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2007 DS G-E OM.book - Golf Buggy Hire UK

1. Page 32 Figure 19 Lubrication Points Gasoline Vehicles 2007 DS Golf Car Owner s Manual 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 Therefore if any repair or servicing needs to be performed we rec ommend that it be performed by an authorized Club Car distributor dealer using Club Car OEM parts BATTERIES ELECTRIC VEHICLES See General Warnings on page 9 A DANGER e Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries Charge batteries in a well ventilated area only Batteries emit hydrogen while being charged Hydrogen is an explosive gas and must never exceed a level of 2 of the air Battery Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes External Flush with water Call a physician immediately Internal Drink large quantities of milk or water followed with milk of magnesia or vegetable oil Call a physician immediately
2. Store vehicle in a cool dry place This will minimize battery self discharge Adjust tires to recommended tire pressure See Vehicle Specifications on page 45 Perform semiannual periodic lubrication See Periodic Lubrication Schedules on page 31 Thoroughly clean front body rear body seats battery compartment and underside of vehicle Do not engage the park brake Chock the wheels to prevent the vehicle from rolling Keep batteries fully charged during storage Leave battery chargers plugged in during storage The onboard computer will automatically activate the charger when necessary If charger cannot remain plugged in or AC power will not be available during extended storage disconnect the batteries for storage Figure 2 Page 11 CAUTION e Be sure to check the vehicle and charger monthly to ensure the charger is operating correctly during storage RETURNING THE STORED ELECTRIC VEHICLE TO SERVICE a bk VN If necessary connect batteries and tighten terminals to 110 in lb 16 5 N m Fully charge batteries Adjust tires to recommended tire pressure See Vehicle Specifications on page 45 Perform the Pre Operation and Daily Safety Checklist on page 19 2007 DS Golf Car Owner s Manual Page 25 Storage Gasoline Vehicles STORAGE GASOLINE VEHICLES See General Warnings on page 9 A DANGER e Do not attempt to drain gasoline when the engine is hot or while it is running e Be sure to clean up
3. Eyes Flush with water for 15 minutes Call a physician immediately A WARNING e Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubber gloves when working on or near batteries e Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring CAUTION e On all electric vehicles turn off all accessories before charging batteries NOTE Recycle or dispose of discarded batteries in accordance with local state and federal regulations Club Car electric vehicles use deep cycle batteries Automotive batteries should never be used in electric vehicles New batteries will not deliver their full capabilities until they have been discharged and recharged 20 to 50 times To obtain the maximum service life from new batteries restrict IQ System electric vehicles with new batteries to 36 holes of use between charges in the first two months of operation Batteries should be 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 2007 DS Golf Car Owner s Manual Page 33 Batteries Electric Vehicles 1 The batteries should be kept clean and free of corrosion Wash tops and terminals of batteries w
4. F forward or R reverse A buzzer will sound as a warning when the Forward Reverse handle or switch is in the REVERSE position Slowly press accelerator pedal The park brake will release automatically and the vehicle will start to move As the accelerator pedal is pressed speed will increase until full speed is reached See following WARNING and NOTE A WARNING e Operator must control vehicle speed when going downhill e Electric vehicles only Pedal down or pedal up motor braking may be used to help control speed when going downhill however steep terrain or other conditions may require that pedal braking be used in conjunction with motor braking Gasoline vehicles only e Do not shift the vehicle out of forward while going downhill If you do you will not be able to shift into reverse or back into forward until stopped e Press the brake pedal as necessary and partially press the accelerator when descending a hill With the accelerator pedal partially pressed the governor will cause the engine to assist the brakes in controlling downhill speed Page 22 2007 DS Golf Car Owner s Manual Towing NOTE If the Forward Reverse handle is shifted into the NEUTRAL position power will be cut off and the engine will stop running STOPPING THE VEHICLE A WARNING e Driving through water may affect the brakes After driving through water check effectiveness of the brakes by gently pressing the brake pedal If the vehicl
5. neglect improper maintenance or unapproved modifications You are responsible for presenting vehicle engine to a CLUB CAR distribution center as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact WARRANTY SERVICES CLUB CAR INC P O Box 204658 Augusta Georgia 309017 4658 U S A 1 706 863 3000 CLUB CAR EXPLANATION OF EMISSION CONTROL WARRANTY 1 WARRANTY CLUB CAR warrants to the ultimate purchaser and each subsequent purchaser that the SORE or equipment is designed built and equipped so as to conform with all applicable regulations and free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in CLUB CARs application for certification The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser or first placed into service The warranty period is two years 2 COVERAGE Subject to certain conditions and exclusions as stated below the warranty on emission related parts is as follows 1 Any warranted part that is not scheduled for replacement as required maintenance in the written instructions supplied is warranted for the warranty period stated above If the part fails during the period of warranty coverage the part will be
6. 13 Choke Figure 14 Low Oil Warning Lamp LOW OIL WARNING LAMP Gasoline Vehicles Only The gasoline golf car is equipped with a low oil warning lamp located on the dash panel just above the steer ing column Figure 14 If the warning lamp comes on oil should be checked and added to the engine as nec essary before continuing to use the vehicle The vehicle should never be driven with the low oil warning lamp remaining on H the warning lamp goes on and off you may proceed but oil should be added at the first opportunity If the oil level is correct and the warning lamp stays on have a trained technician check the vehi cle See following CAUTION CAUTION e Failure to add oil immediately when the low oil warning lamp stays on may result in permanent engine damage 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 Use the following checklist as a guide to inspect the vehicle This checklist should be used daily to ensure that the vehicle is in proper working condition and in conjunction with the Periodic Service Schedules on page 29 Any problems should be corrected by a Club Car distributor dealer or a trained technician e General All the
7. FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REPLACEMENT OR REPAIR OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE DISTRIBUTOR OR DEALER OF CLUB CAR HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY 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 BATTERY CHARGER LOSS OF USE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Damage not resulting from a defect that occurs due to unreasonable use abuse or neglect including failure to provide reasonable or necessary maintenance accident or alteration is excluded from the limited warranty Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitations of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state For further information contact WARRANTY SERVICES CLUB CAR INC P O Box 204658 Augusta Georgia 30917
8. Figure 1 Disconnect the spark plug wire from the spark plug e Frame ground Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wiring Do not allow a positive wire to touch the vehicle frame engine or any other metal component Electric vehicles e 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 e To avoid unintentionally starting the vehicle disconnect the batteries as shown Figure 2 e After disconnecting the batteries wait 90 seconds for the controller capacitors to discharge All vehicles e Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubber gloves when working on or near batteries e Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle or battery charger WARNING CONTINUED ON NEXT PAGE Page 10 2007 DS Golf Car Owner s Manual General Information A WARNING e 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 N switch in TOW PASSENGER SIDE gt S OF VEHICLE Place TOW RUN switch in the TOW position before disconnecting or connecting battery cables negative cable
9. STARTER GENERATOR GASOLINE WARNING DECAL ON VEHICLE FRAME NEAR FUEL TANK A WARNING CAN CAUSE SEVERE INJURY OIL FILL Rotating parts 4 HOT manifold amp muffler KEEP CLEAR cci 1019605 01 FUEL SHUT OFF VALVE Lee FORWARD REVERSE HANDLE NEUTRAL LOCKOUT CAM FRAME GROUND AND GOVERNOR WARNING DECAL ON VEHICLE FRAME NEAR BATTERY Z WARNING 5 Z WARNING Negative frame ground Can cause severe injury A Excessive speed Do not contact positive battery post or cable to frame Can cause severe injury or death Disconnect negative battery lead first Do not tamper with engine governor adjustm ent CCI 1019152 01 2007 DS Golf Car Owner s Manual Page 7 Practice Safety Rotating Parts 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 Understand and become familiar with the DANGER WARNING and CAUTION statements and procedures it contains along with the safety decals that are affixed to your vehicle Take time to understand the language of safety It is a language that can save your life PROPOSITION 65 STATE OF CALIFORNIA A WARNING This product contains or emits chemicals or substances that have been determined by the stat
10. avoid using oxygenated fuels and fuels that are blended with alcohol Vehicles to be stored for extended periods should be prepared for storage as instructed See Preparing the Gasoline Vehicle for Extended Storage on page 26 1 Turn the key switch to the OFF position 2 Lift and remove seat bottom 3 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 CAUTION 4 Replace fuel cap on tank Ensure cap is tightened securely 5 Replace seat bottom 2007 DS Golf Car Owner s Manual Page 43 Cleaning the Vehicle VENT SHUT OFF Ze Figure 31 Fuel Tank CLEANING THE VEHICLE Club Car DS vehicles are equipped with ArmorFlex front and rear bodies Use only commercially available automotive cleaners with a sponge or soft cloth for normal cleaning A garden hose at normal residential water pressure is adequate Club Car does not recommend any type of pressure washing or steam cleaning Such a process especially if the vehicle has an ArmorFlex rear body that is removed will expose electrical components to moisture Moisture entering electrical components can result in water damage and subsequent component failure Use non abrasive wax products Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible stains The seats of the vehicle will last longer with proper cleaning Us
11. container then pour the fuel from the container into vehicle fuel tank Tighten the carburetor drain screw 2 3 Disconnect fuel vent line from fuel tank vent nipple 2 4 Plug the fuel tank vent nipple so that it is air tight We recommend using a slip on vinyl cap 3 Disconnect the battery cables negative cable first Page 26 2007 DS Golf Car Owner s Manual 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 Do not allow this solution to enter the batteries Be sure terminals are tight Let the terminals dry and then coat them with Battery Terminal Protector Spray CCI P N 1014305 CLOSED OFF POSITION SELECTOR IS ALIGNED WITH OFF MARKINGS ON THE SIDES OF VALVE VIEWED FROM SELECTOR SIDE OF VALVE Figure 15 Fuel Shut off Valve Closed Position FULL OPEN ON PARTIALLY CLOSED POSITION POSITION Si VIEWED FROM SELECTOR VIEWED FROM SELECTOR SIDE OF VALVE SIDE OF VALVE Figure 16 Fuel Shut off Valve Open Position Figure 17 Fuel Shut off Valve Partially Closed Position 5 To protect the engine remove spark plug and pour 1 2 ounce 14 2 mL of SAE 10 weight oil into the engine through the spark plug hole Rotate engine crankshaft by hand several times and then install the spark plug 6 Adjust
12. copy of this page to 706 228 2662 Thank You Club Car Technical Publication Department Page 56 2007 DS Golf Car Owner s Manual Publication Part Number 103218309 Edition Code 0706B1207A OMI OMI S Club Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web Phone In Fax www clubcar com 1 706 863 3000 1 800 ClubCar 1 706 863 3000 1 706 863 5808
13. filter forming a channel to direct the filter port oil into the drain pan Dispose of used oil according to the environmental laws and regulations for your area 2007 DS Golf Car Owner s Manual Page 41 Engine Oil Gasoline Vehicles Figure 28 Remove Engine Oil Filter 10 Use a clean rag and wipe the oil filter mounting bracket surface clean where the oil filter gasket seats 11 Install a new oil filter CCI P N 1016467 onto the engine oil filter port Apply a light coat of white lithium NLGI Number 2 grease Dow Corning BR2 Plus or equivalent or new engine oil to the rubber seal around the outside surface of the filter before attaching it to the oil filter port Figure 29 This will help seal the filter to the oil mounting bracket 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 13 Remove the dipstick and add engine oil into the dipstick port Use a funnel or pour spout to direct the oil into the dipstick port With filter change the engine requires 38 ounces 1 12 liters of oil per change Refer to oil viscosity guidelines for selection of oil grade Figure 30 Replace the dipstick 20 C 10 C SAE 10W 30 SAE 10W 40 D K ess St o AE 14 F 32 F 50 F eer 86F 104 F Figure 29 Coat Oil Filter Rubber Seal Figure 30 Oil Viscosity Chart Page 42 2007 DS Golf Car O
