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1999 DS Ele OM

1. ect eb eee dd 17 E 18 Battery Charger sees PUES 19 Cleaning The Vehicle 0 23 ACCOSSOLIOS RR 24 Subsequent Owner Registration 1 24 Fairway Villager tet es weeded ea HOE ene pee ee a 25 DS Electric Vehicle Specifications 0 26 1999 DS Golf Car Electric Vehicle Owner s Manual v Practice Safety IK WARNING Moving 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 1999 DS Golf Car Electric Vehicle Owner s Manual 1 Safety Details SAFETY DETAILS A WARNING 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 n
2. 122 cm 122 65 1 2 65 1 2 65 1 2 Wheelbase 166 cm 166 cm 166 cm 4 1 2 4 1 2 4 1 2 Ground Clearance 11 11 cm 11 34 1 2 34 1 2 34 1 2 Front Wheel Tread 88 cm 88 cm 88 cm 38 1 2 38 1 2 38 1 2 Rear Wheel Tread 98 cm 98 cm 98 cm DN 455 Ibs 477 lbs 448 Ibs Weight Standard electric vehicle without batteries 206 kg 216 kg 203 kg i 495 165 Weight Fairway Villager electric vehicle without batteries 225 kg N A N A 12 15 mph 12 15 mph 12 15 mph Forward Speed At 2700 rpm 19 24 kph 19 24 kph 19 24 kph 17 6 17 6 17 6 Clearance Circle diameter 533 cm 533 cm 533 cm i i 14 14 14 Braking Distance At 12 mph 19 kph 427 cm 427 cm 427 cm 1999 DS Golf Car Electric Vehicle Owner s Manual 27 CLUB CAR LIMITED LIFETIME WARRANTY FOR 1999 FLEET GOLF CARS INTHE UNITED STATES AND CANADA 1 WARRANTY CLUB 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 1999 Model DS golf car purchased from CLUB CAR or an authorized distributor or dealer for use in the United States or Canada shall be free from defects in materials and workmanship under normal use and service as a golf car for the periods s
3. accident or alteration is excluded from this limited warranty This warranty gives you specific legal rights and you may also have other rights which vary from state to state For further information or to submit a warranty claim contact Warranty Administrator CLUB CAR Inc P O Box 204658 Augusta GA 30917 4658 USA 706 863 3000 CLUB CAR FOUR YEAR LIMITED WARRANTY FOR 1999 POWERDRIVE 8 VOLT BATTERIES IN THE UNITED STATES AND CANADA CLUB CAR Inc CLUB hereby warrants to the Original Retail Purchaser that the new PowerDrive 8 volt Battery installed in its new electric vehicle equipped with the PowerDrive System 48 purchased from CLUB CAR or an authorized distributor or dealer will be free from defects in materials and workmanship and will provide 36 hole performance 60 minute discharge capacity for a period of four years or 800 rounds from the date of purchase whichever event first occurs subject to the terms and conditions contained herein This limited warranty only covers defects in materials and workmanship for a period of four years or 800 golf car rounds from date of purchase whichever event first occurs The terms of this four year or 800 round limited warranty shall be as follows Free replacement within four years or 800 rounds whichever event first occurs from date of purchase No labor or transportation expenses are included in this limited warranty The battery should be returned to CLUB CAR or an au
4. Forward Reverse switch Check for proper operation See Controls Page 7 PERIODIC SERVICE SCHEDULE WARNING SERVICE REPAIRS AND ADJUSTMENTS MUST BE MADE PER INSTRUCTIONS IN THE 1999 DS GOLF CAR MAINTENANCE amp SERVICE MANUAL NOTE e IF THE VEHICLE IS CONSTANTLY SUBJECTED TO HEAVY USE OR SEVERE OPERATING CONDITIONS THE PREVENTATIVE MAINTENANCE PROCEDURE SHOULD BE PERFORMED MORE OFTEN THAN RECOMMENDED IN THE SERVICE AND LUBRICATION SCHEDULES BOTH THE PERIODIC SERVICE SCHEDULE AND PERIODIC LUBRICATION SCHEDULE MUST BE FOLLOWED TO KEEP VEHICLE IN OPTIMUM OPERATING CONDITION 1999 DS Golf Car Electric Vehicle Owner s Manual 15 Periodic Lubrication Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Daily Service by Owner Batteries Charge batteries after each use only Check electrolyte level Add water as necessary per Weekly Service by Owner Maintenance and Service Manual Batteries Wash battery tops and clean terminals with baking soda water solution Dispose of waste water properly Tires Check air pressure and adjust as necessary Monthly Service by Owner See Vehicle Capacities Chart on Page 17 or Trained Mechanic Check for cracks or other damage make sure switch Wiper Switch is securely fastened to frame Check movable contact for correct operation General Vehicle Wash battery compartment and underside of vehicle Dispose of waste water
5. THE VEHICLE FROM ROLLING 8 1999 DS Golf Car Electric Vehicle Owner s Manual Controls Figure 6 Forward Reverse Rocker Switch Figure 8 Brake Pedal Figure 9 Park Brake Pedal POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS ELECTRIC VEHICLES ONLY Battery Warning Light PowerDrive System 48 and PowerDrive Plus vehicles feature a dash mounted warning light above steering col umn that when the vehicle is in operation indicates low battery voltage or when the vehicle is being charged indicates a charging problem The battery warning light is controlled by the PowerDrive onboard computer When the vehicle is in operation the warning light will come on and remain illuminated if Batteries voltage drops below 48 when there is no load on the batteries the vehicle is stopped and there are no accessories on Batteries have discharged to less than 25 of their capacity If the warning light comes on during a round of golf there is enough power remaining to finish the round but the car should be charged before being used again If the warning light comes on and the vehicle is unable to finish the round have your Club Car distributor dealer check the vehicle for a possible battery or electrical system problem 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 or 4 the charger malfunctions
