Club Car DS Golf Car Owner's Manual
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Club Car DS Golf Car Owner's Manual

Club Car DS Golf Car Owner's Manual

Electric and gasoline
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DS Golf Car
Owner's Manual
Electric and Gasoline
[Refer to back cover for applicable build code range]

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Summary of Contents for Club Car DS Golf Car

  • Page 1 DS Golf Car Owner’s Manual Electric and Gasoline [Refer to back cover for applicable build code range]...
  • Page 3 Your authorized representative checked the vehicle before it was delivered to you and will provide you a copy of the completed vehicle warranty registration form. 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 Marketing Services, P.O. Box 204658, Augusta, Georgia 30917-4658 USA. We hope you will consider this owner’s manual a permanent part of your Club Car vehicle. If you sell the vehicle, please include the manual so that the next owner will have the important operating, safety, and maintenance information it contains.

  • Page 5: Table Of Contents

    Engine Oil – Gasoline Vehicles ..........................49 Fueling Instructions – Gasoline Vehicles ......................52 Cleaning the Vehicle ............................53 Accessories................................ 53 Subsequent Owner Registration .......................... 54 Vehicle Specifications ............................54 Warranties................................56 EC Declaration of Conformity (Sample Document)....................61 DS Golf Car Owner’s Manual Page 3...

  • Page 6: Safety Decal And Feature Identification

    DS ELECTRIC VEHICLE 2000 101960601 Decal, Rollover Warning (on instrument panel) 102518001 Decal, Operating Instructions (on steering wheel) Decal, Private Speed Notice (below instrument 102228701 103783001 Decal, Operating Instructions (on steering wheel) panel) Page 4 DS Golf Car Owner’s Manual...
  • Page 7 Decal, Battery Danger (on battery caps or on body 1013677 Battery Charger Receptacle under seat) Decal, Tow Switch Warning (on Tow/Run switch 101908601 Forward/Reverse Control plate, under seat) Decal, Component Cover Notice (on electrical 101931501 component cover) DS Golf Car Owner’s Manual Page 5...
  • Page 8 Decal, Rollover Warning (on instrument panel) Park Brake Pedal 102519201 Decal, Operating Instructions (on steering wheel) Accelerator Pedal Decal, Private Speed Notice (below instrument 102555901 Serial Number panel) 103783002 Decal, Operating Instructions (on steering wheel) Brake Pedal Page 6 DS Golf Car Owner’s Manual...
  • Page 9 Decal, Frame Ground/Governor Warning (on 101915201 Oil Fill vehicle frame near battery) Decal, Rotating Parts/Hot Manifold Warning (on 101960501 Choke engine, starter/generator, and transaxle) Forward/Reverse Control Neutral Lockout Cam DS Golf Car Owner’s Manual Page 7...

  • Page 10: Practice Safety

    PROPOSITION 65 – STATE OF CALIFORNIA WARNING • This product contains or emits chemicals or substances that have been determined by the state of California to cause cancer and birth defects or other reproductive harm. Page 8 DS Golf Car Owner’s Manual...

  • Page 11: Safety Details

    • Gasoline – Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. Service only in a well-ventilated area. DANGER CONTINUED ON NEXT PAGE DS Golf Car Owner’s Manual Page 9...
  • Page 12 • The 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.
  • Page 13 1. Place TOW/RUN Switch in TOW before disconnecting or connecting battery cables. 2. Remove negative battery cable. 3. Remove positive battery cable. Connect battery cables in reverse order. Figure 2 Battery Cable Removal – 4x12-Volt Battery Configuration DS Golf Car Owner’s Manual Page 11...
  • Page 14 Ensure the Tow/Run switch is in the TOW position. Connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m). Coat terminals with Battery Terminal Protector Spray (CC P/N 1014305) to minimize corrosion. Page 12 DS Golf Car Owner’s Manual...
  • Page 15 Responsibility for environmental protection must be shared, not only by the manufacturers of 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...

  • Page 16: General Information

    General Information GENERAL INFORMATION This manual features two DS Golf Car models: the IQ System (48-volt) electric vehicle and the gasoline vehicle. 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(s).

  • Page 17: Controls And Indicators

    NOTE: When the key is turned to the OFF position, the main vehicle systems are disabled. The key switch may be used as an emergency stop. The key can be removed only when the key switch is in the OFF position. Figure 8 Key Switch DS Golf Car Owner’s Manual Page 15...
  • Page 18 (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.
  • Page 19 (17.7 km/h), with the accelerator pedal still released, motor braking will be deactivated and the vehicle will coast freely. This feature is selectable. Contact your dealer/distributor to inquire about this selectable feature. See following WARNING. DS Golf Car Owner’s Manual Page 17...
  • Page 20 IQ System 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 onboard computer. Page 18 DS Golf Car Owner’s Manual...
  • Page 21 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 22 With the cam in this position, the vehicle will not operate if the Forward/Reverse handle is placed in either the FORWARD or REVERSE position. Page 20 DS Golf Car Owner’s Manual...
  • Page 23 Hold it during start up and release the choke cover after the engine starts and runs smoothly. DS Golf Car Owner’s Manual Page 21...

