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Table of Contents
Related Manuals for Club Car DS Golf Cars Gasoline and Electric
Summary of Contents for Club Car DS Golf Cars Gasoline and Electric
- Page 1 DS Golf Cars Gasoline and Electric...
- Page 3 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.
- Page 4 We hope you will consider this owner’s manual a permanent part of your Club Car vehicle. If you sell the vehi- cle, please include the manual so that the next owner will have the important operating, safety, and mainte- nance information it contains.
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Page 5: Table Of Contents
TABLE OF CONTENTS Vehicle Feature Identification – DS Electric Vehicle ......... Vehicle Feature Identification –... -
Page 6: Vehicle Feature Identification - Ds Electric Vehicle
Vehicle Feature Identification DS ELECTRIC VEHICLE DRIVER / PASSENGER WARNING DECAL WARNING ROLLOVER OR FALLING OFF MAY CAUSE DEATH. • Before using vehicle, read operating instructions. • Remain seated and hold on to seat handle while moving. • Do not start vehicle until all occupants are seated. •... - Page 7 Vehicle Feature Identification DS ELECTRIC VEHICLE ELECTRICAL COMPONENT DECAL (ON SPEED CONTROLLER COVER) NOTICE Do not operate vehicle without this cover properly installed. Do not direct water stream in this area; will cause damage to components. See vehicle maintenance and service manual before servicing. CCI 101931501 TOW SWITCH WARNING DECAL (ON TOW SWITCH BRACKET UNDER SEAT)
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Page 8: Vehicle Feature Identification - Ds Gasoline Vehicle
Vehicle Feature Identification DS GASOLINE VEHICLE OPERATING INSTRUCTIONS WARNING • Read Owner's Manual and safety warnings located on dash panel prior to driving. • Study and understand controls. ROLLOVER OR FALLING OFF MAY CAUSE DEATH. • Make sure wheels are turned in desired direction. •... - Page 9 Vehicle Feature Identification DS GASOLINE VEHICLE WARNING • GASOLINE EXPLOSION / FIRE. • CAN CAUSE SEVERE INJURY OR DEATH. ROTATING PARTS AND • NO SMOKING, SPARKS, OR OPEN FLAME. • STOP ENGINE, ALLOW TO COOL BEFORE REFUELING. HOT MANIFOLD DECAL •...
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Page 10: Practice Safety
Safety signs like you see above may at first seem shocking, but their impact is mild compared with the reality of severe personal injury. Your safety and satisfaction are of the utmost importance to Club Car. That is why before operating the vehicle, we urge you to review the information in this manual. -
Page 11: Safety Details
If any of the operation or safety decals on the vehicle become damaged, have been removed or cannot be easily read, they should be replaced immediately to avoid possible property damage, personal injury, or death. Contact your Club Car distributor/dealer. ∆... - Page 12 • A Club Car vehicle will not provide protection from lightning, flying objects, or other storm- related hazards. If caught in a storm while driving a Club Car vehicle, exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location.
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Page 13: General Information
See following NOTE. NOTE: Have the vehicle serial number available when ordering parts or making inquiries. SERIAL NUMBER DECAL Club Car SERIAL NUMBER This vehicle is covered by one or more of the AQ0501-123456 following U.S. Patents as applicable: D271008... -
Page 14: Safety Committee
• 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. Warning signs from Club Car are listed below. WARNING SIGN CCI P/N Sharp Left... - Page 15 (REVERSE) to operate vehicle in reverse. When the handle is in the straight up position (NEUTRAL), the vehicle will not operate. Club Car vehicles operate at reduced speed in reverse. The reverse buzzer will sound as a warning when the Forward/Reverse handle is in the REVERSE position.
