Club Car Gasoline/Electric DS Golf Car 1996 Owner's Manual
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Club Car Gasoline/Electric DS Golf Car 1996 Owner's Manual

Club Car Gasoline/Electric DS Golf Car 1996 Owner's Manual

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STEVEN
April 3, 2025

DOES MY 1996 CLUB CART DS GAS HAVE A 2 OR 1 SPEED TRANSMISSION?

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1 comments:
Mr. Anderson
April 3, 2025

The 1996 Club Car DS Gas has a 1-speed transmission.

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Summary of Contents for Club Car Gasoline/Electric DS Golf Car 1996

  • Page 2 WA R N I N G • THE ENGINE EXHAUST FROM THIS PRODUCT CONTA I N S CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAU S E CANCER, BIRTH DEFECTS, OR OTHER REPRODUCTIVE HARM.
  • Page 3 Your authorized representative checked this vehicle before it was delivered to you and will provide you with a completed warranty registration card. 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 CLUB CAR, INC. (“CLUB CAR”) hereby warrants to the original retail purchaser that its new 1996 Model DS golf car purchased from CLUB CAR or an authorized distributor or dealer for use in the United States or Canada shall be free from defects in materials and workmanship under normal use and ser- vice as a golf car for the periods stated below, subject to the provisions, limitations, and exclusions con- tained in this limited warranty.
  • Page 5 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, Georgia 30917-4658.
  • Page 6 Club Car representative perform them. For the name and address of the Club Car representative near- est you, call 706-863-3000, Ext. 261. If you would prefer to write to us, direct your letter to: Club Car, Attention: Product Development Department, P.O. Box 204658, Augusta, Ga. 30917-4658 USA.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Safety Details ......................... . General Warnings .

  • Page 9: Safety Details

    If any of the labels on the vehicle become damaged, have been removed or cannot be easily read they should be replaced immediately to avoid possible personal injury, property damage, or death. Contact your CLUB CAR distributor/dealer. DA N G E R •...

  • Page 10: General Warnings

    GENERAL WA R N I N G S DA N G E R • GASOLINE VAPORS - FLAMMABLE - EXPLOSIVE - DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE. SERVICE ONLY IN WELL-VENTI- LATED AREAS. •...

  • Page 11: Vehicle Feature Identification

    DS GASOLINE VEHICLE FEATURE IDENTIFICAT I O N...
  • Page 12 DS ELECTRIC VEHICLE FEATURE IDENTIFICAT I O N...

  • Page 13: General Information

    . MODEL IDENTIFICAT I O N The serial number of your CLUB CAR is stamped on the data plate mounted on the frame directly above the accelerator pedal (Example: A9601-123456 for Electric or AG9601-123456 for Gasoline) (See Figure 3).

  • Page 14: Pre-Operation Checklist

    P R E - O P E R ATION CHECKLIST Your CLUB CAR has been thoroughly inspected and adjusted at the factory, and also by your CLUB CAR distributor/ dealer. However, upon arrival of your new CLUB CAR(s), you should become familiar with its controls and operation, and carefully inspect each vehicle to be satisfied that it is in prop- er working condition before accepting delivery.

  • Page 15: Controls

    DS PowerDrive System 48 Ve h i cles with Regenerative Braking: • Zero Speed Detect: With the vehicle parked on level ground and the park brake d i s e n g a g e d, turn the ignition key to the O N position and attempt to push the vehicle. It should resist rolling with the forward and reverse switch in any position.
  • Page 16 Figure 5 Figure 4 FORWARD/REVERSE CONTROL - DS Gasoline, DS V-Glide Electric, and DS PowerDrive System 48: The forward/reverse shift lever is located on the seat support panel, below and to the right of the dri- ver’s right knee (See Figure 5). The lever has three distinct positions: F (forward), N (neutral), and R (reverse).
  • Page 17 Figure 7 Figure 6 BRAKE PEDAL - The brake pedal is the large pedal on the left with the word STOP molded into it (See Figure 7). To slow or stop the vehicle, depress the brake pedal with your right foot. WA R N I N G •...
  • Page 18 Neutral Lock-out Continued: For the convenience of the trained mechanic, there is a neutral lock-out cam located on the back of the forward/reverse lever. If the neutral lock-out cam is pulled out approximately 10 millimeters (3/8 inch) and then rotated one-half turn until it snaps into place, the vehicle will be in the SERVICE position ( S e e Figure 10).
  • Page 19 If the warning light comes on and the vehicle is unable to finish the round, have your Club Car distributor/dealer check the vehicle for a possible bat- tery or electrical system problem.

