do not operate vehicle on slopes exceeding 20 grades Pedal Down Motor Braking This feature helps to control vehicle downhill speed Motor braking is activated when the vehicle reaches the programmed top speed and holds the vehicle at that speed Motor braking is automatically disengaged when vehicle speed slows below the programmed top speed See following WARNING Pedal Up Motor Braking When vehicle speed is above 11 mph 17 7 km h releasing the accelerator pedal will activate motor braking which slows the vehicle speed Once vehicle speed slows to below approximately 11 mph 17 7 km h with the accelerator pedal still released motor braking will be deactivated and the vehicle will coast freely This feature is selectable Contact your dealer distributor to inquire about this selectable feature See following WARNING WARNING When batteries are fully charged a warning buzzer will sound during motor braking to alert the driver that motor braking is operating at a reduced level of performance When this occurs use the brake pedal to control vehicle speed BRAKE PEDAL The brake pedal is the large pedal on the left with the word STOP molded into it Figure 10 To slow or stop the vehicle press the brake pedal with your foot Figure 11 78 79 Figure 11 Brake Pe
42. d it should return to the original position and the engine should stop All Club Car vehicles operate at reduced speed in reverse Governor Check maximum speed of the vehicle The vehicle should operate at 12 15 mph 19 24 km h on a level surface DRIVING INSTRUCTIONS WARNING Only licensed drivers should be allowed to drive the vehicle f renting or loaning the vehicle make sure the driver is familiar with all controls and operating procedures before allowing the vehicle to be driven No more than two people should be on the vehicle at one time The vehicle is not specially equipped for handicapped persons Be sure all persons can properly operate the vehicle prior to allowing them to drive the vehicle e Be sure all passengers are capable of securing themselves in a vehicle before allowing them to ride in one For night use the vehicle must be equipped with headlights taillights and reflectors Stop the vehicle before shifting the Forward Reverse handle Failure to do so may result in injury to an unsuspecting passenger and or damage to the vehicle To help avoid being struck do not stand in front of or behind the vehicle Operate the vehicle from the driver seat only To help prevent falls from the vehicle remain seated in a moving vehicle and hold on to hand holds or handrails at all times Driver should keep both hands on the steering wheel when the vehicle is in motion To help prevent
43. dal Figure 12 Park Brake Pedal Page 18 DS Gold Standard Remanufactured Vehicle Owner s Manual Controls and Indicators PARK BRAKE PEDAL The park brake pedal is the small raised portion in the upper left corner of the brake pedal It has the word PARK molded into it and the words PARK BRAKE marked on top of it Figure 11 To set the park brake press the brake pedal firmly and tilt the park brake portion of the pedal forward with your foot Figure 12 See following WARNING WARNING The park brake will release automatically when either the accelerator or brake pedal is pressed The park brake has multiple locking positions and should be firmly pressed and locked to prevent the vehicle from rolling BATTERY WARNING LIGHT IQ System Electric Vehicles Only IQ System vehicles feature a dash mounted warning light above steering column that when the vehicle is in operation indicates low battery voltage or when the vehicle is being charged indicates a charging problem The battery warning light is controlled by the onboard computer When the vehicle is in operation the warning light will illuminate and remain illuminated if Batteries voltage drops below 48 volts when there is no load on the batteries the vehicle is stopped and there are no accessories on Batteries have discharged to less than 25 of rated capacity If the warning light illuminates when the vehicle is operating there will be enough power remaining to
44. drive the vehicle for approximately 30 minutes However the vehicle should be charged at the first opportunity If the warning light illuminates and the vehicle is unable to operate for 30 minutes have your Club Car distributor dealer check the vehicle for a possible battery or electrical system problem When the batteries receive an incomplete charge because 1 the DC power cord is disconnected 2 AC power to the charger is interrupted 3 automatic charger shut off occurs after 16 hours of operation 4 the charger malfunctions or 5 the wrong charger is used the warning light will indicate as follows The warning light will not illuminate if the charge is 90 or more complete The onboard computer will retain in memory the amount of charge needed to fully replenish the batteries and will complete the charge during the next charge cycle When the charger is unplugged the warning light will illuminate and remain illuminated for 10 seconds if the charge is less than 90 complete but the vehicle has enough power for approximately 30 minutes of operation This will alert the operator that the vehicle may be used but that it must be charged to completion as soon as possible The warning light will repeatedly illuminate for 10 seconds with 4 second intervals if the charger times out at 16 hours and the batteries are not sufficiently charged See the battery charger owner s manual This indicates an abnormal charge cycle The charger and batteries
45. during the fueling operation Ifthe vehicle has an all weather enclosure installed be sure the fuel tank is properly vented as shown Figure 32 To avoid the possibility of fire clean up any spilled fuel before operating the vehicle CAUTION Use unleaded gasoline only Whenever possible avoid using oxygenated and blended fuels Do not use any fuel with an alcohol content that exceeds 10 by volume such as E15 and E85 Ethanol is an alcohol that readily absorbs moisture causing corrosion of fuel system components It also damages neoprene and other plastic and rubber components Use of these fuels in this vehicle will void the warranty To allow for expansion do not fill higher than 2 54 cm one inch from the top of the fuel tank Avoid spilling fuel Turn the key switch to the OFF position Lift and remove seat bottom The fuel tank is located on passenger side of vehicle Remove fuel cap and fill the fuel tank with fresh unleaded gasoline only See preceding DANGER and CAUTION Replace fuel cap on tank Ensure cap is tightened securely Replace seat bottom Page 48 DS Gold Standard Remanufactured Vehicle Owner s Manual Cleaning the Vehicle 1 Vent 2 Shut off Valve 3 Vent Tubes 24 Figure 32 Fuel Tank CLEANING THE VEHICLE Club Car DS vehicles are equipped with ArmorFlex front and rear bodies Use only commercially available automotive cleaners with a sponge or soft cloth for normal cleaning
46. e Forward Reverse handle or switch in the NEUTRAL position Remove the key when the vehicle is not in use Electric vehicles only When the Tow Run switch is in the RUN position with the Forward Reverse switch or key switch in any position the walk away braking function will prevent the vehicle from rolling at more than 1 to 3 mph 1 5 to 4 8 km h unless the accelerator is pressed This prevents the possibility of a parked vehicle with the park brake disengaged rolling away too fast to be overtaken on foot Gasoline vehicles only Turn the fuel shut off valve to the closed OFF position when the vehicle is not in use TOWING WARNING Do not tow the vehicle on public streets or highways Use only approved Club Car tow bars Turn the key switch to the OFF position and place the Forward Reverse handle or switch in the NEUTRAL position before towing the vehicle Extreme caution should be used when towing any vehicle Do not exceed 5 mph 8 km h towing speed Do not allow people in the vehicles being towed Avoid sudden starts sudden stops and tight turns when towing Avoid stopping on a hill when towing If you must stop on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning could cause the vehicle to overturn possibly resulting in severe personal injury Do not tow more than one Club Car vehicle with another Club Car vehicle If more than one vehicle
