Club Car DS Golf Cars 2007 Owner's Manual
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Club Car DS Golf Cars 2007 Owner's Manual

Electric and gasoline
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2007
DS Golf
Cars
Electric and Gasoline
Owner's Manual

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Summary of Contents for Club Car DS Golf Cars 2007

  • Page 1 2007 DS Golf Cars Electric and Gasoline Owner’s Manual...
  • Page 3 Your authorized representative checked the vehicle before it was delivered to you and will pro- vide 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 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.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Vehicle Feature Identification ........................Safety Details ............................General Warnings ............................General Information ........................... 11 Model Identification ............................ 12 Safety Committee ............................12 Controls and Indicators ..........................13 Pre-Operation and Daily Safety Checklist ....................19 Performance Inspection ..........................20 Driving Instructions ............................

  • Page 6: Vehicle Feature Identification

    Vehicle Feature Identification DS ELECTRIC VEHICLE DRIVER / PASSENGER WARNING DECAL KEY SWITCH OPERATING INSTRUCTIONS DECAL BATTERY WARNING LAMP SERIAL NUMBER PRIVATE SPEED DECAL (IQ VEHICLES WITH PRIVATE SPEED OPTION) PARK BRAKE PEDAL BRAKE PEDAL ACCELERATOR PEDAL Page 4 2007 DS Golf Car Owner’s Manual...
  • Page 7 Vehicle Feature Identification DS ELECTRIC VEHICLE ELECTRICAL COMPONENT DECAL (ON SPEED CONTROLLER COVER) TOW SWITCH WARNING DECAL (ON TOW SWITCH BRACKET UNDER SEAT) CHARGER RECEPTACLE FORWARD/REVERSE SWITCH BATTERY DANGER DECAL (ON BATTERY CAPS OR ON BODY UNDER SEAT) 2007 DS Golf Car Owner’s Manual Page 5...
  • Page 8 Vehicle Feature Identification DS GASOLINE VEHICLE DRIVER/PASSENGER WARNING DECAL OPERATING INSTRUCTIONS DECAL KEY SWITCH LOW OIL WARNING LAMP PARK BRAKE PEDAL ACCELERATOR PEDAL BRAKE PEDAL SERIAL NUMBER Page 6 2007 DS Golf Car Owner’s Manual...
  • Page 9 Vehicle Feature Identification DS GASOLINE VEHICLE ROTATING PARTS AND HOT MANIFOLD DECAL (ON STARTER/GENERATOR) GASOLINE WARNING DECAL (ON VEHICLE FRAME NEAR FUEL TANK) OIL FILL FUEL SHUT-OFF VALVE FORWARD/REVERSE HANDLE CHOKE NEUTRAL LOCKOUT CAM FRAME GROUND AND GOVERNOR WARNING DECAL (ON VEHICLE FRAME NEAR BATTERY) 2007 DS Golf Car Owner’s Manual Page 7...

  • 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. ý...
  • 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.

  • Page 13: General Information

    General Information ý WARNING • Use insulated tools when working near batteries or electrical connections. Use extreme caution to avoid shorting of components or wiring. Place Tow / Run AS SEEN FROM switch in TOW PASSENGER SIDE OF VEHICLE Place TOW/RUN switch in the TOW position before disconnecting or connecting battery cables.

  • Page 14: Model Identification

    • Maintaining golf cars in a safe driving condition. • 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...

  • Page 15: Controls And Indicators

    Controls and Indicators CONTROLS AND INDICATORS See General Warnings on page 9. ý WARNING • 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. •...

  • Page 16: Accelerator Pedal

    (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 17: Brake Pedal

    Once vehicle speed slows to below approximately 11 mph (17.7 km/h), with the accelerator pedal still released, motor braking will be deac- tivated and the vehicle will coast freely. This feature is selectable. Contact your Club Car dealer/distrib- utor to inquire about this selectable feature BRAKE PEDAL The brake pedal is the large pedal on the left with the word STOP molded into it (Figure 7).
  • Page 18 30 minutes. However, the vehicle should be charged at the first opportunity. If the warning lamp illuminates and the vehicle is unable to operate for 30 minutes, have your Club Car distrib- utor/dealer check the vehicle for a possible battery or electrical system problem.
  • Page 19 Controls and Indicators TOW/RUN SWITCH IQ System Electric Vehicles Only ý 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 20 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).

  • Page 21: 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 22: 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 23: 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 24: Starting The Vehicle

    Driving Instructions ý WARNING • Do not leave children unattended on vehicle. • To help prevent overturning the vehicle, drive slowly straight up and down slopes. Avoid driving the vehicle on slopes exceeding 20% incline. • To help avoid possible injury to an inattentive passenger and (or) damage to the vehicle, avoid sudden starts, sudden stops, and abrupt turns.

