Club Car DS Gold Standard Owner's Manual
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Club Car DS Gold Standard Owner's Manual

Club Car DS Gold Standard Owner's Manual

Electric and gasoline remanufactured vehicle
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DS Gold Standard Remanufactured
Vehicle 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 Gold Standard

  • Page 1 DS Gold Standard Remanufactured Vehicle 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 For the name and address of the authorized Club Car dealer and distributor nearest you, logon to our web site at www.clubcar.com or call 1-800-ClubCar (258-2227). If you would prefer to write to us, direct your letter to: Club Car, Attention: Marketing Services, P.O.

  • Page 5: Table Of Contents

    Engine Oil – Gasoline Vehicles ..........................45 Fueling Instructions – Gasoline Vehicles ......................48 Cleaning the Vehicle ............................49 Accessories................................ 49 Subsequent Owner Registration .......................... 50 Vehicle Specifications ............................50 Warranties................................52 DS Gold Standard Remanufactured Vehicle Owner’s Manual Page 3...

  • Page 6: Safety Decal And Feature Identification

    The following pages contain safety decal and feature identification information. For detailed information on specific features, read the appropriate section in this manual. ELECTRIC VEHICLE 2000A 101960601 Decal, Rollover Warning (on instrument panel) 103783001 Decal, Operating Instructions (on steering wheel) Page 4 DS Gold Standard Remanufactured Vehicle Owner’s Manual...
  • Page 7 Safety Decal and Feature Identification ELECTRIC VEHICLE 272A Decal, Tow Switch Warning (on Tow/Run switch 101908601 Battery Charger Receptacle plate, under seat) Decal, Component Cover Notice (on electrical 101931501 Forward/Reverse Control component cover) DS Gold Standard Remanufactured Vehicle Owner’s Manual Page 5...
  • Page 8 Decal, On/Off Key Switch (above key switch) Park Brake Pedal 101960601 Decal, Rollover Warning (on instrument panel) Accelerator Pedal 103783002 Decal, Operating Instructions (on steering wheel) Serial Number Low Oil Warning Light Brake Pedal Page 6 DS Gold Standard Remanufactured Vehicle 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 Gold Standard Remanufactured Vehicle Owner’s Manual Page 7...
  • Page 10 Safety Decal and Feature Identification FOUR PASSENGER VEHICLE 317A Decal, Falling Off Warning (on rear-facing seat 101705701 hand rail and/or on back side of forward-facing Hand Holds seat backs) Hand Rail Page 8 DS Gold Standard Remanufactured Vehicle Owner’s Manual...

  • Page 11: 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. DS Gold Standard Remanufactured Vehicle Owner’s Manual Page 9...

  • Page 12: 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 Page 10 DS Gold Standard Remanufactured Vehicle Owner’s Manual...
  • Page 13 • 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 14: Disabling The Vehicle

    Connect battery cables in reverse order. 3. Remove positive battery cable. Connect battery cables in reverse order. 1436 Figure 2 Battery Cable Removal – 6x8-Volt Battery Figure 3 Battery Cable Removal – Gasoline Vehicle Configuration Page 12 DS Gold Standard Remanufactured Vehicle 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

    This owner’s manual is valid for the build code range indicated on the back cover of this owner’s manual. Page 14 DS Gold Standard Remanufactured Vehicle Owner’s Manual...