6. The electrolyte level in the batteries should be checked weekly See Figure 12 Page 19 for proper level Add water only after charging unless the water 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 water level For best battery life add only distilled water See following NOTE NOTE ABATTERY WATERING GUN OR BOTTLE IS AVAILABLE 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 Torque hold down retaining nuts to 40 in lb 4 5 N m The terminal connections should be clean and tight and any worn insulation or frayed wires should be replaced Torque battery terminals to 110 12 4 N m See following CAUTION CAUTION e IF BATTERY WIRE TERMINALS ARE DAMAGED OR CORRODED THEY SHOULD REPLACED OR CLEANED AS NECESSARY FAILURE TO DO SO MAY CAUSE 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 INDICATOR CAP PLATES ELECTROLYTE LEVEL AT LEAST 1 2 IN ABOVE PLATES OR TO LEVEL INDICATOR Figure 12 Electrolyte Level in Bat
7. or neglect Transportation expenses for warranty service 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 UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY 28 1999 DS Golf Car Electric Vehicle Owner s Manual 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 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 only liability under this limited warranty or in any action whether based upon warranty contract negligence strict product liability or otherwise is limited to the repair or replacement at CLUB CAR s option of a golf car or component thereof that CLUB CAR deems to be defective Replacement shall mean furnishing during the applicable limited warranty period a new golf car or factory reconditioned vehicle or component thereof which 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 applic
8. properly Brake System Semi annual Service by Trained Mechanic Only Check brake shoes replace if necessary See DS Maintenance and Service Manual Lubricate brake slides per Lubrication Schedule See DS Maintenance and Service Manual Check brake cables for damage replace as required Every 50 hours of operation or 100 rounds of golf Electrical Wiring and connections Check for tightness and damage Forward and 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 Maintenance amp Service Manual Section 7 Annual Service by Trained Mechanic Only Every 100 hours of operation or 200 rounds of golf Batteries Perform battery tests per Maintenance amp Service Manual A WARNING e IF ANY PROBLEMS ARE FOUND 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 PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE REGULAR INTERVAL Semi Annually by Owner or Trained Technician Every 50 hours of operation or every 100 rounds for golf cars SERVICE PLACE RECOMMENDED LUBRICANT Brake shaft bearings 1 Dry Moly Lube Club Car Part No 1012151 Brake Linkage and Pivots 2 Dry Moly Lube Club Car Part
9. 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 against defects in materials and workmanship 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 materials 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 materials 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 s
10. to reduce the risk of electrical shock The charger is equipped with an AC electric cord having an equipment grounding conductor and a grounding type plug and is for use on a nominal 115 Volt 60 Hertz circuit unless otherwise noted on the charger The plug must be grounded to an appropriate dedicated receptacle that is properly installed and grounded in accordance with the National Electrical Code ANSI NFPA 70 and all local codes and ordinances The use of an extension cord with the charger should be avoided If an extension cord must be used a three conductor No 12 AWG heavy duty cord with a ground conductor in good electrical condition must be used Keep it as short as possible no more than twelve feet Locate all cords so that they will not be stepped on tripped over or otherwise subject to damage or stress Ventilation fans should be located at the highest point in the room and must be capable of changing the total volume of air in the room five times per hour Consult a local HVAC engineer TO CHARGE BATTERIES WARNING BE SURE ALL WIRE CONNECTIONS AT THE RECEPTACLE AND THE FUSE LINK ARE CLEAN AND TIGHT 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 13 PAGE 22 DO NOT PULL ON THE DC CORD FIGURE 14 PAGE 22 DO NOT TWIST ROCK OR BEND THE PLUG TO DISCONNECT THE CHARGER PLUG FROM THE VEHICLE RECEPTACLE G
11. 1999 Owners Manual play to win NOTICE The Club Car Limited Warranty for owners of single golf cars appears on the pages following this notice and the Limited Lifetime Fleet Warranty appears at the end of this manual along with limited warranty information for 1999 T 105 6 volt batteries 1999 PowerDrive 8 volt batteries 1999 PowerDrive Battery Chargers 1999 onboard computers and solid state speed controllers No other warranties express or implied are contained herein Your authorized representative checked this vehicle before it was delivered to you and will provide a completed warranty registration card to you Club Car is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual This vehicle conforms to the current American National Standards Institute s 2130 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 and vehi cle are used interchangeably This manual contains proprietary information that is protected by copyright All rights are reserved No part of this manual may be photocopied reproduced or translated to another language without t
