Club Car Gasoline/Electric DS Golf Car 1996, Owner'S Manual

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Page 2: ...WARNING THE ENGINE EXHAUST FROM THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM ...

Page 3: ...f 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 vehicle 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 wi...

Page 4: ...ON FORM IS NOT COMPLETED AND RETURNED TO CLUB CAR AT THE TIME OF THE ORIGINAL RETAIL SALE PURCHASER MUST PROVIDE PROOF OF DATE OF PURCHASE WITH ANY WARRANTY CLAIM 2 EXCLUSIONS Excluded from any CLUB CAR warranty are all optional equipment and accessories fuses filters decals spark plugs lubricants the front body rear body and trim pieces seats routine wear items such as the charger plug and recept...

Page 5: ...TIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REMEDY OF REPLACEMENT OR REPAIR OF THE DEFECTIVE GOLF CAR OR COMPONENT THEREOF IS THE EXCLUSIVE AND SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER R...

Page 6: ...jury If you rent or loan your vehicle to others we rec ommend 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 ser vice 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 t...

Page 7: ...c Vehicle 16 Maintenance 17 Periodic Service Schedule 19 Periodic Lubrication Schedule Gasoline Vehicles 20 Periodic Lubrication Schedule Electric Vehicles 21 Capacities 22 Engine Oil Gasoline Vehicle 23 Fueling Instructions Gasoline Vehicle 23 Battery Gasoline Vehicle 24 Battery Electric Vehicle 25 Battery Charger Electric Vehicle 26 Cleaning 30 Vehicle Controllers Electric Vehicle 31 Accessories...

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Page 9: ...e personal injury property damage or death Contact your CLUB CAR distributor dealer The safety procedures listed must be followed whenever the vehicle is being operated repaired or ser viced Other specific warnings appear throughout this manual and on the vehicle 1 DANGER A DANGER INDICATES AN IMMEDIATE HAZARD WHICH WILL RESULT IN SEVERE PER SONAL INJURY OR DEATH WARNING THIS OWNER S MANUAL SHOULD...

Page 10: ...ECHNICIANS SHOULD REPAIR OR SERVICE THE VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD FOLLOW THE CORRECT PROCE DURES AND OBEY THE WARNINGS LISTED IN THIS MANUAL AS WELL AS THOSE IN THE MAINTENANCE AND SERVICE MANUAL ALWAYS WEAR SAFETY GLASSES OR EYE PROTECTION WHEN SERVICING THE VEHI CLE TURN KEY SWITCH TO OFF REMOVE KEY BLOCK TIRES PLACE FORWARD REVERSE LEVER IN NEUTRAL AND DISCONNEC...

Page 11: ...3 DS GASOLINE VEHICLE FEATURE IDENTIFICATION ...

Page 12: ...4 DS ELECTRIC VEHICLE FEATURE IDENTIFICATION ...

Page 13: ...olf 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 displayed and visible Who should and who should not drive golf cars Instructing first time ...

Page 14: ...ine Oil Page 23 DS Gasoline Fuel Check fuel level See Fueling Instructions Page 23 PERFORMANCE INSPECTION After you have familiarized yourself with the vehicle s controls and have read and understood the dri ving instructions take the vehicle for a test drive Check the following All vehicles Brakes Be sure that the brakes function properly Both rear wheels should brake simultaneously The pedal sho...

Page 15: ...R REPRODUC TIVE HARM 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...

Page 16: ...ly marked on the switch Push down the F forward side of the switch to run the vehicle in the forward direction or push down the R reverse side of the switch to run the vehicle in reverse When the switch is positioned with neither side down the vehicle is in the neutral position and the vehicle will not run if the accelerator is depressed See Figure 6 ACCELERATOR PEDAL The accelerator pedal is the ...

Page 17: ...ss the brake pedal firmly and tilt the park brake portion of the pedal forward with your foot See Figure 9 GASOLINE VEHICLE 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 9 Figure 6 Figure 7 Figure 8 Figure 9 WARNIN...

Page 18: ...st 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 stay...

Page 19: ... occurs after 16 hours of oper ation or 4 the charger malfunctions the warning light will indicate as follows The warning light will not come on if the charge is 90 or more complete The on board computer will retain in memory the amount of charge needed to fully replenish the batteries and will com plete the charge during the next charge cycle When the charger is unplugged the warning light will c...