  • Page 17: Safety Committee

    Forward/Reverse handle or switch in the NEUTRAL position, turn the key switch to the OFF position, and remove the key when leaving the vehicle. WARNING CONTINUED ON NEXT PAGE DS Gold Standard Remanufactured Vehicle 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 When the accelerator is released, power will be cut off and the motor or engine will stop running. DS Gold Standard Remanufactured Vehicle Owner’s Manual Page 17...
  • Page 20 The brake pedal is the large pedal on the left with the word STOP molded into it (Figure 10). To slow or stop the vehicle, press the brake pedal with your foot (Figure 11). Figure 11 Brake Pedal Figure 12 Park Brake Pedal Page 18 DS Gold Standard Remanufactured Vehicle 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 For the convenience of the trained technician, there is a neutral lockout cam located on the back of the Forward/Reverse shifter. If the neutral lockout cam is pulled out approximately 3/8 inch (10 mm) and then rotated Page 20 DS Gold Standard Remanufactured Vehicle Owner’s Manual...
  • Page 23 Hold it during start up and release the choke cover after the engine starts and runs smoothly. DS Gold Standard Remanufactured Vehicle 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 Gold Standard Remanufactured Vehicle 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 Gold Standard Remanufactured Vehicle 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 18). DS Gold Standard Remanufactured Vehicle 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 18 Fuel Shut-off Valve Page 30 DS Gold Standard Remanufactured Vehicle 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 Gold Standard Remanufactured Vehicle Owner’s Manual...
  • Page 35 If batteries are not performing as expected, (every 100 hours of operation or 200 rounds see Batteries Section in the maintenance and service manual. of golf) Safety decals Check safety decals. Replace if damaged or illegible. DS Gold Standard Remanufactured Vehicle Owner’s Manual Page 33...
  • Page 36 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) Page 34 DS Gold Standard Remanufactured Vehicle Owner’s Manual...

  • Page 37: 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 19 Lubrication Points – Electric Vehicles DS Gold Standard Remanufactured Vehicle Owner’s Manual Page 35...
  • Page 38 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 20 Lubrication Points – Gasoline Vehicles Page 36 DS Gold Standard Remanufactured Vehicle Owner’s Manual...

  • Page 39: 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 40: Battery Care

    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 41 • Do not overfill the batteries. NOTE: A battery watering gun or bottle is available from your authorized Club Car dealer. The battery hold-downs should be tight enough so that the batteries do not move while the vehicle is in motion, but not so tight as to crack or buckle the battery case.

  • Page 42: 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 43 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 44 Figure 22 Correct Insertion of Charger DC Plug Figure 23 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 45: Battery - Gasoline Vehicles

    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. BATTERY – GASOLINE VEHICLES See General Warnings on page 10.
  • Page 46 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 25). 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 47: Engine Oil - Gasoline Vehicles

    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 27 Engine Oil Level Check DS Gold Standard Remanufactured Vehicle Owner’s Manual Page 45...
  • Page 48 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 29). See following NOTE. Page 46 DS Gold Standard Remanufactured Vehicle Owner’s Manual...
  • Page 49 11. Coat new oil filter gasket with clean engine oil and install the oil filter onto the engine oil filter port (Figure 30). 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 50: 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 48 DS Gold Standard Remanufactured Vehicle Owner’s Manual...

  • Page 51: 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 52: 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 53 Drive-by noise level to operator — — Uncertainty: 2 Uncertainty: 2 Test method: EN 12053:2001 0.7 m/s 0.8 m/s Vibration at driver’s seat — — Uncertainty: Uncertainty: Test method: EN 13059:2002 0.12 m/s 0.020 m/s DS Gold Standard Remanufactured Vehicle Owner’s Manual Page 51...

  • Page 54: Warranties

    UNLIMITED 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 or unintended strain or use, improper installation of accessories, installation of parts or accessories that are not original equipment including Club Car approved or non-approved GPS systems, non-approved alteration and acts of God.
  • Page 55 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 56 Warranties For warranty-related communication, contact Warranty Services, Club Car, 4125 Washington Rd., Evans, GA 30809, USA, 706.863.3000. WARNING Any modification or change to the vehicle that affects the electrical system, stability or handling of the vehicle, or increases maximum vehicle speed beyond factory specifications, could result in severe personal injury or death.
  • Page 57 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 58 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 59 Warranties DS Gold Standard Remanufactured Vehicle Owner’s Manual Page 57...
  • Page 61 Club Car NOTES...
  • Page 64 BC56042 Publication Part Number 103897209 Edition Code 0412B0412A This manual is valid for vehicles with build codes between 55775 and the one indicated at the top of this page.

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