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1997 DS Golf Cars Electric and Gasoline

1. 1997 DS Golf Cars Electric and Gasoline An QD Ingersoll Rand business A WARNING THE ENGINE EXHAUST FROM THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM NOTICE The Club Car Limited Warranty appears on the pages following this notice and the Limited Lifetime Fleet Warranty appears on the last pages of this manual No other warranties express or implied are contained herein Your authorized representative checked this vehicle before it was delivered to you and will provide you with a completed warranty registration card Club Car is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual This vehicle conforms to the current American National Standards Institute s 2130 Safety and Performance Requirements for Golf Cars This standard which promotes safety in the design application and operation of golf cars defines a golf car as a vehicle used to convey a person or persons and equipment to play the game of golf in an area designated as a golf course Throughout this manual the words golf car and vehi cle are used interchangeably This manual contains proprietary information that is protected by copyright All rights are reserved No part of this manual may be photocopied reproduced or translated to another language without the written consen
2. Trailer Hitch Custom Club Decals Glove Box Hour Meter D Numbers Power Rib Tires Sweater Basket Adjustable Seat Back Extra Traction Tires Information Holder Scuff Guards White Wall Tires Beverage Cooler Canopy Top Chrome Hub Wheel Covers Extra Two bag Attachment Weather proof Enclosure Chrome Sport Wheel Covers Bagwell Liner Tinted Split Windshield Sand Bunker Rake Kit Snap on Tee Holder Clear or Tinted Snap on Sand Bottle Divot Windshield Repair Kit e AM FM Stereo Cassette Radio with Sand Basket and Divot Clock Bucket Repair Kit Lighting Package high low beam head Temporary Tow Bar for Single Vehi lights taillights brake lights and horn cle Towing Deluxe Lighting Package with Turn Permanent Tow Bar for Multiple Signals Vehicle Towing factory installed Optional Equipment Continued on Next Page 35 OPTIONAL EQUIPMENT ELECTRIC VEHICLES ONLY 3 75 hp Electric Motor PowerDrive Sys Battery Indicator tem 48 vehicle only 3 5 hp Electric Motor V Glide 36 volt On board Charger with Rewind vehicle only Cord OPTIONAL EQUIPMENT GASOLINE VEHICLES ONLY Fuel Gauge Spark Arrestor Kit A WARNING TINTED WINDSHIELDS AND WEATHER PROOF ENCLOSURES WILL NOT PROTECT OCCU PANTS FROM FLYING OBJECTS GOLF BALLS ETC SUBSEQUENT OWNER REGISTRATION In the event a vehicle is bought as a used vehicle from another individual or from a distributor deal
3. ABLY EQUIVALENT TO THE WARRANTED PRODUCT OR COMPONENT AT NO COST TO THE PURCHASER REPAIR SHALL MEAN REMEDYING A DEFECT IN THE GOLF CAR OR COMPONENT THEREOF AT NO COST TO THE PURCHASER DURING THE APPLICABLE LIMITED WARRANTY PERIOD IF CLUB CAR ELECTS TO REPAIR THE GOLF CAR IT MAY PROVIDE FACTORY RECONDI TIONED PARTS OR COMPONENTS ALL PARTS AND COMPONENTS REPLACED UNDER WARRANTY SHALL BECOME THE PROPERTY OF CLUB CAR 5 HOW TO MAKE A WARRANTY CLAIM To make a warranty claim under this limited warranty you must present the golf car or defective component to an authorized CLUB CAR distributor or dealer or send the defective component freight prepaid to WAR RANTY ADMINISTRATION CLUB CAR INC 4152 Washington Road P O Box 204658 Augusta Georgia 30917 4658 6 DEFINITIONS For the purpose of this warranty an Original Retail Fleet Purchaser is the original purchaser of the golf car who is in the business of owning or operating golf courses and who purchases such golf car for the purpose of renting it to golf players for use on such courses An Original Retail Fleet Lessee is the first end user of the golf car who is in the business of owning and operating golf courses and who leases such golf car for the pur pose of renting it to golf players for use on such golf courses In the event the golf car is purchased or leased by any entity for the purpose of leasing it to an Original Retail Fleet Lessee then this limited warranty shall extend on
4. POWERDRIVE SYSTEM 48 ELECTRIC POWERDRIVE PLUS ELECTRIC DS 36 VOLT ELECTRIC Overall Height At Steering Wheel 48 122 cm 48 122 cm 48 122 cm 48 122 cm Wheelbase 65 1 2 166 cm 65 1 2 166 cm 65 1 2 166 cm 65 1 2 166 cm Ground Clearance 4 1 2 11 cm 4 1 2 11 cm 4 1 2 11 cm 4 1 2 11 cm Front Wheel Tread 34 1 2 88 cm 34 1 2 88 cm 34 1 2 88 cm 34 1 2 88 cm Rear Wheel Tread Weight Standard electric vehicle without batteries 38 1 2 98 cm 38 1 2 98 cm 455 Ibs 206 kg 38 1 2 98 cm 455 lbs 206 kg 38 1 2 98 cm 448 Ibs 203 kg Weight Fairway Villager electric vehicle without batteries 495 Ibs 225 kg N A N A Weight Standard gasoline powered vehicle dry 593 Ibs 269 kg Weight Fairway Villager gasoline powered vehicle dry 633 Ibs 287 kg Forward Speed 12 15 mph 19 24 kph 12 15 mph 19 24 kph 12 15 mph 19 24 kph 12 15 mph 19 24 kph Clearance Circle diameter Braking Distance At 12 mph 19 kph 17 68 533 cm 17 6 533 cm 17 6 533 cm 17 6 533 cm 39 CLUB CAR LIMITED LIFETIME WARRANTY FOR 1997 FLEET GOLF CARS IN THE UNITED STATES AND CANADA 1 WARRANTY CLUB CAR INC CLUB CAR hereby warra
5. The use of an extension cord with the charger should be avoided If an extension cord must be used a three conductor No 12 AWG heavy duty cord with a ground conductor in good electrical condition must be used Keep it as short as possible no more than twelve feet Locate all cords so that they will not be stepped on tripped over or otherwise subject to damage or stress Ventilation fans should be located at the highest point in the room and must be capable of changing the total volume of air in the room five times per hour Consult a local HVAC engineer TO CHARGE BATTERIES A WARNING BE SURE ALL WIRE CONNECTIONS AT THE RECEPTACLE AND THE FUSE LINK ARE CLEAN AND TIGHT DO NOT ROCK OR BEND THE PLUG TO CONNECT THE CHARGER PLUG TO THE VEHICLE RECEPTACLE GRASP THE PLUG HANDLE AND PUSH THE PLUG STRAIGHT INTO THE RECEPTACLE SEE FIGURE 23 DO NOT PULL ON THE DC CORD SEE FIGURE 24 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 PORTABLE 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
6. 25 Check all daily weekly monthly quarterly and semi annual items listed above IF ANY PROBLEMS ARE FOUND DO NOT OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE FAILURE TO MAKE NECESSARY REPAIRS COULD RESULT IN FIRE PROPERTY DAM AGE SEVERE PERSONAL INJURY OR DEATH ALL SERVICE REPAIRS AND ADJUSTMENTS MUST BE MADE PER INSTRUCTIONS IN THE DS GOLF CAR MAINTENANCE AND SERVICE MANUAL PUBLICATION PART NUMBER 1019051 01 23 PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE GASOLINE VEHICLE REGULAR INTERVAL SERVICE PLACE RECOMMENDED LUBRICANT Quarterly by Owner or Trained Technician Annually by Trained Technician Only Every 200 rounds or 100 hours of operation Brake shaft bearings 1 Dry Moly Lube Club Car Part No 1012151 Brake Linkage and Pivots 2 Dry Moly Lube Club Car Part No 1012151 Accelerator push rod pivots and shifter cable pivots Dry Moly Lube Club Car Part No 1012151 Front Suspension 5 fittings Check fill unitized transaxle to plug level Chassis Lube 27 oz 8 liter 80 90 WT API Class GL 3 or 80 90 WT AGMA Class EP Gear Lube Inspect front wheel bearings Repack as necessary Chassis Lube First Change 100 Hours Additional Change Every 400 Rounds or Every 200 Hours of Operation or Annually Whichever Comes First See Figure 16 below Change engine oil and oil filter DS GASO
7. 86 96 kPa 3 Perform the Pre Operation Checklist See pages 6 and 7 MAINTENANCE GENERAL INFORMATION To ensure trouble free vehicle performance it is very important to follow an established preventive mainte nance program regularly scheduled service even though the vehicle is functional Regular and consistent vehicle maintenance can prevent vehicle down time and expensive repairs that result from neglect Any vehicle not functioning correctly should be removed from use until it is properly repaired This will prevent fur ther damage to the vehicle and avoid the possibility of injury due to unsafe conditions Contact your local Club Car distributor dealer to perform all repairs and semi annual and annual periodic ser vice See Page 19 for Gasoline Vehicle Periodic Service Schedule See Page 21 for Electric Vehicle Periodic Service Schedule See Page 24 for Gasoline Vehicle Periodic Lubrication Schedule See Page 25 for Electric Vehicle Periodic Lubrication Schedule See Page 26 for Vehicle Capacities all DS vehicles A WARNING ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THE VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD FOLLOW THE PROCEDURES EXACTLY AS STATED IN THIS MANUAL AND OBEY THE DANGERS WARNINGS AND CAUTIONS LISTED IN THIS MANUAL AS WELL AS THOSE AFFIXED TO THE VEHICLE 17 Maintenance Continued A WARNING IF ANY PROBLEMS ARE FOUND DURING SCHEDULED INSPECTI
8. OR OTHER OBJECTS MAINTENANCE Refer to Pages 19 through 26 for periodic service schedules and periodic lubrication schedules See NOTE at the top of next page 36 NOTE IF THE VEHICLE IS CONSTANTLY HAULING HEAVY LOADS THE PREVENTIVE MAINTENANCE PROCEDURES SHOULD BE PERFORMED MORE OFTEN THAN RECOMMENDED IN THE SER VICE AND LUBRICATION SCHEDULES STORAGE COMPARTMENT There is an enclosed storage compartment underneath the rear seat with 2 cu ft 06 cu m of storage area Access the storage compartment by lifting the rear seat ELECTRIC FAIRWAY VILLAGER An optional on board charger is available for the Fairway Villager electric The charger should be plugged into a properly grounded nominal 115 Volts AC 60 Hertz outlet The AC line to which the charger is to be con nected must be capable of supplying 15 amperes minimum to the charger The rear seat should be propped open while charging the batteries A WARNING EACH CHARGER SHOULD HAVE ITS OWN DEDICATED 15 OR 20 AMPERE SEPARATELY PRO TECTED CIRCUIT BREAKER OR FUSE SINGLE PHASE BRANCH CIRCUIT IN ACCORDANCE WITH ALL APPLICABLE ELECTRICAL CODES FOR THE LOCATION A CAUTION BEFORE CHARGING BATTERIES TURN OFF ALL ACCESSORIES ON ALL VEHICLES IF USING AN ON BOARD CHARGER BE SURE THE AC PLUG IS UNPLUGGED FROM THE OUT LET BEFORE ATTEMPTING TO DRIVE THE VEHICLE CHARGER AND AC OUTLET WILL BE DAMAGED IF THE CHARGER IS NOT UNPLUGGED B
9. PLACE THE FORWARD AND REVERSE SWITCH IN THE REVERSE POSITION SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THE REVERSE WARNING BUZZER CAN NO LONGER BE HEARD WHEN THE BUZZER STOPS SOUNDING THE CONTROLLER IS DISCHARGED FRONT OF CAR FRONT OF CAR DISCONNECT HERE DISCONNECT HERE DS POWERDRIVE SYSTEM 48 AND V GLIDE 36 VOLT ELECTRIC VEHICLE POWERDRIVE PLUS WITH MOTOR BRAKING FIGURE 14 FIGURE 15 18 PERIODIC SERVICE SCHEDULES A WARNING IF ANY PROBLEMS ARE FOUND DO NOT OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE FAILURE TO MAKE NECESSARY REPAIRS COULD RESULT IN FIRE PROPERTY DAM AGE SEVERE PERSONAL INJURY OR DEATH ALL SERVICE REPAIRS AND ADJUSTMENTS MUST BE MADE PER INSTRUCTIONS IN THE DS GOLF CAR MAINTENANCE AND SERVICE MANUAL PUBLICATION PART NUMBER 1019051 01 PERIODIC SERVICE SCHEDULE GASOLINE VEHICLE REGULAR INTERVAL SERVICE Check for proper operation See Performance Accelerator pedal rod Inspection Page 6 Adjust as necessary Check for proper operation See Performance Inspec Accelerator governor linkage and cables tion Page 6 Adjust as necessary Check for proper operation See Performance Inspec Blake System tion Page 6 Adj