14. for use in any application other than its PowerDrive System 48 PowerDrive Plus and IQ System products As in the use of any electrical device 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 and will exercise due care in working on or around electrical devices Transportation expenses for warranty services are also excluded from this warranty WARRANTY LIMITATIONS 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 replacement or repair of a charger or component thereof that CLUB CAR deems to be defective Replacement shall mean furnishing during the applicable limited warranty period a new charger or component thereof that is identical or reasonably equivalent to the warranted product or defective component at no cost to the purchaser Repair shall mean remedying a defect in the charger or component thereof at no cost to the purchaser during the applicable limited warranty period If CLUB CAR elects to repair the charger it may provide factory reconditioned parts or components All parts and components replaced under warranty shall become the property of CLUB CAR THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS
15. in a fire property damage personal injury or death PERFORMANCE INSPECTION After you have familiarized yourself with the vehicle controls and have read and understood the driving instructions take the vehicle for a test drive 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 Forward Reverse control Check for proper operation See Controls and Indicators on page 13 Brakes Be sure the brakes function properly When brake pedal is fully pressed under moderate pres sure it should not go more than halfway to the floor and vehicle should come to a smooth straight stop within 14 feet 4 3 m If the pedal goes more than halfway to the floor or if the vehicle swerves or fails to stop within 14 feet 4 3 m have the brake system checked and adjusted as required Brake adjustment must be maintained so that the brake pedal cannot be pressed to the floor under any cir cumstance Park brake When latched the park brake should lock the wheels and hold the vehicle stationary on an incline of 20 or less It should release when either the accelerator or brake pedal is pressed Reverse buzzer The reverse buzzer should sound as a warning when the Forward Reverse handle or switch is in the REVERSE position Steering The vehicle should be easy to steer and should not have any play in th
16. repaired or replaced by CLUB CAR according to subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the period 2 Any warranted part that is scheduled only for regular inspection in the written instructions supplied is warranted for the warranty period stated above Any such part repaired or replaced under warranty will be warranted for the remaining warranty period 3 Any warranted part that is scheduled for replacement as required maintenance in the written instructions supplied is warranted for the period of time before the first scheduled replacement date for that part If the part fails before the first scheduled replacement the part will be repaired or replaced by CLUB CAR according to subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the period prior to the first scheduled replacement point for the part 4 Repair or replacement of any warranted part under the warranty provisions herein must be performed at a warranty station at no charge to the owner 5 Notwithstanding the provisions herein warranty services or repairs will be provided at all of our distribution centers that are franchised to service the subject engines or equipment 6 The engine or equipment owner will not be charged for diagnostic labor that is directly associated with diagnosis of a defective emission related warranted part provided that such diagnost
17. so will void the warranty as well as damage the engine and other components and could result in property damage personal injury or death due to unsafe speeds KEY SWITCH The key switch is mounted on the dash to the right of the steering column Figure 4 It has two positions OFF and ON which are clearly labeled See following NOTE NOTE The key can be removed only when the key switch is in the OFF position Figure 4 Key Switch FORWARD REVERSE CONTROL IQ System Electric Vehicles The Forward Reverse rocker switch is located on the seat support panel below and to the right of the driver s right knee The F FORWARD and R REVERSE positions are clearly marked Push down the FORWARD side of the switch to operate the vehicle in the forward direction or push down the REVERSE side of the switch to operate the vehicle in reverse When the rocker switch is positioned in the NEUTRAL position with neither side down the vehicle will not operate if the accelerator pedal is pressed Figure 6 The reverse buzzer will sound as a warning when the Forward Reverse switch is in the REVERSE position 2007 DS Golf Car Owner s Manual Page 13 Controls and Indicators Gasoline Vehicles The Forward Reverse handle is located on the seat support panel below and to the right of the driver s right knee Figure 5 The Forward Reverse handle has three distinct positions F FORWARD R REVERSE and N NEUTRAL Rotate the handle towards the d
18. the original emission relat ed parts e Carburetor and internal parts e Spark plugs e Magneto or electronic ignition system e Fuel filter element e Air cleaner element e Crankcase e Cylinder head e Breather chamber and internal parts e Intake pipe and tube 4 WARNING eAfter refueling make sure the tank cap is closed securely elf gasoline is spilled on the fuel tank wipe it off immediately Oil Viscosity Choose the viscosity according to the tem perature as follows 20C 10C OC L ES 3 0 kee lt SAE 10W 30 SAE 10W 40__ gt 10W 30 SAE 10W 40 See 1 F4 32F 5 FO eet 86F 104F NOTE Using multi grade oils 5W 20 10W 30 and 10W 40 will increase oil consumption Check oil level more frequently when using them Page 55 Your Comments Are Appreciated Please select your category Distributor Dealer Technician Individual Owner Golf Course Superintendent Club Car Associate Representative Other In order to help us better serve you please rate this publication in the following catgories Poor Fair Average Good Excellent 1 Ease of Understanding 2 Ease of Finding Information 3 Clarity of Illustrations 4 Periodic Service and Periodic Lubrication Schedules Comments Suggestions Please fax a
19. 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 Once the lockout is actuated the charger turns on The onboard computer then records the amount of energy being returned to the batteries When the optimum amount of energy needed to replenish the batteries is returned the charger will shut off The control circuit lockout remains activated until the charger plug is dis connected from the vehicle Figure 21 Correct Insertion of Charger DC Plug Figure 22 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 As long as the charger is allowed to shut off by itself the batteries will be fully charged Overcharging and undercharging will normally be prevented 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 w
20. tires to recommended tire pressure See Vehicle Specifications on page 45 7 Perform semiannual periodic lubrication See Periodic Lubrication Schedules on page 31 8 Thoroughly clean front body rear body seats engine compartment and underside of vehicle 9 Do not engage the park brake Chock the wheels to prevent the vehicle from rolling 2007 DS Golf Car Owner s Manual Page 27 Maintenance RETURNING THE STORED GASOLINE VEHICLE TO SERVICE 1 Restore fuel system to operation Figure 31 Page 44 1 1 Remove plug from fuel tank vent 1 2 Connect vent tube to fuel tank vent 2 Connect battery cables positive cable first and tighten terminals to 12 ft lb 16 N m 3 Completely open the fuel shut off valve Figure 16 Make sure the valve is fully open A partially closed fuel shut off valve Figure 17 combined with the use of the choke can result in a fouled spark plug and engine failure 4 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout cam in the MAINTE NANCE position Crank the engine until fuel is pumped into the carburetor and fuel lines and the engine starts Turn the engine off and return the neutral lockout cam to the OPERATE position See following NOTE NOTE Due to the oil added to the engine in preparation for storage engine may smoke excessively for a short time when it is run for the first time after storage 5 Adjust tires to recommended tire pressure See Vehicle Specif
21. 4658 U S A 706 863 3000 CLUB CAR LIMITED FOUR YEAR WARRANTY FOR 2007 ONBOARD COMPUTERS AND SOLID STATE SPEED CONTROLLERS CLUB CAR INC CLUB CAR hereby warrants to the original retail purchaser that the new Onboard Computer and the Solid State Speed Controller hereinafter called Computer and Controller respectively installed in its new electric vehicle equipped with the PowerDrive System 48 PowerDrive Plus or IQ System purchased from CLUB CAR or an authorized distributor or dealer will be free from defects in material and workmanship for a period of four years or 800 rounds whichever first occurs from the date of purchase subject to the terms and conditions contained herein This limited warranty only covers defects in material and workmanship for a period of four years or 800 golf car rounds from date of purchase The terms of this four year or 800 round limited warranty shall be as follows Vehicles used for golf free replacement with respect to parts and labor within four years or 800 rounds whichever first occurs from date of purchase Vehicles used for purposes other than golf free replacement with respect to parts and labor within four years or 16 000 energy units as recorded by the Computer whichever first occurs from date of purchase Page 52 2007 DS Golf Car Owner s Manual The Computer or Controller should be returned to an authorized CLUB CAR distributor or dealer with evidence of proof
22. 7 5 HOW TO MAKE A WARRANTY CLAIM To make a warranty claim under this limited warranty you must present the golf car or defective component to an authorized CLUB CAR distributor or dealer or send the defective component freight prepaid to WARRANTY SERVICES CLUB CAR INC 4125 Washington Road Evans Georgia 30809 U S A 706 863 3000 6 DISCLAIMER THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REMEDY OF THE REPLACEMENT OR REPAIR OF THE DEFECTIVE GOLF CAR OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE DISTRIBUTOR OR DEALER OF CLUB CAR HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY 7 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 GOLF CAR LOSS OF USE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Some states allow neither limitation on the duration of an implied warranty nor exclusions or limit
23. AIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE SOLE REMEDY OF THE REPLACEMENT OR REPAIR OF THE DEFECTIVE GOLF 2007 DS Golf Car Owner s Manual Page 49 CAR OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE DISTRIBUTOR OR DEALER OF CLUB CAR HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY 8 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 GOLF CAR LOSS OF USE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitation of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state 9 INFORMATION For further information contact WARRANTY SERVICES CLUB CAR INC P O Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 10 WARNING Any modification or alteration of any golf car beyond factory specifications including those that affect the weight distribution stability or speed of the golf car can cause ser
24. AUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury CAUTION e A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could result in property damage GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated repaired or ser viced Vehicle feature identification information is also included on pages 4 through 7 Other specific safety statements appear throughout this manual and on the vehicle A DANGER e Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries DANGER CONTINUED ON NEXT PAGE 2007 DS Golf Car Owner s Manual Page 9 General Warnings A DANGER e Gasoline Flammable Explosive Do not smoke Keep sparks and flames away from the vehicle and service area Service only in a well ventilated area e Do not operate gasoline vehicle in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison e 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 applic
25. DENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE OR REVENUE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Damage not resulting from a defect in material or workmanship or that occurs due to abuse or neglect including failure to provide reasonable and necessary maintenance accident or alteration is excluded from this limited warranty Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitations of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state For further information contact WARRANTY SERVICES CLUB CAR INC P O Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 2007 DS Golf Car Owner s Manual Page 53 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT Your new Club Car Inc CLUB CAR vehicle engine complies with both the U S EPA and State of California emission regulations However the use of gasoline powered golf cars in areas of California that do not attain the federal ozone standards is illegal Please refer to the Air Resources Board information at http www arb ca gov enf enf htm for compliance YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and CLUB CAR are pleased to explain the emission control system warranty on your 2007 vehic
