Club Car DS Golf Car, Owner'S Manual

Page 1: ...DS Golf Car Owner s Manual Electric and Gasoline Refer to back cover for applicable build code range...

Page 2: ......

Page 3: ...and equipment to play the game of golf in an area designated as a golf course Throughout this manual the words golf car and vehicle are used interchangeably This manual contains proprietary informati...

Page 4: ...tact your local authorized Club Car dealer or distributor who will be able to provide technical advice perform warranty work and sell parts and service manuals For the name and address of the authoriz...

Page 5: ...ler 27 Storage Electric Vehicles 27 Storage Gasoline Vehicles 29 Maintenance 31 Periodic Service Schedules 32 Periodic Lubrication Schedules 36 Batteries Electric Vehicles 38 Battery Charger Electric...

Page 6: ...ormation on specific features read the appropriate section in this manual DS ELECTRIC VEHICLE 2000 1 3 4 2 1 101960601 Decal Rollover Warning on instrument panel 3 102518001 Decal Operating Instructio...

Page 7: ...al Battery Danger on battery caps or on body under seat 4 Battery Charger Receptacle 2 101908601 Decal Tow Switch Warning on Tow Run switch plate under seat 5 Forward Reverse Control 3 101931501 Decal...

Page 8: ...rning Light 2 101960601 Decal Rollover Warning on instrument panel 7 Park Brake Pedal 3 102519201 Decal Operating Instructions on steering wheel 8 Accelerator Pedal 4 102555901 Decal Private Speed Not...

Page 9: ...el fill or on frame near fuel tank 5 Fuel Shut Off Valve 2 101915201 Decal Frame Ground Governor Warning on vehicle frame near battery 6 Oil Fill 3 101960501 Decal Rotating Parts Hot Manifold Warning...

Page 10: ...information in this manual Understand and become familiar with the DANGER WARNING and CAUTION statements and procedures it contains along with the safety decals that are affixed to your vehicle Take t...

Page 11: ...h Contact your distributor dealer DANGER A DANGER indicates an immediate hazard that will result in severe personal injury or death WARNING A WARNING indicates an immediate hazard that could result in...

Page 12: ...lace and are easy to read Only trained technicians should service or repair the vehicle or battery charger Anyone doing even simple repairs or service should have knowledge and experience in electrica...

Page 13: ...e s from the spark plug s CONNECTING THE BATTERY GASOLINE VEHICLES 1 Connect the battery cables positive cable first 2 Tighten battery terminals to 80 in lb 9 N m 3 Coat terminals with Battery Termina...

Page 14: ...IES ELECTRIC VEHICLES 1 Disable the vehicle See Disabling the Vehicle on page 11 2 Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warnin...

Page 15: ...the batteries but by people who use the batteries as well Please contact your nearest Club Car dealer or distributor for information on how to properly recycle your batteries 1403 Figure 5 Dispose of...

Page 16: ...a given model year See following NOTE NOTE Have the vehicle serial number available when ordering parts or making inquiries Build Code The build code 4 is a five digit number that appears on the vehi...

Page 17: ...ops To avoid unintentionally starting or rolling the vehicle set the park brake place the Forward Reverse handle or switch in the NEUTRAL position turn the key switch to the OFF position and remove th...

Page 18: ...as a warning when the Forward Reverse switch is in the REVERSE position Gasoline Vehicles The Forward Reverse handle is located on the seat support panel below and to the right of the driver s right k...

Page 19: ...locking the park brake The vehicle will roll at about 1 mph 1 6 km h If the walk away braking function remains engaged for two seconds or more a warning buzzer will sound to alert the driver that moto...

Page 20: ...d PARK molded into it and the words PARK BRAKE marked on top of it Figure 12 To set the park brake press the brake pedal firmly and tilt the park brake portion of the pedal forward with your foot Figu...

Page 21: ...ed by your Club Car distributor dealer The warning light will repeatedly illuminate for 10 seconds with 4 second intervals during a charge cycle DC plug is still connected if AC power to the charger i...

Page 22: ...s 7A Figure 14 Tow Run Switch IQ System NEUTRAL LOCKOUT Gasoline Vehicles Only For the convenience of the trained technician there is a neutral lockout cam located on the back of the Forward Reverse s...