10. PLUG AND OR THE VEHICLE S RECEPTACLE DO NOT USE A CHARGER IF THE PLUG IS TOO LOOSE OR DOES NOT MAKE A GOOD CONNECTION THE PLUG AND RECEPTACLE FEEL HOTTER THAN NORMAL DURING CHARGE THE PLUG PINS POWERDRIVE CHARGERS OR BLADES ACCU POWER CHARGERS OR RECEPTACLE CONTACTS ARE BENT OR CORRODED 32 A WARNING DO NOT USE A CHARGER IF 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 THE DC CHARGER CORD AND PLUG ARE WEAR ITEMS AND MUST BE REPLACED WHEN WORN OR DAMAGED NOTE WHEN TEMPERATURES FALL BELOW 65 F 18 3 C BATTERIES CHARGED IN UNHEATED AREAS SHOULD BE PLACED ON CHARGE AS SOON AS POSSIBLE AFTER USE BATTERIES ARE WARMEST IMMEDIATELY AFTER USE AND COLD BATTERIES REQUIRE MORE TIME TO FULLY CHARGE FIGURE 23 FIGURE 24 Insert the chargers DC plug into the vehicle s receptacle The charger will turn on two to ten seconds later Figure 23 When inserting the PowerDrive System 48 DC plug align the raised guide on the plug with the guide slot in the receptacle and push straight in slowly The PowerDrive Charger interacts with an on board computer on the PowerDrive System 48 Golf Car The computer records the amount of energy consumed during vehicle use While the charger is plugged in the golf car s con
11. PROCEDURES EXACTLY AS STATED IN THIS MANUAL AND OBEY ALL DANGERS WARNINGS AND CAUTIONS LISTED IN THIS MANUAL AS WELL AS THOSE AFFIXED TO THE VEHICLE ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN SERVICING THE VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES TURN THE KEY SWITCH TO OFF REMOVE THE KEY CHOCK THE TIRES PLACE THE FOR WARD AND REVERSE SWITCH IN NEUTRAL AND DISCONNECT BATTERY IES PRIOR TO SERVICING THE VEHICLE ON GASOLINE VEHICLES DISCONNECT THE NEGATIVE BAT TERY LEAD FIRST FOR ELECTRIC VEHICLES SEE FIGURES 1 AND 2 ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL CONNECTIONS IMPROPER USE OF THE VEHICLE OR FAILURE TO PROPERLY MAINTAIN IT COULD RESULT IN DECREASED VEHICLE PERFORMANCE OR SEVERE PERSONAL INJURY ANY MODIFICATION OR CHANGE TO THE VEHICLE WHICH AFFECTS THE STABILITY OR HANDLING OF THE VEHICLE OR INCREASES MAXIMUM VEHICLE SPEED BEYOND FACTORY SPECIFICATIONS COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH FRONT OF CAR FRONT OF CAR 9 DISCONNECT HERE DISCONNECT HERE DS POWERDRIVE SYSTEM 48 AND V GLIDE 36 VOLT ELECTRIC VEHICLE POWERDRIVE PLUS WITH MOTOR BRAKING FIGURE 1 FIGURE 2 DS GASOLINE VEHICLE FEATURE IDENTIFICATION OPERATIN
12. THE CHARGER DOES NOT TURN OFF INSTALL SURGE ARRESTORS ON INCOMING AC POWER LINES SURGE ARRESTORS WILL HELP PROTECT ELECTRICAL ELECTRONIC COMPONENTS IN THE CHARGER AND ON THE VEHICLE FROM ALL BUT DIRECT OR VERY CLOSE LIGHTNING STRIKES 31 Battery Charger Electric Vehicle Continued NOTE BECAUSE THE POWERDRIVE CHARGER HAS A STORAGE CHARGE FEATURE THAT AUTO MATICALLY CHECKS AND RECHARGES THE BATTERIES AS NECESSARY EVERY 15 DAYS IT CAN REMAIN PLUGGED TO A POWERDRIVE VEHICLE THROUGHOUT THE STORAGE PERIOD SHORTLY AFTER CHARGING HAS BEGUN THE POWERDRIVE CHARGER WILL SHUT OFF IN ORDER TO RUN A SELF DIAGNOSTIC PROGRAM AMMETER WILL DROP TO 0 CHARGING WILL RESUME IN A FEW MOMENTS AMMETER WILL RETURN TO CURRENT STATE 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 10 amperes minimum per charger The battery charger must be grounded to reduce the risk of electrical shock The charger is equipped with an AC electric cord having an equipment grounding conductor and a grounding type plug and is for use on a nominal 115 Volt 60 Hertz circuit unless otherwise noted on the charger The plug must be grounded to an appropriate dedicated receptacle that is properly installed and grounded in accordance with the National Electrical Code ANSI NFPA 70 and all local codes and ordinances
13. WHICH COULD RESULT IN PROD UCT OR PROPERTY DAMAGE OR MINOR PERSONAL INJURY NOTE A NOTE PROVIDES KEY INFORMATION TO MAKE PROCEDURES MORE EASILY UNDER STOOD GENERAL WARNINGS The safety procedures listed must be followed whenever the vehicle is being operated repaired or serviced Other specific warnings appear throughout this manual and on the vehicle DANGER GASOLINE VAPORS FLAMMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE SERVICE ONLY IN WELL VENTILATED AREAS General Warnings Continued A DANGER BATTERY VAPORS FLAMMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE SERVICE ONLY IN WELL VENTILATED AREAS DO NOT OPERATE GASOLINE VEHICLE IN ENCLOSED AREA WITHOUT PROPER VENTILA TION ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POISON A GOLF CAR WILL NOT PROVIDE PROTECTION FROM LIGHTNING FLYING OBJECTS OR OTHER STORM RELATED HAZARDS IF CAUGHT IN A STORM WHILE DRIVING A GOLF CAR EXIT THE VEHICLE AND SEEK SHELTER IN ACCORDANCE WITH APPLICABLE SAFETY GUIDELINES FOR YOUR LOCATION A WARNING e THE ENGINE EXHAUST FROM THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THE VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD FOLLOW THE
14. battery charger on board computer and solid state controller are covered by separate CLUB CAR warranties Tires are warranted by their manufacturer Also excluded from any CLUB CAR warranty is damage to a golf car or component resulting from a cause other than a defect including unreasonable or unintended strain or use improper installation of accessories installation of parts or accessories that are not original equipment overloading accident alteration abuse or neglect Transportation expenses for warranty service are also excluded from this warranty 3 VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE GOLF CAR IS ABUSED OR USED IN AN UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY INCLUD ING BUT NOT LIMITED TO MODIFICATION OF THE SPEED GOVERNOR BRAKING SYSTEM STEER ING TRANSAXLE OR OTHER OPERATING SYSTEMS OF THE CAR TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKEWISE VOID IF THE CAR SHOWS INDI CATIONS THAT REASONABLE OR NECESSARY MAINTENANCE AS OUTLINED IN THE OWNER S MANUAL AND MAINTENANCE AND SERVICE MANUAL WAS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS 4 SOLE REMEDY CLUB CAR S ONLY LIABILITY UNDER THIS LIMITED WARRANTY OR IN ANY ACTION WHETHER BASED UPON WARRANTY CONTRACT NEGLIGENCE STRICT PRODUCT LIABILITY OR OTHER WISE IS LIMITED TO THE REPAIR OR REPLACEMENT AT CLUB CAR S OPTION OF A GOLF CAR OR COMPONE
15. engine until fuel remaining in the carburetor and fuel lines is used up and the engine stalls Return the neutral lock out cam to OPERATE position 2 2 Loosen do not remove the carburetor drain screw and drain fuel remaining in bowl into a small container then pour the fuel from the container into vehicle fuel tank 2 3 Reconnect fuel line to fuel pump 2 4 Disconnect fuel vent line from fuel tank vent nipple 2 5 Plug the fuel tank vent nipple so that it is air tight We recommend using a slip on vinyl cap 3 To protect the engine remove the spark plug and pour 1 2 ounce of SAE 10 weight oil into the engine through the spark plug hole Rotate the engine s crank shaft several times and then re install the spark plug A WARNING TURN THE KEY SWITCH OFF REMOVE THE KEY AND LEAVE THE FORWARD AND REVERSE SWITCH IN THE NEUTRAL POSITION DURING STORAGE THIS IS TO PREVENT UNINTEN TIONAL STARTING OF THE VEHICLE 15 Storage of Gasoline Vehicle Continued 4 Increase tire pressure to 20 psi 96 kPa 5 Grease front suspension and do all quarterly periodic lubrication See Periodic Lubrication Sched ule Page 24 6 Thoroughly clean front body rear body seats engine compartment and underside of vehicle 7 Do not latch the park brake Block tires to prevent the vehicle from rolling TO RETURN THE STORED VEHICLE TO SERVICE 1 Restore fuel system to operation 1 1 Remove plug from the fuel tank vent nipple and r
16. language of safety It is a language that can save your life vi SAFETY DETAILS A WARNING THIS OWNER S MANUAL SHOULD BE READ COMPLETELY BEFORE ATTEMPTING TO DRIVE OR SERVICE THE VEHICLE FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS MANUAL COULD RESULT IN PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH It is important to note that some vital statements throughout this manual and on the decals affixed to the vehicle are preceded by the words DANGER WARNING CAUTION or NOTE For your protection we rec ommend that you take special notice of these safety procedures Safety procedures are essential and must be followed Throughout this manual and on the operation and warning decals affixed to the vehicle the words golf car and vehicle are used interchangeably Golf car is defined in the Notice of this manual and no other repre sentation is stated or implied If any of the operation or warning decals on the vehicle become damaged have been removed or cannot be easily read they should be replaced immediately to avoid possible personal injury property damage or death Contact your CLUB CAR distributor dealer DANGER A DANGER INDICATES AN IMMEDIATE HAZARD WHICH WILL RESULT IN SEVERE PER SONAL INJURY OR DEATH A WARNING A WARNING INDICATES AN IMMEDIATE HAZARD WHICH COULD RESULT IN SEVERE PER SONAL INJURY OR DEATH A CAUTION ACAUTION INDICATES HAZARDS OR UNSAFE PRACTICES
17. on a bar code decal mounted on the frame directly above the accelerator pedal Example A9701 123456 for Electric or AG9701 123456 for Gasoline See Figure 3 There is also a second serial number decal mounted on the front body frame behind the center dash panel The center dash panel must be removed to access it NOTE ALWAYS HAVE THE VEHICLE SERIAL NUMBER AT HAND WHEN ORDERING PARTS OR MAK ING INQUIRIES IF THE VEHICLE IS EQUIPPED AS A FAIRWAY VILLAGER FOUR PASSENGER VEHICLE READ THE SPECIAL INSTRUCTIONS ON PAGES 36 AND 37 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 feels necessary or appropriate 1 Dispose of litter properly Club Car Inc A970i i23456 FIGURE 3 PRE OPERATION CHECKLIST Your CLUB CAR has been thoroughly inspected and adjusted at the factory and also by your CLUB CAR distri
18. the DS Gasoline or DS Electric you have chosen the finest golf car on the market Please protect your investment and ensure that your Club Car provides years of reliable superior performance by returning your Warranty Registration provided by your distributor dealer and by reading and following the maintenance instructions in this manual Your comfort and safety are important to us as well so we urge you to read and follow the step by step oper ating instructions and safety procedures in this manual These instructions must be followed in order to avoid the risk of severe personal injury If you rent or loan your vehicle to others we recommend that you ask them to read this manual before they operate the vehicle Club Car products are backed by a customer support system designed to offer you fast courteous service In the event that your golf car needs repairs or services we recommend that your local authorized Club Car representative perform them For the name and address of the Club Car representative nearest you call 706 863 3000 Ext 822 If you would prefer to write to us direct your letter to Club Car Attention Product Development Department P O Box 204658 Augusta Ga 30917 4658 USA Your local authorized Club Car representative can also provide technical advice parts and service manuals We hope you will consider this owners manual a permanent part of your golf car If you sell the vehicle please include the manual so that