26. ITED TO LOSS OF USE OR REVENUE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Damage not resulting from a defect in material or workmanship or that occurs due to abuse or neglect including failure to provide reasonable and necessary maintenance accident or alteration is excluded from this limited warranty Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitations of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state For further information contact WARRANTY SERVICES CLUB CAR INC P O Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 CLUB CAR LIMITED FOUR YEAR WARRANTY FOR 2007 POWERDRIVE BATTERY CHARGERS CLUB CAR INC CLUB CAR hereby warrants to the original retail purchaser that its new PowerDrive Chargers purchased from CLUB CAR or an authorized distributor or dealer will be free from defects in material and workmanship under normal use and service for a period of four years from the date of purchase subject to the terms provisions limitations and exclusions contained herein 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
27. KE PEDAL The park brake pedal is the small raised portion in the upper left corner of the brake pedal It has the word PARK molded into it and the words PARK BRAKE marked on top of it Figure 8 To set the park brake press the brake pedal firmly and tilt the park brake portion of the pedal forward with your foot Figure 9 See fol lowing WARNING 2007 DS Golf Car Owner s Manual Page 15 Controls and Indicators A WARNING e The park brake will release automatically when either the accelerator or brake pedal is pressed The park brake has multiple locking positions and should be firmly pressed and locked to prevent the vehicle from rolling BATTERY WARNING LAMP IQ System Electric Vehicles Only IQ System vehicles feature a dash mounted warning lamp above steering column that when the vehicle is in operation indicates low battery voltage or when the vehicle is being charged indicates a charging prob lem The battery warning lamp is controlled by the onboard computer When the vehicle is in operation the warning lamp will illuminate and remain illuminated if e Batteries voltage drops below 48 volts when there is no load on the batteries the vehicle is stopped and there are no accessories on e Batteries have discharged to less than 25 of rated capacity If the warning lamp illuminates when the vehicle is operating there will be enough power remaining to drive the vehicle for approximately 30 minutes However the ve
28. LUB CAR INC CLUB CAR hereby warrants to the Original Retail Purchaser that its new 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 LIMITED THREE YEAR WARRANTY The golf car frame excluding the front and rear bumper mounts rack and pinion steering gearbox unit suspension system defined as the shock absorbers shock mounts A plate leaf springs shackles and associated hardware gasoline engine unitized transaxle torque converters drive and driven starter generator transaxle electric vehicle and electric motor are warranted with respect to parts and labor for a period of three years from the date of purchase LIMITED TWO YEAR WARRANTY All remaining components of the golf car not specified otherwise except options and accessories are warranted with respect to parts and labor against defects in material and workmanship for a period of two years from the date of purchase LIMITED ONE YEAR WARRANTY All original equipment options and accessories supplied by CLUB CAR are warranted with respect to parts and labor against defects in material and workmanship for a period of one year from the date of purchase This limited warranty covers material workmanship and repair labor cost
29. MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY INCLUDING BUT NOT LIMITED TO MODIFICATION OF THE SPEED GOVERNOR BRAKING SYSTEM STEERING TRANSAXLE OR OTHER OPERATING SYSTEMS OF THE VEHICLE TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKEWISE VOID IF THE VEHICLE INVOLVED SHOWS INDICATIONS THAT REASONABLE OR NECESSARY MAINTENANCE AS OUTLINED IN THE OWNERS MANUAL AND MAINTENANCE AND SERVICE MANUAL WAS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS 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 6 HOW TO MAKE A WARRANTY CLAIM To make a warranty claim under this limited warranty you must present the vehicle or defective component to an authorized CLUB CAR dealer or send the defective component freight prepaid to WARRANTY SERVICES CLUB CAR INC 4125 Washington Road Evans Georgia 30809 U S A 706 863 3000 IF THE WARRANTY REGISTRATION FORM IS NOT COMPLETED AND RETURNED TO CLUB CAR AT THE TIME OF THE ORIGINAL RETAIL SALE PURCHASER MUST PROVIDE PROOF OF DATE OF PURCHASE WITH ANY WARRANTY CLAIM Page 54 2007 DS Golf Car Owner s Manual EMISSI
30. N position After placing the Tow Run switch in the RUN position allow 10 seconds to elapse before operating the vehicle The Tow Run switch should be placed in the TOW position under the following conditions e Before Towing the Vehicle Place the Tow Run switch in the TOW position to disable all motor braking functions thus preventing possible damage that could occur to the vehicle or electrical components if the vehicle is towed while the zero speed detect motor braking function is operating e Before Disconnecting or Connecting Battery Cables Place the Tow Run switch in the TOW posi tion to turn off power to the vehicle electrical system thus preventing severe arcing and possible bat tery explosion as the battery cables are disconnected e For Long Term Storage Place the Tow Run switch in the TOW position to turn off power to the vehicle electrical system thus preventing vehicle electrical components from discharging the batteries Figure 10 Tow Run Switch 2007 DS Golf Car Owner s Manual Page 17 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 This will allow the technician to operate
31. ON CONTROL INFORMATION Fuel Information THIS VEHICLE IS CERTIFIED TO OPER ATE ON UNLEADED REGULAR GRADE GASOLINE ONLY A minimum of 87 octane of the anti knock index is recommended The anti knock index is posted on service station pumps in the U S A Emission Control Information To protect the environment in which we all live Club Car has incorporated crankcase emis sion 1 and exhaust emission 2 control sys tems EM in compliance with applicable regu lations of the U S Environmental Protection Agency and California Air Resources Board 1 Crankcase Emission Control System A sealed type crankcase emission control system is used to eliminate blow by gases The blow by gases are led to the breather chamber through the crankcase Then it is led to the air cleaner Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase and then returned back to the bottom of the crankcase 2 Exhaust Emission Control System The exhaust emission control system applied to this engine consists of a carburetor and an ignition system having optimum ignition timing characteristics The carburetors have been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system Maintenance and Warranty Proper maintenance is necessary to ensure that your engine will continue to have low emis sion levels Those items identified by t
32. RVICE Monthly service by owner or trained technician Engine Check engine oil level change if necessary See Periodic Lubrication Schedules on page 31 Check engine cooling air intake clean if necessary Visually inspect the unshrouded area around engine exhaust for grass and debris and clean if necessary Tires Check air pressure and adjust as necessary See Vehicle Specifications on page 45 General vehicle Wash engine compartment and underside of vehicle Do not wash engine when hot Semiannual service by trained technician only every 50 hours of operation or every 100 rounds for golf cars Battery Clean terminals and wash dirt from casing check electrolyte level See Battery Gasoline Vehicles on page 38 Front wheel alignment and camber Check and adjust if necessary See Section 7 Steering and Front Suspension in the appropriate maintenance and service manual Electrical wiring and connections Check for tightness and damage Brake system Check brake shoes replace if necessary Lubricate brake slides See Periodic Lubrication Schedules on page 31 Check brake cables for damage replace if necessary Annual service by trained technician only every 100 hours of operation or every 200 rounds for golf cars Engine Check for leaks around gaskets fill plugs etc Inspect clean and regap spark plug replace if necessary Engin
33. UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY INCLUDING BUT NOT LIMITED TO MODIFICATION OF THE SPEED GOVERNOR BRAKING SYSTEM STEERING TRANSAXLE OR OTHER OPERATING SYSTEMS OF THE CAR TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKEWISE VOID IF THE CAR INVOLVED SHOWS INDICATIONS THAT REASONABLE OR NECESSARY MAINTENANCE AS OUTLINED IN THE OWNER S MANUAL AND MAINTENANCE AND SERVICE MANUAL WAS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS 4 SOLE REMEDY 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 Repair shall mean remedying a defect in the golf car or component thereof at no cost to the purchaser during the applicable limited warranty period If CLUB CAR elects to repair the golf car it may provide factory reconditioned parts or components All parts and components replaced under warranty shall become the property of CLUB CAR 2007 DS Golf Car Owner s Manual Page 4
34. URCE Drive motor Direct drive 48 volts DC shunt wound 3 2 hp Engine 4 cycle OHV 286 cc 9 5 maximum hp 3600 rpm per SAE J 1940 1349 single cyl inder air cooled with pressure lubrication system Fuel system Side draft carburetor with float bowl fixed jets fuel filters and impulse fuel pump Governor Automatic ground speed sensing internally geared in unitized transaxle Ignition Transistor electronic ignition with electronic RPM limiter Transaxle Double reduction helical gear with 12 3 1 direct drive axle Unitized transaxle Fully synchronized forward and reverse with neutral and reduced speed reverse 11 8 1 forward 17 1 1 reverse Torque converter Automatic variable speed dry type Electrical system 48 volts DC reduced speed reverse Electrical system 12 volt 500 cca at 0 F 17 8 C 650 at 32 F 0 C 105 minute reserve capacity and 35 amp charging capacity Batteries High capacity deep cycle 12 volt Charger Automatic 48 volt UL and CSA listed STEERING SUSPENSION BRAKES Steering Self adjusting rack and pinion Suspension Front and rear tapered mono leaf springs with dual hydraulic shocks Brakes Dual rear wheel self adjusting brakes with cast iron drums and single brake pedal with automatic release park brake BODY CHASSIS Frame Chassis Twin Beam welded aluminum Front and rear body ArmorFlex Body finis
35. Y THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE GOLF CAR IS ABUSED OR USED IN AN UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY INCLUDING BUT NOT LIMITED TO MODIFICATION OF THE SPEED GOVERNOR BRAKING SYSTEM STEERING TRANSAXLE OR OTHER OPERATING SYSTEMS OF THE CAR TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKEWISE VOID IF THE CAR INVOLVED SHOWS INDICATIONS THAT REASONABLE OR NECESSARY MAINTENANCE AS OUTLINED IN THE OWNER S MANUAL AND MAINTENANCE AND SERVICE MANUAL WAS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS 4 SOLE REMEDY 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 Repair shall mean remedying a defect in the golf car or component thereof at no cost to the purchaser during the applicable limited warranty period If CLUB CAR elects to repair the golf car it may provide factory reconditioned parts or components All parts and components replaced under warrant
36. able safety guidelines for your location A WARNING Follow the procedures exactly as stated in this manual and heed all DANGER WARNING and CAUTION statements in this manual as well as those on the vehicle and battery charger Do not leave children unattended on vehicle Prior to leaving the vehicle unattended or servicing the vehicle set the park brake place the Forward Reverse handle or switch in the NEUTRAL position turn the key switch to the OFF position and remove the key Chock the wheels when servicing the vehicle Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance severe personal injury or death Any modification or change to the vehicle that affects the stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications could result in severe personal injury or death Check the vehicle for proper location of all vehicle safety and operation decals and make sure they are in place and are easy to read Only trained technicians should service or repair the vehicle or battery charger Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation Gasoline vehicles e To avoid unintentionally starting the vehicle Disconnect battery cables negative cable first
37. any spilled gasoline before operating the vehicle e Store gasoline in an approved gasoline container only Store in a well ventilated area away from sparks open flames heaters or heat sources e Keep gasoline out of reach of children e Do not siphon gasoline from the vehicle A WARNING e 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 e Turn the fuel shut off valve to the closed OFF position Figure 15 A CAUTION e Batteries in a low state of charge will freeze at low temperatures PREPARING THE GASOLINE VEHICLE FOR EXTENDED STORAGE 1 Store vehicle in a cool dry place This will minimize battery self discharge If the battery appears to be weak have it charged by a trained technician Use an automotive type 12 volt battery charger rated at 10 amps or less 2 Drain carburetor and seal the fuel tank 2 1 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout cam in the MAINTENANCE position Turn the fuel shut off valve to the closed OFF position Figure 15 and run the engine until fuel remaining in the carburetor and fuel lines is depleted and the engine stalls Return the neutral lockout cam to the OPERATE position 2 2 Loosen but do not remove the carburetor drain screw and drain fuel remaining in bowl into a small clean