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Page 16: Brake Pedal
Controls and Indicators Figure 7 Accelerator and Brake Pedals ACCELERATOR PEDAL The accelerator pedal is the pedal on the right, with the word GO molded into it (Figure 7) . The operation of the accelerator pedal differs from that of an automobile. When the key switch is in the ON position, and the Forward/Reverse handle or switch is in either in the FORWARD or REVERSE position, pressing the acceler- ator pedal will automatically release the park brake and start the vehicle moving in the direction selected (for- ward or reverse). -
Page 17: Battery Warning Light
30 minutes. However, the vehicle should be charged at the first opportunity. If the warning light illuminates and the vehicle is unable to operate for 30 minutes, have your Club Car distributor/ dealer check the vehicle for a possible battery or electrical system problem. - Page 18 Controls and Indicators TOW/RUN SWITCH IQ System Electric Vehicles Only ∆ WARNING • Place Tow/Run switch in the TOW position before disconnecting or connecting the batteries. Failure to heed this warning could result in a battery explosion or severe personal injury. •...
- Page 19 Controls and Indicators NEUTRAL LOCKOUT Gasoline Vehicles Only For the convenience of the trained technician, there is a neutral lockout cam located on the back of the For- ward/Reverse shifter. If the neutral lockout cam is pulled out approximately 3/8 inch (10 mm) and then rotated one-half turn until it snaps into place, the cam will be in the MAINTENANCE position (Figure 11).
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Page 20: Pre-Operation And Daily Safety Checklist
PRE-OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new vehicle(s), you should become familiar with its controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery. -
Page 21: Performance Inspection
Use the following checklist as a guide to inspect the vehicle and check daily for proper operation. Any prob- lems should be corrected by a Club Car distributor/dealer or a trained technician. All Vehicles •... -
Page 22: Driving Instructions
Motor braking should quickly and smoothly slow the vehicle to approximately 11 mph (17.7 km/h). Motor braking will disengage when vehicle slows to 11 mph (17.7 km/h). This feature is adjustable for IQ System vehicles only. Contact your local Club Car dealer/distrib- utor to inquire about this adjustable feature. -
Page 23: Starting The Vehicle
Driving Instructions ∆ WARNING • To help prevent falls from the vehicle, remain seated in a moving vehicle and hold on to hand holds or handrails at all times. Driver should keep both hands on the steering wheel when the vehicle is in motion. -
Page 24: Towing
Towing ∆ WARNING Gasoline vehicles only: • Do not shift the vehicle out of forward while going downhill. If you do, you will not be able to shift into reverse or back into forward until stopped. • Press the brake pedal as necessary and partially press the accelerator when descending a hill. -
Page 25: Transporting On A Trailer
• For use on public roads, the trailer must meet all federal, state, and local requirements such as taillights, brake lights, etc. • Do not tow a Club Car vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer. -
Page 26: Storage - Electric Vehicles
Storage – Electric Vehicles If the vehicle must be transported over long distances or on public highways, it should be transported on an approved trailer that has the approved load rating of 1200 lb. (544 kg) per vehicle being transported. NOTE: A two-car trailer should be rated at 2 x 1200 = 2400 lb. -
Page 27: Storage - Gasoline Vehicles
Storage – Gasoline Vehicles 2. Fully charge batteries. 3. Adjust tires to recommended tire pressure. See Vehicle Specifications on page 42. 4. Perform the Pre-Operation and Daily Safety Checklist on page 18. STORAGE – GASOLINE VEHICLES See General Warnings on page 9. ∆... - Page 28 Storage – Gasoline Vehicles 4. Batteries should be clean and free of corrosion. Wash tops and terminals of batteries with a solution of baking soda and water (1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water). Rinse solution off bat- teries.
