Related Manuals for Club Car DS 1998
Summary of Contents for Club Car DS 1998
- Page 1 Manual Number 1019682-01 ual Number 1019682-01 Print Code 0897B1297A Print Code 0897B1297A...
- Page 2 WARNING • THE ENGINE EXHAUST FROM THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS, OR OTHER REPRODUCTIVE HARM.
- Page 3 Your authorized representative checked this vehicle before it was delivered to you and will provide a completed warranty registration card to you. 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 1998 Model DS golf car purchased from CLUB CAR or an authorized distributor or dealer for use in the United States or Can- ada shall be free from defects in materials 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 war- ranty.
- Page 5 CLUB CAR’S ONLY LIABILITY UNDER THIS LIMITED WARRANTY, OR IN ANY ACTION, WHETHER BASED UPON WARRANTY, CONTRACT, NEGLIGENCE, STRICT PRODUCT LIABILITY, OR OTHER- WISE, IS LIMITED TO THE REPAIR OR REPLACEMENT, AT CLUB CAR’S OPTION, OF A GOLF CAR OR COMPONENT THEREOF THAT CLUB CAR DEEMS TO BE DEFECTIVE. REPLACEMENT SHALL MEAN...
- Page 6 FOREWORD Thank you for choosing Club Car, the golf car most widely recognized as the industry leader in vehicle effi- ciency and long-lasting value. Whether you have chosen the DS Gasoline or DS Electric, you have chosen the finest golf car on the market. Please protect your investment and ensure that your Club Car provides years of reliable, superior performance by returning your Warranty Registration (provided by your distributor/ dealer), and by reading and following the maintenance instructions in this manual.
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Page 7: Table Of Contents
TABLE OF CONTENTS Safety Details ..............General Warnings . -
Page 8: 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 we urge you to study this owner’s manual, and to read, understand, and heed the warnings in this manual, as well as the safety decals on your vehicle, before operat- ing the vehicle. -
Page 9: Safety Details
If any of the operation or warning decals 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. DANGER •... - Page 10 General Warnings, Continued: DANGER • DO NOT OPERATE GASOLINE VEHICLE IN ENCLOSED AREA WITHOUT PROPER VENTILA- TION. ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS, DEADLY POISON. • BATTERY VAPORS - FLAMMMABLE! EXPLOSIVE! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE. SERVICE ONLY IN WELL-VENTILATED AREAS.
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Page 11: Feature Identification - Gasoline Vehicle
DS GASOLINE VEHICLE FEATURE IDENTIFICATION DRIVER / PASSENGER WARNING DECAL KEY SWITCH OPERATING INSTRUCTIONS DECAL SERIAL NUMBER ACCELERATOR PEDAL BRAKE PEDAL FRAME GROUND AND WARNING GOVERNOR WARNING DECAL LIGHT (ON VEHICLE FRAME NEAR BATTERY) PARK BRAKE PEDAL GASOLINE WARNING DECAL MOVING PARTS AND (ON VEHICLE FRAME NEAR FUEL TANK) HOT MANIFOLD DECAL... -
Page 12: Feature Identification - Electric Vehicle
DS ELECTRIC VEHICLE FEATURE IDENTIFICATION DRIVER / PASSENGER WARNING DECAL KEY SWITCH OPERATING INSTRUCTIONS DECAL BATTERY SERIAL NUMBER WARNING LIGHT ACCELERATOR PEDAL BRAKE PEDAL PARK BRAKE PEDAL DANGER DECAL MOTOR BRAKING DECAL (ON BODY UNDER SEAT) (POWERDRIVE PLUS VEHICLES ONLY) DANGER / POISON FLUSH EYES SULFURIC... -
Page 13: General Information
MODEL IDENTIFICATION The serial number of your CLUB CAR is printed on a bar code decal mounted on the frame directly above the accelerator pedal (Example: A9801-123456 for Electric or AG9801-123456 for Gasoline) (See Figure 3) . -
Page 14: Pre-Operation Checklist
PRE-OPERATION 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 con- trols and operation, and carefully inspect each vehicle to be satisfied that it is in proper working condition before accepting delivery. -
Page 15: Controls
• General: Listen for any unusual noises such as squeaks or rattles. Check the vehicle ride and perfor- mance. Have a CLUB CAR distributor/dealer or a trained mechanic investigate anything unusual. DS PowerDrive Plus Vehicles with Motor Braking: • Zero Speed Detect: With the vehicle parked on level ground and the park brake disengaged, place the tow switch in the RUN position and attempt to push the vehicle. - Page 16 FIGURE 4 FIGURE 5 FORWARD/REVERSE CONTROL DS Gasoline, DS V-Glide Electric, and DS PowerDrive System 48: The forward/reverse shift handle is located on the seat support panel, below and to the right of the driver’s right knee (See Figure 5) . The lever has three distinct positions: F (forward), N (neutral), and R (reverse). Rotate the lever towards the driver, F (forward), to run the vehicle in the forward direction, or towards the pas- senger, R (reverse), to run the vehicle in reverse.