38. as to those items specifically listed above for the periods specified Such repair labor shall be performed only by CLUB CAR its authorized distributors or dealers or a service agency approved by CLUB CAR IF THE WARRANTY REGISTRATION FORM IS NOT COMPLETED AND RETURNED TO CLUB CAR AT THE TIME OF THE ORIGINAL RETAIL SALE PURCHASER MUST PROVIDE PROOF OF DATE OF PURCHASE WITH ANY WARRANTY CLAIM 2 EXCLUSIONS Excluded from any CLUB CAR warranty are all fuses filters decals except safety decals spark plugs light bulbs lubricants trim pieces seats routine wear items such as the charger plug and receptacle brake shoes belts brushes bushings engine mounts mats and pads maintenance adjustments cosmetic deterioration and items which deteriorate or fail due to exposure or ordinary wear and tear Batteries battery charger onboard computer and solid state speed controller are covered under separate CLUB CAR warranties 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 Transportation expenses for warranty services are also excluded from this warranty 3 VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE GOLF CAR IS ABUSED OR USED IN AN
39. ation of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state 8 INFORMATION For further information contact WARRANTY SERVICES CLUB CAR INC P O Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 9 WARNING Any modification or alteration of any golf car beyond factory specifications including those that affect the weight distribution stability or speed of the golf car can cause serious personal injury or death CLUB CAR LIMITED LIFETIME WARRANTY FOR 2007 FLEET GOLF CARS 1 Warranty CLUB CAR INC CLUB CAR hereby warrants to the Original Retail Fleet Purchaser or Original Retail Fleet Lessee as those terms are defined herein and subject to the provisions limitations and exclusions contained in this limited warranty that its new 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 LIMITED LIFETIME WARRANTY The golf car frame excluding the front and rear bumper mounts rack and pinion steering gearbox unit and suspension system defined as the shock absorbers shock mounts A plates leaf s
40. ay from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries Tools wires and metal objects can cause sparks when shorted across a battery Follow all instructions carefully when working with batteries Charge battery in a well ventilated area only Battery Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes DANGER CONTINUED ON NEXT PAGE Page 38 2007 DS Golf Car Owner s Manual Battery Gasoline Vehicles A DANGER External Flush with water Call a physician immediately Internal Drink large quantities of milk or water followed with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately A WARNING e 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 Rinse solution off the battery Do not allow this solution to enter battery Be sure terminals are tight battery terminals should be tightened to 12 ft lb 16 N m Let the terminals dry and
41. cessary See Vehicle Specifications on page 45 General vehicle Wash battery compartment and underside of vehicle Semiannual service by trained technician only every 50 hours of operation or 100 rounds of golf Brake system Check brake shoes replace if necessary See Section 6 Wheel Brake Assemblies in the appropriate maintenance and service manual Lubricate brake slides per Lubrication Schedule See Section 6 Wheel Brake Assemblies in the appropriate maintenance and service manual Check brake cables for damage replace if necessary Electrical wiring and connections Check for tightness and damage Forward Reverse switch Check condition of contacts and wire connections Make sure connections are tight Front wheel alignment and camber Check and adjust as required See Section 7 Steering and Front Suspension in the appropriate maintenance and service manual Motor controller output regulator MCOR Check for loose hardware cracks and other damage Annual service by trained technician only every 100 hours of operation or 200 rounds of golf Batteries If batteries are not performing as expected see Section 13 Batteries in the appropriate maintenance and service supplement 2007 DS Golf Car Owner s Manual Page 29 Periodic Service Schedules PERIODIC SERVICE SCHEDULE GASOLINE VEHICLES REGULAR INTERVAL SE
42. e a solution of 10 liquid soap and warm water applied with a soft cloth For imbedded dirt a soft bristle brush may be used For heavy soiling difficult stains or scratches blemishes or other body damage see Section 4 of the appropriate maintenance and ser vice manual NOTE Dispose of waste water properly ACCESSORIES 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 Care should be taken that these accessories are properly installed by trained technicians and that they are used in the manner for which they were designed See following WARNING A WARNING e Tinted windshields and weather proof enclosures will not protect occupants from flying objects golf balls etc Page 44 2007 DS Golf Car Owner s Manual 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 Inc P O Box 204658 Augusta Georgia 30917 4658 Attention Vehicle Registration VEHICLE SPECIFICATIONS SPECIFICATIONS IQ SYSTEM ELECTRIC GASOLINE POWER SO
43. e air intake system Check air filter element clean or replace if necessary Check clamps for tightness check hose for cracks General vehicle Check for loose hardware and tighten if necessary Two year service by trained technician only every 200 hours of operation or every 400 rounds for golf cars Fuel filters Replace Dispose of used filters properly A WARNING e If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal injury or death Page 30 2007 DS Golf Car Owner s Manual Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE ELECTRIC VEHICLES REGULAR INTERVAL SERVICE LUBRICATION RECOMMENDED LUBRICANT Semlannually by owner Brake pedal shaft beari Dry Moly L P N 1012151 Seine CCH rake pedal shaft bearings ow ry Moly Lube CCI P N 1012151 every 50 hours of f operation or 100 rounds Brake linkage and pivots Dry Moly Lube CCI P N 1012151 of golf Accelerator pivot rod supports E Dry Moly Lube CCI P N 1012151 Charger receptacle A Te WD 40 Brake slides Ga Dry Moly Lube CCI P N 1012151 Front suspension 5 fittings Q Chassis Lube EP NLGI Grade 2 Annually by trained technician only 22 oz 0 67 L SAE 30 WT API Class every 100 hours of C
44. e does not slow down at the normal rate continue to press the brake pedal until the brakes dry out and normal performance returns A CAUTION e When stopped on a hill use the brake pedal to hold your position Do not use the accelerator pedal To stop the vehicle release the accelerator pedal and press the brake pedal with your right foot until the vehi cle comes to a complete stop PARKING AND LEAVING THE VEHICLE 1 After stopping the vehicle firmly press the park brake pedal until it locks This will prevent the vehicle from rolling 2 Turn the key switch to the OFF postion and place the Forward Reverse handle or switch in the NEUTRAL position Remove the key when the vehicle is not in use e Electric vehicles only When the Tow Run switch is in the RUN position with the Forward Reverse switch or key switch in any position the zero speed detect function will prevent the vehicle from roll ing at more than 1 to 3 mph 1 5 to 4 8 km h unless the accelerator is pressed This prevents the pos sibility of a parked vehicle with the park brake disengaged rolling away too fast to be overtaken on foot e Gasoline vehicles only Turn the fuel shut off valve to the closed OFF position when the vehicle is not in use TOWING A WARNING e Do not tow the vehicle on public streets or highways e Use only approved Club Car tow bars e Turn the key switch to the OFF position and place the Forward Reverse handle or switc
45. e of California to cause cancer and birth defects or other reproductive harm Page 8 2007 DS Golf Car Owner s Manual Safety Details SAFETY DETAILS A WARNING e This owner s manual should be read completely before attempting to drive or service the vehicle Failure to follow the instructions in this manual could result in property damage severe personal injury or death It is important to note that some vital statements throughout this manual and on the decals affixed to the vehi cle are preceded by the words DANGER WARNING or CAUTION For your protection we recommend that you take special notice of these safety precautions Safety precautions are essential and must be followed Throughout this manual and on the operation and safety decals affixed to the vehicle the words golf car and vehicle are used interchangeably Golf car is defined in the Notice of this manual and no other representa tion is stated or implied 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 A DANGER e A DANGER indicates an immediate hazard that will result in severe personal injury or death A WARNING e A WARNING indicates an immediate hazard that could result in severe personal injury or death A CAUTION e A C
46. e steering wheel General Listen for any unusual noises such as squeaks or rattles Check the vehicle s ride and perfor mance Have a Club Car distributor dealer or a trained technician investigate anything unusual Electric Vehicles e Accelerator With the key switch in the ON position and the Forward Reverse switch in the FOR WARD position as the accelerator pedal is pressed the motor should start and the vehicle should accelerate smoothly to full speed When the pedal is released it should return to the original position and the motor should rotate freely or go into motor braking mode See Pedal Up Motor Braking below All Club Car vehicles operate at reduced speed in reverse Zero Speed Detect With the vehicle parked on level ground and the park brake disengaged place the Tow Run switch in the RUN position and attempt to push the vehicle Motor braking should engage and cause resistance to rolling moving at no more than 1 to 3 mph 1 5 to 4 8 km h with the Forward Reverse switch in any position When zero speed detect motor braking is engaged the reverse buzzer should emit a distinct pattern of beeps See following WARNING Page 20 2007 DS Golf Car Owner s Manual Driving Instructions A WARNING e Zero speed detect will not limit vehicle speed to 1 mph 1 6 km h on very steep grades Do not operate vehicle on slopes exceeding 20 grades Pedal Up Motor Braking adjustable on IQ System vehicles Accelerate the vehic
47. e them to overheat during operation 4 After use the batteries should be placed on charge The batteries should never be left discharged any longer than absolutely necessary do not leave discharged overnight LEVEL BATTERY CAP INDICATOR ELECTROLYTE LEVEL AT LEAST 1 2 INCH 13 MM ABOVE PLATES OR TO LEVEL INDICATOR Figure 20 Electric Battery Electrolyte Level Page 34 2007 DS Golf Car Owner s Manual Battery Charger Electric Vehicles BATTERY CHARGER ELECTRIC VEHICLES A DANGER The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the charging area must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosion A 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 Connect the charger AC supply cord to a properly grounded three wire outle
48. e while moving s Do not start vehicle until all occupants are seated Two 2 persons per seat maximum Operate from driver side only and not on public roads Keep entire body inside vehicle while moving Drive slowly in turns and straight up and down slopes Do not leave children unattended on vehicle e Never operate under the influence of alcohol or drugs s Use brakes to reduce speed when coasting downhill e Never stand in front of or behind vehicle CCI 101960601 Parkbrake will release and vehicle will start moving when accelerator pedal is pressed Slowly press accelerator pedal to increase speed Tostop release accelerator pedal and press brake pedal BEFORE LEAVING Press park brake pedal until it locks and holds vehicle Place Forward Reverse switch in NEUTRAL position Tum key OFF and remove key when not in use DRIVER PASSENGER WARNING DECAL CCI 102519201 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 Vehicle Feature Identification DS GASOLINE VEHICLE A WARNING GASOLINE EXPLOSION FIRE e Can cause severe injury or death e No smoking sparks or open flame ROTATING PARTS AND St ine allow t bef fueling Turn fuel valve on during operation HOT MANIFOLD DECAL off during storage or transport CCI 101547601 ON
49. ear items and should be inspected daily Visually inspect them for cracks loose connections and frayed wiring they must be replaced when worn or damaged If charger plug or receptacle show signs of corrosion or the plug is difficult to insert or remove the receptacle contacts and plug terminals should be cleaned with a good electrical contact cleaner or lightly sprayed with WD 40 brand spray lubricant The plug should then be inserted and removed several times to ensure ease of inser tion ease of removal and good electrical contact See following NOTE NOTE Ifthe warning tag has been damaged or removed from the DC cord have it replaced immediately 2007 DS Golf Car Owner s Manual Page 37 Battery Gasoline Vehicles 48 VOLT FUSE LINK lt A N e LEAD Figure 23 Receptacle Fuse Link RECEPTACLE FUSE LINK As an additional feature to protect the batteries and charging circuit from an overload the electric vehicle is equipped with a receptacle fuse link Figure 23 If the charger does not come on when the vehicle is placed on charge visually inspect the fuse link See following WARNING A WARNING e 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 A DANGER Battery Explosive gases Do not smoke Keep sparks and flames aw
50. eet Lessee This limited warranty covers material workmanship and repair labor cost as to those items specifically listed above for the periods specified Such repair labor shall be performed only by CLUB CAR its authorized distributors or dealers or a service agency approved by CLUB CAR IF THE WARRANTY REGISTRATION FORM IS NOT COMPLETED AND RETURNED TO CLUB CAR AT THE TIME OF THE ORIGINAL RETAIL SALE PURCHASER MUST PROVIDE PROOF OF DATE OF PURCHASE WITH ANY WARRANTY CLAIM 2 EXCLUSIONS Excluded from any CLUB CAR warranty are all fuses filters decals except safety decals spark plugs light bulbs lubricants trim pieces seats routine wear items such as the charger plug and receptacle brake shoes belts brushes bushings engine mounts mats and pads maintenance adjustments cosmetic deterioration and items which deteriorate or fail due to exposure or ordinary wear and tear Batteries battery charger onboard computer and solid state speed controller are covered under separate CLUB CAR warranties 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 Transportation expenses for warranty services are also excluded from this warranty 3 VOIDING OF WARRANT