12. 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 soeed of the golf car can cause serious personal injury or death CLUB CAR LIMITED THREE YEAR WARRANTY FOR 1999 T 105 6 VOLT BATTERIES IN THE UNITED STATES AND CANADA CLUB CAR INC CLUB warrants to the original retail purchaser that the new Trojan T 105 6 Volt Battery installed in its new electric vehicle purchased from CLUB CAR or an authorized distributor or dealer will be free from defects in materials and workmanship and will provide 36 hole performance 60 minute discharge capacity for a period of three years or 600 rounds from the date of purchase whichever event first occurs subject to the terms and conditions contained herein The terms of this three year or 600 round limited warranty shall be as follows Free replacement within three years or 600 rounds from date of purchase whichever event first occurs No labor or transportation expenses are included in this limited warranty The battery should be returned to CLUB CAR or an authorized 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 ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL BE VOID AND EXCLUDED SUBSEQUENT TO O
13. E TIME TO PREVENT THE POSSIBILITY OF SERIOUS INJURY KEEP YOUR ENTIRE BODY INSIDE THE VEHICLE MAINTENANCE Refer to Pages 15 through 16 for Periodic Service and Lubrication Schedules See following NOTE NOTE e IF THE VEHICLE IS CONSTANTLY HAULING HEAVY LOADS THE PREVENTIVE MAINTENANCE PROCEDURES SHOULD BE PERFORMED MORE OFTEN THAN RECOMMENDED IN THE SERVICE AND LUBRICATION SCHEDULES STORAGE COMPARTMENT There is an enclosed storage compartment underneath the rear seat with 2 cu ft 6 cu m of storage area Access the storage compartment by lifting the rear seat ACCESSORY ONBOARD CHARGER An onboard charger which is installed under the rear seat is available for the Fairway Villager electric vehi cle The charger should be plugged into a properly grounded nominal 115 Volts AC 60 Hertz outlet The AC line to which the charger is to be connected must be capable of supplying 15 amperes minimum to the charger The rear seat should be propped open while charging the batteries See following WARNING and CAUTION WARNING 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 1999 DS Golf Car Electric Vehicle Owner s Manual 25 DS Electric Vehicle Specifications A CAUTION BEFORE CHARGING BATTERIES TURN OFF ALL ACCESSORIES ON ALL VEHICLES e I
14. F USING AN ONBOARD CHARGER BE SURE THE AC PLUG IS UNPLUGGED FROM THE OUTLET BEFORE ATTEMPTING TO DRIVE THE VEHICLE CHARGER AND AC OUTLET WILL BE DAMAGED IF THE CHARGER IS NOT UNPLUGGED BEFORE DRIVING BE SURE THE AC CORD IS PROPERLY WOUND UP ON THE REEL BEFORE DRIVING THE VEHICLE STUDY ALL GENERAL INFORMATION NOTE CAUTION AND WARNING STATEMENTS AS WELL AS ALL INFORMATION NOTE CAUTION AND WARNING STATEMENTS SPECIFIC TO THE POWERDRIVE CHARGER AND POWERDRIVE SYSTEM 48 IN THE BATTERY CHARGER SECTION OF THIS OWNER S MANUAL PAGE 19 SEAT HANDLE PASSENGER WARNING DECAL ON HAND RAIL HAND RAIL FOOT REST Remain seated with entire body inside vehicle and hold onto seat handle or handrail at all times No more than two persons per seat Do not leave children unattended on vehicle at anytime Never stand in front of or behind vehicle CCI 1017057 01 Figure 17 Fairway Villager DS ELECTRIC VEHICLE SPECIFICATIONS POWERDRIVE POWERDRIVE DS SPECIFICATIONS SYSTEM 48 PLUS 36 Volt POWER SOURCE Drive Motor Direct drive 48 volts DC series wound 3 1 hp Drive Motor Direct drive 48 volts DC shunt wound 3 2 hp Drive Motor Direct drive 36 volts DC series wound 2 97 hp Transaxle Double reduction helical gear with 12 28 1 direct drive axle Electrical System 48 volts DC reduced speed reverse Electrical System 36 volts DC reduced speed reverse Veh
15. FROM OVERHEATING DO NOT ALLOW CLOTHING BLANKETS OR OTHER MATERIAL TO COVER THE CHARGER PROVIDE ADEQUATE VENTILATION FOR THE CHARGER 36 VOLT ACCU POWER CHARGER DO NOT LEAVE THE DC CORD PLUGGED INTO A VEHICLE RECEPTACLE WHILE UNATTENDED FOR MORE THAN TWO CONSECUTIVE DAYS SEVERE OVERHEATING AND DAMAGE TO THE BATTERIES MAY RESULT IF THE CHARGER DOES NOT TURN OFF INSTALL SURGE ARRESTORS ON INCOMING AC POWER LINES SURGE ARRESTORS WILL HELP PROTECT ELECTRICAL ELECTRONIC COMPONENTS IN THE CHARGER AND ON THE VEHICLE FROM ALL BUT DIRECT OR VERY CLOSE LIGHTNING STRIKES 20 1999 DS Golf Car Electric Vehicle Owner s Manual Battery Charger NOTE e BECAUSE THE POWERDRIVE CHARGER HAS A STORAGE CHARGE FEATURE THAT AUTOMATICALLY CHECKS AND RECHARGES THE BATTERIES AS NECESSARY EVERY 15 DAYS IT CAN REMAIN PLUGGED TO A POWERDRIVE VEHICLE THROUGHOUT THE STORAGE PERIOD e SHORTLY AFTER CHARGING HAS BEGUN THE POWERDRIVE CHARGER WILL SHUT OFF IN ORDER TO RUN A SELF DIAGNOSTIC PROGRAM AMMETER WILL DROP TO 0 CHARGING WILL RESUME IN A FEW MOMENTS AMMETER WILL RETURN TO CURRENT STATE OF CHARGE e RECYCLE OR DISPOSE OF DISCARDED BATTERIES IN ACCORDANCE WITH LOCAL STATE AND FEDERAL REGULATIONS 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 10 amperes minimum per charger The battery charger must be grounded
16. HE TRAILER CAUTION SHOULD BE USED WHEN TURNING A CORNER REMOVE THE VEHICLE WINDSHIELD BEFORE TRANSPORTING ON A TRAILER 1999 DS Golf Car Electric Vehicle Owner s Manual 13 Storage STORAGE Read DANGER and WARNING on page 3 A WARNING TURN KEY SWITCH TO OFF REMOVE KEY AND LEAVE THE FORWARD REVERSE SWITCH IN NEUTRAL POSITION DURING STORAGE THIS IS TO PREVENT UNINTENTIONALLY STARTING VEHICLE DO NOT ATTEMPT TO CHARGE FROZEN BATTERIES OR BATTERIES WITH BULGED CASES DISCARD THE BATTERIES FROZEN BATTERIES CAN EXPLODE A CAUTION BATTERIES IN LOW STATE OF CHARGE WILL FREEZE AT LOW TEMPERATURES WHEN WASHING THE VEHICLE DO NOT DIRECT WATER STREAM AT THE MULTI STEP POTENTIOMETER 48 VOLT VEHICLES OR V GLIDE SPEED SWITCH 36 VOLT VEHICLE FORWARD REVERSE SWITCH OR OTHER ELECTRICAL COMPONENT 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 POWERDRIVE PLUS VEHICLES ONLY PLACE TOW RUN SWITCH IN THE TOW POSITION 1 Fully charge batteries See Batteries Page 17 Wash off any corrosion around the terminals with a solution of baking soda and water one cup per gal lon of water then rinse solution from the batteries do not allow this solution to enter the batteries Let the terminals dry and coat them with Club Car battery terminal spray Part No 1014305 Store in a cool dry pl