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Page 29: Maintenance
Any vehicle not functioning correctly should be removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service. ∆... -
Page 30: Periodic Service Schedules
Periodic Service Schedules PERIODIC SERVICE SCHEDULES See General Warnings on page 9. ∆ WARNING • Service, repairs, and adjustments must be made per instructions in the maintenance and service manual. NOTE: If the vehicle is constantly subjected to heavy use or severe operating conditions, the preventive maintenance procedure should be performed more often than recommended in the periodic ser- vice and lubrication schedules. - Page 31 Periodic Service Schedules PERIODIC SERVICE SCHEDULE – GASOLINE VEHICLES REGULAR INTERVAL SERVICE Monthly service by owner Check engine oil level; change if or trained technician necessary. See Periodic Lubrication Schedules on page 30. Check engine cooling air intake; clean if Engine necessary.
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Page 32: Periodic Lubrication Schedules
Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE – ELECTRIC VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Semiannually by owner Brake pedal shaft bearings Dry Moly Lube (CCI P/N 1012151) or trained technician (every 50 hours of Brake linkage and pivots Dry Moly Lube (CCI P/N 1012151) operation or 100 rounds... - Page 33 Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULE – GASOLINE VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Semiannually by owner Brake pedal shaft bearings Dry Moly Lube (CCI P/N 1012151) or trained technician (every 50 hours of Brake linkage and pivots Dry Moly Lube (CCI P/N 1012151) operation or every 100 rounds of golf)
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Page 34: Vehicle Controller - Electric Vehicles
VEHICLE CONTROLLER – ELECTRIC VEHICLES The Club Car electric vehicle is equipped with a solid state speed controller. In order to properly service and maintain the solid state controller vehicle, it is necessary to understand the electrical circuitry and the func- tions of all components in both systems. - Page 35 Batteries – Electric Vehicles 1. The batteries should be kept clean and free of corrosion. Wash tops and terminals of batteries with a solu- tion of baking soda and water (1 cup (237 mL) baking soda per gallon (3.8 L) of water). Rinse solution off of the batteries.
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Page 36: Battery Charger - Electric Vehicles
∆ WARNING • Only trained technicians should repair or service the charger. Contact your nearest Club Car distributor/dealer. • Each charger should have its own dedicated 15 or 20 ampere separately protected (circuit breaker or fuse) single phase branch circuit, in accordance with all applicable electrical codes for the location. -
Page 37: Charging Batteries
Battery Charger – Electric Vehicles NOTE: Because the vehicle’s onboard computer (OBC) has a storage charge feature that automatically checks and recharges the batteries as necessary every 15 days, the charger can remain plugged to a IQ System vehicle throughout the storage period. Shortly after charging begins, the PowerDrive Charger will shut off in order to run a self-diagnostic program (ammeter will drop to zero). -
Page 38: Plug And Receptacle
Batteries should be put on charge even if they have been used for only a short period (9 holes of golf or 10 minutes). The charger is automatic and will turn off when batteries are fully charged. If the charger does not seem to be operating properly, or if the batteries seem weak, contact your local Club Car distributor/dealer. PLUG AND RECEPTACLE The charger cord, plug, and receptacle are wear items and should be inspected daily. -
Page 39: Battery - Gasoline Vehicles
∆ 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. BATTERY – GASOLINE VEHICLES See General Warnings on page 9. - Page 40 WARNING • Do not jump start a dead battery using another battery and jumper cables. The battery in the Club Car gasoline vehicle is a 12-volt, low maintenance battery that requires infrequent watering (Figure 24). 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).
