Club Car DS Golf Cars 2007, Owner'S Manual

Page 1: ...Owner s Manual 2007 DS Golf Cars Electric and Gasoline...

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Page 3: ...rds Institute s Z130 Safety and Performance Requirements for Golf Cars This standard which promotes safety in the design application and operation of golf cars defines a golf car as a vehicle used to...

Page 4: ...hat your local authorized Club Car representative perform them For the name and address of the Club Car representative nearest you logon to our web site at www clubcar com or call 1 800 ClubCar 258 22...

Page 5: ...nstructions 21 Towing 23 Transporting on a Trailer 24 Storage Electric Vehicles 25 Storage Gasoline Vehicles 26 Maintenance 28 Periodic Service Schedules 29 Periodic Lubrication Schedules 31 Vehicle C...

Page 6: ...Car Owner s Manual DS ELECTRIC VEHICLE BATTERY WARNING LAMP SERIAL NUMBER BRAKE PEDAL PARK BRAKE PEDAL ACCELERATOR PEDAL OPERATING INSTRUCTIONS DECAL DRIVER PASSENGER WARNING DECAL KEY SWITCH PRIVATE...

Page 7: ...er s Manual Page 5 DS ELECTRIC VEHICLE CHARGER RECEPTACLE TOW SWITCH WARNING DECAL ON TOW SWITCH BRACKET UNDER SEAT BATTERY DANGER DECAL FORWARD REVERSE SWITCH ON SPEED CONTROLLER COVER ELECTRICAL COM...

Page 8: ...ification Page 6 2007 DS Golf Car Owner s Manual DS GASOLINE VEHICLE DRIVER PASSENGER WARNING DECAL LOW OIL WARNING LAMP SERIAL NUMBER BRAKE PEDAL PARK BRAKE PEDAL OPERATING INSTRUCTIONS DECAL ACCELER...

Page 9: ...NE VEHICLE F N R GASOLINE WARNING DECAL ON VEHICLE FRAME NEAR FUEL TANK FRAME GROUND AND GOVERNOR WARNING DECAL ON VEHICLE FRAME NEAR BATTERY CHOKE HANDLE OIL FILL FUEL SHUT OFF VALVE ROTATING PARTS A...

Page 10: ...at first seem shocking but their impact is mild compared with the reality of severe personal injury Your safety and satisfaction are of the utmost importance to Club Car That is why before operating t...

Page 11: ...y should be replaced immediately to avoid possible property damage personal injury or death Contact your Club Car distributor dealer DANGER A DANGER indicates an immediate hazard that will result in s...

Page 12: ...ions could result in severe personal injury or death Check the vehicle for proper location of all vehicle safety and operation decals and make sure they are in place and are easy to read Only trained...

Page 13: ...ghted We urge the owner operator to read and understand this manual and to pay special attention to the features specific to his her vehicle s Figure 1 Gasoline Vehicle Figure 2 IQ System Electric Veh...

Page 14: ...hould 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...

Page 15: ...h are clearly labeled See following NOTE NOTE The key can be removed only when the key switch is in the OFF position FORWARD REVERSE CONTROL IQ System Electric Vehicles The Forward Reverse rocker swit...

Page 16: ...a warning when the Forward Reverse handle is in the REVERSE position ACCELERATOR PEDAL The accelerator pedal is the pedal on the right with the word GO molded into it Figure 7 The operation of the ac...

Page 17: ...at that speed Motor braking is automatically disengaged when vehicle speed slows below the programmed top speed Pedal Up Motor Braking When vehicle speed is above 11 mph 17 7 km h releasing the accel...

Page 18: ...rger is interrupted 3 automatic charger shut off occurs after 16 hours of operation 4 the charger malfunctions or 5 the wrong charger is used the warning lamp will indicate as follows The warning lamp...

Page 19: ...seconds to elapse before switching back to the RUN position After placing the Tow Run switch in the RUN position allow 10 seconds to elapse before operating the vehicle The Tow Run switch should be pl...

Page 20: ...snaps into place Figure 12 See following WARNING and NOTE WARNING With the cam in the MAINTENANCE position and the engine running the vehicle may move suddenly if the Forward Reverse handle is shifted...

Page 21: ...njunction with the Periodic Service Schedules on page 29 Any problems should be corrected by a Club Car distributor dealer or a trained technician General All the parts should be in place and properly...

Page 22: ...3 m have the brake system checked and adjusted as required Brake adjustment must be maintained so that the brake pedal cannot be pressed to the floor under any cir cumstance Park brake When latched t...

Page 23: ...ginal position and the engine should stop All Club Car vehicles operate at reduced speed in reverse Governor Check maximum speed of the vehicle The vehicle should operate at 12 15 mph 19 24 km h on a...

Page 24: ...procedures Read and understand all instructions prior to driving the vehicle STARTING THE VEHICLE 1 Study and understand controls 2 Make sure everyone is seated and holding onto seat hand holds or han...

Page 25: ...FF postion and place the Forward Reverse handle or switch in the NEUTRAL position Remove the key when the vehicle is not in use Electric vehicles only When the Tow Run switch is in the RUN position wi...

Page 26: ...lic roads the trailer must meet all federal state and local requirements such as taillamps brake lamps etc Do not tow a Club Car vehicle behind a passenger vehicle or truck on a public road unless it...

Page 27: ...ter the batteries Be sure terminals are tight Let the terminals dry and then coat them with Battery Terminal Protector Spray CCI P N 1014305 3 Store vehicle in a cool dry place This will minimize batt...