  • Page 20: Driving Instructions

    Battery Warning Light continued: • The warning light will come on during a charge cycle (DC plug is still connected) if AC power to the charger is interrupted. The light will go out when AC power is restored. DRIVING INSTRU C T I O N S WA R N I N G •...
  • Page 21 To ensure safe operation of the vehicle, follow exactly and in order, all of the procedures listed below. Read and understand all instructions prior to driving the vehicle. S TA RTING THE VEHICLE 1 . Enter the vehicle. 2 . Study and understand controls. 3 .

  • Page 22: Towing

    • DO NOT ALLOW PEOPLE IN THE VEHICLES BEING TOWED. • AVOID SUDDEN STARTS, STOPS, AND TIGHT TURNS WHEN TOWING. • DO NOT TOW MORE THAN ONE (1) VEHICLE WITH ANOTHER CLUB CAR. IF MORE THAN ONE VEHICLE MUST BE TOWED, A PROPERLY FITTED VEHICLE WITH A TOW HITCH HEIGHT OF 11 INCHES SHOULD BE USED.

  • Page 23: Storage - Gasoline Vehicle

    S TO R AGE - GASOLINE VEHICLE To prepare your vehicle for extended off season storage: 1 . Store vehicle in a cool place. This will prevent self discharge of the battery. If the battery appears to be weak, have it charged using an automotive type 12 volt battery charger rated 10 amps or l e s s .

  • Page 24: Storage - Electric Vehicle

    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.

  • Page 25: Maintenance

    This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe c o n d i t i o n s . Contact your local CLUB CAR distributor/dealer to perform all repairs and semi-annual and annual peri- odic service.
  • Page 26 Maintenance Continued: WA R N I N G • ALWAYS WEAR SAFETY GLASSES OR EYE PROTECTION WHEN SERVICING THE VEHI- C L E . • DO NOT WEAR LOOSE CLOTHING OR JEWELRY (RINGS, WATCHES, CHAINS, ETC.) WHILE SERVICING THE VEHICLE. •...

  • Page 27: Periodic Service Schedule

    PERIODIC SERVICE SCHEDULE Regular Interval Service Elec Check steering and linkages • • Check brake operation • • Check to be sure all warning labels are in place (Pages 3, 4) • • Check tires for wear and damage • •...

  • Page 28: Periodic Lubrication Schedule - Gasoline Vehicles

    Service Recommended Lubricant Quarterly by Owner or 1. Brake shaft bearings Dry Moly Lube - Club Car P/N 1012151 Trained Personnel Only 2. Brake linkage and pivots Dry Moly Lube - Club Car P/N 1012151 3. Accelerator push rod pivots and...

  • Page 29: Periodic Lubrication Schedule - Electric Vehicles

    Regular Interval Service Recommended Lubricant Quarterly by Owner or 1. Brake shaft bearings Dry Moly Lube - Club Car P/N 1012151 Trained Personnel Only 2. Brake linkage and pivots Dry Moly Lube - Club Car P/N 1012151 3. Accelerator pivots Dry Moly Lube - Club Car P/N 1012151 4.

  • Page 30: Capacities

    Figure 18 C A PAC I T I E S : GASOLINE ELECTRIC Engine Crankcase .98 liters (32 oz.) without Filter Engine Crankcase 1.16 liters (38 oz.) with Filter Transmission .61 liters (20 oz.) Drive Unit .67 liters (22 oz.) .67 liters (22 oz.) Gasoline Tank 26.5 liters (7 U.S.

  • Page 31: Engine Oil - Gasoline Vehicle

    ENGINE OIL - GASOLINE VEHICLE Even though the oil warning light on the dash should warn you if your oil is getting low, engine oil level should be checked monthly (See Figure 19). N OT E • ENGINE MUST BE IN LEVEL POSITION. Remove oil level dipstick from the oil filler tube and wipe oil from it with a clean cloth or paper towel.