- Page 17 FIGURE 6 FIGURE 7 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 (See Figure 8). WARNING •...
- 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 for- ward/reverse lever. If the neutral lock-out cam is pulled out approximately 3/8 inch (10 millimeters) and then rotated one-half turn until it snaps into place, the cam will be in the SERVICE position (See 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 battery or electrical system problem.
- Page 20 Controls, Continued: POWERDRIVE PLUS ELECTRIC VEHICLES ONLY: Tow/Run Switch WARNING • TO AVOID POSSIBLE BATTERY EXPLOSION, THE TOW/RUN SWITCH MUST BE IN THE TOW POSITION BEFORE DISCONNECTING OR CONNECTIING BATTERY WIRES. • WHEN THE TOW/RUN SWITCH IS IN THE TOW POSITION, ALL MOTOR BRAKING FUNCTIONS, INCLUDING ZERO-SPEED DECTECT, ARE DISABLED.
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Page 21: Driving Instructions
DRIVING INSTRUCTIONS 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. • NO MORE THAN TWO PEOPLE SHOULD BE ON THE VEHICLE AT ONE TIME. •... -
Page 22: Starting The Vehicle
Driving Instructions, Continued: STARTING THE VEHICLE 1. Enter the vehicle. 2. Study and understand controls. 3. Be sure everyone is seated and holding onto seat handles or handrails. 4. Read safety warnings located on dash and (or) above pedals. 5. Make sure wheels are turned in desired direction. 6. -
Page 23: Towing
• DO NOT ALLOW PEOPLE IN THE VEHICLES BEING TOWED. • AVOID SUDDEN STARTS, SUDDEN STOPS, AND TIGHT TURNS WHEN 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 (TRAC- TOR OR FULL SIZED TRUCK) PROPERLY FITTED, WITH A TOW HITCH HEIGHT OF 11 INCHES SHOULD BE USED. -
Page 24: Storage - Gasoline Vehicle
Transporting on a Trailer, Continued: WARNING • BECAUSE OF THE ADDED LENGTH OF THE TRAILER, CAUTION SHOULD BE USED WHEN TURNING A CORNER. • REMOVE THE VEHICLE WINDSHIELD BEFORE TRANSPORTING ON A TRAILER. • GASOLINE VEHICLE ONLY: TURN FUEL SHUT-OFF VALVE TO OFF (FIGURE 15, PAGE 12). STORAGE - GASOLINE VEHICLE To prepare your vehicle for extended off season storage: 1. -
Page 25: Storage - Electric Vehicle
3. To protect the engine, remove the spark plug and pour 1/2 ounce of SAE 10 weight oil into the engine through the spark plug hole. Rotate the engine crankshaft several times and then re-install the spark plug. WARNING • TURN THE KEY SWITCH OFF, REMOVE THE KEY, AND LEAVE THE FORWARD AND REVERSE SWITCH IN THE NEUTRAL POSITION DURING STORAGE. -
Page 26: Maintenance
(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. 3. Store in a cool, dry place. This will prevent self-discharge of the batteries. - Page 27 Contact your local Club Car distributor/dealer to perform all repairs and semi-annual and annual periodic ser- vice. • See Page 20 for Gasoline Vehicle Periodic Service Schedule. • See Page 22 for Electric Vehicle Periodic Service Schedule. • See Page 25 for Gasoline Vehicle Periodic Lubrication Schedule.
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Page 28: Periodic Service Schedule - Gasoline Vehicle
Maintenance, Continued: FRONT OF CAR FRONT OF CAR NEG. POS. NEG. POS. POS. POS. NEG. NEG. NEG. NEG. POS. POS. NEG. NEG. POS. POS. DISCONNECT HERE DISCONNECT HERE DS POWERDRIVE SYSTEM 48 AND V-GLIDE 36 VOLT ELECTRIC VEHICLE POWERDRIVE PLUS WITH MOTOR BRAKING FIGURE 16 FIGURE 17 PERIODIC SERVICE SCHEDULES... - Page 29 PERIODIC SERVICE SCHEDULE - GASOLINE VEHICLE REGULAR INTERVAL SERVICE Clean terminals and wash dirt from case, check elec- Battery trolyte level (See Pages 28 and 29). Electrical wiring and connections Check for tightness and damage. Torque Converter Rinse with water. Dispose of waste water properly. Check for loose hardware and tighten Weekly Service by Owner as required.
