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Table of Contents
Related Manuals for Club Car DS Golf Cars 2004
Summary of Contents for Club Car DS Golf Cars 2004
- Page 1 DS Golf Cars Gasoline and Electric...
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Page 3: 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 4 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 5 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 6 Page 4 2004 DS Golf Car Owner’s Manual...
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Page 7: Table Of Contents
Vehicle Specifications ..............® Club Car Limited Three Year Warranty for 2004 Individual Golf Cars ...... -
Page 8: 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 9: 2004 Ds Golf Car Owner's Manual
Vehicle Feature Identification DS ELECTRIC VEHICLE WARNING HOT RESISTORS (COILED WIRE) CAN CAUSE SEVERE BURNS. RESISTOR WARNING DECAL (ON BODY UNDER SEAT ON ELECTRICAL COMPONENT DECAL V-GLIDE 36-VOLT VEHICLE) (ON SPEED CONTROLLER COVER IQ SYSTEM VEHICLE ONLY) FORWARD/REVERSE NOTICE HANDLE (POWERDRIVE SYSTEM 48 Do not operate vehicle without this cover properly installed. -
Page 10: 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 11: 2004 Ds Golf Car Owner's Manual
Vehicle Feature Identification DS GASOLINE VEHICLE ROTATING PARTS AND HOT MANIFOLD DECAL (ON STARTER/GENERATOR AND ENGINE) WARNING • GASOLINE EXPLOSION / FIRE. • CAN CAUSE SEVERE INJURY OR DEATH. • NO SMOKING, SPARKS, OR OPEN FLAME. • STOP ENGINE, ALLOW TO COOL BEFORE REFUELING. •... -
Page 12: 2004 Ds Golf Car Owner's Manual
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 13: 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 14: 2004 Ds Golf Car Owner's Manual
• 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 15: 2004 Ds Golf Car Owner's Manual
General Warnings - Turn key switch to the ON position and place the Forward/Reverse handle in the REVERSE position. - Slowly press the accelerator pedal and keep it pressed until the reverse warning buzzer can no longer be heard. When the buzzer stops sounding, the controller capacitors are discharged. All vehicles: •... -
Page 16: General Information
The center dash panel must be removed to view this decal. 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 AQ0401-123456 P O BOX 204658 following U.S. -
Page 17: Controls And Indicators
Controls and Indicators • Instructing first time drivers. • 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. -
Page 18: 2004 Ds Golf Car Owner's Manual
(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: 2004 Ds Golf Car Owner's Manual
Controls and Indicators operate if the accelerator pedal is pressed (Figure 8) . The reverse buzzer will sound as a warning when the Forward/Reverse switch is in the REVERSE position. Figure 9 Accelerator and Brake Pedals ACCELERATOR PEDAL The accelerator pedal is the pedal on the right, with the word GO molded into it (Figure 9) . The operation of the accelerator pedal differs from that of an automobile. -
Page 20: 2004 Ds Golf Car Owner's Manual
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 21: 2004 Ds Golf Car Owner's Manual
Controls and Indicators TOW/RUN SWITCH IQ System 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 22: 2004 Ds Golf Car Owner's Manual
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 SERVICE position (Figure 13). -
Page 23: 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 24: Engine Oil
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 25: 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 26: 2004 Ds Golf Car Owner's Manual
Driving Instructions ∆ WARNING • To help avoid possible injury to an inattentive passenger and (or) damage to the vehicle, avoid sudden starts, sudden stops, and abrupt turns. • To help avoid the possibility of losing control of or overturning the vehicle, reduce speed for adverse driving conditions such as wet grass or rough terrain. -
Page 27: 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 28: 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 29: Storage - Electric Vehicle
Storage – Electric Vehicle STORAGE – ELECTRIC VEHICLE See General Warnings on page 11. ∆ 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 30: Storage - Gasoline Vehicle
Storage – Gasoline Vehicle STORAGE – GASOLINE VEHICLE See General Warnings on page 11. ∆ 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 31 Storage – Gasoline Vehicle CLOSED (OFF) POSITION (SELECTOR IS ALIGNED WITH OFF MARKINGS ON THE SIDES OF VALVE) VIEWED FROM SELECTOR SIDE OF VALVE Figure 17 Fuel Shut-off Valve – Closed Position PARTIALLY CLOSED FULL OPEN (ON) POSITION POSITION VIEWED FROM SELECTOR VIEWED FROM SELECTOR SIDE OF VALVE SIDE OF VALVE...