Page 20: ...O AN UNSUSPECTING PASSENGER AND OR DAMAGE TO THE VEHICLE 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 REMAIN SEATED IN A MOVING VEHICLE AND HOLD ON TO SEAT HANDLES OR HANDRAILS AT ALL TIMES TO PREVENT FALLS DRIVER SHOULD KEEP BOTH HANDS ON STEERING WHEEL AT ALL TIMES KEEP ALL BODY PARTS INSIDE THE VEHICLE TO ...

Page 21: ...ark brake pedal until it locks This will prevent the vehicle from rolling 2 Turn the key switch to OFF and place the shift lever in the NEUTRAL position Remove the key when the vehicle is not in use Regenerative Braking Vehicles Only When the vehicle is in use with the key switch ON the zero speed detect function will resist vehicle rolling See Zero Speed Detect Page 7 13 NOTE Operator must contro...

Page 22: ...THE TRAILER WITH THE SHIFT LEVER IN NEUTRAL KEY SWITCH OFF AND THE PARK BRAKE FIRMLY DEPRESSED AND LOCKED WHEN TOWING A TRAILER NORMAL SPEED SHOULD BE REDUCED AND CARE SHOULD BE USED WHEN TURNING A CORNER DUE TO THE ADDED LENGTH OF THE TRAILER REMOVE THE VEHICLE S WINDSHIELD BEFORE TRANSPORTING IT ON A TRAILER WARNING NEVER TOW THE VEHICLE ON PUBLIC STREETS OR HIGHWAYS USE ONLY APPROVED CLUB CAR T...

Page 23: ... 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 15 WARNING TURN KEY SWITCH OFF REMOVE KEY AND LEAVE THE FORWARD REVERSE LEVER IN NEUTRAL POSITION DURING STORAGE THIS IS TO PREVENT UNINTENTIONAL STARTING OF THE VEHICLE CAUTION BATTERIES IN...

Page 24: ...ecklist See pages 6 and 7 STORAGE ELECTRIC VEHICLE 1 Fully charge batteries See Battery Electric Vehicle Page 25 2 Wash off any corrosion around the terminals with a solution of baking soda and water then rinse NOTE Do not allow this solution to enter the batteries Let the terminals dry and coat them with CLUB CAR battery terminal spray Part No 1014305 16 NOTE WHEN RUNNING THE ENGINE FOR THE FIRST...

Page 25: ...erform 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 maintenance program regularly scheduled service even though the vehicle is functional Regular and consistent vehicle maintenance can prevent the vehicle down time and expensive repairs that result from neglect Any v...

Page 26: ... FORWARD REVERSE LEVER IN NEUTRAL POSITION AND BLOCK 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 SYSTEM ATTEMPTING TO DO SO COULD CAUSE SEVERE BURNS REMOVE THE SPARK PLUG WIRE AND DISCONNECT THE BATTERY TO AVOID UNIN TENTIONAL STARTING OF THE ENGINE WHEN SERVICING TH...

Page 27: ...en coils or loose connections PowerDrive Regenerative Braking Vehicles and V Glide 36volt Vehicles Only Check all daily weekly and monthly items listed above Semi Annual Service by Trained Personnel Only Every 100 Rounds or every 50 hours of operation Check clean and adjust brake system Check front wheel alignment and camber adjust as necessary Test batteries Check battery electrolyte level Check ...

Page 28: ...lly by Trained Personnel Only 5 Check fill drive unit to plug level 6 Inspect front wheel bearings Repack as necessary 7 Check fill transmission to plug level 67 liters 22 oz SAE 30 WT API Class SE SF or SG Oil or higher Chassis Lube 80 90 WT API Class GL 3 or 80 90 WT AGMA Class EP Gear Lube First Change 100 Hours Additional Change Every 400 Rounds or Every 200 Hours or Operation or Annually Whic...

Page 29: ...rward and reverse switch contacts and Charger Receptacle 5 Front suspension 5 fittings Dry Moly Lube Club Car P N 1012151 Dry Moly Lube Club Car P N 1012151 Dry Moly Lube Club Car P N 1012151 WD 40 Chassis Lube Annually by Trained Personnel Only 6 Check fill drive unit to plug level 7 Inspect front wheel bearings Repack as necessary 67 liters 22 oz SAE 30 WT API Class SE SF or SG Oil or higher Cha...