Page 23: ...ent this chock the front and rear wheels and firmly set the park brake before servicing or leaving the vehicle NOTE Be sure to return the cam to the OPERATE position after servicing the vehicle or it...

Page 24: ...factory however upon receiving your new vehicle s you should become familiar with its controls indicators and operation Carefully inspect each vehicle to ensure that it is in proper working condition...

Page 25: ...vehicle should come to a smooth straight stop within 14 feet 4 3 m If the pedal goes more than halfway to the floor or if the vehicle swerves or fails to stop within 14 feet 4 3 m have the brake syst...

Page 26: ...n a level surface DRIVING INSTRUCTIONS WARNING Only licensed drivers should be allowed to drive the vehicle If renting or loaning the vehicle make sure the driver is familiar with all controls and ope...

Page 27: ...ntrols 2 Make sure everyone is seated and holding onto seat hand holds or handrails 3 Read safety and information decals located on the vehicle 4 Make sure wheels are turned in desired direction 5 Tur...

Page 28: ...r is pressed This prevents the possibility of a parked vehicle with the park brake disengaged rolling away too fast to be overtaken on foot Gasoline vehicles only Turn the fuel shut off valve to the c...

Page 29: ...turns when towing Avoid stopping on a hill when towing If you must stop on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning could cause the vehicle t...

Page 30: ...the Tow Run Switch remains in the RUN position rather than in the TOW position required for all other vehicles 4 Batteries should be clean and free of corrosion Wash tops and terminals of batteries wi...

Page 31: ...ensures the cable will not come into contact with battery terminal RETURNING THE STORED ELECTRIC VEHICLE TO SERVICE 1 If necessary connect batteries See Connecting the Batteries Electric Vehicles on p...

Page 32: ...e carburetor drain screw and drain fuel remaining in bowl into a small clean container then pour the fuel from the container into vehicle fuel tank Tighten the carburetor drain screw 2 3 Disconnect fu...

Page 33: ...smoke excessively for a short time when it is run for the first time after storage 5 Adjust tires to recommended tire pressure See Vehicle Specifications on page 54 6 Perform the Pre Operation and Dai...

Page 34: ...r metal objects to contact frame when disconnecting batteries or other electrical wiring Never allow a positive wire to touch the vehicle frame engine or other metal component PERIODIC SERVICE SCHEDUL...

Page 35: ...ed technician General vehicle Wash battery compartment and underside of vehicle Initial one time inspection by owner or trained technician after six weeks of use Batteries For vehicles newly equipped...

Page 36: ...lly check battery electrolyte levels of all cells to verify correct valve operation See page See Battery Care Vehicles Equipped with the Single Point Watering System on page 39 Annual service by train...

Page 37: ...ering and Front Suspension in the maintenance and service manual Electrical wiring and connections Check for tightness and damage Check brake shoes replace if necessary Lubricate brake slides See Peri...

Page 38: ...e CC P N 1012151 Charger receptacle WD 40 Brake slides Dry Moly Lube CC P N 1012151 Semiannually by owner or trained technician every 50 hours of operation or 100 rounds of golf Front suspension 5 fit...

Page 39: ...every 50 hours of operation or every 100 rounds of golf Brake slides Dry Moly Lube CC P N 1012151 Annually by trained technician only every 100 hours of operation or every 200 rounds of golf Check fi...

Page 40: ...ever be used in electric vehicles New batteries will not deliver their full capabilities until they have been discharged and recharged 20 to 50 times To obtain the maximum service life from new batter...

Page 41: ...RITY ALLOWABLE CONTENT PARTS PER MILLION EFFECTS OF IMPURITY Suspended matter Trace Total solids 100 0 Organic and volatile matter 50 0 Corrosion of positive plates Ammonia 8 0 Slight self discharge o...

Page 42: ...s on page 40 See Watering Batteries with the SPWS on page 46 CAUTION The watering interval must adequately maintain the electrolyte level above the top of the plates See Figure 22 Water the batteries...

Page 43: ...tight enough so that the batteries do not move while the vehicle is in motion but not so tight as to crack or buckle the battery case For 12 volt batteries tighten hold down retaining nuts to 72 in l...

Page 44: ...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...