47. e Fueling Instructions Gasoline Vehicles on page 48 Check fuel tank lines cap pump fuel filters and carburetor for fuel leakage Exhaust system gasoline vehicles Check for leaks Performance Inspection Inspect as instructed See Performance Inspection on page 23 WARNING Besure the plastic has been removed from the seat bottom before operating the vehicle Failure to do so may result in a fire property damage personal injury or death PERFORMANCE INSPECTION After you have familiarized yourself with the vehicle controls and have read and understood the driving instructions take the vehicle for a test drive Use the following checklist in conjunction with the Daily Pre Operation and Safety Checklist as a guide to inspect the vehicle and check daily for proper operation Any problems should be corrected by a Club Car distributor dealer or a trained technician All Vehicles Forward Reverse control Check for proper operation See Controls and Indicators on page 15 Brakes Be sure the brakes function properly When brake pedal is fully pressed under moderate pressure it should not go more than halfway to the floor and vehicle should come to a smooth straight stop within 14 feet 4 3 m If the pedal goes more than halfway to the floor or if the vehicle swerves or fails to stop within 14 feet 4 3 m have the brake system checked and adjusted as required Brake adjustment must be maintained so that the br
48. e removal or rendering inoperative by any person other than for purposes of maintenance repair or replace ment of any device or element of design incor porated into any new engine for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the engine after such device or element of design has been removed or rendered inopera tive by any person Among those acts presumed to constitute tampering are the acts listed below Do not tamper with the original emission relat ed parts Carburetor and internal parts Spark plugs Magneto or electronic ignition system Fuel filter element Air cleaner element Crankcase Cylinder head Breather chamber and internal parts Intake pipe and tube A WARNING After refueling make sure the tank cap is closed securely If gasoline is spilled on the fuel tank wipe it off immediately Cil Viscosity Choose the viscosity according to the tem perature as follows 10 C 0 C 20 C 10C 20 p lt SAE10W 30 SAE 10w 40 gt 10W 30 SAE 10W 40 S 14 F a 50 F 68 F 86F 104 F 30 C 40 C NOTE Using multi grade oils BW 20 10W 30 and 10W 40 will increase oil consumption Check oil level more frequently when using them Page 57 NOTES BC56042 Publication Part Number 103
49. e vehicle is in proper working condition and in conjunction with the Performance Inspection on page 23 and the Periodic Service Schedules on page 32 Any problems should be corrected by a Club Car distributor dealer or a trained technician General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tight On gasoline vehicles check all hose clamps for tight fit as well as the starter belt for tightness Safety and information decals Check to ensure that all safety and information decals are in place See Safety Decal and Feature Identification on page 4 Tires Check for proper tire pressure Visually inspect tires for wear damage and proper inflation on a daily basis See Vehicle Specifications on page 47 Page 22 DS Gold Standard Remanufactured Vehicle Owner s Manual Pre Operation and Daily Safety Checklist Battery ies Check electrolyte to ensure that it is at its proper level Figure 21 Page 39 or Figure 26 Page 44 Check battery posts Wires should be tight and free of corrosion On electric vehicles charge batteries fully before first use of vehicle Charger cord plug and receptacle electric vehicles Visually inspect for cracks loose connections and frayed wiring See Plug and Receptacle on page 42 Engine gasoline vehicles Check for proper engine oil level See Engine Oil Gasoline Vehicles on page 45 Fuel gasoline vehicles Check fuel level Se
50. es in vehicles that do not receive proper charging 6 Every vehicle must have an operational charger on its own circuit Number of operational chargers must equal the number of operational vehicles 7 Vehicles charged by systems other than the CLUB CAR Charger Page 52 DS Gold Standard Remanufactured Vehicle Owner s Manual Warranties 8 Semiconductor parts such diodes and fuses that are vulnerable to electrical overloads including lightning beyond the control of CLUB CAR 9 Charger DC cord set with plug which is a wear item and subject to user abuse 10 Use of gasoline containing more than 1096 ethanol Without limiting the generality of the foregoing in any way and as part of its limited warranty exclusion CLUB CAR does not warrant that its vehicle or components such as batteries computer controller or electrical device are suitable for use in any application other than in its products As in the use of any vehicle batteries computer controller or electrical device a prudent owner will read and study the owner s manual the operator instructions and the warning labels and will exercise due care in working on or around vehicles batteries or electrical devices Transportation expenses for warranty services are also excluded from this warranty VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICLE OR COMPONENT IS ABUSED OR USED IN AN UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY
51. fication ELECTRIC VEHICLE NOTICE Do not operate vehicle without this cover properly installed Do not direct water stream in this area will cause damage to components See vehicle maintenance and service manual before servicing CCI 101931501 TOW RUN Place Tow Run switch in TOW position before FAILURE TO HEED THIS Disconnecting or connecting batteries WARNING COULD RESULT Bos IN A BATTERY EXPLOSION daa storage OR SEVERE PERSONAL ervicing INJURY CCI 101908601 Decal Tow Switch Warning on Tow Run switch 1 101908601 3 Battery Charger Receptacle plate under seat Decal Component Cover Notice on electrical 2 101931501 4 Forward Reverse Control component cover DS Gold Standard Remanufactured Vehicle Owner s Manual Page 5 Safety Decal and Feature Identification GASOLINE VEHICLE ROLLOVER OR FALLING OFF MAY CAUSE DEATH Before using vehicle read operating instructions Remain seated and hold on to seat handle while moving Do not start vehicle until all occupants are seated Two 2 persons per seat maximum Operate from driver side only and not on public roads Keep entire body inside vehicle while moving Drive slowly in turns and straight up and down slopes Do not leave children unattended on vehicle Never operate under the influence of alcohol or drugs Use brakes to reduce speed when coasting downhill OPERATING INSTRUCTIONS Never stand in front of or behind vehicle CCI
52. flying objects golf balls etc DS Gold Standard Remanufactured Vehicle Owner s Manual Page 49 Subsequent Owner Registration SUBSEQUENT OWNER REGISTRATION In the event a vehicle is bought as a used vehicle we strongly urge the new owner to register the vehicle with Club Car This will enable us to contact you if the need arises Please send your name address and serial number s of the vehicle s to Club Car LLC P O Box 204658 Augusta Georgia 30917 4658 Attention Vehicle Registration VEHICLE SPECIFICATIONS GASOLINE ELECTRIC SPECIFICATIONS ripa GASOLINE FOUR FOUR PASSENGER PASSENGER POWER SOURCE Engine 4 cycle OHV 351 cc 11 5 maximum hp 3600 RPM per SAE J 1940 1349 single cylinder air cooled with pressure lubrication system Fuel system Side draft carburetor with float bowl fixed jets fuel filters and impulse fuel pump Governor Automatic ground speed sensing internally geared in unitized transaxle Ignition Transistor electronic ignition with electronic RPM limiter BEEN Transaxle Double reduction helical gear with 12 3 1 direct drive Loe fe eee axle Unitized transaxle Fully synchronized forward and reverse with neutral and reduced speed reverse 11 8 1 forward 17 1 1 reverse Electrical system 12 volt 500 cca at 0 F 17 8 C 650 at 32 F 0 C 105 minute reserve capacity and 35 amp charging capacity Batteries High capacity deep cycle Charger Automatic 48 volt UL and CSA