19. the golf car not specified otherwise are warranted with respect to parts and labor against defects in materials and workmanship for a period of two years from the date of purchase while owned by the Original Retail Fleet Purchaser or in the possession of the Original Retail Fleet Lessee This limited warranty covers materials workmanship and repair labor cost as to those items specifically listed above for the periods specified Such repair labor shall be performed only by CLUB CAR its authorized dis tributors or dealers or a service agency approved by CLUB CAR IF THE WARRANTY REGISTRATION FORM IS NOT COMPLETED AND RETURNED TO CLUB CAR AT THE TIME OF THE ORIGINAL RETAIL SALE PURCHASER MUST PROVIDE PROOF OF DATE OF PUR CHASE WITH ANY WARRANTY CLAIM 2 EXCLUSIONS Excluded from any CLUB CAR warranty are all optional equipment and accessories fuses filters decals except safety decals spark plugs lubricants and trim pieces seats routine wear items such as the charger plug and receptacle brake shoes belts brushes bushings engine mounts mats and pads mainte nance adjustments cosmetic deterioration and items which deteriorate or fail due to exposure or ordinary wear and tear Batteries the battery charger on board computer and solid state speed controller are cov ered under separate CLUB CAR warranties Tires are warranted by their manufacturer Also excluded from any CLUB CAR warranty is damage to a golf car or component resul
20. 15 25 in Ibs 1 7 2 9 N m A loose hold down bracket may allow the battery to become damaged from vibration or jarring A hold down bracket that is too tight may buckle or crack the battery case If battery appears weak have it charged by a trained mechanic The battery should never be left discharged any longer than absolutely necessary do not leave discharged overnight BATTERIES ELECTRIC VEHICLE DANGER BATTERY EXPLOSIVE GASSES DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE TOOLS WIRES AND METAL OBJECTS CAN CAUSE SPARKS WHEN SHORTED ACROSS A BATTERY FOLLOW ALL INSTRUCTIONS CAREFULLY WHEN DEALING WITH BATTERIES CHARGE BATTERIES IN A WELL VENTILATED AREA ONLY BATTERIES EMIT HYDROGEN WHILE BEING CHARGED HYDROGEN IS AN EXPLOSIVE GAS AND MUST NEVER EXCEED A LEVEL OF 2 OF THE AIR POISON CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING ANTIDOTES EXTERNAL FLUSH WITH WATER FOR 15 MINUTES CALL A PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOWED WITH MILK OF MAGNESIA OR VEGETABLE OIL CALL A PHYSICIAN IMMEDIATELY EYES FLUSH WITH WATER FOR 15 MINUTES CALL A PHYSICIAN IMMEDIATELY A WARNING ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN SERVICING THE VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL CONNECT
21. DOR LESS DEADLY POISION A WARNING ANY MODIFICATION OR CHANGE TO THE VEHICLE WHICH AFFECTS THE STABILITY OR HANDLING OF THE VEHICLE OR INCREASES MAXIMUM VEHICLE SPEED BEYOND FACTORY SPECIFICATIONS COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH IF RENTING OR LOANING THE VEHICLE MAKE SURE THE DRIVER IS FAMILIAR WITH ALL CONTROLS AND OPERATING PROCEDURES BEFORE ALLOWING THE VEHICLE TO BE DRIVEN DO NOT TAMPER WITH THE GASOLINE VEHICLE S 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 DO NOT MODIFY OR CHANGE THE VEHICLE IN ANY WAY WHICH MIGHT AFFECT ITS STABIL ITY OR HANDLING OR INCREASE MAXIMUM SPEED BEYOND FACTORY SPECIFICATIONS PROPERTY DAMAGE PERSONAL INJURY OR DEATH COULD RESULT DO NOT SHIFT THE FORWARD REVERSE SWITCH WHILE THE VEHICLE IS IN MOTION TO AVOID INJURY TO AN UNSUSPECTING PASSENGER OR DAMAGE TO THE VEHICLE ALWAYS BRING THE VEHICLE TO A FULL STOP BEFORE SHIFTING THE SWITCH A BUZZER WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE RELEASE THE ACCELERATOR PEDAL AND THEN DEPRESS THE BRAKE PEDAL FIRMLY UNTIL THE VEHICLE STOPS TO AVOID UNINTENTIONAL STARTING OR ROLLING OF THE VEHICLE SET THE PARK BRAKE TURN THE KEY SWITCH TO OFF AND REMOVE THE KEY WHEN LEAVING THE VEHICLE KE The pos Y SWITCH key switch is mounted on the dash to the right of the ste
22. E Monthly Service by Owner or Trained Mechanic Battery Wash battery top with baking soda water solution See Page 28 Check brake cables for damage replace as required Brake System Check for proper operation See Performance Inspec tion Page 6 Check brake pedal free play Adjust as necessary See DS Maintenance amp Service Manual Make sure that both ground wires are tight and properly connected Engine Check engine oil level change as required See Gas Vehicle Lubrication Chart Page 24 Exhaust System Check for leaks Check for wear and damage Tires Check air pressure and adjust as necessary See Vehicle Capacities Chart on Page 26 Check all daily and weekly items listed above Quarterly Service by Owner or Trained Mechanic Engine Check engine oil level change as required See Gas Vehicle Lubrication Chart Page 24 Engine air intake hose Check clamps for tightness check hose for cracks Accelerator pedal rod Check for proper operation adjust as necessary See NOTE Page 8 Accelerator governor linkage and cables Check for proper operation adjust as necessary Steering Lubricate per Gas Vehicle Lubrication Chart on Page 24 General Vehicle Lubricate per Gas Vehicle Lubrication Chart on Page 24 Check all daily weekly and monthly items listed above Semi annual Service by Trained Mechanic Onl
23. E PEDAL The park brake pedal is the small raised portion in the upper left corner of the brake pedal It has the word PARK molded into it and the words PARK BRAKE marked on top of it See Figure 8 To set the park brake depress the brake pedal firmly and tilt the park brake portion of the pedal forward with your foot Figure 9 FIGURE 8 FIGURE 9 GASOLINE VEHICLES ONLY Neutral Lock out The vehicle has a neutral lock out circuit that prevents the driver from starting the vehicle in NEUTRAL If the vehicle is started in forward or reverse and then shifted to neutral the engine will stop running Neutral Lock out Continued For the convenience of the trained mechanic there is a neutral lock out cam located on the back of the for ward reverse lever If the neutral lock out cam is pulled out approximately 3 8 inch 10 millimeters and then rotated one half turn until it snaps into place the vehicle will be in the SERVICE position See Figure 10 This will allow the mechanic to run the engine in NEUTRAL for certain maintenance procedures With the cam in this position the vehicle will not operate if the forward reverse lever is placed in either the forward or reverse position To put the vehicle back into the OPERATE position pull the cam out approximately 3 8 inch 10 millimeters and rotate it one half turn until it snaps into place See Figure 11 See WARNING and NOTE below A WARNING WITH THE CAM IN THE SERVICE POSITION AND
24. EFORE DRIVING BE SURE THE AC CORD IS PROPERLY WOUND UP ON THE REEL BEFORE DRIVING THE VEHICLE STUDY ALL GENERAL INFORMATION NOTES CAUTIONS AND WARNINGS AS WELL AS ALL INFORMA TION NOTES CAUTIONS AND WARNINGS SPECIFIC TO THE POWERDRIVE CHARGER AND POWERDRIVE SYSTEM 48 IN THE BATTERY CHARGER SECTION OF THIS OWNER S MANUAL PAGE 30 SEAT HANDLE HAND RAIL FOOT REST FIGURE 27 37 VEHICLE SPECIFICATIONS SPECIFICATIONS DS GASOLINE POWERDRIVE SYSTEM 48 ELECTRIC POWERDRIVE PLUS ELECTRIC DS 36 VOLT ELECTRIC POWER SOURCE Engine 4 cycle OHV 286 cc 9 0 hp rated single cylinder air cooled with pressure lubrication system Drive Motor Direct drive 48 volts DC series wound 3 1 hp Drive Motor Direct drive 48 volts DC shunt wound 3 2 hp Drive Motor Direct drive 36 volts DC series wound 2 97 hp Fuel System Side draft carburetor with float bowl fixed jets fuel filter and impulse fuel pump Governor Automatic ground speed sensing internally geared in unitized transaxle Ignition Transistor electronic ingnition with electronic RPM limiter Unitized Transaxle Fully synchronized forward and reverse with neutral 11 8 1 forward 17 1 1 reverse Transaxle Double reduction helical gear with 12 28 1 direct drive axle Electrical System 12 volt 460 cold cranking amp battery and 35 amp charging capacity Electrical System 48 volt
25. G INSTRUCTIONS DECAL KEY SWITCH PRACTICE GOLF ETIQUETTE OPERATING INSTRUCTIONS SERIAL NUMBER ACCELERATOR OIL PEDAL WARNING LIGHT BRAKE PEDAL PARK BRAKE PEDAL GASOLINE TANK DANGER DECAL HOT MANIFOLD AND ON BODY ADJACENT TO MUFFLER DECAL FUEL TANK ON ENGINE MOVING PARTS AL N WARNING PERIODIC SERVICE DECAL M DANGER SCHEDULE DECAL ON FRAME gt 5 MOVING PARTS can cause severe burns ON AIR INTAKE BOX Periodic Service Schedule ClubCar Service Regular Interval OIL FILL FORWARD REVERSE LEVER NEUTRAL LOCK OUT CAM CHOKE FRAME GROUND WARNING DECAL N WARNING H Negative frame ground Do not contact positive H battery post or cable to frame as this can cause battery explosion electrical shocks and burns KEEP OUT OF THE REACH OF CHILDREN DO NOT TIP KEEP VENT CAPS TIGHT AND LEVEL DANGER DECAL ON FRAME ON BODY UNDER SEAT DS ELECTRIC VEHICLE FEATURE IDENTIFICATION PRACTICE GOLF ETIQUETTE Observe club rules KEY SWITCH Drive on golf car paths when possible Keep proper distance from greens DECAL Replace divots Repair ball marks on greens Rake sand traps Allow faster players to play through Help speed up play Dispose of litter properly Club Car OPERATING INSTRUCTIONS DECAL OPERATING IN
26. HE EXCLUSIVE AND SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE DISTRIBUTOR OR DEALER OF CLUB CAR HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY 7 NO CONSEQUENTIAL DAMAGES IN NO EVENT SHALL CLUB CAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAM AGES INCLUDING BUT NOT LIMITED TO LOSS RELATED TO PROPERTY OTHER THAN THE GOLF CAR LOSS OF USE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitation of inci dental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state 8 INFORMATION For further information contact WARRANTY ADMINISTRATION CLUB CAR INC P O Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 9 WARNING Any modification or alteration of any golf car beyond factory specifications including those that affect the weight distribution stability or speed of the golf car can cause serious personal injury or death lii FOREWORD Thank you for choosing Club Car the golf car most widely recognized as the industry leader in vehicle effi ciency and long lasting value Whether you have chosen
27. HE PLASTIC HAS BEEN REMOVED FROM THE SEAT BOTTOM BEFORE OPERAT ING THE VEHICLE FAILURE TO DO SO MAY RESULT IN A FIRE PROPERTY DAMAGE PER SONAL INJURY OR DEATH PERFORMANCE INSPECTION After you have familiarized yourself with the vehicle s controls and have read and understood the driving instructions take the vehicle for a test drive Use the following checklist as a guide to inspect your new vehi cle Any problems should be corrected only by your CLUB CAR distributor dealer or a trained technician All vehicles Brakes Be sure the brakes function properly When brake pedal is fully depressed under moderate pressure it should not go more than halfway to the floor and vehicle should come to a smooth straight stop within 14 feet If the pedal goes more than halfway to the floor or if the vehicle swerves or fails to stop within 14 feet have the brake system checked and adjusted as required Brake adjustment must be maintained so that the brake pedal cannot be depressed to the floor under any circumstances Park Brake When latched the park brake should lock the wheels and hold the vehicle stationary on incline of 2096 or less It should release when either the accelerator or brake pedal is depressed Steering The vehicle should be easy to steer and should not have any play in the steering wheel Accelerator As the accelerator pedal is depressed the engine or motor should start and the vehicle should come up smooth