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Page 30: Periodic Service Schedule - Electric Vehicle
PERIODIC SERVICE SCHEDULE - GASOLINE VEHICLE REGULAR INTERVAL SERVICE Check spark plug wire and boot for damage and Engine proper routing. Check engine oil level. Check head and exhaust/header pipe flange connec- tion gasket for leaks. Exhaust System Check muffler condition. Check and adjust as required (See DS Maintenance Semi-annual Service by Front Wheel Alignment and Camber... - Page 31 PERIODIC SERVICE SCHEDULE - ELECTRIC VEHICLE REGULAR INTERVAL SERVICE Multi-Step Potentiometer (48 volt) or V- Check for proper operation (See DS Maintenance and Glide Wiper Switch (36 volt) Service Manual). Batteries Charge batteries. Check for proper operation (See Performance Inspec- Brake System tion, Page 6).
- Page 32 PERIODIC SERVICE SCHEDULE - ELECTRIC VEHICLE REGULAR INTERVAL SERVICE Check specific gravity, electrolyte level, and on- Batteries charge voltage. Check brake shoes, replace if necessary. Brake System Lubricate slide plates with graphite (See DS Mainte- nance & Service Manual). Semi-annual Service by Electrical Wiring Check for cracked or worn insulation.
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Page 33: Periodic Lubrication Schedule - Gasoline Vehicle
REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT PLACE Brake shaft bearings Dry Moly Lube - Club Car Part No. 1012151 Brake Linkage and Pivots Dry Moly Lube - Club Car Part No. 1012151 Quarterly by Owner Accelerator push rod pivots and Dry Moly Lube - Club Car Part No. 1012151... -
Page 34: Periodic Lubrication Schedule - Electric Vehicle
REGULAR INTERVAL SERVICE PLACE RECOMMENDED LUBRICANT Brake shaft bearings Dry Moly Lube - Club Car Part No. 1012151 Brake Linkage and Pivots Dry Moly Lube - Club Car Part No. 1012151 Quarterly by Owner Accelerator pivots Dry Moly Lube - Club Car Part No. 1012151... -
Page 35: Vehicle Capacities
VEHICLE CAPACITIES CAPACITIES GASOLINE VEHICLES ELECTRIC VEHICLES Engine Crankcase without filter 32 oz. (.98 liters) Engine Crankcase with filter 38 oz. (1.16 liters) Unitized Transaxle (gas vehicle) 27 oz. (.8 liters) Transaxle (electric vehicle) 22 oz. (.67 liters) Gasoline Tank 7 gallons (26.5 liters) Tire Pressure 12-14 psi (83-96 kPa) -
Page 36: Fueling Instructions - Gasoline Vehicle
FUELING INSTRUCTIONS - GASOLINE VEHICLE DANGER • GASOLINE - FLAMMABLE! EXPLOSIVE! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY FROM THE VEHICLE FUELING OR SERVICE AREA. • SERVICE OR REPAIR IN WELL-VENTILATED AREA ONLY. • NEVER ATTEMPT TO POUR GASOLINE INTO THE FUEL TANK WHEN THE ENGINE IS HOT OR WHILE IT IS RUNNING. - Page 37 Any corrosion around the positive (+) or negative (-) terminals should be washed off with a solution of baking soda and water (1 cup per gallon of 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). CAUTION •...