53. ic vehicle is equipped with a receptacle fuse link Figure 24 If the charger does not come on when the vehicle is placed on charge visually inspect the fuse link See following WARNING A WARNING Ifthe receptacle fuse link is blown determine the source of the electrical problem and correct it before replacing the fuse Contact your nearest Club Car distributor dealer BATTERY GASOLINE VEHICLES See General Warnings on page 10 DANGER Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries Tools wires and metal objects can cause sparks when shorted across a battery Follow all instructions carefully when working with batteries DANGER CONTINUED ON NEXT PAGE DS Gold Standard Remanufactured Vehicle Owner s Manual Page 43 Battery Gasoline Vehicles DANGER Charge battery in a well ventilated area only Battery Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes External Flush with water Call a physician immediately Internal Drink large quantities of milk or water followed with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately WARNING Do not j
54. imitation of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state HOW TO MAKE A WARRANTY CLAIM To make a warranty claim under this limited warranty you must present the vehicle or defective component with evidence of proof of purchase date and number of energy units if applicable to an authorized CLUB CAR dealer DS Gold Standard Remanufactured Vehicle Owner s Manual Page 53 Warranties For warranty related communication contact Warranty Services Club Car 4125 Washington Rd Evans GA 30809 USA 706 863 3000 WARNING Any modification or change to the vehicle that affects the electrical system stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications could result in severe personal injury or death Page 54 DS Gold Standard Remanufactured Vehicle Owner s Manual Warranties CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and Club Car LLC CLUB CAR are pleased to explain the emission control system warranty on your 2009 and newer vehicle engine the emission warranty In California new small off road engines SORE must be designed built and equipped to meet the State s stringent anti smog standards CLUB CAR shall warrant
55. ing the residual oil in the filter port and filter to drain into the oil drain pan 2 Figure 29 See following NOTE Page 46 DS Gold Standard Remanufactured Vehicle Owner s Manual Engine Oil Gasoline Vehicles NOTE An oil drip guard 3 can be used to prevent excess oil from dripping into the engine base plate Use an empty quart one liter container and cut the bottom off at an angle then slide the open area of the container up and under the oil filter prior to removing Position the port of the plastic container so oil will be directed into the oil pan Or make a drip guard by folding a piece of cardboard thin metal or plastic under the oil filter forming a channel to direct the filter port oil into the drain pan Dispose of used oil according to the environmental laws and regulations for your area 26 Figure 29 Remove Engine Oil Filter 10 Use a clean rag and wipe the oil filter mounting bracket surface clean where the oil filter gasket seats 11 Coat new oil filter gasket with clean engine oil and install the oil filter onto the engine oil filter port Figure 30 NOTE Use only Club Car oil filters CC P N 103887901 designed for this engine 12 Hand tighten 2 3 to 3 4 turn after filter gasket contacts mounting surface 13 Remove the dipstick and add engine oil into the dipstick port Use a funnel or pour spout to direct the oil into the dipstick port With filter change the engine requires 38 ounces 1 12 liters of
56. ld drive the vehicle without first being instructed in the proper operation and use of the vehicle s controls An experienced operator should accompany each first time driver on a test drive before allowing him her to operate the vehicle alone To ensure safe operation of the vehicle follow exactly and in order all of the following procedures Read and understand all instructions prior to driving the vehicle STARTING THE VEHICLE Study and understand controls Make sure everyone is seated and holding onto seat hand holds or handrails Read safety and information decals located on the vehicle Make sure wheels are turned in desired direction Turn the key to the ON position and make sure nothing is in your path Select direction by placing the Forward Reverse handle or switch in desired position F forward or R reverse A buzzer will sound as a warning when the Forward Reverse handle or switch is in the REVERSE position Dak ON gt 7 Slowly press accelerator pedal The park brake will release automatically and the vehicle will start to move As the accelerator pedal is pressed speed will increase until full speed is reached See following WARNING and NOTE WARNING Operator must control vehicle speed when going downhill Electric vehicles only Pedal down or pedal up motor braking may be used to help control speed when going downhill however steep terrain or other conditions may require that pedal braking be used in
57. nd Periodic Lubrication Schedule must be followed to keep vehicle in optimum operating condition Page 32 DS Gold Standard Remanufactured Vehicle Owner s Manual Periodic Service Schedules PERIODIC SERVICE SCHEDULE ELECTRIC VEHICLES REGULAR INTERVAL SERVICE See Pre Operation and Daily Safety Pre Operation and Daily Safety Checklist Checklist on page 22 Daily service by owner Performance Inspection See Performance Inspection on page 23 Charge batteries after each daily use only Check electrolyte level Add water if Weekly service by owner Batteries necessary See page 39 Monthly service by owner or trained Wash battery tops and clean terminals with technician Batteries baking soda water solution Apply Battery i Terminal Protector Spray CC P N 1014305 to battery terminals Tires Check air pressure and adjust if necessary i See Vehicle Specifications on page 50 Wash battery compartment and underside of General vehicle vehicle Check brake shoes replace if necessary Lubricate brake slides per Lubrication Schedule Brake system Check brake cables for damage replace if necessary Check brake cable equalizer adjustment Semiannual service by trained technician adjust if necessary only every 50 hours of operation or 100 Electrical wiring and connections Check for tightness and damage rounds of golf j Check condition of contacts and wire Forward Reverse switch connections Make sure
58. nd production week during which the vehicle was built The six digits 3 following the hyphen represent the unique sequential number assigned to each vehicle built within a given model year See following NOTE NOTE Have the remanufactured vehicle s serial number available when ordering parts or making inquiries Build Code The build code 4 is a five digit number that appears on the vehicle serial number decal The build code exists to enable the user to identify the correct owner s manual for a vehicle This owner s manual is valid for the build code range indicated on the back cover of this owner s manual Page 14 DS Gold Standard Remanufactured Vehicle Owner s Manual Safety Committee Og NEC f Rl SERIAL NUMBER PH0901 123456 ASSEMBLED IN USA BC54679 1400 Figure 6 Serial Number Decal 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 Ensuring that proper warnings of driving hazards are displayed and visible Who should and who should not drive golf cars Instructing first time drivers Maintaining golf cars in a safe driving condition How various rules are to be enforced The safety committee should include all these items and such others as the committee feel