28. INE DAMAGE POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS ELECTRIC VEHICLES ONLY Battery Warning Light PowerDrive System 48 and PowerDrive Plus vehicles feature a dash mounted warning light above steering column that when the vehicle is in operation indicates low battery voltage or when the vehicle is being charged indicates a charging problem The battery warning light is controlled by the PowerDrive on board computer 10 NEUTRAL FORWARD NEUTRAL FORWARD SERVICE POSITION OPERATE POSITION FIGURE 10 FIGURE 11 FIGURE 12 FIGURE 13 When the vehicle is in operation the warning light will come on and remain illuminated if Batteries voltage drops below 48 when there is no load on the batteries the vehicle is stopped and there are no accessories on Batteries have discharged to less than 25 of rated capacity If the warning light comes on during a round of golf there is enough power remaining to finish the round but the car should be charged before being used again If the warning light comes on and the vehicle is unable to finish the round have your Club Car distributor dealer check the vehicle for a possible battery or electrical system problem When the batteries receive an incomplete charge because 1 the DC power cord is disconnected 2 AC power to the charger is interrupted 3 automatic charger shut off occurs after 16 hours of operation or 4 the charger malfunctions the warning light will indic
29. IONS A CAUTION ON ALL VEHICLES TURN OFF ALL ACCESSORIES BEFORE CHARGING BATTERIES 29 Batteries Electric Vehicles Continued The batteries in DS V Glide 36 Volt Electric Vehicles are 6 volts each The batteries in PowerDrive System 48 and PowerDrive Plus Electric Vehicles are 8 volts each Both the 6 and 8 volt batteries are deep cycle batteries specially built for electric vehicle application Auto motive batteries should never be used New batteries will not deliver their full capabilities until they have been discharged and recharged 20 to 50 times To obtain the maximum service life from new batteries restrict vehicle with new batteries to 36 holes of use between charges in the first two months of operation Batteries should be fully charged before first use of new vehicle before first use of a vehicle after storage and before releasing vehicle for use each day BATTERY CARE To keep batteries in good working condition follow this maintenance program on a regular basis 1 The batteries should be kept clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water 1 cup baking soda per gallon of water Rinse solution off batteries NOTE Do not allow this solution to enter the battery Be sure terminals are tight Let the terminals dry and then spray them with CLUB CAR battery protector spray Part No 1014305 2 The water level in the batteries should be ch
30. LE OUT OF FORWARD WHILE GOING DOWNHILL IF YOU DO YOU WILL NOT BE ABLE TO SHIFT INTO REVERSE OR BACK INTO FORWARD UNTIL STOPPED GASOLINE VEHICLE ONLY DEPRESS THE BRAKE PEDAL AS NECESSARY AND PARTIALLY DEPRESS THE ACCELERATOR WHEN DESCENDING A HILL WITH THE ACCELERATOR PEDAL PARTIALLY DEPRESSED THE GOVERNOR WILL CAUSE THE ENGINE TO ASSIST THE BRAKES IN CONTROLLING DOWNHILL SPEED POWERDRIVE PLUS VEHICLE WITH MOTOR BRAKING ONLY PEDAL DOWN OR PEDAL UP MOTOR BRAKING MAY BE USED TO CONTROL SPEED WHEN GOING DOWNHILL SEE PERFORMANCE INSPECTION ON PAGE 7 HOWEVER TERRAIN OR OTHER CONDITIONS MAY REQUIRE THAT PEDAL BRAKING BE USED IN CONJUNCTION WITH MOTOR BRAKING STOPPING THE VEHICLE WARNING DRIVING THROUGH WATER MAY AFFECT THE BRAKES AFTER DRIVING THROUGH WATER CHECK EFFECTIVENESS OF THE BRAKES BY GENTLY DEPRESSING THE BRAKE PEDAL IF THE VEHICLE DOES NOT SLOW DOWN AT THE NORMAL RATE CONTINUE TO DEPRESS THE BRAKES UNTIL THEY DRY OUT AND NORMAL PERFORMANCE RETURNS A CAUTION WHEN STOPPED ON A HILL USE THE BRAKE PEDAL TO HOLD YOUR POSITION DO NOT USE THE ACCELERATOR PEDAL To stop the vehicle release the accelerator pedal and depress the brake pedal with your right foot until the vehicle comes to a complete stop PARKING AND LEAVING THE VEHICLE 1 After stopping the vehicle firmly depress the park brake pedal until it locks This will prevent the vehicle from rolling 2 Turn the ke
31. LINE VEHICLE LUBRICATION POINTS 32 oz 97 liter without filter 38 oz 1 16 liters with filter 10W30 above 32 F 0 C or SAE 5W20 below 32 F 0 C API Class SE SF or SG Oil or higher 24 FIGURE 16 PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE ELECTRIC VEHICLE REGULAR INTERVAL SERVICE PLACE RECOMMENDED LUBRICANT Brake shaft bearings f Dry Moly Lube Club Car Part No 1012151 Brake Linkage and Pivots Dry Moly Lube Club Car Part No 1012151 Quarterly by Owner Accelerator pivots Dry Moly Lube Club Car Part No 1012151 or Trained Technician Forward and reverse switch contacts and charger receptacle WD 400 Front Suspension 5 fittings Chassis Lube Annually by Trained Check fill transaxle to plug level 22 oz 67 liter SAE 30 WT API Technician Only Class SE SF or SG Oil or higher Every 200 rounds or 100 hours of operation Inspect front wheel bearings Chassis Lube Repack as necessary See Figure 17 below and Figure 18 on Page 26 POWERDRIVE SYSTEM 48 VEHICLE AND POWERDRIVE PLUS VEHICLE LUBRICATION POINTS FIGURE 17 25 V GLIDE 36 VOLT VEHICLE LUBRICATION POINTS FIGURE 18 VEHICLE CAPACITIES CAPACITIES GASOLINE VEHICLE
32. MABLE MATERIALS AND VAPORS DO NOT EXPOSE TO RAIN OR ANY LIQUID KEEP THE CHARGER DRY e NEVER PUSH OBJECTS OF ANY KIND INTO THE CHARGER THROUGH CABINET SLOTS THEY MAY TOUCH DANGEROUS VOLTAGE POINTS OR CAUSE AN ELECTRICAL SHORT CIR CUIT THAT COULD RESULT IN FIRE OR ELECTRICAL SHOCK 36 VOLT ACCU POWER CHARGER DO NOT DISCONNECT THE DC OUTPUT PLUG FROM THE VEHICLE RECEPTACLE WHEN THE CHARGER IS ON THE RESULTING ARCING AND BURNING COULD DAMAGE THE PLUG AND RECEPTACLE AND COULD CAUSE BATTERIES TO EXPLODE IF THE CHARGER MUST BE STOPPED DISCONNECT THE AC SUPPLY PLUG FROM THE WALL OUTLET BEFORE DISCONNECTING THE CHARGER DC CORD FROM THE VEHICLE RECEPTACLE 48 VOLT POWERDRIVE CHARGER WHEN THE CHARGER IS ON THE CHARGER DC CORD MAY BE DISCONNECTED FROM THE VEHICLE RECEPTACLE SLOWLY JERKING OR PULL ING THE DC CORD OUT QUICKLY COULD CAUSE ARCING AND BURNING THAT COULD DAM AGE THE PLUG AND RECEPTACLE AND COULD CAUSE BATTERIES TO EXPLODE A CAUTION DO NOT BLOCK OR COVER SLOTS AND OPENINGS IN THE BACK AND BOTTOM OF CHARGER CABINET THEY PROVIDE VENTILATION AND PROTECT THE CHARGER FROM OVERHEATING DO NOT ALLOW CLOTHING BLANKETS OR OTHER MATERIAL TO COVER THE CHARGER PROVIDE ADEQUATE VENTILATION FOR THE CHARGER 36 VOLT ACCU POWER CHARGER DO NOT LEAVE THE DC CORD PLUGGED INTO A VEHI CLE RECEPTACLE WHILE UNATTENDED FOR MORE THAN TWO DAYS IN A ROW SEVERE OVERHEATING AND DAMAGE TO THE BATTERIES MAY RESULT IF
33. NT THEREOF THAT CLUB CAR DEEMS TO BE DEFECTIVE REPLACEMENT SHALL MEAN FURNISHING DURING THE APPLICABLE LIMITED WARRANTY PERIOD A NEW GOLF CAR OR FAC TORY RECONDITIONED VEHICLE OR COMPONENT THEREOF WHICH IS IDENTICAL OR REASON ABLY EQUIVALENT TO THE WARRANTED PRODUCT OR COMPONENT AT NO COST TO THE PURCHASER REPAIR SHALL MEAN REMEDYING A DEFECT IN THE GOLF CAR OR COMPONENT THEREOF AT NO COST TO THE PURCHASER DURING THE APPLICABLE LIMITED WARRANTY PERIOD IF CLUB CAR ELECTS TO REPAIR THE GOLF CAR IT MAY PROVIDE FACTORY RECONDI TIONED PARTS OR COMPONENTS ALL PARTS AND COMPONENTS REPLACED UNDER WARRANTY SHALL BECOME THE PROPERTY OF CLUB CAR 5 HOW TO MAKE A WARRANTY CLAIM To make a warranty claim under this limited warranty you must present the golf car or defective component to an authorized CLUB CAR distributor or dealer or send the defective component freight prepaid to WAR RANTY ADMINISTRATION CLUB CAR INC 4152 Washington Road P O Box 204658 Augusta Georgia 30917 4658 6 DISCLAIMER THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESS OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS ORTIME LIMITS STATED IN THIS WAR RANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REMEDY OF REPLACEMENT OR REPAIR OF THE DEFECTIVE GOLF CAR OR COMPONENT THEREOF IS T
34. O ALLOWING THEM TO DRIVE THE VEHICLE FOR NIGHT USE THE VEHICLE MUST BE EQUIPPED WITH HEADLIGHTS TAILLIGHTS AND REFLECTORS STOP THE VEHICLE BEFORE SHIFTING THE FORWARD AND REVERSE SWITCH FAILURE TO DO SO MAY RESULT IN INJURY TO AN UNSUSPECTING PASSENGER AND OR DAMAGE TO THE VEHICLE A BUZZER WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE WHEN DRIVING THE VEHICLE OPERATE THE VEHICLE FROM THE DRIVER S SEAT ONLY TO PREVENT FALLS FROM THE VEHICLE REMAIN SEATED IN A MOVING VEHICLE AND HOLD ON TO SEAT HANDLES OR HANDRAILS AT ALL TIMES DRIVER SHOULD KEEP BOTH HANDS ON THE STEERING WHEEL WHEN THE VEHICLE IS IN MOTION e KEEP ALL BODY PARTS INSIDE THE VEHICLE TO PREVENT THEM FROM GETTING CAUGHT BETWEEN THE VEHICLE AND THE GROUND OR OTHER OBJECTS TO PREVENT OVERTURNING OF THE VEHICLE DRIVE SLOWLY IN TURNS TO PREVENT OVERTURNING OF THE VEHICLE DRIVE SLOWLY STRAIGHT UP AND DOWN SLOPES DO NOT DRIVE THE VEHICLE ON SLOPES EXCEEDING 20 INCLINE TO AVOID POSSIBLE INJURY TO AN UNSUSPECTING PASSENGER AND OR DAMAGE TO THE VEHICLE AVOID SUDDEN STARTS SUDDEN STOPS AND ABRUPT TURNS TO AVOID THE POSSIBILITY OF LOSING CONTROL OF OR OVERTURNING THE VEHICLE REDUCE SPEED FOR ADVERSE DRIVING CONDITIONS SUCH AS WET GRASS OR ROUGH TERRAIN DO NOT USE THE VEHICLE ON PUBLIC ROADS IT IS NOT DESIGNED OR INTENDED FOR STREET USE AND SHOULD NOT BE LICENSED FOR USE ON PUBLIC ROADS OBEY ALL LOCAL RULES CONCERNING G
35. OLF CARS THE VEHICLE SHOULD BE DRIVEN IN ONLY SPECIFIED AREAS BY TRAINED PEOPLE TO AVOID BEING STRUCK DO NOT STAND IN FRONT OF OR BEHIND THE VEHICLE DO NOT DRIVE WHILE UNDER THE INFLUENCE OF ALCOHOL DRUGS OR MEDICATIONS No one should drive the vehicle without first being instructed in the proper operation and use of the vehicle s controls An experienced operator should accompany each first time driver on a test drive before allowing him her to operate the vehicle alone Only licensed drivers should be allowed to drive this vehicle To ensure safe operation of the vehicle follow exactly and in order all of the following procedures Read and understand all instructions prior to driving the vehicle 12 STARTING THE VEHICLE 1 Enter the vehicle Study and understand controls Be sure everyone is seated and holding onto seat handles or handrails Read safety warnings located above pedals Make sure wheels are turned in desired direction Turn key to the ON position and be sure nothing is in your path Select direction by placing shift lever in desired position F forward or R reverse Slowly depress accelerator pedal The park brake will release automatically and the vehicle will start to move As the accelerator pedal is depressed speed will increase until full speed is reached 661 5 Or A WARNING VEHICLE OPERATOR MUST CONTROL SPEED WHEN GOING DOWNHILL NEVER SHIFT THE VEHIC
36. ON 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 ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN SERVICING THE VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL CONNECTIONS TURN KEY SWITCH TO OFF REMOVE THE KEY PLACE THE FORWARD AND REVERSE SWITCH IN THE NEUTRAL POSITION AND CHOCK TIRES PRIOR TO SERVICING MOVING PARTS DO NOT ATTEMPT TO SERVICE GASOLINE VEHICLE WHILE THE ENGINE IS RUNNING HOT DO NOT ATTEMPT TO SERVICE HOT ENGINE MOTOR RESISTORS OR EXHAUST SYS TEM ATTEMPTING TO DO SO COULD CAUSE SEVERE BURNS GASOLINE VEHICLES ONLY TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE BEFORE SERVICING ALWAYS DISCONNECT THE BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG FRAME GROUND DO NOT ALLOW WRENCH 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 INNER FRAME OR OTHER METAL COMPONENT ELECTRIC VEHICLES ONLY TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE DISCONNECT THE BATTERIES AS SHOWN SEE FIGURES 14 AND 15 ON POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES ALSO DISCHARGE THE CONTROLLER AS FOLLOWS TURN THE KEY SWITCH TO ON AND