51. f the receptacle Do not connect a charger to the receptacle if the charger cord plug or the vehicle receptacle is broken damaged in any manner or does not make a good electrical connection Fire or personal injury can result Have it replaced by a qualified service person immediately 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 The plug and receptacle feel hotter than normal during charge The plug pins or receptacle contacts are bent or corroded The plug receptacle or cords are cut worn have any exposed wires or are damaged in any way Using the charger with any of the above symptoms could result in a fire property damage personal injury or death NOTE When temperatures fall below 65 F 18 3 CL batteries charged in unheated areas should be placed on charge as soon as possible after use Batteries are warmest immediately after use and cold batteries require more time to fully charge Page 36 2007 DS Golf Car Owner s Manual Battery Charger Electric Vehicles Insert the charger DC plug into the vehicle receptacle The charger will turn on two to ten seconds later Figure 21 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
52. first DISCONNECT BATTERY CABLES BEFORE WORKING ON VEHICLE E Remove negative cable first Figure 1 Gasoline Vehicle Figure 2 IQ System Electric Vehicle 12 Volt Battery Configuration GENERAL INFORMATION This manual features two DS Golf Car models the IQ System 48 volt electric vehicle and the gasoline vehi cle Throughout this manual important features unique to each model are highlighted We urge the owner operator to read and understand this manual and to pay special attention to the features specific to his her vehicle s 2007 DS Golf Car Owner s Manual Page 11 Model Identification MODEL IDENTIFICATION The serial number of the vehicle is printed on a bar code decal mounted on the frame directly above the accel erator pedal Example AQ0601 123456 Figure 3 There is also a second serial number decal mounted on the front body frame behind the center dash panel 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 AQO601 123456 il Figure 3 Serial Number Decal SAFETY COMMITTEE If the golf car is to be rented or is part of a fleet we strongly recommend that a safety committee be appointed One of the main concerns of this committee should be the safe operation of the golf cars This should include at a minimum e Where golf cars should be dri
53. from the oil filler tube and wipe oil off dipstick 1 Figure 26 See follow ing CAUTION CAUTION e Do not remove dipstick while engine is running 2 Check oil by fully inserting the dipstick into the oil filler tube 2 and immediately removing it 3 If the oil level is at or below the low level mark on the dipstick gauge add oil until the level is between low and full levels safe level 3 4 Insert the dipstick into the oil filler tube See following NOTE NOTE Properly recycle or dispose of used oil in accordance with local state and federal regulations Figure 26 Engine Oil Level Check ENGINE OIL AND FILTER CHANGE Engine oil and oil filter should be changed after the first 100 hours of operation After that they should be changed every 200 hours of operation or annually whichever comes first 1 Turn the key switch to the OFF position then remove the key Place the Forward Reverse handle in the neutral POSITION Chock the front wheels 2 Access the engine compartment 3 Disconnect the battery cables negative cable first See WARNING To avoid unintentionally start ing on page 10 4 Position a pan designed for oil changes under the front drain plug Figure 27 Page 40 2007 DS Golf Car Owner s Manual 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 d
54. h Matched paint finish over molded in color Tires 18 x 8 5 8 tubeless 4 ply rated DIMENSIONS WEIGHT Overall length 91 5 in 232 cm Overall width 47 25 in 120 cm Overall height with canopy 68 5 in 174 cm Overall height at steering wheel 48 in 122 cm Wheelbase 65 5 in 166 cm Vehicle Specifications continued on next page 2007 DS Golf Car Owner s Manual Page 45 Vehicle Specifications IQ SYSTEM SPECIFICATIONS ELECTRIC GASOLINE 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 Ib 224 kg Weight dry without battery 619 Ib 281 kg Forward speed 12 15 mph 19 24 km h Curb clearance circle diameter 17 ft 6 in 533 cm Braking distance at 12 mph 19 km h 14 ft 427 cm Standard seating capacity 2 LIQUID CAPACITIES Transaxle 22 oz 0 67 L Engine crankcase without filter 32 oz 0 95 L Engine crankcase with filter 38 oz 1 12 L Unitized transaxle 27 oz 0 8 L Fuel tank 7 gallons 26 5 L TIRE PRESSURE Frontandtear 1 241 38 Bars 0 88 0 96 Bars Page 46 2007 DS Golf Car Owner s Manual CLUB CAR LIMITED THREE YEAR WARRANTY FOR 2007 INDIVIDUAL GOLF CARS 1 WARRANTY C
55. h in the NEUTRAL position before towing the vehicle e Extreme caution should be used when towing any vehicle e Do not exceed 5 mph 8 km h towing speed e Do not allow people in the vehicles being towed e Avoid sudden starts sudden stops and tight turns when towing WARNING CONTINUED ON NEXT PAGE 2007 DS Golf Car Owner s Manual Page 23 Transporting on a Trailer A WARNING Avoid stopping on a hill when towing If you must stop on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning could cause the vehicle to overturn possibly resulting in severe personal injury 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 Only heavy duty tow bars should be used for multi vehicle towing Never tow more than five vehicles at one time Electric vehicles only Place the Tow Run switch in TOW position otherwise the vehicle will not roll while being towed Gasoline vehicles only Turn the fuel shut off valve to the closed OFF position Figure 15 Page 27 All vehicles are equipped with both front and rear tow bar attaching points A light duty tow bar is available for break down towing and single vehicle towing A heavy duty tow bar and an onboard tow bar are available for multi vehicle
56. he Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards The Club Car Limited Emission Control System Warranty requires that you return your engine to an authorized Club Car Dealer for remedy under warranty Please read the warranty carefully and keep it valid by complying with the owner s obligations it contains Tampering with Emission System Prohibited California State law prohibits the following Control FUEL AND OIL RECOMMENDATIONS Fuel Use only clean fresh unleaded regular grade gasoline Octane Rating The octane rating of a gasoline is a measure of its resistance to knocking Use of a mini mum of 87 octane of the anti knock index is recommended The anti knock index is posted on service station pumps in the U S A NOTE elf knocking or pinging occurs use a different brand of gasoline or higher octane rating 4 CAUTION so not mix oil with gasoline Oxygenated Fuel If you use oxygenated fuel either ethanol or MTBE added to gasoline be sure it is unleaded and meets the minimum octane rating require ment The following are the EPA approved percent ages of fuel oxygenates ETHANOL Ethyl or Grain Alcohol You may use gasoline containing up to 10 ethanol by volume MTBE Methyl Tertiary Butyl Ether You may use gasoline containing up to 15 MTBE by volume METHANOL Methanol or Wood Alcohol 5 by volume You may use gasoline conta
57. he warning lamp will repeatedly illuminate for 10 seconds with 4 second intervals during a charge cycle DC plug is still connected if AC power to the charger is interrupted The lamp will go out when AC power is restored LED lamp In addition to the warning lamp there is an infrared LED in the dash lamp assembly which trans mits an infrared signal from the onboard computer OBC This signal is received by the optional Communi cation Display Module CCI P N 101831801 which provides information on the condition of the vehicle and batteries Page 16 2007 DS Golf Car Owner s Manual Controls and Indicators TOW RUN SWITCH IQ System Electric Vehicles Only A WARNING e 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 e When the Tow Run switch is in the TOW position all motor braking functions including zero speed detect are disabled IQ System vehicles are equipped with a Tow Run switch located under the seat just above the Forward Reverse switch Figure 10 The switch must be in the RUN position in order to operate the vehicle When the switch is in the TOW position power to the vehicle electrical components is turned off and the vehicle will not operate See following NOTE NOTE After placing the Tow Run switch in the TOW position allow 10 seconds to elapse before switching back to the RU
58. heck fill transaxle to plug level Q 8 Operation or 200 rounds SE SF or SG Oil or higher of golf Figure 18 Lubrication Points Electric Vehicles 2007 DS Golf Car Owner s Manual Page 31 Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULE GASOLINE VEHICLES REGULAR INTERVAL SERVICE LUBRICATION RECOMMENDED LUBRICANT Semiannually by owner Brake pedal shaft bearings Oo Dry Moly Lube CCI P N 1012151 or trained technician every 50 hours of f operation or every 100 Brake linkage and pivots Dry Moly Lube CCI P N 1012151 rounds of golf Eeer SEET ccelerator push rod pivots mounts and shifter cable pivots Ek Dry Moly Lube CCI P N 1012151 Front suspension 5 fittings Chassis Lube EP NLGI Grade 2 Brake slides Ga Dry Moly Lube CCI P N 1012151 Annually by trained technician only 2 27 oz 0 8 L 80 90 WT API Class every 100 hours of GE E er GL 3 or 80 90 WT AGMA Class EP Operation or every 200 plug Gear Lube rounds of golf First change 100 hours additional change every 200 hours of i St 32 oz 0 95 L without filter 38 oz 1 12 operation or every 400 Change engine oil and oil filter 7 L with filter rounds of golf or annually whichever comes first
59. hicle 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 When the batteries receive an incomplete charge because 1 the DC power cord is disconnected 2 AC power to the charger is interrupted 3 automatic charger shut off occurs after 16 hours of operation 4 the charger malfunctions or 5 the wrong charger is used the warning lamp will indicate as follows e The warning lamp will not illuminate if the charge is 90 or more complete The onboard computer will retain in memory the amount of charge needed to fully replenish the batteries and will complete the charge during the next charge cycle When the charger is unplugged the warning lamp will illuminate and remain illuminated for 10 seconds if the charge is less than 90 complete but the vehicle has enough power for approximately 30 min utes of operation This will alert the operator that the vehicle may be used but that it must be charged to completion as soon as possible The warning lamp will repeatedly illuminate for 10 seconds with 4 second intervals if the charger times out at 16 hours and the batteries are not sufficiently charged See the battery charger owner s man ual This indicates an abnormal charge cycle The charger and batteries should be checked by your Club Car distributor dealer T
60. ic work is performed at a warranty station 7 CLUB CAR is liable for damages to other engine or equipment components proximately caused by a failure under warranty of any warranted part 8 Throughout the engine or equipment warranty period stated above CLUB CAR will maintain a supply of warranted parts sufficient to meet the expected demand for such parts 9 Any replacement part may be used in the performance of any warranty maintenance or repairs and must be provided without charge to the owner Such use will not reduce the warranty obligations of CLUB CAR 10 Add on or modified parts that are not exempted by the Air Resources Board may not be used The use of any non exempted add on or modified parts by the ultimate purchaser will be grounds for disallowing a warranty claims 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 CLUB CAR its authorized dealers or a service agency approved by CLUB CAR ITEMS COVERED BY THIS WARRANTY The repair or replacement of any warranted part otherwise eligible for warranty coverage may be excluded from such warranty coverage if CLUB CAR demonstrates that the engine or equipment has been abused neglected or improperly maintained and that such abuse neglect or improper maintenance was the direct cause of the need for repair or replacement of the part That notwithstanding any adjustment of a component that has a factory insta
61. ications on page 45 6 Perform the Pre Operation and Daily Safety Checklist on page 19 MAINTENANCE See General Warnings on page 9 To ensure trouble free vehicle performance it is very important to follow an established preventive mainte nance program Regular and consistent vehicle maintenance can prevent vehicle downtime and expensive repairs that can result from neglect Use the Pre Operation and Daily Safety Checklist on page 19 and the fol lowing Periodic Service Schedules and Periodic Lubrication Schedules to keep the vehicle in proper working condition 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 A WARNING e If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal injury or death e Hot Do not attempt to service hot engine motor resistors or exhaust system Attempting to do so could cause severe burns Gasoline vehicles only Moving parts Do not attempt to service gasoline vehicle while the engine is running Turn the fuel shut off valve to the closed OFF position Figure 15 Page 27 To avoid uni