Page 30: ...rankcase without Filter 98 liters 32 oz Engine Crankcase with Filter 1 16 liters 38 oz Transmission 61 liters 20 oz Drive Unit 67 liters 22 oz 67 liters 22 oz Gasoline Tank 26 5 liters 7 U S gallons Tire Pressure 12 14 psi 18 20 psi Figure 18 ...

Page 31: ...WAY FROM THE AREA OF THE VEHICLE SERVICE OR REPAIR IN A WELL VENTILATED AREA ONLY NEVER POUR GASOLINE INTO GAS TANK WHILE THE ENGINE IS HOT OR RUNNING TO AVOID ELECTRIC ARC CAUSED BY STATIC ELECTRICITY THE FUEL STORAGE PUMP ING DEVICE MUST BE GROUNDED IF THE PUMP IS NOT GROUNDED THE VEHICLE MUST BE GROUNDED TO THE PUMP BEFORE AND DURING THE FUELING OPERATION IF THE VEHICLE HAS AN ALL WEATHER ENCLO...

Page 32: ...AILURE TO DO SO MAY CAUSE THEM TO OVERHEAT DURING OPERATION CAUTION DO NOT OVERFILL FUEL TANK AVOID FUEL SPILLAGE DANGER BATTERY EXPLOSIVE GASES 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 CARE FULLY WHEN DEALING WITH BATTERIES VENTILATE WHEN CHARGING IN AN ENCLOSED SPACE ...

Page 33: ...pplication 25 DANGER BATTERY EXPLOSIVE GASES 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 CARE FULLY WHEN DEALING WITH BATTERIES VENTILATE WHEN CHARGING IN AN ENCLOSED SPACE POISON CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING ANTIDOTES EXTERNAL...

Page 34: ...e add only distilled water 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 i...

Page 35: ...NECT THE DC OUTPUT PLUG FROM THE BATTERY RECEPTACLE WHEN THE CHARGER IS ON THE RESULTING ARCING AND BURNING COULD DAMAGE THE PLUG AND RECEPTACLE AND COULD CAUSE BATTER IES TO EXPLODE IF THE CHARGER MUST BE STOPPED DISCONNECT THE AC SUPPLY PLUG FROM THE WALL OUTLET BEFORE DISCONNECTING THE CHARGER DC OUT PUT PLUG 48 VOLT POWERDRIVE CHARGER WHEN THE CHARGER IS ON DISCONNECT THE DC OUTPUT PLUG FROM T...

Page 36: ...n 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 control circuit is locked out preventing operation of the vehi cle as well as the possibility of consequent damage to the charger and the vehi...

Page 37: ...HE 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...

Page 38: ...G The vehicle is equipped with an Armorflex front body and rear body Use only mild dishwashing liq uid soap with a sponge or soft cloth for normal cleaning Minor scratches or blemishes in the front body or the rear body can be buffed out using most com mercially available polishing compounds and polishes The seats of the vehicle will last longer with proper cleaning Mild soap or detergent with a s...

Page 39: ...n 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 31 WARNING TINTED WINDSHIELDS WILL NOT PROTECT OCCUPANTS FROM FLYING OBJECTS GOLF BALLS ETC Spark Arrestor Kit Fuel Guage Information Holder Sweater Basket Extra Two Bag Attachment Bagwell Liner Snap on Tee Holder S...

Page 40: ... underneath the rear seat with 06 cu m 2 cu ft 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 connected must be capable of supplying 15 amp...

Page 41: ...IF USING AN ON BOARD CHARGER BE SURE THE AC PLUG IS UNPLUGGED FROM THE OUTLET BEFORE ATTEMPTING TO DRIVE THE VEHICLE CHARGER AND AC OUTLET WILL BE DAMAGED IF CHARGER IS NOT UNPLUGGED BEFORE DRIVING BE SURE THE AC CORD IS PROPERLY WOUND UP ON THE REEL BEFORE DRIVING THE VEHICLE STUDY ALL GENERAL INFORMATION NOTES CAUTIONS AND WARNINGS AS WELL AS ALL INFORMATION NOTES CAUTIONS AND WARNINGS SPECIFIC ...

Page 42: ...34 VEHICLE SPECIFICATIONS ...

Page 43: ...ar 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 pur chase 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 specifi cally listed above for...

Page 44: ...TS 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 com ponent to an authorized CLUB CAR distributor or dealer or send the defective component freight pre paid to WARRANTY ADMINISTRATION CLUB CAR INC 4152 Washington Road P O Box 204658 Augusta G...

Page 45: ...INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitation of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state 9 INFORMATION For further informatio...

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