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Page 32: 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 33: 2004 Ds Golf Car Owner's Manual
Periodic Service Schedules 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. Both the Periodic Service Schedule and Periodic Lubrication Schedule must be followed to keep vehicle in optimum operating condition. -
Page 34: Engine Oil
Periodic Service Schedules PERIODIC SERVICE SCHEDULE – GASOLINE VEHICLE REGULAR INTERVAL SERVICE Monthly service by owner Check engine oil level; change if or trained technician necessary. See Periodic Lubrication Schedules on page 33. Check engine cooling air intake; clean if Engine necessary. -
Page 35: Periodic Lubrication Schedules
Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE – ELECTRIC VEHICLE LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINT 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 36: Engine Oil
Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULE – GASOLINE VEHICLE 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 37: Vehicle Controller - Electric Vehicle
VEHICLE CONTROLLER – ELECTRIC VEHICLE The Club Car electric vehicle is equipped with either a solid state speed controller (PowerDrive System 48 and IQ System) or a V-Glide speed controller (36-volt vehicle). In order to properly service and maintain the solid state controller vehicle or the V-Glide speed controller vehicle, it is necessary to understand the electrical cir- cuitry and the functions of all components in both systems. -
Page 38: 2004 Ds Golf Car Owner's Manual
Batteries – Electric Vehicle fully charged before first use of new vehicle, before first use of a vehicle after storage, and before releasing vehicle for use each day. BATTERY CARE To keep batteries in good working condition, follow this maintenance program on a regular basis: 1. -
Page 39: Battery Charger - Electric Vehicle
∆ 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 40: 2004 Ds Golf Car Owner's Manual
Battery Charger – Electric Vehicle ∆ WARNING • Do not block or cover the charger ventilation slots. The slots provide ventilation and protect the charger from overheating. • Do not allow clothing, blankets, or other material to cover the charger. •... -
Page 41: 2004 Ds Golf Car Owner's Manual
Battery Charger – Electric Vehicle • Do not use a charger if: - The plug is too loose or does not make a good connection. - The plug and receptacle feel hotter than normal during charge. - The plug pins (PowerDrive Chargers), blades (Accu-Power Chargers), or receptacle contacts are bent or corroded. -
Page 42: 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 43: Battery - Gasoline Vehicle
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 27). 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 44: Engine Oil - Gasoline Vehicle
Engine Oil – Gasoline Vehicle Be sure battery clamp is properly tightened. Tighten to 12 ft-Ib (16.3 N·m). A loose battery clamp may allow the battery to become damaged from vibration or jarring. If battery appears weak, have it charged by a trained technician. The battery should never be left discharged any longer than absolutely necessary (do not leave discharged overnight). -
Page 45: Fueling Instructions - Gasoline Vehicle
Fueling Instructions – Gasoline Vehicle FUELING INSTRUCTIONS – GASOLINE VEHICLE See General Warnings on page 11. ∆ DANGER • Turn 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 46: Cleaning The Vehicle
In the event a vehicle is bought as a used vehicle from another individual or from a distributor/dealer, we strongly urge the new owner to register the vehicle with Club Car. This will enable us to contact you if the need arises. -
Page 47: Vehicle Specifications
Vehicle Specifications VEHICLE SPECIFICATIONS POWERDRIVE IQ SYSTEM 36-VOLT SPECIFICATIONS SYSTEM 48 GASOLINE ELECTRIC ELECTRIC ELECTRIC POWER SOURCE Drive motor: Direct drive, 48 volts DC, series-wound, 3.1 hp • Drive motor: Direct drive, 48 volts DC, shunt-wound, 3.2 hp • Drive motor: Direct drive, 36 volts DC, series-wound, 2.97 hp •... -
Page 48: Specifications
Vehicle Specifications POWERDRIVE IQ SYSTEM 36-VOLT SPECIFICATIONS SYSTEM 48 GASOLINE ELECTRIC ELECTRIC ELECTRIC DIMENSIONS/WEIGHT, Continued Ground clearance 4.5 in. (11 cm) Front wheel tread 34.5 in (88 cm) Rear wheel tread 38.5 in. (98 cm) Weight (standard electric vehicle with canopy, without batteries) 476 lb. -
Page 49: Club Car ® Limited Three Year Warranty For 2004 Individual Golf Cars
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: Club Car ® Limited Lifetime Warranty For 2004 Fleet Golf Cars
2004 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 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...
- Page 53 OF THIS WARRANTY. This battery is intended to be used by persons with training and experience with batteries and only in CLUB CAR electric vehicles. Any other use renders the Limited Warranties expressed herein and all implied warranties null and void and same are hereby excluded.
- Page 54 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 55 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 Ultra-Power II or Accu-Power Charger is suitable for use in any application other than its 36-volt products.
- Page 56 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 57 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 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 2004 DS Golf Car Owner’s Manual...
- Page 60 Publication Part Number 102397401 Edition Code 0803B1203A 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...