  • Page 24: 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 25 Use the following checklist, in conjunction with the Daily Pre-Operation and Safety Checklist, as a guide to inspect the vehicle and check daily for proper operation. Any problems should be corrected by a Club Car distributor/dealer or a trained technician.

  • Page 26: Driving Instructions

    When the pedal is released it should return to the original position and the engine should stop. All Club Car vehicles operate at reduced speed in reverse.
  • Page 27 NOTE: If the Forward/Reverse handle is shifted into the NEUTRAL position, power will be cut off and the engine will stop running. DS Golf Car Owner’s Manual Page 25...

  • Page 28: 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 (tractor or full sized truck) properly fitted, with a tow hitch height of 11 inches (28 cm) should be used.

  • Page 29: 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 30 To check charger function, disconnect the DC cord (stationary charger) from the vehicle or the AC cord (onboard charger) from the power source, wait five seconds, then reconnect it. The charger is functioning properly if the ammeter indicates current. Page 28 DS Golf Car Owner’s Manual...

  • Page 31: Storage - Gasoline Vehicles

    • Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse handle in the NEUTRAL position during storage. This is to prevent unintentionally starting the vehicle or a fire hazard. • Turn the fuel shut-off valve to the closed (OFF) position (Figure 19). DS Golf Car Owner’s Manual Page 29...
  • Page 32 Spray (CC P/N 1014305). 1. Fuel Shut-off Valve 2. Closed (OFF) 3. Open (ON) NOTE: When selecting valve position, ensure that it is fully opened or fully closed. Figure 19 Fuel Shut-off Valve Page 30 DS Golf Car Owner’s Manual...

  • Page 33: 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. WARNING •...

  • Page 34: Periodic Service Schedules

    Both the Periodic Service Schedule and Periodic Lubrication Schedule must be followed to keep vehicle in optimum operating condition. Page 32 DS Golf Car Owner’s Manual...
  • Page 35 Check and adjust as required. See Steering Front wheel alignment and camber and Front Suspension in the maintenance and service manual. Check for loose hardware, cracks and other Motor controller output regulator (MCOR) damage. DS Golf Car Owner’s Manual Page 33...
  • Page 36 Annual service by trained technician only Single Point Watering System) with the Single-Point Watering System on (every 100 hours of operation or 200 rounds page 39.. of golf) Check safety decals. Replace if damaged or Safety decals illegible. Page 34 DS Golf Car Owner’s Manual...
  • Page 37 Check safety decals. Replace if damaged or Safety decals illegible. Two year service by trained technician only (every 200 hours of operation or every 400 Fuel filters Replace. Dispose of used filters properly. rounds for golf cars) DS Golf Car Owner’s Manual Page 35...

  • Page 38: Periodic Lubrication Schedules

    22 oz. (0.67 L) SAE 30 WT. API Class SE, Check/fill transaxle to plug level operation or 200 rounds of SF, or SG Oil (or higher) golf) Figure 20 Lubrication Points – Electric Vehicles Page 36 DS Golf Car Owner’s Manual...
  • Page 39 32 oz. (0.95 L) without filter; 38 oz. (1.12 Change engine oil and oil filter every 400 rounds of golf), or L) with filter annually, whichever comes first. Figure 21 Lubrication Points – Gasoline Vehicles DS Golf Car Owner’s Manual Page 37...

  • Page 40: Batteries - Electric Vehicles

    This process creates a finished product free of minerals, having left all the impurities in the original water sample. Club Car, along with our battery manufacturers, highly recommends that distilled water be used in electric vehicle batteries.
  • Page 41 Your local water company should be able to perform testing and compare their results to the chart. If using tap water, Club Car’s Service Parts Department offers two different deionizer systems: one for vehicles equipped with the Single Point Water System (SPWS) CC P/N AM1240701 and the other for vehicles without SPWS, CC P/N AM10974.
  • Page 42 See preceding CAUTION. BATTERY CARE – VEHICLES WITHOUT THE SINGLE-POINT WATERING SYSTEM To keep batteries in good working condition, follow this maintenance program on a regular basis: Page 40 DS Golf Car Owner’s Manual...
  • Page 43 (do not leave discharged overnight). 1. Level Indicator 2. Cap 3. Plates Maintain electrolyte level from at least ½ inch (13 mm) above plates to ¼ inch (6 mm) below level indicator. Figure 22 Battery Electrolyte Level DS Golf Car Owner’s Manual Page 41...