Page 45: ...ug straight into the receptacle Figure 23 Page 44 Do not pull on the DC cord Figure 24 Page 44 Do not twist rock or bend the plug To disconnect the charger plug from the vehicle receptacle grasp the p...

Page 46: ...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 operati...

Page 47: ...following WARNING WARNING If the receptacle fuse link is blown determine the source of the electrical problem and correct it before replacing the fuse Contact your nearest Club Car distributor dealer...

Page 48: ...onnect the purger 5 to the female coupler 8 on the end of the hose end assembly Figure 27 1 2 3 5 4 5 7 6 8 3 68 Figure 26 Connecting Hose with Filter to Water Source 69 Figure 27 Checking the Water F...

Page 49: ...r balls stop moving immediately press the grey button to disconnect the hose end assembly from the battery fill coupling 9 and squeeze the dust cover 10 to lightly secure it to the male connector of t...

Page 50: ...s infrequent watering Figure 30 Any corrosion around the positive or negative terminals should be washed off with a solution of baking soda and water 1 cup 237 mL per gallon 3 8 L of water Rinse solut...

Page 51: ...on a level surface when checking oil Do not overfill with oil ENGINE OIL LEVEL CHECK 1 Remove the oil level dipstick from the oil filler tube and wipe oil off dipstick 1 Figure 32 See following CAUTI...

Page 52: ...in plug turning it counterclockwise and allow the engine oil to drain into the pan See following WARNING WARNING Do not attempt to change engine oil when the engine is hot or even warm Engine oil can...

Page 53: ...l Filter 10 Use a clean rag and wipe the oil filter mounting bracket surface clean where the oil filter gasket seats 11 Coat new oil filter gasket with clean engine oil and install the oil filter onto...

Page 54: ...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 be sure the fuel tank is properly vented as show...

Page 55: ...to prevent possible stains The seats of the vehicle will last longer with proper cleaning Use a solution of 10 liquid soap and warm water applied with a soft cloth For imbedded dirt a soft bristle br...

Page 56: ...limiter Transaxle Double reduction helical gear with 12 3 1 direct drive axle Unitized transaxle Fully synchronized forward and reverse with neutral and reduced speed reverse 11 8 1 forward 17 1 1 re...

Page 57: ...ing distance at 12 mph 19 km h 14 ft 427 cm Standard seating capacity 2 LIQUID CAPACITIES Transaxle 22 oz 0 67 L Engine crankcase without filter 32 oz 0 95 L Engine crankcase with filter 38 oz 1 12 L...

Page 58: ...em 3 YEARS 3 YEARS ALL REMAINING COMPONENTS Solenoid MCOR limit switches voltage regulators F R switches brake components wiring harness electrical switches canopy systems seats pedal group assembly b...

Page 59: ...FICATION OF THE SPEED GOVERNOR BRAKING SYSTEM STEERING TRANSAXLE OR OTHER OPERATING SYSTEMS OF THE CAR TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKEWISE VOID IF THE VEHIC...

Page 60: ...erefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state HOW TO MAKE A WARRANTY...

Page 61: ...1 706 863 3000 CLUB CAR EXPLANATION OF EMISSION CONTROL WARRANTY 1 WARRANTY CLUB CAR warrants to the ultimate purchaser and each subsequent purchaser that the SORE and related emissions equipment is...

Page 62: ...adjustment of a component that has a factory installed and properly operating adjustment limiting device is still eligible for warranty coverage The following emission warranty parts list are covered...

Page 63: ...EC Declaration of Conformity Sample Document EC DECLARATION OF CONFORMITY SAMPLE DOCUMENT When properly configured the vehicle complies with the listed Directives DS Golf Car Owner s Manual Page 61...

Page 64: ...rer Club Car LLC 4125 Washington Road Evans Georgia 30809 USA Club Car Ingersoll Rand Alma Court Building Lenneke Marelaan 6 B 1932 Sint Stevens Woluwe Belgium EC DECLARATION OF CONFORMITY GASOLINE AN...

Page 65: ...Club Car R NOTES...

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Page 68: ...er 103472502 Edition Code 0608T1111R 103472502 This manual is valid for vehicles built during the 2009 model year It is also valid for vehicles with build codes between 54699 and the one indicated at...