37. ORAGE PUMP ING DEVICE MUST BE GROUNDED IF THE PUMP IS NOT GROUNDED THE VEHICLE MUST BE GROUNDED TO THE PUMP BEFORE AND DURING THE FUELING OPERATION IF THE VEHICLE HAS AN ALL WEATHER ENCLOSURE INSTALLED THE GAS TANK MUST BE PROPERLY VENTED AS SHOWN FIGURE 20 TO AVOID THE POSSIBILITY OF FIRE BE SURE TO CLEAN UP ANY SPILLED GASOLINE BEFORE OPERATING THE VEHICLE NOTE e WHENEVER POSSIBLE AVOID USING OXYGENATED FUELS AND FUELS THAT ARE BLENDED WITH ALCOHOL VEHICLES TO BE STORED FOR EXTENDED PERIODS SHOULD BE PREPARED FOR STORAGE AS INSTRUCTED ON PAGE 15 OF THIS MANUAL 27 Fueling Instructions Continued 1 Lift and remove seat bottom 2 The fuel tank is located on passenger side of vehicle Remove fuel cap and fill the fuel tank with fresh unleaded gasoline only A CAUTION DO NOT OVERFILL THE FUEL TANK AVOID SPILLING FUEL 3 Replace fuel cap on tank being sure cap is tightened securely 4 Replace seat bottom BATTERY GASOLINE VEHICLE A DANGER BATTERY EXPLOSIVE GASSES DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE TOOLS WIRES AND METAL OBJECTS CAN CAUSE SPARKS WHEN SHORTED ACROSS A BATTERY FOLLOW ALL INSTRUCTIONS CAREFULLY WHEN WORKING WITH BATTERIES CHARGE BATTERY IN A WELL VENTILATED AREA ONLY POISON CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING ANTIDOTES EXTERNAL FLUSH WITH WATER FOR 15 MINUTE
38. S CALL A PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOWED WITH MILK OF MAGNESIA OR VEGETABLE OIL CALL A PHYSICIAN IMMEDIATELY EYES FLUSH WITH WATER FOR 15 MINUTES CALL A PHYSICIAN IMMEDIATELY A WARNING DO NOT JUMP START THE VEHICLE TO CHARGE THE BATTERY USE AN AUTOMOTIVE TYPE 12 VOLT CHARGER RATED AT 10 AMPS OR LESS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN SERVICING THE VEHICLE ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL CONNECTIONS The battery in the DS Gasoline Vehicle is a 12 volt low maintenance battery that requires infrequent water ing Figure 21 Any corrosion around the positive or negative terminals should be washed off with a solution of baking soda and water 1 cup per gallon of water Rinse solution off the battery Be sure terminals are tight Let the terminals dry and then spray them with CLUB CAR battery terminal spray Club Car Part No 1014305 A CAUTION e IF BATTERY WIRE TERMINALS ARE DAMAGED OR CORRODED THEY SHOULD BE REPLACED OR CLEANED AS NECESSARY FAILURE TO DO SO MAY CAUSE THEM TO OVER HEAT DURING OPERATION 28 BATTERY 1 CAP PLATES WATER LEVEL AT LEAST 1 2 ABOVE PLATES OR TO LEVEL INDICATOR FIGURE 21 FIGURE 22 Be sure battery hold down bracket is properly tightened Torque to
39. S ELECTRIC VEHICLES Engine Crankcase without filter 32 oz 98 liters Engine Crankcase with filter 38 oz 1 16 liters Unitized Transaxle gas vehicle 27 oz 8 liters Transaxle electric vehicle 22 oz 67 liters Gasoline Tank 7 gallons 26 5 liters Tire Pressure 12 14 psi 83 96 kPa 18 20 psi 124 138 kPa 26 ENGINE OIL GASOLINE VEHICLE Even though the oil warning light on the dash should warn you if your oil is getting low engine oil level should be checked monthly See Figure 19 NOTE TO CHECK ENGINE OIL THE ENGINE MUST BE IN LEVEL POSITION REMOVE THE OIL LEVEL DIPSTICK FROM THE OIL FILLER TUBE AND WIPE OIL FROM IT WITH A CLEAN DRY CLOTH OR PAPER TOWEL CHECK OIL BY INSERTING THE DIPSTICK FULLY INTO THE OIL FILLER TUBE AND IMMEDIATELY REMOVING IT AGAIN IF THE OIL LEVEL IS AT OR BELOW THE ADD MARK ON THE DIPSTICK GAUGE ADD OIL UNTIL THE LEVEL IS BETWEEN ADD AND FULL SAFE LEVEL DO NOT OVERFILL REINSERT DIPSTICK INTO THE OIL FILLER TUBE VENT TUBE FIGURE 19 FIGURE 20 FUELING INSTRUCTIONS GASOLINE VEHICLE DANGER GASOLINE FLAMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE SERVICE OR REPAIR IN WELL VENTILATED AREA ONLY NEVER ATTEMPT TO POUR GASOLINE INTO THE FUEL TANK WHEN THE ENGINE IS HOT OR WHILE IT IS RUNNING TO AVOID ELECTRIC ARC CAUSED BY STATIC ELECTRICITY THE FUEL ST
40. STRUCTIONS GOLF ETIQUETTE DECAL V GLIDE 36 VOLT AND POWERDRIVE SYSTEM 48 VEHICLES OR SERIAL NUMBER ACCELERATOR PEDAL MOTOR BRAKING DECAL POWERDRIVE PLUS VEHICLE ONLY BRAKE PEDAL BATTERY WARNING LIGHT PARK BRAKE PEDAL SAFETY WARNING DECAL DANGER DECAL ON BODY UNDER SEAT DANGER POISON FLUSH EYES SULFURIC IMMEDIATELY ACID R CAN CAUSE BLINDNESS OR SEVERE BURNS HOT RESISTORS CAN CAUSE SEVERE BURNS FORWARD REVERSE RESISTOR WARNING DECAL LEVER V GLIDE 36 VOLT AND POWERDRIVE PLUS VEHICLES POWERDRIVE SYSTEM 48 ON BODY UNDER SEAT AND V GLIDE 36 VOLT VEHICLES 1 FORWARD REVERSE CAUTION 12 9 28 SWITCH COVER IN PLACE DO NOT DIRECT WATER STREAM AT THIS SWITCH CHARGER POWERDRIVE PLUS SPEED SWITCH CAUTION DECAL RECEPTACLE V GLIDE 36 VOLT VEHICLE ONLY ON WIPER SWITCH COVER GENERAL INFORMATION There are four DS Golf Car models the DS gasoline powered vehicle the DS V Glide 36 volt electric pow ered vehicle the DS PowerDrive System 48 48 volt electric vehicle and the DS PowerDrive Plus 48 volt electric vehicle with motor braking Throughout this manual important features unique to each model are highlighted We urge the owner operator to read and understand this manual and to pay special attention to the features specific to his her vehicle MODEL IDENTIFICATION The serial number of your CLUB CAR is printed
41. See Performance Inspec tion Page 6 Adjust as necessary Accelerator Switch Wiper Switch or Continuously Variable Potentiometer Check for proper operation See DS Maintenance and Service Manual Periodic Service Schedule Continued on Next Page 21 PERIODIC SERVICE SCHEDULE ELECTRIC VEHICLE REGULAR INTERVAL SERVICE Daily Service by Owner Continued Batteries Brake System Charge batteries Check for proper operation See Performance Inspec tion Page 6 Adjust as necessary Charger and Receptacle Check for damage and snug fit Park Brake Reverse Warning Buzzer Check for proper operation See Performance Inspec tion Page 6 Adjust as necessary Check for proper operation See NOTE middle of Page 8 Steering and linkages Check for proper operation Tires Check for wear and damage Vehicle warning decals Make sure all are in place See Electric Vehicle Fea ture Identification Page 4 Weekly Service by Owner Batteries Clean terminals and wash dirt from casing check electrolyte level See Page 29 Electrical wiring and connections Check for tightness and damage General Vehicle Check for loose hardware and tighten as required Check maximum speed of vehicle Maximum vehicle speed should be 12 15 mph 19 24 kph Check all daily items listed above Monthly Service by Owner or Trained Mech
42. THE ENGINE RUNNING THE VEHICLE MAY MOVE SUDDENLY IF THE FORWARD REVERSE LEVER IS SHIFTED OR ACCIDENTALLY BUMPED TO PREVENT THIS CHOCK THE FRONT AND REAR WHEELS AND ALWAYS FIRMLY SET THE PARK BRAKE BEFORE SERVICING OR LEAVING THE VEHICLE NOTE BE SURE TO RETURN THE CAM TO THE OPERATE POSITION AFTER SERVICING THE VEHI CLE OR IT WILL NOT RUN WITH THE FORWARD AND REVERSE SWITCH IN EITHER THE FORWARD OR REVERSE POSITION Choke The choke is located on the seat support panel below and to the left of the driver s left knee See Figure 12 If the vehicle is hard to start in cool or cold temperatures simply push in the choke cover with your left hand to activate it Hold it during start up and release the choke cover after the engine starts and runs smoothly Oil Light The DS Gasoline golf car is equipped with a low oil warning light located on the dash panel just above the steering column See Figure 13 If the oil warning light comes on oil should be checked and added to the engine as necessary before continuing to use the vehicle The vehicle should never be driven with the oil warning light remaining on If the oil warning light goes on and off you may proceed but oil should be added at the first opportunity If the oil level is correct and the light stays on have a trained mechanic check the vehicle A CAUTION FAILURE TO ADD OIL IMMEDIATELY WHEN THE OIL WARNING LIGHT STAYS ON MAY RESULT IN PERMANENT ENG
43. THE VEHICLE CAN BE TOWED THE VEHICLE WILL NOT ROLL OTHERWISE All vehicles are equipped with both front and rear tow bar attaching points A light duty tow bar is available for break down towing and single vehicle towing A heavy duty tow bar and an on board tow bar are avail able for multi vehicle towing Observe all of the above warnings when towing TRANSPORTING ON A TRAILER If your vehicle must be transported over long distances or on public highways it should be done on an approved trailer observing all the following warnings A WARNING FOR USE ON PUBLIC ROADS THE TRAILER MUST MEET ALL FEDERAL STATE AND LOCAL REQUIREMENTS SUCH AS TAILLIGHTS BRAKE LIGHTS ETC ALWAYS USE AN APPROVED TRAILER THAT HAS A LOAD RATING OF 1200 LBS 544 KG PER VEHICLE TO BE TOWED EXAMPLE A TWO CAR TRAILER SHOULD BE RATED AT 2 X 1200 2400 LBS 2 X 544 1088 KG NEVER TOW A CLUB CAR VEHICLE BEHIND A PASSENGER VEHICLE OR TRUCK ON A PUB LIC ROAD UNLESS IT IS ON AN APPROVED TRAILER THE VEHICLE TO BE TOWED SHOULD BE TIED SECURELY TO THE TRAILER WITH THE FOR WARD AND REVERSE SWITCH IN NEUTRAL THE KEY SWITCH OFF AND THE PARK BRAKE FIRMLY DEPRESSED AND LOCKED WHEN TOWING ON A TRAILER NORMAL ROAD SPEED OF THE TOW VEHICLE SHOULD BE REDUCED BECAUSE OF THE ADDED LENGTH OF THE TRAILER CAUTION SHOULD BE USED WHEN TURNING A CORNER REMOVE THE VEHICLE WINDSHIELD BEFORE TRANSPORTING ON A TRAILER 14 S
44. TO AVOID THE ACCUMULATION OF HYDROGEN GAS INSIDE THE ENCLOSURE THE CHARGING AREA MUST BE VENTILATED HYDROGEN LEVEL IN THE AIR MUST NEVER EXCEED 2 THE TOTAL VOLUME OF AIR IN THE BUILDING MUST BE CHANGED FIVE TIMES PER HOUR EXHAUST FANS SHOULD BE LOCATED AT THE HIGHEST POINT OF THE ROOF CONTACT A LOCAL HVAC ENGINEER 30 A WARNING EACH CHARGER SHOULD HAVE ITS OWN DEDICATED 15 OR 20 AMPERE SEPARATELY PRO TECTED CIRCUIT BREAKER OR FUSE SINGLE PHASE BRANCH CIRCUIT IN ACCORDANCE WITH ALL APPLICABLE ELECTRICAL CODES FOR THE LOCATION CONNECT THE CHARGER AC SUPPLY CORD TO A PROPERLY GROUNDED THREE WIRE OUTLET OF THE PROPER VOLTAGE AND FREQUENCY AS SHOWN ON THE CHARGER DO NOT USE AN ADAPTER TO PLUG THE CHARGER WITH A THREE PRONG PLUG INTO A TWO PRONG OUTLET IMPROPER CONNECTION OF THE EQUIPMENT GROUNDING CON DUCTOR CAN RESULT IN A FIRE OR AN ELECTRICAL SHOCK AN EXTENSION CORD OR ELECTRICAL OUTLET MUST ACCEPT A THREE PRONG PLUG THE USE OF IMPROPER EXTENSION CORD COULD RESULT IN FIRE OR AN ELECTRICAL SHOCK ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THE CHARGER CONTACT YOUR NEAREST CLUB CAR DISTRIBUTOR DEALER DO NOT OPERATE THE CHARGER IF IT HAS RECEIVED A SHARP BLOW WAS DROPPED OR OTHERWISE DAMAGED IN ANY WAY HAVE WORN CUT OR DAMAGED POWER CORDS OR WIRES REPLACED IMMEDIATELY DO NOT USE NEAR FUELS GRAIN DUST SOLVENTS THINNERS OR OTHER FLAMMABLES CHARGERS CAN IGNITE FLAM
45. TORAGE GASOLINE VEHICLE To prepare your vehicle for extended off season storage 1 Store vehicle in a cool place This will prevent self discharge of the battery If the battery appears to be weak have it charged using an automotive type 12 volt battery charger rated 10 amps or less DANGER GASOLINE FLAMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE NEVER ATTEMPT TO DRAIN GASOLINE WHEN THE ENGINE IS HOT OR WHILE IT IS RUN NING BE SURE TO CLEAN UP ANY SPILLED GASOLINE BEFORE OPERATING THE VEHICLE STORE GASOLINE IN AN APPROVED GASOLINE CONTAINER ONLY STORE IN A WELL VEN TILATED AREA AWAY FROM SPARKS OPEN FLAMES HEATERS OR HEAT SOURCES DO NOT SERVICE REPAIR OR OPERATE IN AN ENCLOSED AREA WITHOUT PROPER VEN TILATION THE ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POISON KEEP GASOLINE OUT OF THE REACH OF CHILDREN DO NOT SIPHON GASOLINE FROM THE VEHICLE A WARNING DO NOT ATTEMPT TO CHARGE A BATTERY IF IT IS FROZEN OR IF THE CASE IS BULGED DISCARD THE BATTERY FROZEN BATTERIES CAN EXPLODE A CAUTION BATTERIES IN A LOW STATE OF CHARGE WILL FREEZE AT LOW TEMPERATURES 2 Drain carburetor and seal the fuel tank 2 1 Place the Foward and Reverse Lever in the NEUTRAL position and the neutral lock out cam in the SERVICE position Disconnect the fuel line from the inlet side of the fuel pump and run the