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Page 41: Engine Oil - Gasoline Vehicles
Engine Oil – Gasoline Vehicles ENGINE OIL – GASOLINE VEHICLES See General Warnings on page 9. Even though the low oil warning light on the dash should illuminate if oil level becomes low, engine oil level should be checked monthly. Vehicle should be on a level surface when checking oil. Do not overfill with oil. ENGINE OIL LEVEL CHECK 1. -
Page 42: Fueling Instructions - Gasoline Vehicles
Fueling Instructions – Gasoline Vehicles FUELING INSTRUCTIONS – GASOLINE VEHICLES See General Warnings on page 9. ∆ DANGER • Turn the key switch to the OFF position before fueling. • Do not pour gasoline into the fuel tank when the engine is hot or while it is running. •... -
Page 43: Cleaning The Vehicle
In the event a vehicle is bought as a used vehicle, we strongly urge the new owner to register the vehicle with Club Car. This will enable us to contact you if the need arises. Please send your name, address, and serial number(s) of the vehicle(s) to Club Car, Inc., P.O. -
Page 44: Vehicle Specifications
Vehicle Specifications VEHICLE SPECIFICATIONS IQ SYSTEM SPECIFICATIONS GASOLINE ELECTRIC POWER SOURCE Drive motor: Direct drive, 48 volts DC, shunt-wound, 3.2 hp • Engine: 4-cycle OHV, 286 cc, 9.0 hp rated, single-cylinder, air-cooled, with pressure lubrication • system Fuel system: Side-draft carburetor with float bowl, fixed jets, fuel filters, and impulse fuel pump •... -
Page 45: Specifications
Vehicle Specifications IQ SYSTEM SPECIFICATIONS GASOLINE ELECTRIC 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) Unitized transaxle 27 oz. (0.8 L) Fuel tank 7 gallons (26.5 L) TIRE PRESSURE 18-20 psi 12-14 psi... -
Page 46: Warranties
CLUB CAR’s liability under this limited warranty, or in any action whether based upon warranty, contract, negligence, strict product liability, or otherwise, shall be the repair or replacement, at CLUB CAR’s option, of the 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 factory-reconditioned vehicle or component thereof that is identical or reasonably equivalent to the warranted product or component at no cost to the purchaser. - Page 47 2005 Model DS golf car purchased from CLUB CAR or an authorized distributor or dealer shall be free from defects in material 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 warranty.
- Page 48 CLUB CAR’s liability under this limited warranty, or in any action whether based upon warranty, contract, negligence, strict product liability or otherwise, shall be the repair or replacement, at CLUB CAR’s option, of the 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 factory-reconditioned vehicle or component thereof that is identical or reasonably equivalent to the warranted product or component at no cost to the purchaser.
- Page 49 5) A battery damaged by a defective charger. Without limiting the generality of the foregoing in any way, and as part of its limited warranty exclusion, CLUB CAR does not warrant that its PowerDrive battery is suitable for use in any application other than in its products. As in the use of any battery, a prudent owner will read and study the charger owner’s manual, the electric vehicle owner’s manual, the operator...
- Page 50 The limited warranty with respect to parts and labor only covers defects in material and workmanship for a period of four years from the date of purchase. Such repair labor shall be performed only by CLUB CAR or by an authorized distributor or dealer.
- Page 51 Without limiting the generality of the foregoing in any way, and as part of its limited warranty exclusion, CLUB CAR does not warrant that the PowerDrive Charger is suitable for use in any application other than its PowerDrive System 48, PowerDrive Plus, and IQ System products.
- Page 52 4) Vehicles charged by systems other than the CLUB CAR PowerDrive Charger. Without limiting the generality of the foregoing in any way, and as part of its limited warranty exclusion, CLUB CAR does not warrant that the Computer or Controller is suitable for use in any application other than its PowerDrive System 48, PowerDrive Plus, and IQ System products.
- Page 53 2. Ease of Finding Information 3. Clarity of Illustrations 4. Periodic Service and Periodic Lubrication Schedules Comments/Suggestions Please fax a copy of this page to (706) 228-2662. Thank You! Club Car Technical Publication Department 2005 DS Golf Car Owner’s Manual...
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Page 54: Emission Control Information
• Magneto or electronic ignition system system is used to eliminate blow-by gases. The System Warranty requires that you return your engine to an authorized Club Car Dealer for blow-by gases are led to the breather chamber • Fuel filter element through the crankcase. - Page 56 Publication Part Number 102680202 Edition Code 0704A00000 Club Car, Inc. www.clubcar.com P.O. Box 204658 Phone 1.706.863.3000 Augusta, GA 30917-4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...