17. IAL NUMBER DECAL 9901 12345 Figure 3 Serial Number Location 1999 DS Golf Car Electric Vehicle Owner s Manual 5 Pre Operation Checklist PRE OPERATION CHECKLIST Your Club Car has been thoroughly inspected and adjusted at the factory and also by your Club Car distributor dealer However upon arrival of your new Club Car s you should become familiar with its controls and operation and carefully inspect each vehicle to be satisfied that it is in proper working condition before accepting delivery Use the following checklist as a guide to inspect your new vehicle and in conjunction with the Periodic Ser vice Schedule on page 15 Any problems should be corrected only by your Club Car distributor dealer or a trained mechanic General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tight Warning Decals Check to ensure that all warning and operation decals are in place See page 4 Tires Check for proper tire pressure See Vehicle Capacities Page 17 Batteries Check electrolyte to ensure that it is at its proper level Figure 12 Page 19 Check battery posts Wires should be tight and free of corrosion Charge batteries fully before first use of vehicle Multi Step Potentiometer 48 volt electric vehicles and V Glide Wiper Switch 36 volt electric vehicles Be sure accelerator switch cover is properly secured prior to operat
18. IES EXPRESSED HEREIN AND ANY IMPLIED WARRANTIES NULL AND VOID AND SAME ARE HEREBY EXCLUDED WARRANTY LIMITATIONS CLUB CAR S only liability under this limited warranty or in any action whether based upon warranty contract negligence strict product liability or otherwise is limited to the replacement or repair at CLUB CAR S option of a charger or component thereof that CLUB CAR deems to be defective Replacement shall mean furnishing during the applicable limited warranty period except for repair labor costs after the first year a new charger or component thereof which 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 except for repair labor costs after the first year 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 Damage not resulting from a defect of which 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 THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESS OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTIC
19. 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 REPLACEMENT OR REPAIR OF THE DEFECTIVE GOLF CAR OR COMPONENT THEREOF 15 THE EXCLUSIVE AND 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 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 8 INFORMATION For further information contact WARRANTY ADMINISTRATION 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 factor
20. IND EXPRESS 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 REPAIR OR REPLACEMENT OF THE DEFECTIVE GOLF CAR OR COMPONENT THEREOF IS THE EXCLUSIVE AND 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 1999 DS Golf Car Electric Vehicle Owner s Manual 29 9 INFORMATION For further information contact WARRANTY ADMINISTRATION CLUB INC Box 204658 Augusta Georgia 30917 4658 U S
21. ING ON VEHICLE Figure 2 PowerDrive System 48 Figure 1 V Glide 36 Volt Vehicle and PowerDrive Plus Vehicles 2 1999 DS Golf Car Electric Vehicle Owner s Manual General Warnings GENERAL WARNINGS The safety procedures listed must be followed whenever the vehicle is being operated repaired or serviced Vehicle feature identification information is also included on page 4 Other specific WARNING statements appear throughout this manual and on the vehicle DANGER BATTERY VAPORS FLAMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE SERVICE ONLY IN WELL VENTILATED AREAS A GOLF CAR WILL NOT PROVIDE PROTECTION FROM LIGHTNING FLYING OBJECTS OR OTHER STORM RELATED HAZARDS IF CAUGHT IN A STORM WHILE DRIVING A GOLF CAR EXIT THE VEHICLE AND SEEK SHELTER IN ACCORDANCE WITH APPLICABLE SAFETY GUIDELINES FOR YOUR LOCATION WARNING NEVER LEAVE CHILDREN UNATTENDED IN THE VEHICLE ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THE VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD FOLLOW THE PROCEDURES EXACTLY AS STATED IN THIS MANUAL AND FOLLOW ALL DANGER WARNING AND CAUTION PROCEDURES LISTED IN THIS MANUAL AS WELL AS THOSE AFFIXED TO THE VEHICLE ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN SERVICING THE VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES TURN THE KEY SWITCH TO OFF REMOVE THE KEY CHOCK THE WHEELS PLACE THE FORWA
22. N ALL MOTOR BRAKING FUNCTIONS INCLUDING ZERO SPEED DETECT ARE DISABLED Figure 10 Tow Run Switch All 1999 DS PowerDrive Plus vehicles are equipped with a Tow Run switch located under the seat just above the Forward Reverse switch Figure 10 Page 10 The switch must be in the RUN position in order to oper ate 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 SWITCH IN TOW POSITION ALLOW 10 SECONDS BEFORE SWITCHING BACK TO RUN AFTER PLACING THE SWITCH IN RUN POSITION ALLOW 10 SECONDS BEFORE OPERATING THE VEHICLE The Tow Run switch should be placed in the TOW position under the following conditions 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 10 1999 DS Golf Car Electric Vehicle Owner s Manual Driving Instructions Before Disconnecting or Attaching Battery Wires Place the Tow Run switch in the TOW position to turn off power to the vehicle electrical system thus preventing severe arcing and possible battery explosion as the battery wires are disconnected For Long Term Storage Place the Tow Run switch in the TOW posi