  • Page 32: Battery - Gasoline Vehicle

    Any corrosion around the positive (+) or negative (-) terminals should be washed off with a solution of baking soda and water. Rinse solution off the battery. Be sure terminals are tight. Let the terminals dry and then spray them with CLUB CAR battery terminal spray (Club Car Part No.1014305). C AU T I O N •...

  • Page 33: Battery - Electric Vehicle

    Figure 22 Figure 21 Be sure battery hold-down bracket is properly tightened. Torque to 15-25 in.Ibs. (1.7/2.9 N-m). A loose hold-down bracket may allow the battery to become damaged from vibration or jarring. A hold-down bracket that is too tight may buckle or crack the battery case. If battery appears weak, have it charged by a trained mechanic.

  • Page 34: Battery Charger - Electric Vehicle

    Be sure terminals are tight. Let the terminals dry and then spray them with CLUB CAR battery protector spray (Part No. 1014305). 2 . The water level in the batteries should be checked weekly (See Figure 22, Page 25, for proper l e v e l ).
  • Page 35 TRICAL SHOCK. • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THE CHARGER. CON- TACT YOUR NEAREST CLUB CAR DISTRIBUTOR/DEALER. • DO NOT OPERATE THE CHARGER IF IT HAS RECEIVED A SHARP BLOW, WAS DROPPED, OR OTHERWISE DAMAGED IN ANY WAY.
  • Page 36 Because of these unique features, only PowerDrive System 48 vehicles are compatible with the PowerDrive Charger (Neither vehicles made by other manufacturers, nor other Club Car models are compatible).
  • Page 37 charger does not seem to be operating properly, or if the batteries seem weak, contact your local CLUB CAR distributor/dealer. NOTE: When temperatures fall below 18.3 C (65° F), batteries charged in unheated areas should be placed on charge as soon after use as possible. Batteries are warmest immediately after use, and cold batteries require more time to fully charge.

  • Page 38: Cleaning

    • IF THE FUSE LINK IS BLOWN, DETERMINE THE SOURCE OF THE ELECTRICAL PROBLEM AND CORRECT IT BEFORE REPLACING THE FUSE. CONTACT YOUR NEAREST CLUB CAR D I S T R I B U T O R / D E A L E R .

  • Page 39: Vehicle Controllers - Electric Vehicle

    Vehicle, it is necessary to understand the electrical circuitry and the functions of all components in both systems. Therefore, if any repair or servicing needs to be performed, we recommend that it be performed by an authorized CLUB CAR distributor/dealer using CLUB CAR OEM parts. ACCESSORIES AND OPTIONS The vehicle is available with a complete line of optional equipment items and accessories.

  • Page 40: Subsequent Owner Registration

    In the event a vehicle is bought used from another individual or from a distributor/dealer, we strong- ly urge the new owner to re-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 41 WA R N I N G • EACH CHARGER SHOULD HAVE ITS OWN DEDICATED 15 OR 20 AMPERE SEPARATELY PROTECTED (CIRCUIT BREAKER OR FUSE) SINGLE PHASE BRANCH CIRCUIT, IN ACCOR- DANCE WITH ALL APPLICABLE ELECTRICAL CODES FOR THE LOCATION. C AU T I O N •...

  • Page 42: Vehicle Specifications

    VEHICLE SPECIFICAT I O N S...
  • Page 43 Club Car warranties. Tires are warranted by their manufacturer. Also excluded from any CLUB CAR warranty is damage to a golf car or component resulting from a cause other than a defect including unreasonable or unintended strain or use, improper installation of accessories, installation of parts or accessories that are not original equipment, overloading, accident, alteration, abuse or neglect.
  • Page 44 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, Georgia 30917-4658.
  • Page 45 THE TERMS OF THIS WARRANTY. 8. NO CONSEQUENTIAL DAMAGES: IN NO EVENT SHALL CLUB CAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAM- AGES INCLUDING, BUT NOT LIMITED TO, LOSS RELATED TO PROPERTY OTHER THAN THE GOLF CAR, LOSS OF USE, LOSS OF TIME, INCONVENIENCE, OR ANY OTHER ECONOMIC L O S S .

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