  • Page 25: Towing

    WARNING • Do not tow the vehicle on public streets or highways. • Use only approved Club Car tow bars. • Turn the key switch to the OFF position and place the Forward/Reverse handle or switch in the NEUTRAL position before towing the vehicle.

  • Page 26: Transporting On A Trailer

    • For use on public 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 is on an approved trailer.

  • Page 27: Storage - Electric Vehicles

    Storage – Electric Vehicles STORAGE – ELECTRIC VEHICLES See General Warnings on page 9. ý WARNING • Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse handle or switch in the NEUTRAL position during storage. This is to prevent unintentionally starting the vehicle or a fire hazard.

  • Page 28: Storage - Gasoline Vehicles

    Storage – Gasoline Vehicles STORAGE – GASOLINE VEHICLES See General Warnings on page 9. ý DANGER • Do not attempt to drain gasoline when the engine is hot or while it is running. • Be sure to clean up any spilled gasoline before operating the vehicle. •...
  • Page 29 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.

  • Page 30: 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. ý...

  • Page 31: Periodic Service Schedules

    Periodic Service Schedules PERIODIC SERVICE SCHEDULES See General Warnings on page 9. ý 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 32 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 31. Check engine cooling air intake; clean if Engine necessary.

  • Page 33: 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 of golf)
  • Page 34 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)

  • Page 35: 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 36 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.

  • Page 37: Battery Charger - Electric Vehicles

    ý 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 38: 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. At one hour and at two hours into the charge cycle, the charger will shut off in order to run a self- diagnostic program (ammeter will drop to zero).

  • Page 39: 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 40: Battery - Gasoline Vehicles

    ý 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 41 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).

  • Page 42: Engine Oil - Gasoline Vehicles

    Engine Oil – Gasoline Vehicles ENGINE OIL – GASOLINE VEHICLES See General Warnings on page 9. Even though the low oil warning lamp 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 43 Engine Oil – Gasoline Vehicles OIL FILTER DRAIN PAN DRAIN PLUG Figure 27 Engine Oil Drain Plug and Pan 5. Use a 14 mm socket or box end (do not use an open end) wrench to remove the drain plug, turning it counterclockwise, and allow the engine oil to drain into the pan.
  • Page 44 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.

  • Page 45: Fueling Instructions - Gasoline Vehicles

    Fueling Instructions – Gasoline Vehicles 14. Connect the battery cables, positive (+) cable first, and tighten terminals to 12 ft-lb (16 N·m). Coat ter- minals with Battery Terminal Protector Spray (CCI P/N 1014305). 15. With the Forward/Reverse handle in the NEUTRAL position, start and run the engine for a few minutes. Observe both the drain plug and the oil filter from under the vehicle and watch for oil leaks.

  • Page 46: 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.club- car.com and clicking the “Dealer Locator” link.

  • Page 47: 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, Inc., P.O.

  • Page 48: Specifications

    Vehicle Specifications IQ SYSTEM SPECIFICATIONS GASOLINE ELECTRIC DIMENSIONS/WEIGHT Ground clearance 4.5 in. (11 cm) Front wheel tread 34.5 in (88 cm) Rear wheel tread 38.5 in. (98 cm) Weight (vehicle with canopy, without batteries) 494 lb. (224 kg) Weight (dry, without battery) 619 lb.
  • Page 49 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 50 2007 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 51 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 52 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 instructions, and the battery warning labels;...
  • Page 53 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 54 Limited Warranties expressed herein and any implied warranties null and void and same are hereby excluded. 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 55 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 56 5. NO CONSEQUENTIAL DAMAGES: In no event shall Club Car be liable for any incidental or consequential damages including, but not limited to, loss related to property other than the vehicle, loss of use, loss of time, inconvenience, or any other economic loss. This warranty is applicable only where the California or U.S. EPA emission control system warranty regulation is in effect.

  • Page 57: Emission Control Information

    System Warranty requires that you return your • Magneto or electronic ignition system blow-by gases are led to the breather chamber engine to an authorized Club Car Dealer for • Fuel filter element through the crankcase.Then, it is led to the air remedy under warranty.Please read the warranty...
  • Page 58 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 Page 56 2007 DS Golf Car Owner’s Manual...
  • Page 60 Publication Part Number 103218309 Edition Code 0706B1207A Club Car, Inc. www.clubcar.com P.O. Box 204658 Phone 1.706.863.3000 Augusta, GA 30917-4658 1.800.ClubCar Intl’l +1 706.863.3000 1.706.863-5808...

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