23. NE YEAR FROM THE DATE OF PURCHASE THE REPLACEMENT OF THE BATTERY IS THE EXCLUSIVE REMEDY UNDER THIS WRITTEN WARRANTY OR ANY IMPLIED WARRANTY 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 LIMITED WARRANTY LIMITED WARRANTY EXCLUSIONS Without limiting the generality of the foregoing in any way and as part of its limited warranty exclusion CLUB CAR does not warrant that its battery is suitable for use in any application other than in its golf car or utility vehicle 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 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 or 5 A ba
24. NS BEFORE USING VEHICLE FAILURE TO DO SO CAN Study and understand controls CAUSE SEVERE INJURY OR DEATH Operation from driver side by authorized persons only Make sure wheels are tarned in desired direction and only in designated areas not on public roads Turn key to ON position and be sure nothing is in your path x DO stare vede und occupants two 2 per seat While is stopped select direction by placing Remain seated with entire body inside vehicle and hold shift lever or switch in desired position irepl A slopes F Forward N Neutral Reverse Buzzer will sound Never stand in front of or behind vehicle Vehicle will start moving when accelerator pedal is depressed ri operate while under the influence of alcohol or Slowly depress accelerator pedal to increase speed Park brake will DO NOT leave children unattended on vehicle at any time release when accelerator pedal is depressed Se ee To stop release accelerator pedal and depress brake pedal After stopping firmly depress park brake until it locks Place forward and reverse switch in neutral position Turn key OFF and remove key when not in use 1016216 01 OPERATING INSTRUCTIONS DECAL BATTERY SERIAL NUMBER ACCELERATOR PEDAL DANGER DECAL ON BODY UNDER SEAT with accelerator pedal depressed lt Vehicle will brake gently when accelerator pedal i
25. NS SHOULD REPAIR OR SERVICE THE CHARGER CONTACT YOUR NEAREST CLUB CAR DISTRIBUTOR DEALER DO NOT OPERATE THE CHARGER IF IT HAS RECEIVED A SHARP BLOW WAS DROPPED OR OTHERWISE DAMAGED IN ANY WAY 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 36 VOLT ACCU POWER CHARGER DO NOT DISCONNECT THE DC OUTPUT PLUG FROM THE VEHICLE RECEPTACLE WHEN THE CHARGER IS ON THE RESULTING ARCING AND BURNING COULD DAMAGE THE PLUG AND RECEPTACLE AND COULD CAUSE BATTERIES TO EXPLODE IF THE CHARGER MUST BE STOPPED DISCONNECT THE AC SUPPLY PLUG FROM THE WALL OUTLET BEFORE DISCONNECTING THE CHARGER DC CORD FROM THE VEHICLE RECEPTACLE 48 VOLT POWERDRIVE CHARGER WHEN THE CHARGER IS ON THE CHARGER DC CORD MAY BE DISCONNECTED FROM THE VEHICLE RECEPTACLE SLOWLY JERKING OR PULLING THE CORD OUT QUICKLY COULD CAUSE ARCING AND BURNING THAT COULD DAMAGE THE PLUG AND RECEPTACLE AND COULD CAUSE BATTERIES TO EXPLODE A CAUTION DO NOT BLOCK OR COVER SLOTS AND OPENINGS IN THE BACK AND BOTTOM OF CHARGER CABINET THEY PROVIDE VENTILATION AND PROTECT THE CHARGER
26. NSUSPECTING PASSENGER AND OR DAMAGE TO THE VEHICLE AVOID SUDDEN STARTS SUDDEN STOPS AND ABRUPT TURNS TO 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 TO AVOID BEING STRUCK DO NOT STAND IN FRONT OF OR BEHIND THE VEHICLE DO NOT DRIVE WHILE UNDER THE INFLUENCE OF ALCOHOL DRUGS OR MEDICATIONS 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 Only licensed drivers should be allowed to drive this vehicle 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 1999 DS Golf Car Electric Vehicle Owner s Manual 11 Driving Instructions STARTING THE VEHICLE 1 Study and understand controls Make sure everyone is seated and holding onto seat handles or handrails Read safety warnings located on dash and or above pedals Make sure wheels are turned in
27. No 1012151 Accelerator push rod pivots and mounts 3 Dry Moly Lube Club Car Part No 1012151 Forward Reverse Switch Contacts and 4 WD 40 charger receptacle Brake Slides 5 Dry Moly Lube Club Car Part No 1012151 Front Suspension 5 fittings 6 Chassis Lube EP NLGI Grade 2 Periodic Lubrication Schedule continued on following page 16 1999 DS Golf Car Electric Vehicle Owner s Manual Vehicle Capacities PERIODIC LUBRICATION SCHEDULE REGULAR INTERVAL SERVICE PLACE RECOMMENDED LUBRICANT 22 67 liter SAE 30 WT API Annually by Trained Check fill transaxle to plug level 7 Class SE SF or SG Oil or higher Technician Only Every 100 hours of operation Inspect front wheel bearings or 200 rounds of golf Repack as necessary 8 Chassis Lube EP NLGI Grade 2 See Figure 11 Page 17 Figure 11 Vehicle Lubrication Points VEHICLE CAPACITIES CAPACITIES Transaxle 22 oz 67 liters Tire Pressure 18 20 psi 124 138 kPa VEHICLE CONTROLLER The DS electric vehicle is equipped with either a Solid State Speed Controller PowerDrive System 48 and PowerDrive Plus or a V Glide Speed Controller 36 Volt Vehicle In order to properly service and maintain the Solid State Controller Vehicle or the V Glide Speed Controller Vehicle it is necessary to understand the electrica
28. RASP THE PLUG BY THE HANDLE AND PULL THE PLUG STRAIGHT OUT OF 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 POWERDRIVE CHARGERS OR BLADES ACCU POWER CHARGERS 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 WARNING CONTINUED ON FOLLOWING PAGE 1999 DS Golf Car Electric Vehicle Owner s Manual 21 Battery Charger A WARNING USING THE CHARGER WITH ANY OF THE ABOVE SYMPTOMS COULD RESULT IN A FIRE PROPERTY DAMAGE PERSONAL INJURY OR DEATH THE DC CHARGER CORD AND PLUG ARE WEAR ITEMS AND MUST BE REPLACED WHEN WORN OR DAMAGED NOTE WHEN TEMPERATURES FALL BELOW 65 F 18 3 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 Insert t