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Page 38: Batteries - Electric Vehicle
BATTERIES - ELECTRIC VEHICLE DANGER • BATTERY - EXPLOSIVE GASES! DO NOT SMOKE! KEEP SPARKS AND FLAMES A SAFE DISTANCE FROM THE VEHICLE. TOOLS, WIRES, AND METAL OBJECTS CAN CAUSE SPARKS WHEN SHORTED ACROSS A BATTERY. FOLLOW ALL INSTRUCTIONS CAREFULLY WHEN DEALING WITH BATTERIES. -
Page 39: Battery Charger - Electric Vehicle
• DO NOT ALLOW THIS SOLUTION TO ENTER THE BATTERY. • DISPOSE OF WASTE WATER PROPERLY. Be sure terminals are tight. Let the terminals dry and then spray them with CLUB CAR battery protec- tor spray (Part No. 1014305). 2. The water level in the batteries should be checked weekly (See Figure 23, Page 29, for proper level). - Page 40 BLE. THE USE OF IMPROPER EXTENSION CORD COULD RESULT IN FIRE OR AN ELECTRI- CAL SHOCK. • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THE CHARGER. CONTACT 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 41 CAUTION • INSTALL SURGE ARRESTORS ON INCOMING AC POWER LINES. SURGE ARRESTORS WILL HELP PROTECT ELECTRICAL/ELECTRONIC COMPONENTS IN THE CHARGER AND ON THE VEHICLE FROM ALL BUT DIRECT OR VERY CLOSE LIGHTNING STRIKES. NOTE • BECAUSE THE POWERDRIVE CHARGER HAS A STORAGE CHARGE FEATURE THAT AUTO- MATICALLY CHECKS AND RECHARGES THE BATTERIES AS NECESSARY EVERY 15 DAYS, IT CAN REMAIN PLUGGED TO A POWERDRIVE VEHICLE THROUGHOUT THE STORAGE PERIOD.
- Page 42 To Charge Batteries, Continued: WARNING • FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE CHARGER CORD, THE PLUG, AND (OR) THE VEHICLE RECEPTACLE. DO NOT USE A CHARGER IF: • THE PLUG IS TOO LOOSE OR DOES NOT MAKE A GOOD CONNECTION. •...
- Page 43 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 If the charger plug becomes difficult to insert or disconnect, the receptacle contacts should be lightly sprayed...
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Page 44: Cleaning The Vehicle
The vehicle is available with a complete line of optional equipment items and accessories that are available from Club Car and our dealers/distributors. Care should be taken that these accessories and options are properly installed by trained technicians, and that they are used in the manner for which they were designed. -
Page 45: Subsequent Owner Registration
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 re-register the vehicle with Club Car. This will enable us to contact you if the need arises. - Page 46 Fairway Villager, Continued: WARNING • DO NOT LEAVE CHILDREN UNATTENDED ON THE REAR SEAT WHILE VEHICLE IS MOVING. • NO MORE THAN FOUR PERSONS SHOULD BE ON THE VEHICLE AT ONE TIME. • TO PREVENT THE POSSIBILITY OF SERIOUS INJURY, KEEP YOUR ENTIRE BODY (INCLUDING HEAD, HANDS, ARMS, LEGS AND FEET) INSIDE THE VEHICLE .
- Page 47 FAIRWAY VILLAGER SEAT HANDLE PASSENGER WARNING HAND RAIL DECAL (ON HAND RAIL) FOOT REST FIGURE 28...
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Page 48: Vehicle Specifications
VEHICLE SPECIFICATIONS POWERDRIVE POWERDRIVE SPECIFICATIONS SYSTEM 48 PLUS 36 VOLT GASOLINE ELECTRIC ELECTRIC ELECTRIC POWER SOURCE Engine: 4 cycle, OHV, 286 cc, 9.0 hp rated., single cylinder, air cooled, • with pressure lubrication system. Drive Motor: Direct drive, 48 volts DC, series wound, 3.1 hp. •... - Page 49 POWERDRIVE POWERDRIVE SPECIFICATIONS SYSTEM 48 PLUS 36 VOLT GASOLINE ELECTRIC ELECTRIC ELECTRIC 48” 48” 48” 48” Overall Height: At Steering Wheel. (122 cm) (122 cm) (122 cm) (122 cm) 65-1/2” 65-1/2” 65-1/2” 65-1/2” Wheelbase (166 cm) (166 cm) (166 cm) (166 cm) 4-1/2”...
- Page 50 Fleet Lessee, as those terms are defined herein, and subject to the provisions, limitations and exclusions contained in this limited warranty, that its new 1998 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 service as a golf car for the periods stated below.
- Page 51 CLUB CAR’S ONLY LIABILITY UNDER THIS LIMITED WARRANTY, OR IN ANY ACTION WHETHER BASED UPON WARRANTY, CONTRACT, NEGLIGENCE, STRICT PRODUCT LIABILITY OR OTHER- WISE, IS LIMITED TO THE REPAIR OR REPLACEMENT, AT CLUB CAR’S OPTION, OF A GOLF CAR OR COMPONENT THEREOF THAT CLUB CAR DEEMS TO BE DEFECTIVE. REPLACEMENT SHALL MEAN...
- Page 52 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 LOSS.
- Page 56 Golf Cars Club Car Inc. P.O. Box 204658 Augusta, GA 30917-4658...