Page 28: ...OLINE VEHICLE FOR EXTENDED STORAGE 1 Store vehicle in a cool dry place This will minimize battery self discharge If the battery appears to be weak have it charged by a trained technician Use an automo...

Page 29: ...crankshaft by hand several times and then install the spark plug 6 Adjust tires to recommended tire pressure See Vehicle Specifications on page 45 7 Perform semiannual periodic lubrication See Period...

Page 30: ...stent vehicle maintenance can prevent vehicle downtime and expensive repairs that can result from neglect Use the Pre Operation and Daily Safety Checklist on page 19 and the fol lowing Periodic Servic...

Page 31: ...ust if necessary See Vehicle Specifications on page 45 General vehicle Wash battery compartment and underside of vehicle Semiannual service by trained technician only every 50 hours of operation or 10...

Page 32: ...or every 100 rounds for golf cars Battery Clean terminals and wash dirt from casing check electrolyte level See Battery Gasoline Vehicles on page 38 Front wheel alignment and camber Check and adjust i...

Page 33: ...Lube CCI P N 1012151 Brake linkage and pivots Dry Moly Lube CCI P N 1012151 Accelerator pivot rod supports Dry Moly Lube CCI P N 1012151 Charger receptacle WD 40 Brake slides Dry Moly Lube CCI P N 101...

Page 34: ...s Dry Moly Lube CCI P N 1012151 Front suspension 5 fittings Chassis Lube EP NLGI Grade 2 Brake slides Dry Moly Lube CCI P N 1012151 Annually by trained technician only every 100 hours of operation or...

Page 35: ...Internal Drink large quantities of milk or water followed with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately WARNING...

Page 36: ...add only distilled water See following CAUTION and NOTE CAUTION Do not overfill the batteries NOTE A battery watering gun or bottle is available at many auto parts dealers 3 The hold down straps shoul...

Page 37: ...ire Gauge and be as short as possible The use of improper extension cord could result in fire or an electrical shock Do not operate the charger if it has received a sharp blow was dropped or otherwise...

Page 38: ...12 feet 3 7 m Place all cords so they will not be stepped on tripped over or otherwise subject to dam age or stress Ensure that the charger ventilation slots are unobstructed and that there is adequat...

Page 39: ...other manufacturers are not compatible As long as the charger is allowed to shut off by itself the batteries will be fully charged Overcharging and undercharging will normally be prevented Batteries...

Page 40: ...rest Club Car distributor dealer BATTERY GASOLINE VEHICLES See General Warnings on page 9 DANGER Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Vent...

Page 41: ...n to enter battery Be sure terminals are tight battery terminals should be tightened to 12 ft lb 16 N m Let the terminals dry and then spray them with Battery Terminal Protector Spray CCI P N 1014305...

Page 42: ...he dipstick gauge add oil until the level is between low and full levels safe level 3 4 Insert the dipstick into the oil filler tube See following NOTE NOTE Properly recycle or dispose of used oil in...

Page 43: ...lockwise and tighten to 18 ft lb 24 4 N m 8 Relocate the oil drain pan to a position under the engine oil filter Figure 27 9 Remove the engine oil filter 1 turning it counterclockwise allowing the res...

Page 44: ...unting bracket NOTE Use only Club Car oil filters CCI P N 1016467 designed for this engine 12 Tighten the oil filter by hand until tight Do not use a band wrench or channel lock plier to tighten 13 Re...

Page 45: ...tric arc caused by static electricity the fuel storage pumping device must be grounded If the pump is not grounded the vehicle must be grounded to the pump before and during the fueling operation If t...

Page 46: ...seats of the vehicle will last longer with proper cleaning Use a solution of 10 liquid soap and warm water applied with a soft cloth For imbedded dirt a soft bristle brush may be used For heavy soilin...

Page 47: ...n 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 reverse Torque converter Automatic v...

Page 48: ...kg Forward speed 12 15 mph 19 24 km h Curb clearance circle diameter 17 ft 6 in 533 cm Braking distance at 12 mph 19 km h 14 ft 427 cm Standard seating capacity 2 LIQUID CAPACITIES Transaxle 22 oz 0 6...

Page 49: ...ats 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...

Page 50: ...olf 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 CLUB CAR LIMITED LIFETIME WARRAN...

Page 51: ...AS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS 4 SOLE REMEDY CLUB CAR s liability under this limited warranty or in any action whether based upon warranty contract negligence...

Page 52: ...This limited warranty only covers defects in material and workmanship for a period of four years or 800 golf car rounds from date of purchase The terms of this four year or 800 round limited warranty...

Page 53: ...e and necessary maintenance accident or alteration is excluded from this limited warranty Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitations of i...

Page 54: ...EHICLE OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE DISTRIBUTOR OR DEALER OF CLUB CAR HAS THE...

Page 55: ...ther than golf whichever first occurs except for transportation expenses All parts and components replaced under this limited warranty become the property of CLUB CAR THIS LIMITED WARRANTY IS EXCLUSIV...

Page 56: ...must be performed at a warranty station at no charge to the owner 5 Notwithstanding the provisions herein warranty services or repairs will be provided at all of our distribution centers that are fran...

Page 57: ...optimum ignition timing characteristics The carburetors have been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system M...

Page 58: ...llustrations 4 Periodic Service and Periodic Lubrication Schedules Poor Fair Average Good Excellent Comments Suggestions In order to help us better serve you please rate this publication in the follow...

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Page 60: ...Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Intl l 1 706 863 3000 Fax 1 706 863 5808 Publication Part Number 103218309 Edition Code 0706B12...