29. RD REVERSE SWITCH IN NEUTRAL AND DISCONNECT BATTERIES PRIOR TO SERVICING THE VEHICLE POWERDRIVE PLUS VEHICLES ONLY PLACE TOW RUN SWITCH IN THE TOW POSITION BEFORE DISCONNECTING BATTERIES TO AVOID UNINTENTIONALLY STARTING THE VEHICLE DISCONNECT THE BATTERIES AS SHOWN FIGURE 1 AND FIGURE 2 PAGE 2 ON POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES ALSO DISCHARGE THE CONTROLLER AS FOLLOWS TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD REVERSE SWITCH IN THE REVERSE POSITION SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THE REVERSE WARNING BUZZER CAN NO LONGER BE HEARD WHEN THE BUZZER STOPS SOUNDING THE CONTROLLER IS DISCHARGED ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL CONNECTIONS IMPROPER USE OF THE VEHICLE OR FAILURE TO PROPERLY MAINTAIN IT COULD RESULT IN DECREASED VEHICLE PERFORMANCE OR SEVERE PERSONAL INJURY ANY MODIFICATION OR CHANGE TO THE VEHICLE WHICH AFFECTS THE STABILITY OR HANDLING OF THE VEHICLE OR INCREASES MAXIMUM VEHICLE SPEED BEYOND FACTORY SPECIFICATIONS COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH 1999 DS Golf Car Electric Vehicle Owner s Manual 3 Vehicle Feature Identification DS ELECTRIC VEHICLE DRIVER PASSENGER WARNING DECAL A WARNING READ AND FOLLOW THESE WARNINGS AND THE OPERATING KEY SWITCH OPERATING INSTRUCTIONS Read Owner s Manual and safety warnings located dash panel prior to driving INSTRUCTIO
30. SPECIFIED IN SUCH MANUALS ii 1999 DS Golf Car Electric Vehicle Owner s Manual 4 SOLE REMEDY CLUB only liability under this limited warranty or in any action whether based upon warranty contract negligence strict product liability or otherwise is limited to the repair or replacement at CLUB CAR s option of a golf car or component thereof that CLUB CAR deems to be defective Replacement shall mean furnishing during the applicable limited warranty period a new golf car or factory reconditioned vehicle or component thereof which 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 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 ADMINISTRATION CLUB CAR INC P O Box 204658 4152 Washington Road Augusta Georgia 30907 4658 6 DISCLAIMER THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESS OR IMPLIED ANY
31. T FUSE FUSE LINK Figure 15 Receptacle Fuse Link for 36 Volt Vehicle Figure 16 Receptacle Fuse Link for 48 Volt Vehicle CLEANING THE VEHICLE DS vehicles are equipped with Armorflex front and rear bodies Use only mild dishwashing liquid soap with a sponge or soft cloth for normal cleaning See following CAUTION and NOTE CAUTION e IF A PRESSURE WASHER IS USED DO NOT EXCEED 500 PSI 3448 KPA NOZZLE SHOULD BE SET TO WIDE ANGLE SPRAY 1999 DS Golf Car Electric Vehicle Owner s Manual 23 Accessories NOTE DISPOSE OF WASTE WATER PROPERLY Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to pre vent possible stains Because the finish on the vehicle is the same as the finish on today s automobiles com mercial automotive cleaning products may be used The seats of the vehicle will last longer with proper cleaning Use a solution of 10 liquid dish soap and warm water applied with a soft cloth For imbedded dirt a soft bristle brush may be used For heavy soiling or difficult stains see Section 4 of the DS Maintenance and Service Manual Also for scratches blemishes or other body damage see Section 4 of the DS Maintenance and Service Manual ACCESSORIES A complete line of accessories is available from Club Car and our dealers distributors Care should be taken that these accessories are properly installed by trained technicians and that they a
32. ULAR 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 REPAIR OR REPLACEMENT OF THE DEFECTIVE CHARGER OR COMPONENT THEREOF IS THE EXCLUSIVE AND 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 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 CLUB CAR FOUR YEAR LIMITED WARRANTY FOR 1999 ONBOARD COMPUTERS AND SOLID STATE SPEED CONTROLLERS IN THE UNITED STATES AND CANADA CLUB CAR INC CLUB CAR warrants to the original retail purchaser that the new Onboard Computer and the Solid State Speed Controller hereinafter called Computer and Controller re
33. ULD BE USED FOR MULTI VEHICLE TOWING NEVER TOW MORE THAN FIVE VEHICLES AT ONE TIME POWERDRIVE PLUS VEHICLE ONLY PLACE THE TOW RUN SWITCH IN TOW POSITION THE VEHICLE WILL NOT ROLL OTHERWISE 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 towing Observe all of the previous WARNING statements when towing TRANSPORTING ON A TRAILER If your vehicle must be transported over long distances or on public highways it should be done on an approved trailer and all the following WARNING procedures should be followed A WARNING FOR USE ON PUBLIC ROADS THE TRAILER MUST MEET ALL FEDERAL STATE AND LOCAL REQUIREMENTS SUCH AS TAILLIGHTS BRAKE LIGHTS ETC ALWAYS USE AN APPROVED TRAILER THAT HAS A LOAD RATING OF 1200 LBS 544 KG PER VEHICLE TO BE TOWED EXAMPLE A TWO CAR TRAILER SHOULD BE RATED AT 2 X 1200 2400 LBS 2 X 544 1088 KG NEVER 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 SWITCH IN NEUTRAL THE KEY SWITCH OFF AND THE PARK BRAKE FIRMLY DEPRESSED AND LOCKED WHEN TOWING ON A TRAILER NORMAL ROAD SPEED OF THE TOW VEHICLE SHOULD BE REDUCED BECAUSE OF THE ADDED LENGTH OF T
34. able 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 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 ADMINISTRATION CLUB CAR INC P O Box 204658 4152 Washington Road Augusta Georgia 30907 4658 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 K