46. anic Batteries Wash battery tops with baking soda water solution Brake System Check for proper operation See Performance Inspec tion Page 6 Check brake pedal free play Adjust as necessary See DS Maintenance amp Service Manual Check brake cables for damage and replace as required Tires Check for wear and damage Check air pressure and adjust as necessary See Vehicle Capacities Chart on Page 26 Accelerator Switch Wiper Switch or Continuously Variable Potentiometer Check for cracks or other damage make sure switch is securely fastened to frame Check all daily and weekly items listed above Quarterly Service by Owner or Trained Mechanic Accelerator pedal rod Check for proper operation adjust as necessary See NOTE bottom of Page 8 Steering Lubricate per Electric Vehicle Lubrication Chart on Page 25 General Vehicle Lubricate per Electric Vehicle Lubrication Chart on Page 25 Check all daily weekly and monthly items listed above Periodic Service Schedule Continued on Next Page 22 PERIODIC SERVICE SCHEDULE ELECTRIC VEHICLE REGULAR INTERVAL SERVICE Semi annual Service by Trained Mechanic Only Every 100 rounds or 50 hours of operation Batteries Check specific gravity electrolyte level and on charge voltage Brake System Check for proper operation See Performance Inspec tion Page 6 Check brake
47. ate as follows The warning light will not come on if the charge is 90 or more complete The on board computer will retain in memory the amount of charge needed to fully replenish the batteries and will complete the charge during the next charge cycle When the charger is unplugged the warning light will come on and remain illuminated for 10 seconds if the charge is less than 90 complete but the car has enough power to complete 36 holes of golf This will alert the fleet operator that the car may be used but that it must be charged to completion as soon as possible The warning light will come on and remain illuminated if the charger times out at 16 hours see charger manual and the batteries are not sufficiently charged This indicates an abnormal charge cycle The charger and batteries should be checked by your Club Car distributor dealer 11 Battery Warning Light Continued The warning light will come on 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 DRIVING INSTRUCTIONS A 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 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 T
48. ated hardware gasoline engine unitized transaxle torque converters drive and driven starter generator transaxle electric vehicle and electric motor are warranted with respect to parts and labor against defects in materials and workmanship for a period of three years from the date of purchase LIMITED TWO YEAR WARRANTY All remaining components of the golf car not specified otherwise are warranted with respect to parts and labor against defects in materials and workmanship for a period of two years from the date of purchase This limited warranty covers materials workmanship and repair labor cost as to those items specifically listed above for the periods specified Such repair labor shall be performed only by CLUB CAR its authorized distributors or dealers or a service agency approved by CLUB CAR IF THE WARRANTY REGISTRATION FORM IS NOT COMPLETED AND RETURNED TO CLUB CAR AT THE TIME OF THE ORIGINAL RETAIL SALE PURCHASER MUST PROVIDE PROOF OF DATE OF PUR CHASE WITH ANY WARRANTY CLAIM 2 EXCLUSIONS Excluded from any CLUB CAR warranty are all optional equipment and accessories fuses filters decals except safety decals spark plugs lubricants trim pieces seats routine wear items such as the charger plug and receptacle brake shoes belts brushes bushings engine mounts mats and pads maintenance adjustments cosmetic deterioration and items which deteriorate or fail due to exposure or ordinary wear and tear Batteries
49. butor dealer However upon arrival of your new CLUB CAR s you should become familiar with its con trols and operation and carefully inspect each vehicle to be satisfied that it is in proper working condition before accepting delivery Use the following checklist as a guide to inspect your new vehicle and in conjunction with the Periodic Ser vice Schedules pages 19 through 23 Any problems should be corrected only by your CLUB CAR distribu tor dealer or a trained mechanic General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tight On the DS Gasoline vehicle check all hose clamps for tight fit as well as the starter belt for tightness Warning Decals Check to ensure that all warning and operation decals are in place See Pages 3 and 4 Tires Check for proper tire pressure See Vehicle Capacities Page 26 Batteries electric vehicles Check electrolyte to ensure that it is at its proper level See Figure 22 Page 29 Check battery posts Wires should be tight and free of corrosion Charge batteries fully before first use of vehicle V Glide Speed Switch V Glide 36 volt electric vehicles Be sure speed switch cover is properly secured prior to operating the vehicle Engine gasoline vehicles Check for proper engine oil level See Engine Oil Page 27 Fuel gasoline vehicles Check fuel level See Fueling Instructions Page 27 A WARNING BE SURE T
50. d above Annual Service by Trained Mechanic Only Every 200 rounds or 100 hours of operation Engine Air Intake Check engine oil level change as required See Gas Vehicle Lubrication Chart Page 24 Check for leaks around gaskets fill plugs etc Inspect clean and regap spark plug replace if necessary Check air filter element clean or replace Fuel Filters Replace Front Wheel Bearings Inspect and check for free play repack with chassis lube and adjust as necessary Starter Generator Check brush length remove excess carbon dust replace as necessary Unitized Transaxle Check fill transaxle to plug level See Gas Vehicle Lubrication Chart on Page 24 General Vehicle Lubricate per Gas Vehicle Lubrication Chart on Page 24 Check all daily weekly monthly quarterly and semi annual items listed above PERIODIC SERVICE SCHEDULES A WARNING 1019051 01 IF ANY PROBLEMS ARE FOUND DO NOT OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE FAILURE TO MAKE NECESSARY REPAIRS COULD RESULT IN FIRE PROPERTY DAM AGE SEVERE PERSONAL INJURY OR DEATH ALL SERVICE REPAIRS AND ADJUSTMENTS MUST BE MADE PER INSTRUCTIONS IN THE DS GOLF CAR MAINTENANCE AND SERVICE MANUAL PUBLICATION PART NUMBER PERIODIC SERVICE SCHEDULE ELECTRIC VEHICLE REGULAR INTERVAL SERVICE Daily Service by Owner Accelerator pedal rod Check for proper operation
51. e brush may be used Do not use harsh detergents or cleaning solvents on the front body the rear body or the seat Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to pre vent possible stains Use commercial automotive products because the finish on the vehicle is the same as the finish on today s automobiles VEHICLE CONTROLLER ELECTRIC VEHICLE The DS Electric vehicle is equipped with either a Solid State Speed Controller PowerDrive System 48 and PowerDrive System 48 with Motor Braking or a V Glide Speed Controller 36 Volt Vehicle In order to properly service and maintain the Solid State Controller Vehicle or the V Glide Speed Controller Vehicle it is necessary to understand the electrical circuitry and the functions of all components in both sys tems Therefore if any repair or servicing needs to be performed we recommend that it be performed by an authorized CLUB CAR distributor dealer using CLUB CAR OEM parts ACCESSORIES AND OPTIONS The vehicle is available with a complete line of optional equipment items and accessories that are available from Club Car and our dealers distributors Care should be taken that these accessories and options are properly installed by trained technicians and that they are used in the manner for which they were designed OPTIONAL EQUIPMENT ALL DS GOLF CARS Accent Striping Ashtray On board Tow Bar Woodgrain Decal Rear View Mirror
52. ecked weekly See Figure 22 Page 29 for proper level Add water only after charging unless the water level is below the top of the plates In this case add just enough water to cover the plates charge and then check the level again Never charge batteries if plates are exposed above water level For best battery life add only distilled water NOTE A BATTERY WATERING GUN IS AVAILABLE AT MANY AUTO PARTS DEALERS 3 The hold down straps should be tight enough so that the batteries do not move while the vehicle is in motion but not so tight as to crack or buckle the battery case Torque hold down retaining nuts to 15 25 in lbs 1 7 2 8 N m The terminal connections should be clean and tight and any worn insulation or frayed wires should be replaced Torque battery terminals to 90 100 in Ibs 10 11 3 N m A CAUTION e IF BATTERY WIRE TERMINALS ARE DAMAGED OR CORRODED THEY SHOULD BE REPLACED OR CLEANED AS NECESSARY FAILURE TO DO SO MAY CAUSE THEM TO OVER HEAT DURING OPERATION 4 After use the batteries should be placed on charge The batteries should never be left discharged any longer than absolutely necessary do not leave discharged overnight BATTERY CHARGER ELECTRIC VEHICLE A DANGER BATTERIES EMIT HYDROGEN WHILE BEING CHARGED HYDROGEN IS AN EXPLOSIVE GAS IF THE VEHICLE IS EQUIPPED WITH A WEATHERPROOF ENCLOSURE IT SHOULD BE UNZIPPED AND PULLED BACK WHILE BATTERIES ARE BEING CHARGED THIS IS
53. econnect fuel vent line to tank 1 2 Place the Forward and Reverse Lever in the NEUTRAL position and the neutral lock out cam in the SERVICE position Crank the engine until fuel is pumped into the carburetor and fuel lines and the engine starts Turn engine off and return neutral lock out cam to the OPERATE position 2 Readjust tire pressure to 12 14 psi 57 67 kPa 3 Perform the Pre Operation Checklist See pages 6 and 7 NOTE WHEN RUNNING THE ENGINE FOR THE FIRST TIME AFTER STORAGE IT MAY SMOKE EXCESSIVELY FOR A SHORT WHILE DUE TO THE OIL ADDED TO THE ENGINE IN PREPARA TION FOR STORAGE STORAGE ELECTRIC VEHICLE A WARNING TURN THE KEY SWITCH OFF REMOVE THE KEY AND LEAVE THE FORWARD AND REVERSE SWITCH IN THE NEUTRAL POSITION DURING STORAGE THIS IS TO PREVENT UNINTEN TIONAL STARTING OF THE VEHICLE DO NOT ATTEMPT TO CHARGE FROZEN BATTERIES OR BATTERIES WITH BULGED CASES DISCARD THE BATTERY FROZEN BATTERIES CAN EXPLODE A CAUTION BATTERIES IN LOW STATE OF CHARGE WILL FREEZE AT LOW TEMPERATURES WHEN WASHING THE VEHICLE DO NOT DIRECT WATER STREAM AT THE SPEED SWITCH FORWARD AND REVERSE SWITCH OR OTHER ELECTRICAL COMPONENT e IF BATTERY WIRE TERMINALS ARE DAMAGED OR CORRODED THEY SHOULD BE REPLACED OR CLEANED AS NECESSARY FAILURE TO DO SO MAY CAUSE THEM TO OVER HEAT DURING OPERATION 1 Fully charge batteries See Batteries Electric Vehicle Page 29 2 Wash
54. er we strongly urge the new owner to re register the vehicle with Club Car This will enable us to contact you if the need arises Please send your name address and serial number s of the vehicle s to CLUB CAR INC P O Box 204658 Augusta GA 30917 4658 ATTN Vehicle Registration FAIRWAY VILLAGER The Fairway Villager is designed to provide a smooth and comfortable ride for four passengers and is offered in both gasoline and PowerDrive System 48 electric power configurations An optional rack for two golf bags is also available Contact your nearest Club Car distributor dealer This Owners Manual should be read thor oughly prior to operating the vehicle The Fairway Villager should be driven and maintained as stated in this Owner s Manual with the following exceptions A WARNING TO PREVENT POSSIBLE INJURY TO AN UNSUSPECTING PASSENGER OR DAMAGE TO THE VEHICLE AVOID SUDDEN STARTS SUDDEN STOPS AND ABRUPT TURNS VEHICLE SHOULD BE DRIVEN AT SLOWER SPEEDS WHEN FOUR PASSENGERS ARE IN THE VEHICLE PASSENGERS SHOULD HOLD ON TO SEAT HANDLES OR HAND RAILS AT ALL TIMES SEE FIGURE 27 DRIVER SHOULD KEEP BOTH HANDS ON THE STEERING WHEEL WHILE VEHI CLE IS MOVING DO NOT LEAVE CHILDREN UNATTENDED ON THE REAR SEAT WHILE VEHICLE IS MOVING NO MORE THAN FOUR PASSENGERS SHOULD BE ON THE VEHICLE AT ONE TIME e KEEP ALL BODY PARTS INSIDE THE VEHICLE TO PREVENT THEM FROM GETTING CAUGHT BETWEEN THE VEHICLE AND THE GROUND