59. ngine to a CLUB CAR distribution center as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact WARRANTY SERVICES CLUB CAR LLC P O Box 204658 Augusta Georgia 30917 4658 U S A 1 706 863 3000 CLUB CAR EXPLANATION OF EMISSION CONTROL WARRANTY 1 WARRANTY CLUB CAR warrants to the ultimate purchaser and each subsequent purchaser that the SORE and related emissions equipment is designed built and equipped so as to conform with all applicable California environmental emission regulations and free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in CLUB CAR s application for certification with CARB The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser or first placed into service The warranty period is two years from the date of purchase 2 COVERAGE Subject to certain conditions and exclusions as stated below the warranty on emission related parts is as follows 1 Any warranted part that is not scheduled for replacement as required maintenance in the written instructions supplied is warranted for the warranty period stated above If the part fails during the period of warranty coverage the part will be repaired or replaced by
60. ntenance can prevent vehicle downtime and expensive repairs that can result from neglect Use the Pre Operation and Daily Safety Checklist on page 22 and the following Periodic Service Schedules and Periodic Lubrication Schedules to keep the vehicle in proper working condition Any vehicle not functioning correctly should be removed from use until it is properly repaired This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions Contact your local Club Car distributor dealer to perform all repairs and semiannual and annual periodic service A WARNING If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal injury or death Only trained technicians should service or repair the vehicle or battery charger Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation Electric vehicles WARNING CONTINUED ON NEXT PAGE DS Gold Standard Remanufactured Vehicle Owner s Manual Page 31 Periodic Service Schedules WARNING Hot Do not attempt to service hot motor Attempting to do so could cause severe burns To avoid unintentionally starting the vehicle disconnect the bat
61. nto the charger through cabinet slots They may touch dangerous voltage points or cause an electrical short circuit that could result in fire or electrical shock Do not connect a stationary charger to the receptacle if the charger cord plug or the vehicle receptacle is broken damaged or does not make a good electrical connection Fire or personal injury can result Have a qualified technician replace the parts When the charger is on the charger DC cord may be disconnected from the vehicle receptacle slowly Jerking or pulling the DC cord out quickly could cause arcing and burning that could damage the plug and receptacle and could cause batteries to explode Do not block or cover the charger ventilation slots The slots provide ventilation and protect the charger from overheating Do not allow clothing blankets or other material to cover the charger Do not allow the charger to operate for more than 30 minutes at 19 or more amperes Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightning strikes Because the vehicle s onboard computer OBC has a storage charge feature that automatically checks and recharges the batteries as necessary every 15 days the charger can remain plugged to a IQ System vehicle throughout the storage period Page 40 DS Gold Standard Remanufactured Vehicle Owner s Manual Battery Charger
62. oil per change Refer to oil viscosity guidelines for selection of oil grade Figure 31 Replace the dipstick 20 C 10 C 0 C SAE 10W 30 SAE 10W 40 Rison See 4 F 14 F 32 F 50 F 68 F 86 F 104 F 27 213 Figure 30 Coat Oil Filter Rubber Seal Figure 31 Oil Viscosity Chart DS Gold Standard Remanufactured Vehicle Owner s Manual Page 47 Fueling Instructions Gasoline Vehicles 14 15 16 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 12 With the Forward Reverse handle in the NEUTRAL position run engine for 3 minutes and check for leaks Observe both the drain plug and the oil filter from under the vehicle and watch for oil leaks If filter leaks tighten additional 1 4 turn and retest if oil drain plug leaks re torque and retest Remove the dipstick and check the engine oil as a final step Replace the dipstick FUELING INSTRUCTIONS GASOLINE VEHICLES See General Warnings on page 10 DANGER Turn the key switch to the OFF position before fueling Do not pour fuel into the fuel tank when the engine is hot or while it is running Be sure the fuel tank ground wire located next to the fuel shut off valve is properly connected before fueling the vehicle e To avoid electric arc caused by static electricity the fuel storage pumping device must be grounded If the pump is not grounded the vehicle must be grounded to the pump before and
63. ompartment and underside of vehicle Do not engage the park brake Chock the wheels to prevent the vehicle from rolling o OND RETURNING THE STORED GASOLINE VEHICLE TO SERVICE 1 Restore fuel system to operation Figure 32 1 1 Remove plug from fuel tank vent 1 2 Connect vent tube to fuel tank vent 2 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 12 3 Completely open the fuel shut off valve Figure 18 Make sure the valve is fully open A partially closed fuel shut off valve combined with the use of the choke can result in a fouled spark plug and engine failure 4 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout cam in the MAINTENANCE position Crank the engine until fuel is pumped into the carburetor and fuel lines and the engine starts Turn the engine off and return the neutral lockout cam to the OPERATE position See following NOTE NOTE Due to the oil added to the engine in preparation for storage engine may smoke excessively for a short time when it is run for the first time after storage 5 Adjust tires to recommended tire pressure See Vehicle Specifications on page 50 6 Perform the Pre Operation and Daily Safety Checklist on page 22 MAINTENANCE See General Warnings on page 10 To ensure trouble free vehicle performance it is very important to follow an established preventive maintenance program Regular and consistent vehicle mai
64. on 1 101547601 5 Fuel Shut Off Valve frame near fuel tank Decal Frame Ground Governor Warning on m 2 101915201 Oil Fill vehicle frame near battery Decal Rotating Parts Hot Manifold Warning on 3 101960501 7 Choke engine starter generator and transaxle Ia Forward Reverse Control l Neutral Lockout Cam DS Gold Standard Remanufactured Vehicle Owner s Manual Page 7 Safety Decal and Feature Identification FOUR PASSENGER VEHICLE FALLING OFF COULD RESULT IN SEVERE INJURY OR DEATH Remain seated with entire body inside vehicle and hold on to seat handle or handrail at all times Two 2 persons per bench seat maximum One 1 person per bucket seat maximum Do not leave children unattended on vehicle at anytime e Never stand in front of or behind vehicle CCI 101705701 317A Decal Falling Off Warning on rear facing seat 1 101705701 hand rail and or on back side of forward facing 3 Hand Holds seat backs Page 8 DS Gold Standard Remanufactured Vehicle Owner s Manual Practice Safety PRACTICE SAFETY N WARNING Rotating Parts 399 Figure 1 Practice Safety 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 us That is why before operating the vehicle we urge you to review the information in this manual Understand and become familiar