35. ace This will prevent self discharge of the batteries 4 Adjust tire pressure to 20 psi 138 kPa Grease front suspension and do all other semi annual periodic lubrication See Periodic Lubrication Schedule Page 16 Thoroughly clean front body rear body seats battery compartment and underside of vehicle Do not latch the park brake Chock wheels to prevent the vehicle from rolling 8 Keep batteries fully charged during storage See Batteries Page 17 e If possible charge 36 volt vehicles with Accu Power battery chargers every 6 8 weeks as necessary If it is not possible or practical to charge the batteries leave them disconnected while the vehicle is in storage Leave PowerDrive System 48 and PowerDrive Plus vehicles with PowerDrive chargers plugged in dur ing storage The PowerDrive storage charge feature will automatically charge the batteries as needed throughout storage period See Batteries Page 17 See following NOTE NOTE A POWERDRIVE SYSTEM 48 OR POWERDRIVE PLUS VEHICLE WILL NOT OPERATE WHILE PLUGGED TO A CHARGER TO RETURN THE STORED VEHICLE TO SERVICE 1 2 3 14 Fully charge batteries Batteries 17 Readjust tire pressure to 18 20 psi 124 138 kPa Perform the Pre Operation Checklist See page 6 1999 DS Golf Car Electric Vehicle Owner s Manual Maintenance MAINTENANCE Read DANGER and WARNING on page 3 GENERAL INFORMATION To ensure trouble free vehicle p
36. ccelerator With the key switch ON and the Forward Reverse switch in the FORWARD position as the accelerator pedal is depressed the motor should start and the vehicle should come up smoothly to full speed When the pedal is released it should return to the original position and the motor should stop All DS vehicles run at reduced speed in reverse General Listen for any unusual noises such as squeaks or rattles Check the vehicle s ride and performance Have a Club Car distributor dealer or a trained mechanic investigate anything unusual DS PowerDrive Plus Vehicles Zero Speed Detect With the vehicle parked on level ground and the park brake disengaged place the tow switch in the RUN position and attempt to push the vehicle It should resist rolling moving at no more than 1 or 2 mph with the Forward Reverse switch in any position 6 1999 DS Golf Car Electric Vehicle Owner s Manual Controls Pedal Up Motor Braking Accelerate the vehicle to full soeed and then release the accelerator pedal Motor braking should quickly and smoothly slow the vehicle to approximately 9 mph Motor brak ing will disengage when vehicle slows to 9 mph Pedal Down Motor Braking Accelerate down an incline with the accelerator pedal depressed When the vehicle reaches approximately 15 mph motor braking should engage and moderate vehicle speed between 15 and 16 mph depending upon the grade of the hill CONTROLS Read DANGER and WARNING on pag
37. desired direction Turn key to the ON position and make sure nothing is in your path Select direction by placing Forward Reverse handle in desired position F forward or R reverse Slowly depress accelerator pedal The park brake will release automatically and the vehicle will start to move As the accelerator pedal is depressed speed will increase until full is reached See following WARNING 3009 WARNING VEHICLE OPERATOR MUST CONTROL SPEED WHEN GOING DOWNHILL POWERDRIVE PLUS VEHICLE ONLY PEDAL DOWN OR PEDAL UP MOTOR BRAKING MAY BE USED TO CONTROL SPEED WHEN GOING DOWNHILL SEE PERFORMANCE INSPECTION ON PAGE 7 HOWEVER TERRAIN OR OTHER CONDITIONS MAY REQUIRE THAT PEDAL BRAKING BE USED IN CONJUNCTION WITH MOTOR BRAKING STOPPING THE VEHICLE A WARNING DRIVING THROUGH WATER MAY AFFECT THE BRAKES AFTER DRIVING THROUGH WATER CHECK EFFECTIVENESS OF THE BRAKES BY GENTLY DEPRESSING THE BRAKE PEDAL IF THE VEHICLE DOES NOT SLOW DOWN AT THE NORMAL RATE CONTINUE TO DEPRESS THE BRAKE PEDAL UNTIL THE BRAKES DRY OUT AND NORMAL PERFORMANCE RETURNS CAUTION 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 depress the brake pedal with your right foot until the vehicle comes to a complete stop PARKING AND LEAVING THE VEHICLE 1 After stopp
38. distributor dealer we strongly urge the new owner to re register the vehicle with Club Car This will enable us to contact you if the need arises Please send your name address and serial number s of the vehicle s to CLUB CAR INC P O Box 204658 Augusta GA 30917 4658 ATTN Vehicle Registration 24 1999 DS Golf Car Electric Vehicle Owner s Manual Fairway Villager FAIRWAY VILLAGER The electric Fairway Villager is designed to provide a smooth and comfortable ride for four passengers and is offered in the PowerDrive System 48 electric power configuration only A rack for two golf bags is also available Contact your nearest Club Car distributor dealer This Owner s Manual should be read thoroughly prior to operating the vehicle The Fairway Villager should be driven and maintained as stated in this Owner s Manual with the following additions A WARNING TO PREVENT POSSIBLE INJURY TO AN UNSUSPECTING PASSENGER OR DAMAGE TO THE VEHICLE AVOID SUDDEN STARTS SUDDEN STOPS AND ABRUPT TURNS VEHICLE SHOULD BE DRIVEN AT SLOWER SPEEDS WHEN FOUR PERSONS ARE IN THE VEHICLE PASSENGERS SHOULD HOLD ON TO SEAT HANDLES OR HAND RAILS AT ALL TIMES FIGURE 17 PAGE 26 DRIVER SHOULD KEEP BOTH HANDS ON THE STEERING WHEEL WHILE VEHICLE IS MOVING NEVER LEAVE CHILDREN UNATTENDED IN THE VEHICLE DO NOT LEAVE CHILDREN UNATTENDED ON THE REAR SEAT WHILE VEHICLE IS MOVING NO MORE THAN FOUR PERSONS SHOULD BE ON THE VEHICLE AT ON
39. e 3 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 DO NOT MODIFY OR CHANGE THE VEHICLE IN ANY WAY WHICH MIGHT AFFECT ITS STABILITY OR HANDLING OR INCREASE MAXIMUM SPEED BEYOND FACTORY SPECIFICATIONS PROPERTY DAMAGE PERSONAL INJURY OR DEATH COULD RESULT DO NOT SHIFT THE FORWARD REVERSE F amp R 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 F amp R SWITCH A BUZZER WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE e RELEASE THE ACCELERATOR PEDAL AND THEN DEPRESS THE BRAKE PEDAL FIRMLY UNTIL THE VEHICLE STOPS TO AVOID UNINTENTIONALLY STARTING OR ROLLING THE VEHICLE SET THE PARK BRAKE TURN THE KEY SWITCH TO OFF AND REMOVE THE KEY WHEN LEAVING THE VEHICLE KEY SWITCH The key switch is mounted on the dash to the right of the steering column Figure 4 Page 7 It has two posi tions OFF and ON which are clearly labeled See following NOTE Figure 4 Key Switch Figure 5 Forward Reverse Handle NOTE THE KEY BE REMOVED WHEN THE KEY SWITCH IS IN THE OFF POSITION ONLY 1999 DS Golf Car Electric Vehicle Owner s Manual 7 Controls FORWARD REVERSE CONTROL DS V Glide Electric and DS PowerDrive System 48 The Forward Reverse F amp R handle is located o