55. ering column See Figure 4 Page 8 It has two itions OFF and ON which are clearly labeled NOTE THE KEY CAN BE REMOVED WHEN THE KEY SWITCH IS IN THE OFF POSITION ONLY FIGURE 4 FIGURE 5 FORWARD REVERSE CONTROL DS Gasoline DS V Glide Electric and DS PowerDrive System 48 The forward reverse shift lever is located on the seat support panel below and to the right of the driver s right knee See Figure 5 The lever has three distinct positions F forward N neutral and R reverse Rotate the lever towards the driver F forward to run the vehicle in the forward direction or towards the passenger R reverse to run the vehicle in reverse When the lever is in the straight up or N neutral position the vehi cle will not run The engine on the DS Gasoline will stop if it is shifted to this position while running The DS Electric vehicle operates at reduced speed in reverse When the vehicle is in reverse the reverse warning buzzer will sound DS PowerDrive Plus With Motor Braking The forward reverse shift switch is located in the same place as the forward reverse shift lever on all other DS models on the seat support panel below and to the right of the driver s right knee The Forward F and Reverse R positions are clearly marked on the switch Push down the F forward side of the switch to run the vehicle in the forward direction or push down the R reverse side of the switch to run the vehicle in rever
56. ertion ease of removal and good electrical contact NOTE IF THE WARNING TAG HAS BEEN DAMAGED OR REMOVED FROM THE DC CORD HAVE IT REPLACED IMMEDIATELY Receptacle Fuse Link As an additional feature to protect the batteries and charging circuit from an overload the electric vehicle is equipped with a receptacle fuse link Figure 25 V Glide 36 volt vehicle or Figure 26 PowerDrive System 48 vehicle If the portable charger does not come on when the vehicle is placed on charge visually inspect the fuse link A WARNING F THE RECEPTACLE FUSE LINK IS BLOWN DETERMINE THE SOURCE OF THE ELECTRICAL PROBLEM AND CORRECT IT BEFORE REPLACING THE FUSE CONTACT YOUR NEAREST CLUB CAR DISTRIBUTOR DEALER FIGURE 25 FIGURE 26 CLEANING THE VEHICLE The vehicle is equipped with an Armorflex amp front body and rear body Use only mild dishwashing liquid soap with a sponge or soft cloth for normal cleaning See CAUTION at the top of next page 34 A CAUTION IF A PRESSURE WASHER IS USED DO NOT EXCEED 500 PSI 3448 KPA NOZZLE SHOULD BE SET TO WIDE ANGLE SPRAY Minor scratches or blemishes in the front body or the rear body can be buffed out using most commercially available polishing compounds and polishes The seats of the vehicle will last longer with proper cleaning Mild soap or detergent with a sponge or soft cloth for normal cleaning is recommended For stubborn or imbedded dirt a soft bristl
57. iodic Lubrication Schedule Electric 25 Vehicle Capacities si sacri herr 26 Engine Oil Gasoline Vehicle 27 Fueling Instructions Gasoline 27 Battery Gasoline Vehicle rrr 28 Battery Electric Vehicle Rn 29 Battery Charger Electric 30 Cleaning The Vehicle 34 Vehicle Controller Electric 35 Accessories and Options erre 35 Subsequent Owner Registration 0000 cece eee 36 Fairway Villagers zie uiu earth E teens Ene p E teu 36 Vehicle Specifications 0000 rrr 38 Practice Safety ANNI Moving Parts Safety signs like you see above may at first seem shocking but their impact is mild compared with the reality of severe personal injury Your safey and satisfaction are of the utmost importance to Club Car That is why we urge you to study this owner s manual and to read understand and heed the warn ings in this manual as well as the safety decals on your vehicle before operating the vehicle Take time to understand the
58. ly to full speed When the pedal is released it should return to the original posi tion and the engine or motor should stop The DS Electric vehicle runs at reduced speed in reverse Governor gasoline vehicles Check maximum speed of the vehicle The vehicle should run at 12 15 MPH 19 24 KPH on a level surface General Listen for any unusual noises such as squeaks or rattles Check the vehicle s ride and perfor mance Have a CLUB CAR distributor dealer or a trained mechanic investigate anything unusual DS PowerDrive Plus Vehicles with Motor Braking Zero Speed Detect With the vehicle parked on level ground and the park brake disengaged turn the ignition key to the ON position and attempt to push the vehicle It should resist rolling moving at no more than 1 or 2 mph with the forward and reverse switch in any position Pedal Up Motor Braking Accelerate the vehicle to full speed and then release the accelerator pedal The vehicle should quickly and smoothly slow to approximately 9 mph Pedal Down Motor Braking Accelerate down an incline with the accelerator pedal depressed When the vehicle reaches approximately 15 mph regenerative motor braking should engage and mod erate vehicle speed between 15 and 16 mph depending upon the grade of the hill CONTROLS A DANGER DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI LATION GASOLINE ENGINES PRODUCE CARBON MONOXIDE GAS WHICH IS AN O
59. ly to the first Original Retail Fleet Lessee and not to such entity or to any subsequent lessee of the golf car 7 DISCLAIMER THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESS OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WAR RANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REMEDY OF REPAIR OR REPLACE MENT OF THE DEFECTIVE GOLF CAR OR COMPONENT THEREOF IS THE EXCLUSIVE AND SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE DISTRIBUTOR OR DEALER OF CLUB CAR HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY 8 NO CONSEQUENTIAL DAMAGES IN NO EVENT SHALL CLUB CAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAM AGES INCLUDING BUT NOT LIMITED TO LOSS RELATED TO PROPERTY OTHER THAN THE GOLF CAR LOSS OF USE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS 41 Limited Warranty Continued Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitation of inci dental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may al
60. nts to the Original Retail Fleet Purchaser or Original Retail Fleet Lessee as those terms are defined herein and subject to the provisions limitations and exclusions contained in this limited warranty that its new 1997 Model DS golf car purchased from CLUB CAR or an authorized distributor or dealer for use in the United States or Canada shall be free from defects in materials and workmanship under normal use and service as a golf car for the periods stated below LIMITED LIFETIME WARRANTY The golf car frame excluding the front and rear bumper mounts the rack and pinion steering gearbox unit and the suspension system defined as the shock absorbers shock mounts A plates leaf springs shackles and associated hardware are warranted with respect to parts and labor against defects in materials and workmanship for the lifetime of the vehicle while owned by the Original Retail Fleet Purchaser or in the pos session of the Original Retail Fleet Lessee LIMITED THREE YEAR WARRANTY The gasoline engine transmission torque converter drive and driven unitized transaxle starter generator transaxle electric vehicle and electric motor are warranted with respect to parts and labor against defects in materials and workmanship for a period of three years from the date of purchase while owned by the Orig inal Retail Fleet Purchaser or in the possession of the Original Retail Fleet Lessee LIMITED TWO YEAR WARRANTY All remaining components of
61. off any corrosion around the terminals with a solution of baking soda and water one cup per gal lon of water then rinse solution from the batteries NOTE Do not allow this solution to enter the bat teries Let the terminals dry and coat them with CLUB CAR battery terminal spray Part No 1014305 16 3 Store in a cool dry place This will prevent self discharge of the batteries 5 Adjust tire pressure to 20 psi 96 kPa 5 Grease front suspension and do all quarterly periodic lubrication See Periodic Lubrication Sched ule Page 25 Thoroughly clean front body rear body seats battery compartment and underside of vehicle N Do not latch the park brake Block tires to prevent the vehicle from rolling eo Keep batteries fully charged during storage See Batteries Electric Vehicle Page 29 Recharge 36 volt vehicles with Accu Power battery chargers every 6 8 weeks as necessary Leave PowerDrive System 48 and PowerDrive Plus vehicles with PowerDrive chargers plugged in dur ing storage The PowerDrive storage charge feature will automatically charge the batteries as needed throughout storage period See Batteries Electric Vehicle Page 29 NOTE A POWERDRIVE SYSTEM 48 OR POWERDRIVE PLUS VEHICLE WILL NOT OPERATE WHILE PLUGGED TO A CHARGER TO RETURN THE STORED VEHICLE TO SERVICE 1 Fully charge batteries See Batteries Electric Vehicle Page 29 2 Readjust tire pressure to 18 20 psi
62. pedal free play Clean and adjust as necessary See DS Maintenance amp Service Manual Check brake shoes replace if necessary Lubricate slide plates with graphite See DS Mainte nance amp Service Manual Electrical Wiring Check for cracked or worn insulation Forward and Reverse Switch Check condition of contacts and wire connections Make sure connections are tight Front Wheel Alignment and Camber Check and adjust as required See DS Maintenance amp Service Manual General Vehicle Lubricate per Electric Vehicle Lubrication Chart on Page 25 Check all daily weekly monthly and quarterly items listed above Annual Service by Trained Mechanic Only Every 200 rounds or 100 hours of operation A WARNING Accelerator Switch Wiper Switch or Continuously Variable Potentiometer Check for proper operation remove cover and check for wear and damage See Maintenance amp Service Manual Wiper switch type only check contacts for burns excessive heat or arcing check brush for wear Batteries Perform discharge test Motor Front Wheel Bearings Check motor brushes replace as necessary Inspect and check for free play repack with chassis lube and adjust as necessary Transaxle Check fill transaxle to plug level see Electric Vehicle Lubrication Chart on Page 25 General Vehicle Lubricate per Electric Vehicle Lubrication Chart on Page
63. s DC reduced speed reverse Electrical System 36 volts DC reduced speed reverse Batteries High capacity deep cycle Trojan PowerDrive 8 volt 117 min capacity Batteries High capacity deep cycle Trojan PowerDrive 6 volt 115 min capacity Charger Automatic 17 amp PowerDrive UL and CSA listed Charger Automatic 21 amp Accu Power UL and CSA listed Torque Converter Automatic variable speed dry type STEERING SUSPENSION BRAKES Steering Self adjusting rack and pinion Suspension Front and rear tapered mono leaf springs with dual hydrau lic shocks Brakes Dual rear wheel self adjusting brakes with cast iron drums and single brake pedal with automatic release park brake BODY CHASSIS Frame Chassis Twin I Beam welded aluminum Front and Rear Body Armorflex amp Body Finish Protective coat over molded in color Tires 18 00 x 8 50 8 00 tubeless 4 ply rated SEATING CAPACITY FUEL CAPACITY Standard Seating Capacity 2 persons Fairway Villager Seating Capacity 4 persons Fuel Tank 7 gallons 26 5 liters unleaded gasoline only DIMENSIONS WEIGHT Overall Length 91 1 2 232 cm 91 1 2 232 cm 91 1 2 232 cm 91 1 2 232 cm Overall Width 47 1 4 120 cm 47 1 4 120 cm 47 1 4 120 cm 47 1 4 120 cm Specifications Continued on Next Page 38 SPECIFICATIONS DS GASOLINE