65. or every and shifter cable pivots 100 rounds of golf Front suspension 5 fittings Chassis Lube EP NLGI Grade 2 Brake slides Dry Moly Lube CC P N 1012151 80 90 WT AGMA Class EP Gear Lube operation or every 200 rounds level of golf First change 100 hours additional change every 200 hours of operation or fx 32 oz 0 95 L without filter 38 oz 1 12 Change engine oil and oil filter wa an every 400 rounds of golf or L with filter annually whichever comes first Annually by trained technician only every 100 hours of Check fill unitized transaxle to plug 27 oz 0 8 L 80 90 WT API Class GL 3 or 16 Figure 20 Lubrication Points Gasoline Vehicles Page 36 DS Gold Standard Remanufactured Vehicle Owner s Manual Batteries Electric Vehicles BATTERIES ELECTRIC VEHICLES See General Warnings on page 10 DANGER e Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries Charge batteries in a well ventilated area only Batteries emit hydrogen while being charged Hydrogen is an explosive gas and must never exceed a level of 2 of the air e Battery Poison Contains acid Causes se
66. perate the vehicle Club Car products are backed by a customer support system designed to offer you fast courteous service In the event that your Club Car vehicle needs repairs or service please contact your local authorized Club Car dealer or distributor who will be able to provide technical advice perform warranty work and sell parts and service manuals For the name and address of the authorized Club Car dealer and distributor nearest you logon to our web site at www clubcar com or call 1 800 ClubCar 258 2227 If you would prefer to write to us direct your letter to Club Car Attention Marketing Services P O Box 204658 Augusta Georgia 30917 4658 USA We hope you will consider this owner s manual a permanent part of your Club Car vehicle 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 Engine Oil Filter 286 cc and 351 cc Spark Plug O H V 286 cc and 351 cc CC P N 103887901 CC P N AM10724 or 101881101 Engine Air Filter 286 cc and 351 cc Spring Tune Up Kit Engine Fuel Filter 286 cc and 351 cc CC P N 102003201 Battery Terminal Protector Spray CC P N 1014305 Dry Moly Lube Page 2 DS Gold Standard Remanufactured Vehicle Owner s Manual TABLE OF CONTENTS Safety Decal and Feature Identification s aeaii ra rne KA RE NER nne enne nannten enhn nnns AARE nine nano nnns 4 Practice Safety orte E entia fue eit e
67. r or replacement of the part That notwithstanding any adjustment of a component that has a factory installed and properly operating adjustment limiting device is still eligible for warranty coverage The following emission warranty parts list are covered SYSTEMS COVERED PARTS DESCRIPTION Fuel Metering Carburetor assembly fuel injection pump fuel injection nozzle fuel regulator Exhaust Catalytic Converter Exhaust Manifold Air Induction Air filter housing air filter crankcase breather tube Ignition Flywheel magneto ignition pulse generator ignition coil assembly ignition control module spark plug cap spark plug Positive Crankcase Ventilation PCV System PCV valve oil filler cap Evaporative System Fuel Tank Fuel Cap Fuel Lines Fuel Line Fittings Clamps Pressure Relief Valves Purge Valves Vapor Hoses Carbon Canister Canister Mounting Brackets Carbon Canister Purge Port Connector Misc Parts Belts hosing tubing fittings seals gaskets clamps and switches associated with the above systems Emission related parts will vary between vehicles therefore certain vehicles may not include all of the listed parts or may include equivalent parts 3 VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICLE IS ABUSED OR USED IN AN UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY INCLUDING BUT NOT LIMITED TO MODIFICATION OF THE SPEED GOVERNOR BRAKING SYSTEM STEERING TRANSAXLE OR
68. rged An accumulation of hydrogen gas could result in an explosion WARNING NOTE Only trained technicians should repair or service the charger Contact your nearest Club Car distributor dealer Each charger should have its own dedicated 15 or 20 ampere separately protected circuit breaker or fuse single phase branch circuit in accordance with all applicable electrical codes for the location Connect the charger AC supply cord to a properly grounded three wire outlet of the proper voltage and frequency as shown on the charger Do not use an adapter to plug the charger with a three prong plug into a two prong outlet Improper connection of the equipment grounding conductor can result in a fire or an electrical shock An extension cord or electrical outlet must accept a three prong plug Extension cord should be a three wire No 12 AWG American Wire Gauge or no 14 British Standard Wire Gauge and be as short as possible no more than 12 feet 3 7 m The use of improper extension cord could result in fire or an electrical shock Do not operate the charger if it has received a sharp blow was dropped or otherwise damaged in any way Have worn cut or damaged power cords or wires replaced immediately Do not use near fuels grain dust solvents thinners or other flammables Chargers can ignite flammable materials and vapors Do not expose to rain or any liquid Keep the charger dry Never push objects of any kind i
69. rward Reverse switch in any position When walk away braking is engaged the reverse buzzer should emit a distinct pattern of beeps See following WARNING DS Gold Standard Remanufactured Vehicle Owner s Manual Page 23 Driving Instructions WARNING Walk away braking will not limit vehicle speed to 1 mph 1 6 km h on very steep grades Do not operate vehicle on slopes exceeding 20 grades Pedal Up Motor Braking adjustable on IQ System vehicles Accelerate the vehicle to full speed and then release the accelerator pedal Motor braking should quickly and smoothly slow the vehicle to approximately 11 mph 17 7 km h Motor braking will disengage when vehicle slows to 11 mph 17 7 km h This feature is adjustable for IQ System vehicles only Contact your local Club Car dealer distributor to inquire about this adjustable feature Pedal Down Motor Braking Accelerate down an incline with the accelerator pedal pressed When the vehicle reaches maximum programmed speed motor braking should engage and limit the vehicle to its maximum programmed speed On very steep grades the vehicle may slightly exceed its maximum programmed speed requiring use of the brake pedal Gasoline Vehicles Accelerator With the key switch in the ON position and the Forward Reverse switch in the FORWARD position as the accelerator pedal is pressed the engine should start and the vehicle should accelerate smoothly to full speed When the pedal is release
70. s 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 The charger cord plug and receptacle are wear items and should be inspected daily Visually inspect them for cracks loose connections and frayed wiring they must be replaced when worn or damaged If charger plug or receptacle show signs of corrosion or the plug is difficult to insert or remove the receptacle contacts and plug terminals should be cleaned with a good electrical contact cleaner or lightly sprayed with WD 409 brand spray lubricant The plug should then be inserted and removed several times to ensure ease of insertion ease of removal and good electrical contact See following NOTE NOTE If the warning tag has been damaged or removed from the DC cord have it replaced immediately Page 42 DS Gold Standard Remanufactured Vehicle Owner s Manual Battery Gasoline Vehicles 20 Figure 24 Receptacle Fuse Link RECEPTACLE FUSE LINK As an additional feature to protect the batteries and charging circuit from an overload the electr