62. ining up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may also dam age metal rubber and plastic parts of your fuel system A WARNING Gasoline is extremely flammable and can be explosive under certain con ditions Turn the engine switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Never fill the tank so the fuel level rises into the filler neck H the tank is overfilled heat may cause the fuel to expand and overflow through the vent in the fuel tank Engine Oil The following engine oils are recommended API Service Classification SC SD SE SF SG or SH 2007 DS Golf Car Owner s Manual acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replace ment of any device or element of design incor porated into any new engine for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the engine after such device or element of design has been removed or rendered inopera tive by any person Among those acts presumed to constitute tampering are the acts listed below Do not tamper with
63. ious personal injury or death CLUB CAR LIMITED FOUR YEAR WARRANTY FOR 2007 DEEP CYCLE 12 VOLT BATTERIES CLUB CAR INC CLUB CAR hereby warrants to the original retail purchaser that the Deep Cycle 12 volt Battery installed in its new DS electric vehicle equipped with the IQ System purchased from CLUB CAR or an authorized distributor or dealer will be free from defects in material and workmanship and will provide 36 hole performance 60 minute discharge capacity for a period of four years or 800 rounds whichever first occurs from the date of purchase subject to the terms and conditions contained herein This limited warranty only covers defects in material and workmanship for a period of four years or 800 golf car rounds from date of purchase The terms of this four year or 800 round limited warranty shall be as follows Vehicles used for golf free replacement with respect to parts and labor within four years or 800 rounds whichever first occurs from date of purchase Vehicles used for purposes other than golf free replacement with respect to parts and labor within four years or 16 000 energy units as recorded by the Onboard Computer whichever first occurs from the date of purchase The battery should be returned to an authorized CLUB CAR distributor or dealer with evidence of proof of purchase date and number of rounds freight prepaid CLUB CAR reserves the right to test and recharge any battery returned for adjustment and to
64. ith 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 Do not allow this solution to enter the battery Be sure terminals are tight Let the terminals dry and then coat with Battery Terminal Protector Spray CCI P N 1014305 See following NOTE NOTE Dispose of waste water properly 2 The electrolyte level in the batteries should be checked weekly Figure 20 Add water only after charg ing unless the electrolyte level is below the top of the plates In this case add just enough water to cover the plates charge and then check the level again Never charge batteries if plates are exposed above electrolyte level For best battery life add only distilled water See following CAUTION and NOTE A CAUTION e Do not overfill the batteries NOTE A battery watering gun or bottle is available at many auto parts dealers 3 The hold down straps 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 Tighten hold down retaining nuts to 55 in lb 6 2 N m The terminal connections should be clean and tight and any worn insulation or frayed wires should be replaced Tighten battery terminals to 110 in Ib 12 4 N m See following CAUTION A CAUTION e If battery wire terminals are damaged or corroded they should be replaced or cleaned as necessary Failure to do so may caus
65. iver park on a slope and leave the vehicle without locking the park brake The vehicle will roll at about 1 mph 1 6 km h If the zero speed detect function remains engaged for two seconds or more a warning buzzer will sound to alert the driver that motor braking has been activated See following WARNING A WARNING e Zero speed detect will not limit vehicle speed to 1 mph 1 6 km h on very steep grades Do not operate vehicle on slopes exceeding 20 grades e Pedal Down Motor Braking This feature helps to control vehicle downhill speed Motor braking is activated when the vehicle reaches the programmed top speed and holds the vehicle at that speed Motor braking is automatically disengaged when vehicle speed slows below the programmed top speed e Pedal Up Motor Braking When vehicle speed is above 11 mph 17 7 km h releasing the accelerator pedal will activate motor braking which slows the vehicle speed 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 To slow or stop the vehicle press the brake pedal with your foot Figure 8 Figure 8 Brake Pedal Figure 9 Park Brake Pedal PARK BRA
66. le engine In California new small off road engines SORE must be designed built and equipped to meet the State s stringent anti smog standards CLUB CAR must warrant the emission control system on the vehicle engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your small off road engine Your emission control system may include parts such as the carburetor or fuel injection system the ignition system and catalytic converter Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists CLUB CAR will repair your vehicle engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE This emission control system is warranted for two years If any emission related part on your equipment is defective the part will be repaired or replaced by CLUB CAR OWNER S WARRANTY RESPONSIBILITIES As the vehicle engine owner you are responsible for the performance of the required maintenance listed in your owner s manual 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 As the vehicle engine owner you should however be aware that CLUB CAR may deny you warranty coverage if vehicle engine or a part has failed due to abuse
67. le to full speed and then release the accelerator pedal 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 Pedal Down Motor Braking Accelerate down an incline with the accelerator pedal pressed When the vehicle reaches maximum designed speed motor braking should engage and limit the vehicle to its maximum designed speed On very steep grades the vehicle may slightly exceed its maximum designed speed requiring use of the brake pedal Gasoline Vehicles e Accelerator With the key switch in the ON position and the Forward Reverse switch in the FOR WARD position as the accelerator pedal is pressed the engine should start and the vehicle should accelerate smoothly to full soeed 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 e Governor Check maximum speed of the vehicle The vehicle should operate at 12 15 mph 19 24 km h on a level surface DRIVING INSTRUCTIONS A WARNING Only licensed drivers should be allowed to drive the vehicle If renting or loaning the vehicle make sure the driver is familiar with all controls and Operating procedures before allowing the
68. lled and properly operating adjustment limiting device is still eligible for warranty coverage The following emission warranty parts list are covered SYSTEMS COVERED PARTS DESCRIPTION Fuel Metering Carburetor assembly fuel injection pump fuel injection nozzle fuel regulator Exhaust Catalyst Air Induction Air filter housing air filter crankcase breather tube Ignition Flywheel magneto ignition pulse generator ignition coil assembly ignition control module spark plug cap spark plug Positive Crankcase Ventilation PCV System PCV valve oil filler cap Misc Parts Belts fuel hose hosing tubing fittings seals gasket and clamps associated with the above systems Emission related parts will vary between vehicles therefore certain vehicles my not include all of the listed parts or may include equivalent parts 3 EXCLUSIONS Excluded from this warranty is damage to a vehicle 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 This warranty covers only those failures resulting from defects in material or workmanship Transportation expenses for warranty services are also excluded from this warranty 4 VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICLE IS ABUSED OR USED IN AN UNINTENDED
69. manual may be photocopied reproduced or translated to another language without the written consent of Club Car Inc The information contained in this document is subject to change without notice Club Car reserves the right to make design changes to vehicles without obligation to make these changes on units previously sold These vehicles do not conform to Federal Motor Vehicle Safety Standards for automobiles or to FMVSS 500 for low speed vehicles and are not equipped for operation on public streets roads or highways Club Car P O Box 204658 Augusta Georgia 30917 4658 USA Telephone 706 863 3000 Service Parts Fax 706 855 7413 www clubcar com Copyright 2006 Club Car Inc Club Car PowerDrive and ArmorFlex are registered trademarks of Club Car Inc This manual effective July 31 2006 2007 DS Golf Car Owner s Manual Page 1 FOREWORD Thank you for choosing Club Car the name most widely recognized as the industry leader in vehicle efficiency and long lasting value You have chosen the finest golf car on the market Please protect your investment and ensure that your Club Car vehicle s provides years of reliable superior performance by reading and following the maintenance instructions in this manual Your comfort and safety are important to us so we urge you to read and follow the step by step operating instructions and safety procedures in this manual These instructions must be followed in order to avoid the
70. nded The charger is equipped with an AC electric cord having an equipment grounding conductor and a grounding type plug The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electrical Code and all local codes and ordinances See the owner s manual supplied with the charger for specific operating instructions before using the charger The use of an extension cord with the charger should be avoided If an extension cord must be used use a three conductor no 12 AWG American Wire Gauge or no 14 SWG British Standard Wire Gauge heavy duty cord with ground properly wired and in good electrical condition Keep it as short as possible no more than 12 feet 3 7 m Place all cords so they will not be stepped on tripped over or otherwise subject to dam age or stress Ensure that the charger ventilation slots are unobstructed and that there is adequate ventilation CHARGING BATTERIES A WARNING e Be sure all wire connections at the receptacle and the fuse link are clean and tight e Do not rock or bend the plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 21 Page 37 Do not pull on the DC cord Figure 22 Page 37 Do not twist rock or bend the plug To disconnect the charger plug from the vehicle receptacle grasp the plug by the handle and pull the plug straight out o
71. ntentionally starting the vehicle before servicing always disconnect the battery negative cable first Figure 1 Page 11 and disconnect the spark plug wire from the spark plug Frame ground Do not allow tools or other metal objects to contact frame when disconnecting batteries or other electrical wiring Never allow a positive wire to touch the vehicle frame engine or other metal component Page 28 2007 DS Golf Car Owner s Manual PERIODIC SERVICE SCHEDULES See General Warnings on page 9 A WARNING Periodic Service Schedules e 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 Both the Periodic Service Schedule and Periodic Lubrication Schedule must be followed to keep vehicle in optimum operating condition PERIODIC SERVICE SCHEDULE ELECTRIC VEHICLES REGULAR INTERVAL SERVICE Daily service by owner Batteries Charge batteries after each use only A Check electrolyte level Add water if Weekly service by owner Batteries necessary See page 34 Monthly service by owner Batteries Wash battery tops and clean terminals or trained technician with baking soda water solution Check air pressure and adjust if Tires ne
72. o not use an open end wrench to remove the drain plug turning it counterclockwise and allow the engine oil to drain into the pan See following WARNING A WARNING e Do not attempt to change engine oil when the engine is hot or even warm Engine oil can cause skin burns e Wear safety glasses or approved eye protection when servicing the vehicle Wear rubber gloves when handling oil drain plug oil filter and oil drain pan 6 Clean the oil drain plug threads with solvent to remove oil and oil residue Make sure that the compres sion washer remains on the drain plug 7 Use a 14 mm socket or box end do not use an open end wrench and replace the front oil drain plug turning it clockwise and tighten to 18 ft lb 24 4 N m 8 Relocate the oil drain pan to a position under the engine oil filter Figure 27 9 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 28 See following NOTE NOTE An oil drip guard 3 can be used to prevent excess oil from dripping into the engine base plate Use an empty quart one liter container and cut the bottom off at an angle then slide the open area of the container up and under the oil filter prior to removing Position the port of the plastic container so oil will be directed into the oil pan Or make a drip guard by folding a piece of card board thin metal or plastic under the oil
73. of purchase date and number of rounds freight prepaid CLUB CAR reserves the right to test any Computer returned for warranty and to verify number of rounds played by accessing information contained in the Computer LIMITED WARRANTY EXCLUSIONS THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOT APPLY TO FAILURE DUE TO 1 Abuse or neglect such as improper battery fluid levels loose wiring or rusted or corroded hardware 2 Lack of proper maintenance as outlined in the electric vehicle owner s manual 3 Damages caused by improper installation of the Computer or Controller 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 As in the use of any battery operated device 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 and will exercise due care in working on or around batteries Transportation expenses for warranty services are also excluded from this warranty WARRANTY LIMITATIONS CLUB CAS liability under this limited warranty shall be to replace a defective Computer or Controller Replacement shall be furnishing a new or recondi