64. se When the switch is positioned with neither side down the vehicle is in the NEUTRAL position and the vehicle will not run if the accelerator is depressed See Figure 6 NOTE THE REVERSE BUZZER WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE ACCELERATOR PEDAL The accelerator pedal is the pedal on the right with the word GO molded into it See Figure 7 NOTE THE OPERATION OF THE ACCELERATOR PEDAL DIFFERS FROM THAT OF AN AUTOMO BILE WHEN THE KEY SWITCH IS ON AND THE SHIFT LEVER IS IN EITHER FORWARD OR REVERSE DEPRESSING THE ACCELERATOR PEDAL WILL AUTOMATICALLY RELEASE THE PARK BRAKE AND START THE VEHICLE MOVING IN THE DIRECTION SELECTED FORWARD OR REVERSE AS THE ACCELERATOR PEDAL IS DEPRESSED SPEED WILL INCREASE UNTIL FULL SPEED IS REACHED WHEN THE ACCELERATOR IS RELEASED POWER WILL BE CUT OFF AND THE ENGINE OR MOTOR WILL STOP RUNNING POWERDRIVE PLUS VEHICLES ONLY SEE PEDAL UP AND PEDAL DOWN MOTOR BRAK ING ON PAGE 7 FIGURE 6 FIGURE 7 BRAKE PEDAL The brake pedal is the large pedal on the left with the word STOP molded into it See Figure 7 To slow or stop the vehicle depress the brake pedal with your right foot See Figure 8 A WARNING THE PARK BRAKE WILL RELEASE AUTOMATICALLY WHEN EITHER THE ACCELERATOR OR BRAKE PEDAL IS DEPRESSED THE PARK BRAKE HAS MULTIPLE LOCKING POSITIONS AND SHOULD BE FIRMLY PRESSED TO PREVENT THE VEHICLE FROM ROLLING PARK BRAK
65. so have other rights which vary from state to state 9 INFORMATION For further information contact WARRANTY ADMINISTRATION CLUB CAR INC PO Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 10 WARNING Any modification or alteration of any golf car beyond factory specifications including those that affect the weight distribution stability or speed of the golf car can cause serious personal injury or death 42 Publication Part Number 101906301 Edition Code 0796D1005A Club Car Inc 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
66. t of Club Car Inc The information contained in this document is subject to change without notice Club Car reserves the right to make design changes to either gasoline or electric vehicles without obligation to make these changes on units previously sold These vehicles are designed and manufactured for off road use only They do not conform to Federal Motor Vehicle Safety Standards or EPA regulations and are not equipped for operation on public streets roads or highways 01996 Club Car Inc Club Car Armorflex PowerDrive PowerDrive Plus and Tranquility are registered trademarks of Club Car Inc This manual effective August 1 1996 CLUB CAR LIMITED THREE 3 YEAR WARRANTY FOR 1997 INDIVID UAL GOLF CARS IN THE UNITED STATES AND CANADA 1 WARRANTY CLUB CAR INC CLUB CAR hereby warrants to the original retail purchaser that its new 1997 Model DS golf car purchased from CLUB CAR or an authorized distributor or dealer for use in the United States or Can ada shall be free from defects in materials and workmanship under normal use and service as a golf car for the periods stated below subject to the provisions limitations and exclusions contained in this limited war ranty LIMITED THREE YEAR WARRANTY The golf car frame excluding the front and rear bumper mounts rack and pinion steering gearbox unit sus pension system defined as the shock absorbers shock mounts A plate leaf springs shackles and associ
67. the next owner will have the important operating safety and maintenance information it contains TABLE OF CONTENTS Safety Details Tarur et ep bid bed ee ea a eee 1 General Warnings ss xr e Pa 7 1 Feature Identification Gasoline Vehicle 3 Feature Identification Electric 4 General Information 2 5 5 Model ldentification See aioe ee a fex Pav PER RE ICON ee 5 Safety Committee ene eet 5 Pr Operation GHecklist 7 Raho ache ER nu REC HUE qu e a pate pale 6 CONOIS ics pb bd ex debe dE bume dE debate ed ans 7 Drivinig e VERS E E tasto 6 ean au Me e ot aA al de eda 12 tUm eei bre 14 Transporting ona Tallero hn 14 Storage Gasoline Vehicle 6 46 666 15 Storage Electric Vehicle hh 16 EU 17 Periodic Service Schedule Gasoline Vehicle 19 Periodic Service Schedule Electric Vehicle 21 Periodic Lubrication Schedule Gasoline Vehicle 24 Per
68. ting from a cause other than a defect including unreasonable or unintended strain or use improper installation of accessories installation of parts or accessories that are not original equipment overloading accident alteration abuse or neglect Transportation expenses for warranty service are also excluded from this warranty 3 VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE GOLF CAR IS ABUSED OR USED IN AN UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY INCLUD ING BUT NOT LIMITED TO MODIFICATION OF THE SPEED GOVERNOR BRAKING SYSTEM STEER ING TRANSAXLE OR OTHER OPERATING SYSTEMS OF THE CAR TO CAUSE IT TO PERFORM 40 OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKEWISE VOID IF THE CAR SHOWS INDI CATIONS THAT REASONABLE OR NECESSARY MAINTENANCE AS OUTLINED IN THE OWNER S MANUAL AND MAINTENANCE AND SERVICE MANUAL WAS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS 4 SOLE REMEDY CLUB CAR S ONLY LIABILITY UNDER THIS LIMITED WARRANTY OR IN ANY ACTION WHETHER BASED UPON WARRANTY CONTRACT NEGLIGENCE STRICT PRODUCT LIABILITY OR OTHER WISE IS LIMITED TO THE REPAIR OR REPLACEMENT AT CLUB CAR S OPTION OF A GOLF CAR OR COMPONENT THEREOF THAT CLUB CAR DEEMS TO BE DEFECTIVE REPLACEMENT SHALL MEAN FURNISHING DURING THE APPLICABLE LIMITED WARRANTY PERIOD A NEW GOLF CAR OR FAC TORY RECONDITIONED VEHICLE OR COMPONENT THEREOF WHICH IS IDENTICAL OR REASON
69. trol circuit is locked out preventing operation of the vehicle as well as the possibility of consequent damage to the charger and the vehicle Once the lock out is actuated the charger turns on The on board computer then records the amount of energy being returned to the batteries When the optimum amount of energy needed to replenish the batteries is returned the charger will shut off The control circuit lock out remains activated until the charger plug is disconnected from the vehicle Because of these unique features only PowerDrive System 48 vehicles are compatible with the PowerDrive Charger Neither vehicles made by other manufacturers nor other Club Car models are compatible 33 To Charge Batteries Continued As long as the charger is allowed to shut off by itself the batteries will be fully charged Overcharging and undercharging will normally be prevented Batteries should be put on charge even if they have been used for only a short period 9 holes of golf or 10 minutes The charger is automatic and will turn off when batteries are fully charged If the charger does not seem to be operating properly or if the batteries seem weak contact your local Club Car distributor dealer PLUG AND RECEPTACLE If the charger plug becomes difficult to insert or disconnect the receptacle contacts should be lightly sprayed with WD 40 brand spray lubricant The plug should then be inserted and removed several times to ensure ease of ins
70. ust as necessary Choke Check for proper operation See Page 10 Engine Check for proper operation Engine air intake system Check air filter element clean as necessary Engine cooling air intake Check for clogging clean as necessary Daily Service by Owner Check fuel tank lines cap pump and carburetor for Fuel System fuel leakage Check for proper operation See Performance Park Brake Inspection Page 6 Reverse Warning Buzzer Check for proper operation See NOTE Page 8 Check for proper operation See Performance Inspec Steering and linkages tion Page 6 Tires Check for wear and damage Unitized Transaxle Check shift linkage for proper operation Make sure all are in place See Gasoline Vehicle Vehicle warning decals Feature Identification Page 3 Clean terminals and wash dirt from casing check Battery electrolyte level See Page 29 Electrical wiring and connections Check for tightness and damage Torque Converter Rinse with water Check for loose hardware and tighten Weekly Service by Owner as required Check maximum speed of vehicle Maximum vehicle General Vehicle speed should be 12 15 mph 19 24 kph Wash engine compartment and underside of vehicle Check all daily items listed above Periodic Service Schedule Continued on Next Page 19 PERIODIC SERVICE SCHEDULE GASOLINE VEHICLE REGULAR INTERVAL SERVIC
71. y Every 100 rounds or 50 hours of operation Check for proper operation See Performance Inspec tion Page 6 Check brake pedal free play Clean and adjust as necessary See DS Maintenance amp Service Manual Brake System Check brake shoes replace if necessary Lubricate slide plates with graphite See DS Mainte nance amp Service Manual Drive Belt Check for cracks wear or glazing replace if neces sary Electrical Wiring Check for cracked or worn insulation Engine Check spark plug wire and boot for damage and proper routing Exhaust System Check head and exhaust header pipe flange connec tion gasket for leaks Check muffler condition Front Wheel Alignment and Camber Check and adjust as required See DS Maintenance amp Service Manual Periodic Service Schedule Continued on Next Page 20 PERIODIC SERVICE SCHEDULE GASOLINE VEHICLE REGULAR INTERVAL SERVICE Semi annual Service by Trained Mechanic Only Every 100 rounds or 50 hours of operation Continued Torque Converter Drive Belt Check for proper operation Inspect belt and replace as required Starter Generator Belt Check for cracks wear and glazing replace if neces sary Check belt tension adjust as required General Vehicle Lubricate per Gas Vehicle Lubrication Chart on Page 24 Check all daily weekly monthly and quarterly items liste
72. y switch to OFF and place the shift lever in the NEUTRAL position Remove the key when the vehicle is not in use PowerDrive Plus Vehicles Motor Braking Only When the vehicle s key switch is ON with the for ward and reverse switch in any position the zero speed detect function will prevent the vehicle from rolling at more than 1 or 2 mph unless the accelerator is depressed This prevents the possibility of a parked vehicle with the park brake disengaged rolling away too fast to be overtaken on foot See Zero Speed Detect Page 7 13 TOWING A WARNING NEVER TOW THE VEHICLE ON PUBLIC STREETS OR HIGHWAYS USE ONLY APPROVED CLUB CAR TOW BARS TURN THE KEY SWITCH TO OFF AND PLACE THE FORWARD AND REVERSE SWITCH IN NEU TRAL BEFORE TOWING THE VEHICLE EXTREME CAUTION SHOULD BE USED WHEN TOWING ANY VEHICLE DO NOT EXCEED 5 MPH 8 KPH TOWING SPEED DO NOT ALLOW PEOPLE IN THE VEHICLES BEING TOWED AVOID SUDDEN STARTS SUDDEN STOPS AND TIGHT TURNS WHEN TOWING DO NOT TOW MORE THAN ONE CLUB CAR VEHICLE WITH ANOTHER CLUB CAR VEHICLE IF MORE THAN ONE VEHICLE MUST BE TOWED AN ADEQUATELY POWERED VEHICLE TRAC TOR OR FULL SIZED TRUCK PROPERLY FITTED WITH A TOW HITCH HEIGHT OF 11 INCHES SHOULD BE USED ONLY HEAVY DUTY TOW BARS SHOULD BE USED FOR MULTI VEHICLE TOWING NEVER TOW MORE THAN FIVE VEHICLES AT ONE TIME POWERDRIVE PLUS VEHICLE WITH MOTOR BRAKING ONLY THE KEY SWITCH MUST BE OFF BEFORE

1997 DS Golf Cars Electric and Gasoline

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