71. s necessary or appropriate CONTROLS AND INDICATORS See General Warnings on page 10 WARNING f renting or loaning the vehicle make sure the driver is familiar with all controls and operating procedures before allowing the vehicle to be driven e Do not shift the Forward Reverse handle or switch while the vehicle is moving To avoid injury to an unsuspecting passenger or damage to the vehicle always bring the vehicle to a full stop before shifting the Forward Reverse handle or switch Release the accelerator pedal and then press the brake pedal firmly until the vehicle stops To avoid unintentionally starting or rolling the vehicle set the park brake place the Forward Reverse handle or switch in the NEUTRAL position turn the key switch to the OFF position and remove the key when leaving the vehicle WARNING CONTINUED ON NEXT PAGE DS Gold Standard Remanufactured Vehicle Owner s Manual Page 15 Controls and Indicators WARNING Gasoline vehicles only Do not tamper with the governor Doing so will void the warranty as well as damage the engine and other components and could result in property damage personal injury or death due to unsafe speeds KEY SWITCH The key switch is mounted on the dash to the right of the steering column Figure 7 It has two positions OFF and ON which are clearly labeled See following NOTE NOTE When the key is turned to the OFF position the main vehicle systems are disa
72. should be checked by your Club Car distributor dealer The warning light will repeatedly illuminate for 10 seconds with 4 second intervals during a charge cycle DC plug is still connected if AC power to the charger is interrupted The light will go out when AC power is restored NOTE The battery warning light will flash quickly after inserting the DC plug if the charger relay voltage suppressor has failed in the closed position LED Light In addition to the warning light there is an infrared LED in the dash light assembly which transmits an infrared signal from the onboard computer OBC This signal is received by the optional Communication Display Module CC P N 101831801 which provides information on the condition of the vehicle and batteries DS Gold Standard Remanufactured Vehicle Owner s Manual Page 19 Controls and Indicators TOW RUN SWITCH IQ System Electric Vehicles Only WARNING Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning could result in a battery explosion or severe personal injury When the Tow Run switch is in the TOW position all motor braking functions including walk away braking are disabled IQ System vehicles are equipped with a Tow Run switch located under the seat just above the Forward Reverse switch Figure 13 The switch must be in the RUN position in order to operate the vehicle When the switch is in the TOW posi
73. td tu tt it T TG IE LER PUE ds 9 Proposition 65 State of California ssssssssssssssssssssssssssssseseen e enhn e hne en n hh sn nnn e n enr rene hne nnne nnne 9 SABLE 10 EI TIMIDI 10 General IMO ANON D Q 14 Model e Tupdifez iio eem 14 safety Committee sates Dc 15 Controls and Indicators 1 nene eben Saeed dena based dena Lee senna bee ren Geet susie bu re an oe dee edu oe ue dde aa dd due e nu geile ews den eua dd 15 Pre Operation and Daily Safety Checklist eee eect enter enn ener ner ee nnne enhn enhn nnne erre nnns 22 Dnving Instr ctioris x one d e pen n DR ID Ep eee int ET uin e ette end RE 24 oie p UMP 26 Aransporting on a fraller 9 55 sc seat stessa oec otra iet er Ert er oix Epi o exe ueste aedes betttutes arbos tuat aea Pond 27 Storage Electric Vehicles rreak ccce odd e ode ede cule eee dede Sdn enel Sone seed Conn eves ed up sane bd ua ede eai e ede kae d d 27 Storage Gasoline VENICISS i iio Hoo o ect obe it bee betae e Re e oe Pea P Hb pete HER ER Poet p Oeo Pat E AERE n Eats 29 MEInIREDIe MU 31 Periodic Service Schedules e ota ope ER I RE xe d EE deer RE TETAS eee tai user a ated e ATT 32 Periodic Lubrication Schedules ies deesse ndi ea tien diera ii dd esas dd deese i dd nne hri dieere in ddnde add
74. te engine in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison The vehicle will not provide protection from lightning flying objects or other storm related hazards If caught in a storm while driving a Club Car vehicle exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location WARNING Follow the procedures exactly as stated in this manual and heed all DANGER WARNING and CAUTION statements in this manual as well as those on the vehicle and battery charger Do not leave children unattended on vehicle Prior to leaving the vehicle unattended or servicing the vehicle set the park brake place the Forward Reverse handle or switch in the NEUTRAL position turn the key switch to the OFF position and remove the key Chock the wheels when servicing the vehicle Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance severe personal injury or death Any modification or change to the vehicle that affects the electrical system stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications could result in severe personal injury or death Check the vehicle for proper location of all vehicle safety and operation decals and make sure they are in place and are easy to read Only trained technicians should service or repair the
75. te ventilation CHARGING BATTERIES WARNING Besure all wire connections at the receptacle and the fuse link are clean and tight Do notrock or bend the plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 22 Page 42 Do not pull on the DC cord Figure 23 Page 42 Do not twist rock or bend the plug To disconnect the charger plug from the vehicle receptacle grasp the plug by the handle and pull the plug straight out of the receptacle Do not connect a charger to the receptacle if the charger cord plug or the vehicle receptacle is broken damaged in any manner or does not make a good electrical connection Fire or personal injury can result Have it replaced by a qualified service person immediately Failure to follow these instructions could result in damage to the charger cord the plug and or the vehicle receptacle Do not use a charger if The plug is too loose or does not make a good connection The plug and receptacle feel hotter than normal during charge The plug pins or receptacle contacts are bent or corroded The plug receptacle or cords are cut worn have any exposed wires or are damaged in any way Using the charger with any of the above symptoms could result in a fire property damage personal injury or death NOTE When temperatures fall below 65 F 18 3 C batteries charged in unheated areas
76. teries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 13 Gasoline vehicles Moving parts Do not attempt to service gasoline vehicle while the engine is running Hot Do not attempt to service hot engine or exhaust system Failure to heed this warning could result in severe burns Turn the fuel shut off valve to the closed OFF position Figure 18 To avoid unintentionally starting the vehicle disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 12 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 PERIODIC SERVICE SCHEDULES See General Warnings on page 10 WARNING Service repairs and adjustments must be made per instructions in the maintenance and service manual e If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal injury or death NOTE If the vehicle is constantly subjected to heavy use or severe operating conditions the preventive maintenance procedure should be performed more often than recommended in the periodic service and lubrication schedules Both the Periodic Service Schedule a