  • Page 44: 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 45 When inserting the DC plug, align the raised guide on the plug with the guide slot in the receptacle and push straight in slowly. Club Car battery chargers interact with the vehicle onboard computer. The computer records the amount of energy consumed during vehicle use. While the charger is plugged in, the vehicle’s control circuit is locked out, preventing operation of the vehicle as well as the possibility of consequent damage to the charger and the vehicle.
  • Page 46 Figure 23 Correct Insertion of Charger DC Plug Figure 24 Incorrect Insertion of Charger DC Plug Only PowerDrive System 48 and IQ System vehicles are compatible with PowerDrive chargers. Other Club Car models or vehicles made by other manufacturers are not compatible.

  • Page 47: Single Point Watering System (Spws)

    See 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. SINGLE POINT WATERING SYSTEM (SPWS) WARNING •...
  • Page 48 If the light indicates unacceptable water quality, the cartridge must be replaced. After ensuring adequate water flow rate, press the grey button (7) on the end of the female coupler (8) to disconnect the purger from the pressure regulator. Page 46 DS Golf Car Owner’s Manual...

  • Page 49: Battery - Gasoline Vehicles

    • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries. DANGER CONTINUED ON NEXT PAGE DS Golf Car Owner’s Manual Page 47...
  • Page 50 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 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).

  • Page 51: Engine Oil - Gasoline Vehicles

    Insert the dipstick into the oil filler tube. See following NOTE. NOTE: Properly recycle or dispose of used oil in accordance with local, state, and federal regulations. 1. Full level 2. Safe level 3. Low level Figure 32 Engine Oil Level Check DS Golf Car Owner’s Manual Page 49...

  • Page 52: Engine Oil And Filter Change

    Relocate the oil drain pan to a position under the engine oil filter (Figure 33). Remove the engine oil filter (1), turning it counterclockwise, allowing the residual oil in the filter port and filter to drain into the oil drain pan (2) (Figure 34). See following NOTE. Page 50 DS Golf Car Owner’s Manual...
  • Page 53 11. Coat new oil filter gasket with clean engine oil and install the oil filter onto the engine oil filter port (Figure 35). NOTE: Use only Club Car oil filters (CC P/N 103887901) designed for this engine. 12. Hand tighten 2/3 to 3/4 turn after filter gasket contacts mounting surface.

  • Page 54: Fueling Instructions - Gasoline Vehicles

    The fuel tank is located on passenger side of vehicle. Remove fuel cap and fill the fuel tank with fresh unleaded gasoline only. See preceding DANGER and CAUTION. Replace fuel cap on tank. Ensure cap is tightened securely. Replace seat bottom. Page 52 DS Golf Car Owner’s Manual...

  • Page 55: Cleaning The Vehicle

    There is a complete line of accessory equipment available from Club Car and our dealers/distributors. You can obtain the name and phone number of your closest Club Car contact by visiting our web site at www.clubcar.com and clicking the “Dealer Locator” link.

  • Page 56: Subsequent Owner Registration

    SUBSEQUENT OWNER REGISTRATION 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, LLC, P.O.
  • Page 57 Drive-by noise level to operator Test method: EN 12053:2001 Uncertainty: 2 dBA Uncertainty: 2 dBA 0.7 m/s 0.8 m/s Vibration at driver’s seat Test method: EN 13059:2002 Uncertainty: 0.12 m/s Uncertainty: 0.020 m/s DS Golf Car Owner’s Manual Page 55...

  • Page 58: Warranties

    EXCLUSIONS Excluded from any CLUB CAR warranty is damage to a vehicle or component resulting from a cause other than a defect including poor maintenance, neglect, abuse, accident and collision, maintenance adjustments, unreasonable...
  • Page 59 10. Use of gasoline containing more than 10% ethanol. 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 vehicle or components such as batteries, computer, controller or electrical device are suitable for use in any application other than in its products.
  • Page 60 To make a warranty claim under this limited warranty, you must present the vehicle or defective component with evidence of proof of purchase date and number of energy units (if applicable) to an authorized CLUB CAR dealer. For warranty-related communication, contact Warranty Services, Club Car, 4125 Washington Rd., Evans, GA 30809, USA, 706.863.3000.
  • Page 61 CLUB CAR recommends that you retain all receipts covering maintenance on your vehicle engine, but CLUB CAR cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
  • Page 62 CLUB CAR will not be liable to warrant failures of warranted parts caused by the use of a non-exempted add-on or modified part.

  • Page 63: Ec Declaration Of Conformity (Sample Document)

    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 KG, MG Complies with Directive: 2006/42/EC Machinery 2006/66/EC Battery Manufacturer: Club Car, LLC Club Car Ingersoll Rand 4125 Washington Road Alma Court Building, Lenneke Marelaan 6 Evans, Georgia 30809 USA B-1932 Sint-Stevens-Woluwe, Belgium Page 62 DS Golf Car Owner’s Manual...
  • Page 65 Club Car NOTES...
  • Page 68 BC55880 Publication Part Number 103472502 Edition Code 0608T1111R 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 the top of this page.

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