74. of 1200 Ib 544 kg per vehicle being transported NOTE A two car trailer should be rated at 2 x 1200 2400 Ib 2 x 544 1088 kg Page 24 2007 DS Golf Car Owner s Manual Storage Electric Vehicles STORAGE ELECTRIC VEHICLES See General Warnings on page 9 A WARNING e 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 Place Tow Run switch in the TOW position e Do not attempt to charge frozen batteries or batteries with bulged cases Discard the battery Frozen batteries can explode A CAUTION e Batteries in a low state of charge will freeze at low temperatures e To avoid exposing electrical components to moisture and subsequent damage do not use any type of pressure washing or steam cleaning equipment to wash the vehicle PREPARING THE ELECTRIC VEHICLE FOR EXTENDED STORAGE 1 2 ON OO AR w Fully charge batteries See Charging Batteries on page 36 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 Do not allow this solution to enter the batteries Be sure terminals are tight Let the terminals dry and then coat them with Battery Terminal Protector Spray CCI P N 1014305
75. or by an authorized distributor or dealer Purchaser shall be responsible for all freight costs to and from CLUB CAP s facility LIMITED WARRANTY EXCLUSIONS THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOT APPLY TO FAILURE DUE TO 1 Lack of normal maintenance services such as preventive maintenance checks and tightening loose wire connections 2 Semiconductor parts such as diodes and fuses which are vulnerable to electrical overloads including lightning beyond the control of CLUB CAR 3 Charger DC cord set with plug which is a wear item and subject to user abuse Any warranty service which includes labor during the first year must be performed by CLUB CAR or by an authorized distributor or dealer For repairs made by qualified technicians other than CLUB CAR s factory technicians or an authorized distributor or dealer CLUB CAR will provide only the replacement parts or components 2007 DS Golf Car Owner s Manual Page 51 The PowerDrive Chargers are intended to be used by persons with knowledge of the chargers and proper charging practices and only on CLUB CAR PowerDrive System 48 PowerDrive Plus and IQ System vehicles Any other use renders the 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
76. parts should be in place and properly installed Be sure that all nuts bolts and screws are tight On gasoline vehicles check all hose clamps for tight fit as well as the starter belt for tightness e Safety and information decals Check to ensure that all safety and information decals are in place See pages 4 through 7 e Tires Check for proper tire pressure Visually inspect tires for wear damage and proper inflation on a daily basis See Vehicle Specifications on page 45 e Battery ies Check electrolyte to ensure that it is at its proper level Figure 20 Page 34 or Figure 25 Page 39 Check battery posts Wires should be tight and free of corrosion On electric vehicles charge batteries fully before first use of vehicle 2007 DS Golf Car Owner s Manual Page 19 Performance Inspection e Charger cord plug and receptacle electric vehicles Visually inspect for cracks loose connec tions and frayed wiring See Plug and Receptacle on page 37 e Engine gasoline vehicles Check for proper engine oil level See Engine Oil Gasoline Vehicles on page 40 e Fuel gasoline vehicles Check fuel level See Fueling Instructions Gasoline Vehicles on page 43 Check fuel tank lines cap pump fuel filters and carburetor for fuel leakage e Exhaust system gasoline vehicles Check for leaks A WARNING e Be sure the plastic has been removed from the seat bottom before operating the vehicle Failure to do so may result
77. prings shackles and associated hardware are warranted for the lifetime of the vehicle with respect to parts and labor against defects in material and workmanship from the date of purchase while owned by the Original Retail Fleet Purchaser or in the possession of the Original Retail Fleet Lessee LIMITED THREE YEAR WARRANTY The gasoline engine torque converter drive and driven unitized transaxle starter generator transaxle electric vehicle and electric motor are warranted for a period of three years with respect to parts and labor against defects in material and workmanship from the date of purchase while owned by the Original Retail Fleet Purchaser or in the possession of the Original Retail Fleet Lessee LIMITED TWO YEAR WARRANTY All remaining components of the golf car not specified otherwise except options and accessories are warranted for a period of two years with respect to parts and labor against defects in material and workmanship from the date of purchase while owned by the Original Retail Fleet Purchaser or in the possession of the Original Retail Fleet Lessee Page 48 2007 DS Golf Car Owner s Manual LIMITED ONE YEAR WARRANTY All original equipment options and accessories supplied by CLUB CAR are warranted with respect to parts and labor against defects in material and workmanship for a period of one year from the date of purchase while owned by the Original Retail Fleet Purchaser or in the possession of the Original Retail Fl
78. ren 2007 DS Golf Cars Hectric and Gasoline Owner s Manual aim Ingersoll fone Compact Vehicle Technologies NOTICE The Club Car Limited Warranty for owners of individual golf cars and the Limited Lifetime Fleet Warranty appear at the end of this manual along with limited warranty information for 2007 Deep Cycle 12 Volt Batter ies 2007 PowerDrive Battery Chargers 2007 Onboard Computers and Solid State Speed Controllers and the California Emission Control Warranty Statement No other warranties expressed or implied are con tained herein 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 This vehicle conforms to the current American National Standards Institute s Z130 Safety and Performance Requirements for Golf Cars This standard which promotes safety in the design application and operation of golf cars defines a golf car as a vehicle used to convey a person or persons and equipment to play the game of golf in an area designated as a golf course Throughout this manual the words golf car and vehicle are used interchangeably This manual contains proprietary information that is protected by copyright All rights are reserved No part of this
79. risk of severe personal injury If you rent or loan your vehicle to others we recommend that you ask them to read this manual before they operate the vehicle Club Car products are backed by a customer support system designed to offer you fast courteous service In the event that your Club Car vehicle needs repairs or service we recommend that your local authorized Club Car representative perform them For the name and address of the Club Car representative 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 Box 204658 Augusta Georgia 30917 4658 USA Your local authorized Club Car representative can also provide technical advice parts and service manuals 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 REGULAR MAINTENANCE ITEMS PERIODIC MAINTENANCE ITEMS Engine Oil Filter 286 cc and 351 cc Battery gasoline vehicle CCI P N 1016467 CCI P N 1012328 Engine Air Filter 286 cc and 351 cc Spark Plug O H V 286 cc and 351 cc CCI P N 1015426 CCI P N 101881101 Engine Fuel Filter 286 cc and 351cc Spring Tune Up Kit CCI P N 102003201 CCI P N 101611003 Battery Terminal Protector Spra
80. river FORWARD to operate the vehicle in the forward direction or towards the passenger 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 Figure 5 Forward Reverse Handle Figure 6 Forward Reverse Rocker Switch Figure 7 Accelerator and Brake Pedals ACCELERATOR PEDAL The accelerator pedal is the pedal on the right with the word GO molded into it Figure 7 The operation of the accelerator pedal differs from that of an automobile When the key switch is in the ON position and the Forward Reverse handle or switch is in either in the FORWARD or REVERSE position pressing the acceler ator pedal will automatically release the park brake and start the vehicle moving in the direction selected for ward or reverse As the accelerator pedal is pressed speed will increase until full speed is reached When the accelerator is released power will be cut off and the motor or engine will stop running Page 14 2007 DS Golf Car Owner s Manual Controls and Indicators IQ System vehicles use a special electrical system which employs motor braking in some modes of opera tion In those modes the vehicle operates as follows e Zero Speed Detect This prevents the vehicle from rolling away uncontrolled should the dr
81. rking or pulling the DC cord out quickly could cause arcing and burning that could damage the plug and receptacle and could cause batteries to explode 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 Do not allow the charger to operate for more than 30 minutes at 19 or more amperes Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightning strikes 2007 DS Golf Car Owner s Manual Page 35 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 Charging will resume in a few moments ammeter returns to previous rate of charge Each electric vehicle is supplied with a fully automatic battery charger as standard equipment The AC cord to each charger is to be connected to a source capable of supplying 15 amperes minimum per charger To reduce the risk of electric shock the battery charger must be grou
82. rther reduce vehicle speed as required System is activated only when tow switch is in the RUN position When towing this vehicle tow switch must be in the TOW position CMM CCI 102518001 OPERATING INSTRUCTIONS DECAL 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 Two 2 persons per seat maximum Operate from driver side only and not on public roads Keep entire body inside vehicle while moving Drive slowly in turns and straight up and down slopes Do not leave children unattended on vehicle e Never operate under the influence of alcohol or drugs s Use brakes to reduce speed when coasting downhill e Never stand in front of or behind vehicle CCI 101960601 KEY SWITCH BATTERY WARNING LAMP SERIAL NUMBER PRIVATE SPEED DECAL IQ VEHICLES WITH PRIVATE SPEED OPTION PARK BRAKE PEDAL This vehicle does not conform to ANSI 2130 1 Standard for Golf Cars Safety and Performance Requirements because it is capable of speeds in excess of 15 miles per hour Exercise caution BRAKE PEDAL CCI 102228701 ACCELERATOR PEDAL Page 4 2007 DS Golf Car Owner s Manual Vehicle Feature Identification DS ELECTRIC VEHICLE ELECTRICAL COMPONENT DECAL ON SPEED CONTROLLER COVER Do not operate vehicle without this cover properly installed Do not direct water stream in thi
83. s 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 Do not use the vehicle on public roads It is not designed or intended for street use and should not be licensed for use on public roads Obey all local rules concerning golf cars The vehicle should be driven in only specified areas by trained drivers Do not drive while under the influence of alcohol drugs or medications To prevent overturning the vehicle drive slowly in turns Use brakes to reduce speed when coasting downhill No one should drive the vehicle without first being instructed in the proper operation and use of the vehicle s controls An experienced operator should accompany each first time driver on a test drive before allowing him her to operate the vehicle alone To ensure safe operation of the vehicle follow exactly and in order all of the following procedures Read and understand all instructions prior to driving the vehicle STARTING THE VEHICLE 1 Par wD Study and understand controls Make sure everyone is seated and holding onto seat hand holds or handrails Read safety warnings located on dash and or above pedals Make sure wheels are turned in desired direction Turn the key to the ON position and make sure nothing is in your path Select direction by placing the Forward Reverse handle or switch in desired position
84. s AA 38 Engine Oil Gasoline Vehicles A 40 Fueling Instructions Gasoline Vehicles cccceeeeeceeceeeeeeeaeeeceeeeeesaaeeseeeeeeeaaeeeeceeeessaeseseaeeeeeeeeeesaeeneaes 43 Gleaning BE e 44 ACCES OTO S deen eege ee dee ee e ege eae the 44 Subsequent Owner Registration sposini sinea arrai an eenaa ae aaa aAa ara a aana ainia 45 Vehicle SpeCifiC atin TEE 45 2007 DS Golf Car Owner s Manual Page 3 Vehicle Feature Identification DS ELECTRIC VEHICLE DRIVER PASSENGER WARNING DECAL WARNING ROLLOVER OR FALLING OFF MAY CAUSE DEATH Read owner s manual and dash mounted safety warnings prior to driving Study and understand controls TO OPERATE Turn wheels to desired direction and ensure path is clear Turn key to ON position While stopped place Forward Reverse switch in desired position F Forward N Neutral R Reverse Buzzer will sound Park brake will release and vehicle will start moving when accelerator pedal is pressed Slowly press accelerator pedal to increase speed Tostop release accelerator pedal and press brake pedal BEFORE LEAVING Press park brake pedal until it locks and holds vehicle Place Forward Reverse switch in NEUTRAL position Turnkey OFF and remove key when notin use MOTOR BRAKING Electric motor braking provides speed regulation functions For parked vehicle beeping alarm indicates vehicle roll away In operation beeping alarm indicates reduction in motor braking Apply brakes to fu
85. s area will cause damage to components See vehicle maintenance and service manual before servicing cc 101831501 TOW SWITCH WARNING DECAL ON TOW SWITCH BRACKET UNDER SEAT A WARNING Place Tow Run switch in TOW position before FAILURE TO HEED THIS Disconnecting or connecting batteries WARNING COULD RESULT seals IN A BATTERY EXPLOSION Extended storage Op SEVERE PERSONAL Servicing INJURY CCI 101908601 CHARGER RECEPTACLE FORWARD REVERSE SWITCH BATTERY DANGER DECAL ON BATTERY CAPS OR ON BODY UNDER SEAT DANGER POISON FI H SULFURIC IMMEDIATELY NO ACID WITH WATER SPARKS Sy mam can cause GET FLAMES BLINDNESS OR OM MEDICAL d HELP LUSH EYES EYES EXPLOSIVE S SMOKING K GASES CAN CAUSE SEVERE BURNS Ri WE BLINDNESS OR INJURY KEEP OUT OF THE REACH OF CHILDREN DO NOT TIP KEEP VENT CAPS TIGHT AND LEVEL 2007 DS Golf Car Owner s Manual Page 5 Vehicle Feature Identification DS GASOLINE VEHICLE A WARNING ROLLOVER OR FALLING OFF MAY CAUSE DEATH Read owner s manual and safety warnings located on dash panel prior todriving Study and understand controls TO OPERATE Turn wheels to desired direction and ensure path is clear Turnkey to ON position While stopped place shift lever in desired position F Forward N Neutral R Reverse Buzzer will sound Before using vehicle read operating instructions Remain seated and hold on to seat handl