77. teries can explode These batteries should be taken out of service DS Gold Standard Remanufactured Vehicle Owner s Manual Page 27 Storage Electric Vehicles CAUTION Batteries in a low state of charge will freeze at low temperatures To avoid exposing electrical components to moisture and subsequent damage do not use any type of pressure washing or steam cleaning equipment to wash the vehicle PREPARING THE ELECTRIC VEHICLE FOR EXTENDED STORAGE Check Battery Water Levels Two Weeks Prior to Storage Check water levels at least two weeks prior to winter storage to ensure proper mixing of water and electrolyte Note that it takes approximately five charge cycles with a minimum of 10 energy units EUs removed to properly mix the water with electrolyte Do NOT water batteries immediately prior to storage because this will not provide sufficient charge time to mix the water with the electrolyte Freezing can occur when batteries are stored in this condition 1 Check the water levels in each battery cell If water is required fill the cells to cover the plates charge the batteries and then use distilled water to fill each cell to the correct level Electrolyte level should be from 75 inch 13 mm above plates to inch 6 mm below the level indicator Figure 21 Immediately Prior to Storage Perform the Following Steps 1 Turn the key switch to the OFF position remove the key and leave the Forward Reverse switch in the NE
78. th diagnosis of a defective emission related warranted part provided that such diagnostic work is performed at a warranty station 7 CLUB CAR is liable for damages to other engine or equipment components proximately caused by a covered failure under warranty of any warranted part 8 Throughout the engine or equipment warranty period stated above CLUB CAR will maintain a supply of warranted parts sufficient to meet the expected demand for such parts 9 Any replacement part may be used in the performance of any warranty maintenance or repairs and must be provided without charge to the owner Such use will not reduce the warranty obligations of CLUB CAR 10 Add on or modified parts that are not exempted by the Air Resources Board may not be used The use of any non exempted add on or modified parts by the ultimate purchaser will be grounds for disallowing a warranty claims CLUB CAR will not be liable to warrant failures of warranted parts caused by the use of a non exempted add on or modified part CLUB CAR its authorized dealers or a service agency approved by CLUB CAR ITEMS COVERED BY THIS WARRANT Y The repair or replacement of any warranted part otherwise eligible for warranty coverage may be excluded from such warranty coverage if CLUB CAR demonstrates that the engine or equipment has been abused neglected or improperly maintained and that such abuse neglect or improper maintenance was the direct cause of the need for repai
79. the possibility of serious injury keep your entire body inside the vehicle Do not leave children unattended on vehicle To help prevent overturning the vehicle drive slowly straight up and down slopes Avoid driving the vehicle on slopes exceeding 20 incline e To help avoid possible injury to an inattentive passenger and or damage to the vehicle avoid sudden starts sudden stops and abrupt turns WARNING CONTINUED ON NEXT PAGE Page 24 DS Gold Standard Remanufactured Vehicle Owner s Manual Driving Instructions WARNING To help avoid the possibility of losing control of or overturning the vehicle reduce speed for adverse driving conditions such as wet grass or rough terrain Do notuse the vehicle on public roads It is not designed or intended for street use and should not be licensed for use on public roads Obey all local rules concerning golf cars The vehicle should be driven in only specified areas by trained drivers Do not drive while under the influence of alcohol drugs or medications To prevent overturning the vehicle drive slowly in turns Use brakes to reduce speed when coasting downhill This vehicle is not intended to be used where risk of falling objects exists If your vehicle will be used in such an environment contact your local dealer Do not drive the vehicle under tree limbs bridges tunnels or other objects that are less than 80 inches from the ground No one shou
80. they should be replaced immediately to avoid possible property damage personal injury or death Contact your distributor dealer DANGER ADANGER indicates an immediate hazard that will result in severe personal injury or death WARNING AWARNING indicates an immediate hazard that could result in severe personal injury or death CAUTION A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury CAUTION A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could result in property damage GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated repaired or serviced See Safety Decal and Feature Identification on page 4 Other specific safety statements appear throughout this manual and on the vehicle DANGER Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries Gasoline Flammable Explosive Do not smoke Keep sparks and flames away from the vehicle and service area Service only in a well ventilated area DANGER CONTINUED ON NEXT PAGE Page 10 DS Gold Standard Remanufactured Vehicle Owner s Manual General Warnings DANGER Do not opera
81. tion power to the vehicle electrical components is turned off and the vehicle will not operate See following NOTE NOTE After placing the Tow Run switch in the TOW position allow 10 seconds to elapse before switching back to the RUN position After placing the Tow Run switch in the RUN position allow 10 seconds to elapse before operating the vehicle The Tow Run switch should be placed in the TOW position under the following conditions Before Towing the Vehicle Place the Tow Run switch in the TOW position to disable all motor braking functions thus preventing possible damage that could occur to the vehicle or electrical components if the vehicle is towed while the walk away braking motor braking function is operating Before Disconnecting or Connecting Battery Cables Place the Tow Run switch in the TOW position to turn off power to the vehicle electrical system thus preventing severe arcing and possible battery explosion as the battery cables are disconnected For Long Term Storage Place the Tow Run switch in the TOW position to turn off power to the vehicle electrical system thus preventing vehicle electrical components from discharging the batteries 7A Figure 13 Tow Run Switch IQ System NEUTRAL LOCKOUT Gasoline Vehicles Only For the convenience of the trained technician there is a neutral lockout cam located on the back of the Forward Reverse shifter If the neutral lockout cam is pulled out approximately 3 8
82. ual Page 51 Warranties WARRANTIES CLUB CAR LIMITED WARRANTY FOR GOLD STANDARD VEHICLES WARRANTY CLUB CAR LLC CLUB CAR hereby warrants its Gold Standard Remanufactured vehicle purchased from CLUB CAR or an authorized distributor dealer or agent shall be free from defects in material and workmanship under normal use and service for the period as stated in years below as terms are defined herein and subject to the provisions limitations and exclusions contained in this warranty IF THE WARRANTY REGISTRATION FORM IS NOT COMPLETED AND RETURNED TO CLUB CAR AT THE TIME OF THE ORIGINAL RETAIL SALE PURCHASER MUST PROVIDE PROOF OF DATE OF PURCHASE WITH ANY WARRANTY CLAIM ENERGY GASOLINE ELECTRIC TO THE ORIGINAL OWNER ONLY NON TRANSFERABLE VEHICLE VEHICLE UNITS COVERED LIMITED TWO YEAR All original equipment 2 YEARS 2 YEARS UNLIMITED MEE e 2 YEARS UNLIMITED BATTERYCHARGER sss CHARGER 2 YEARS UNLIMITED 16000 BATTERY 2 YEARS Electric Only ONBOARD COMPUTER 0000000000000 COMPUTER 2 YEARS UNLIMITED EXCLUSIONS Excluded from any CLUB CAR warranty is damage to a vehicle or component resulting from a cause other than a defect including poor maintenance neglect abuse accident and collision maintenance adjustments unreasonable or unintended strain or use improper installation of accessories installation of parts or accessories that are not original equipment including Club Car approved or non approved GPS systems
83. uel If you use oxygenated fuel either ethanol or MTBE added to gasoline be sure it is unleaded and meets the minimum octane rating require ment The following are the EPA approved percent ages of fuel oxygenates ETHANOL Ethyl or Grain Alcohol You may use gasoline containing up to 10 ethanol by volume MTBE Methyl Tertiary Butyl Ether You may use gasoline containing up to 15 MTBE by volume METHANOL Methanol or Wood Alcohol 5 by volume You may use gasoline containing up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 596 methanol by volume may cause starting and or performance problems It may also dam age metal rubber and plastic parts of your fuel System A WARNING Gasoline is extremely flammable and can be explosive under certain con ditions Turn the engine switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Never fill the tank so the fuel level rises into the filler neck If the tank is overfilled heat may cause the fuel to expand and overflow through the vent in the fuel tank Engine Oil The following engine oils are recommended API Service Classification SC SD SE SF SG or SH DS Gold Standard Remanufactured Vehicle Owner s Manual Warranties acts or the causing thereof 1 th
84. ump start a dead battery using another battery and jumper cables The battery in the Club Car gasoline vehicle is a 12 volt low maintenance battery that requires infrequent watering Figure 25 Any corrosion around the positive or negative terminals should be washed off with a solution of baking soda and water 1 cup 237 mL per gallon 3 8 L of water Rinse solution off the battery Do not allow this solution to enter battery Be sure terminals are tight Let the terminals dry and then spray them with Battery Terminal Protector Spray CC P N 1014305 See Connecting the Battery Gasoline Vehicles on page 12 See preceding WARNING and following WARNING WARNING f battery wire terminals are damaged or corroded replace or clean them as necessary Failure to do so may cause them to overheat during operation and could result in a fire property damage or personal injury 1 Level Indicator 2 Cap 3 Plates Electrolyte level at least 1 2 inch 13 MM above plates or to level indicator 21 22 Figure 25 Battery Gasoline Vehicle Figure 26 Gasoline Battery Electrolyte Level Page 44 DS Gold Standard Remanufactured Vehicle Owner s Manual Engine Oil Gasoline Vehicles Be sure battery clamp is properly tightened Tighten to 144 in Ib 16 N m A loose battery clamp may
85. vehicle or battery charger Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation Electric vehicles only Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning could result in a battery explosion or severe personal injury To avoid unintentionally starting an electric vehicle disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 13 Gasoline vehicles only To avoid unintentionally starting a gasoline vehicle disconnect the battery and spark plug wire See Disconnecting the Battery Gasoline Vehicles on page 12 Frame ground Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wiring Do not allow a positive wire to touch the vehicle frame engine or any other metal component All vehicles Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle or battery charger Use insulated tools when working near batteries or electrical connections Use extreme
86. vement Do not allow people in the trailer or vehicle being towed Avoid sudden starts sudden stops and tight turns when towing Avoid stopping on a hill when towing If you must stop on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning could cause the vehicle to overturn possibly resulting in severe personal injury When towing on a trailer normal road speed of the tow vehicle should be reduced Because of the added length of the trailer use caution when making turns Remove the vehicle windshield and secure the seat bottom before transporting on a trailer Gasoline vehicles only Turn the fuel shut off valve to the closed OFF position Figure 18 Page 30 If the vehicle must be transported over long distances or on public highways it should be transported on an approved trailer that has the approved load rating of 1200 Ib 544 kg per vehicle being transported NOTE A two car trailer should be rated at 2 x 1200 2400 Ib 2 x 544 1088 kg STORAGE ELECTRIC VEHICLES See General Warnings on page 10 WARNING Turn the key switch to the OFF position remove the key and leave the Forward Reverse handle or Switch in the NEUTRAL position during storage This is to prevent unintentionally starting the vehicle or a fire hazard Place Tow Run switch in the TOW position Do not attempt to charge frozen batteries or batteries with bulged cases Frozen bat
87. vere burns Avoid contact with skin eyes or clothing Antidotes External Flush with water Call a physician immediately nternal 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 Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubber gloves when working on or near batteries Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring CAUTION 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 Club Car electric vehicles use deep cycle batteries Automotive batteries should never be used in electric vehicles 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 electric vehicles with new batteries to 36 holes of use between charges in the first two months of operation Batteries should be fully charged before first use of new vehicle before first use of a vehicle after storage and before releasing vehicle for use each day WATER QUALITY To keep batteries in good
88. with the DANGER WARNING and CAUTION statements and procedures it contains along with the safety decals that are affixed to your vehicle Take time to understand the language of safety It is a language that can save your life PROPOSITION 65 STATE OF CALIFORNIA WARNING This product contains or emits chemicals or substances that have been determined by the state of California to cause cancer and birth defects or other reproductive harm DS Gold Standard Remanufactured Vehicle Owner s Manual Page 9 Safety Details SAFETY DETAILS WARNING This owner s manual should be read completely before attempting to drive or service the vehicle Failure to follow the instructions in this manual could result in property damage severe personal injury or death It is important to note that some vital statements throughout this manual and on the decals affixed to the vehicle are preceded by the words DANGER WARNING or CAUTION For your protection we recommend that you take special notice of these safety precautions Safety precautions are essential and must be followed Throughout this manual and on the operation and safety decals affixed to the vehicle the words golf car and vehicle are used interchangeably Golf car is defined in the Notice of this manual and no other representation is stated or implied If any of the operation or safety decals on the vehicle become damaged have been removed or cannot be easily read
89. wner s Manual Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE ELECTRIC VEHICLES LUBRICATION REGULAR INTERVAL SERVICE POINTS RECOMMENDED LUBRICANT Brake pedal shaft bearings Dry Moly Lube CC P N 1012151 Brake linkage and pivots Dry Moly Lube CC P N 1012151 Semiannually by owner or trained technician every 50 Accelerator pivot rod supports Dry Moly Lube CC P N 1012151 hours of operation or 100 Charger receptacle WD 40 rounds of golf Brake slides Dry Moly Lube CC P N 1012151 Front suspension 5 fittings Chassis Lube EP NLGI Grade 2 Annually by trained technician only every 100 hours of 22 oz 0 67 L SAE 30 WT API Class SE g Check fill transaxle to plug level i operation or 200 rounds of SF or SG Oil or higher golf 15 Figure 19 Lubrication Points Electric Vehicles DS Gold Standard Remanufactured Vehicle Owner s Manual Page 35 Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULE GASOLINE VEHICLES LUBRICATION REGULAR INTERVAL SERVICE POINTS RECOMMENDED LUBRICANT Brake pedal shaft bearings Dry Moly Lube CC P N 1012151 Brake linkage and pivots Dry Moly Lube CC P N 1012151 Semiannually by owner or trained technician every 50 Acoelerator push rod pivots mounts oa Dry Moly Lube CC P N 1012151 hours of operation

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