86. t of the proper voltage and frequency as shown on the charger Do not use an adapter to plug the charger with a three prong plug into a two prong outlet Improper connection of the equipment grounding conductor can result in a fire or an electrical shock An extension cord or electrical outlet must accept a three prong plug Extension cord should be a three wire No 12 AWG American Wire Gauge or No 14 SWG British Standard Wire Gauge and be as short as possible The use of improper extension cord could result in fire or an electrical shock Do not operate the charger if it has received a sharp blow was dropped or otherwise damaged in any way Have worn cut or damaged power cords or wires replaced immediately Do not use near fuels grain dust solvents thinners or other flammables Chargers can ignite flammable materials and vapors Do not expose to rain or any liquid Keep the charger dry Never push objects of any kind into the charger through cabinet slots They may touch dangerous voltage points or cause an electrical short circuit that could result in fire or electrical shock Do not connect a stationary charger to the receptacle if the charger cord plug or the vehicle receptacle is broken damaged or does not make a good electrical connection Fire or personal injury can result Have a qualified technician replace the parts When the charger is on the charger DC cord may be disconnected from the vehicle receptacle slowly Je
87. the engine in neutral for certain maintenance procedures With the cam in this position the vehicle will not operate if the Forward Reverse handle is placed in either the FORWARD or REVERSE position NEUTRAL NEUTRAL MAINTENANCE POSITION OPERATE POSITION Figure 11 Neutral Lockout Maintenance Figure 12 Neutral Lockout Operate To put the cam back into the OPERATE position pull the cam out approximately 3 8 inch 10 mm and rotate it one half turn until it snaps into place Figure 12 See following WARNING and NOTE A WARNING e With the cam in the MAINTENANCE position and the engine running the vehicle may move suddenly if the Forward Reverse handle is shifted or accidentally bumped To prevent this chock the front and rear wheels and firmly set the park brake before servicing or leaving the vehicle NOTE Be sure to return the cam to the OPERATE position after servicing the vehicle or it will not operate with the Forward Reverse handle in either the FORWARD or REVERSE position CHOKE Gasoline Vehicles Only The choke is located on the seat support panel below and to the left of the driver s left knee Figure 13 If the vehicle is hard to start in cool or cold temperatures simply push in the choke cover to activate it Hold it during start up and release the choke cover after the engine starts and runs smoothly Page 18 2007 DS Golf Car Owner s Manual Pre Operation and Daily Safety Checklist Figure
88. then spray them with Battery Terminal Protector Spray CCI P N 1014305 See preceding WARNING and following CAUTION A CAUTION e If battery wire terminals are damaged or corroded they should be replaced or cleaned as necessary Failure to do so may cause them to overheat during operation BATTERY CAP LEVEL J INDICATOR PLATES F ee A ELECTROLYTE LEVEL AT LEAST 1 2 INCH 13 MM ABOVE PLATES OR TO LEVEL INDICATOR 3 Ee Figure 24 Battery Gasoline Vehicle Figure 25 Gasoline Battery Electrolyte Level Be sure battery clamp is properly tightened Tighten to 12 ft lb 16 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 2007 DS Golf Car Owner s Manual Page 39 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 Remove the oil level dipstick
89. tioned Computer or Controller that is identical or reasonably equivalent to the warranted product at no cost to the purchaser during the four year or 800 round limited warranty period for golf use or 4 years or 16 000 energy units for use other than golf whichever first occurs except for transportation expenses All parts and components replaced under this limited warranty become the property of CLUB CAR THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REPLACEMENT OR REPAIR OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE DISTRIBUTOR OR DEALER OF CLUB CAR HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY This computer or controller is intended to be used only in CLUB CAR PowerDrive System 48 PowerDrive Plus and IQ System electric vehicles Any other use renders the Limited Warranties expressed herein and all implied warranties null and void and same are hereby excluded ALSO EXCLUDED FROM THIS LIMITED WARRANTY ARE ANY AND ALL INCI
90. towing Observe all of the previous WARNING statements when towing TRANSPORTING ON A TRAILER A WARNING 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 The vehicle to be towed should be tied securely to the trailer with the Forward Reverse handle or switch in the NEUTRAL position the key switch in the OFF position and the park brake firmly pressed and locked Do not allow people in the trailer or vehicle being towed Avoid sudden starts sudden stops and tight turns when towing Avoid stopping on a hill when towing If you must stop on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning could cause the vehicle to overturn possibly resulting in severe personal injury When towing on a trailer normal road speed of the tow vehicle should be reduced Because of the added length of the trailer caution should be used when turning a corner Remove the vehicle windshield and secure the seat bottom before transporting on a trailer Gasoline vehicles only Turn the fuel shut off valve to the closed OFF position Figure 15 Page 27 If the vehicle must be transported over long distances or on public highways it should be transported on an approved trailer that has the approved load rating
91. vehicle to be driven No more than two people should be on the vehicle at one time The vehicle is not specially equipped for handicapped persons Be sure all persons can properly operate the vehicle prior to allowing them to drive the vehicle Be sure all passengers are capable of securing themselves in a vehicle before allowing them to ride in one For night use the vehicle must be equipped with headlamps taillamps and reflectors Stop the vehicle before shifting the Forward Reverse handle Failure to do so may result in injury to an unsuspecting passenger and or damage to the vehicle To help avoid being struck do not stand in front of or behind the vehicle Operate the vehicle from the driver seat only To help prevent falls from the vehicle remain seated in a moving vehicle and hold on to hand holds or handrails at all times Driver should keep both hands on the steering wheel when the vehicle is in motion To help prevent the possibility of serious injury keep your entire body inside the vehicle WARNING CONTINUED ON NEXT PAGE 2007 DS Golf Car Owner s Manual Page 21 Driving Instructions A 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 stop
92. ven e Ensuring that proper warnings of driving hazards are displayed and visible e Who should and who should not drive golf cars e Instructing first time drivers e Maintaining golf cars in a safe driving condition e 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 Sharp Left 9911211 Sharp Right 9921211 Steep Hill 9931211 Page 12 2007 DS Golf Car Owner s Manual Controls and Indicators CONTROLS AND INDICATORS See General Warnings on page 9 A WARNING e 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 e Do not shift the Forward Reverse handle or switch while the vehicle is moving To avoid injury to an unsuspecting passenger or damage to the vehicle always bring the vehicle to a full stop before shifting the Forward Reverse handle or switch e Release the accelerator pedal and then press the brake pedal firmly until the vehicle stops To avoid unintentionally starting or rolling the vehicle set the park brake place the 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 e Gasoline vehices only Do not tamper with the governor Doing
93. verify number of rounds played by accessing information contained in the IQ System Onboard Computer LIMITED WARRANTY EXCLUSIONS THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOT APPLY TO FAILURE DUE TO 1 Abuse such as overcharging undercharging improper fluid levels loose wiring or rusted or corroded hardware 2 Lack of proper maintenance as outlined in the electric vehicle owner s manual 3 Damages caused by improper installation of the battery 4 Neglect breakage freezing fire explosion wreckage the addition of any chemical or the operation of the battery in an uncharged condition below half charge 1 200 specific gravity 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 and will exercise due care in working on or around batteries Transportation expenses for warranty services are also excluded from this warranty Page 50 2007 DS Golf Car Owner s Manual WARRANTY LIMITATIONS CLUB CAR s liability under this limited warranty shall be to replace a defective battery Replacement shall be furnishing a new or used battery
94. with sufficient life to complete the remainder of the warranty term which is identical or reasonably equivalent to the warranted product at no cost to the purchaser during the four year 800 round or 16 000 Energy Unit limited warranty period whichever first occurs All batteries which are replaced under this limited warranty become the property of CLUB CAR THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REPLACEMENT OR REPAIR OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE DISTRIBUTOR OR DEALER OF CLUB CAR HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS 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 ALSO EXCLUDED FROM THIS LIMITED WARRANTY ARE ANY AND ALL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIM
95. wner s Manual 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 If leaks appear begin with step 1 and repeat the appropriate step for either or both items to correct the problem 16 Remove the dipstick and check the engine oil as a final step Replace the dipstick FUELING INSTRUCTIONS GASOLINE VEHICLES See General Warnings on page 9 A DANGER e Turn the key switch to the OFF position before fueling e Do not pour gasoline into the fuel tank when the engine is hot or while it is running e To avoid electric arc caused by static electricity the fuel storage pumping device must be grounded If the pump is not grounded the vehicle must be grounded to the pump before and during the fueling operation e If the vehicle has an all weather enclosure installed be sure the fuel tank is properly vented as shown Figure 31 e To avoid the possibility of fire clean up any spilled gasoline before operating the vehicle A CAUTION e To allow for expansion do not fill higher than one inch from the top of the fuel tank Avoid fuel Spillage NOTE Whenever possible
96. y shall become the property of CLUB CAR 5 HOW TO MAKE A WARRANTY CLAIM To make a warranty claim under this limited warranty you must present the golf car or defective component to an authorized CLUB CAR distributor or dealer or send the defective component freight prepaid to WARRANTY SERVICES CLUB CAR INC 4125 Washington Road Evans Georgia 30809 U S A 706 863 3000 6 DEFINITIONS For the purpose of this warranty an Original Retail Fleet Purchaser is the original purchaser of the golf car who is in the business of owning or operating golf courses and who purchases such golf car for the purpose of renting it to golf players for use on such courses An Original Retail Fleet Lessee is the first end user of the golf car who is in the business of owning and operating golf courses and who leases such golf car for the purpose of renting it to golf players for use on such golf courses In the event the golf car is purchased or leased by any entity for the purpose of leasing it to an Original Retail Fleet Lessee then this limited warranty shall extend only to the first Original Retail Fleet Lessee and not to such entity or to any subsequent lessee of the golf car 7 DISCLAIMER THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCL
97. y Battery 12 Volt electric vehicle CCI P N 1014305 CCI P N 102511301 wet Dry Moly Lube CCI P N 1012151 Page 2 2007 DS Golf Car Owner s Manual TABLE OF CONTENTS Vehicle Feature Identification 20 2 eee cccecceescecceeeeeeceeeeeeeeceeeeeeeaeeeeeeeaceeeeeaeacaeeeeeseaaaeeeseacaeeeseeaeeeeeeneaaeeeneneeas 4 Safety Details serenana naaa aaant aa raai aaa aaa aa aE ued Eege 9 General Warnings EE 9 General Informat EE 11 Mogell entatgnt ia e e EE R R AE E E Ze 12 EE elen ut 12 Controls and Indicators niisiis ia aiea ea ie dea cn ee 13 Pre Operation and Daily Safety Checklist ossosseeeseeeseesneesneeesnessressrtnsstnnstnsstunstnnnennntnnnennnntnnennnnnnnnnt 19 PErOrMance INSPECHON yae EE E EEA N E TE 20 Diving Meracie ae Aa E AA ATANT AET 21 TON EE 23 Transporng otra Trailer eoria a ET ey eee R eee 24 Storage Electric Vehicles AE 25 Storage eene 26 Maintenance cies aati e a a a iis Ae at ee 28 Periodic Service Schedules cccceceeeeceseeececeeeesaaeeeeneeeceaeeseeaaeecaeeeeeaaeeegaeeeeeaaeesgeneeesaeseeeeeeeseieesseaaeeneaes 29 Periodic Lubrication Schedules gier EENEG thar aaa a aa a aa aaa a aa aaa aaa aa nia aata 31 Vehicle Controller Electric Vehicles cececceceseceeeneeeeeeeeeeeaeeeeeeeeceaaeseceeeeecaaeseseaeeseaeeesaaeseaaeeessaeeneneees 33 Batteries leet Vehicles esar EA AAA E NEAR A ERIA E A E ES 33 Battery Charger Electric Vehicles AAA 35 Battery Gasoline Vehicle

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