40. e batteries in PowerDrive System 48 and PowerDrive Plus Electric Vehicles are 8 volts each Both the 6 and 8 volt batteries are deep cycle batteries specially built for electric vehicle application Auto motive batteries should never be used 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 PowerDrive System 48 vehicles with new batteries to 36 holes of use between charges in the first two months of operation V Glide 36 volt vehicles should be limited to 18 holes between charges in the first two months Batteries should be fully charged before first use of new vehi cle before first use of a vehicle after storage and before releasing vehicle for use each day BATTERY CARE To keep batteries in good working condition follow this maintenance program on a regular basis 1 The batteries should be kept clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water 1 cup baking soda per gallon of water once per week Rinse solution off batteries See following NOTE NOTE DO NOT ALLOW THIS SOLUTION TO ENTER THE BATTERY DISPOSE OF WASTE WATER PROPERLY Be sure terminals are tight Let the terminals dry and then spray them with CLUB CAR battery protec tor spray Part No 1014305 18 1999 DS Golf Car Electric Vehicle Owner s Manual Battery Charger 2
41. eorgia 30917 4658 U S A 706 863 3000 ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL BE VOID AND EXCLUDED SUBSEQUENT TO ONE YEAR FROM THE DATE OF PURCHASE THE REPLACEMENT OF THE COMPUTER OR CONTROLLER IS THE EXCLUSIVE REMEDY UNDER THIS WRITTEN WARRANTY TO ANY IMPLIED WARRANTY 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 LIMITED WARRANTY LIMITED WARRANTY EXCLUSIONS 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 golf car or utility vehicle 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 THE PROVISIONS FOR THIS LIMITED WARRANTY SHALL NOT APPLY TO FAILURE DUE TO Abuse or neglect such as improper battery fluid levels loose wiring or rusted or corroded hardware Lack of proper maintenance as outlined in the electric vehicle owner s manual Damage caused by improper installation of the Computer or Controll
42. er and Vehicles charged by systems other than the CLUB CAR PowerDrive Charger THIS COMPUTER OR CONTROLLER IS INTENDED TO BE USED ONLY IN CLUB CAR POWERDRIVE SYSTEM 48 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 LIMITED TO LOSS OF USE OR REVENUE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS NOR THE EXCLUSIONS OR LIMITATIONS OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU WARRANTY LIMITATIONS CLUB CAR s only liability under this limited warranty shall be to replace a defective Computer or Controller Replacement shall mean furnishing a new or reconditioned Computer or Controller which 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 whichever event first occurs except for transportation expenses All parts and components replaced under warranty shall become the property of CLUB CAR Damage not resulting from a defect in materials or workmanship or which occurs due to abuse or neglect including failure to provide reasonable and necessary maintenance accident or alteration is excluded from this
43. er 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 Figure 13 Correct Insertion of Charger DC Plug Figure 14 Incorrect Insertion of Charger DC Plug 22 1999 DS Golf Car Electric Vehicle Owner s Manual Cleaning The Vehicle PLUG AND RECEPTACLE If the charger plug becomes difficult to insert or disconnect the receptacle contacts should be lightly sprayed with WD 40 brand spray lubricant The plug should then be inserted and removed several times to ensure ease of insertion ease of removal and good electrical contact See following NOTE NOTE IF THE WARNING TAG HAS BEEN DAMAGED OR REMOVED FROM THE DC CORD HAVE IT REPLACED IMMEDIATELY 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 15 Page 23 for V Glide 36 Volt vehicle or Figure 16 Page 23 for PowerDrive System 48 vehicle If the charger does not come on when the vehicle is placed on charge visually inspect the fuse link See following WARNING WARNING IF THE RECEPTACLE FUSE LINK IS BLOWN DETERMINE THE SOURCE OF THE ELECTRICAL PROBLEM AND CORRECT IT BEFORE REPLACING THE FUSE CONTACT YOUR NEAREST CLUB CAR DISTRIBUTOR DEALER 48 VOLT FUSE LINK SENSE LEAD 36 VOL
44. erformance it is very important to follow an established preventive mainte nance program regularly scheduled service even though the vehicle is functional Regular and consistent vehicle maintenance can prevent vehicle down time and expensive repairs that result from neglect Any vehi cle 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 semi annual and annual periodic ser vice See following WARNING A WARNING IF 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 HOT DO NOT ATTEMPT TO SERVICE HOT MOTOR OR RESISTORS ATTEMPTING TO DO SO COULD CAUSE SEVERE BURNS DAILY PRE OPERATION SAFETY CHECKLIST Inspect and drive the vehicle using the Pre operation Checklist Page 6 and Performance Inspection Page 6 as a guide to check the following items Vehicle warning decals Brake system Park brake Reverse warning buzzer Steering and linkages Proper acceleration and maximum speed Batteries Accelerator Switch In addition check the items listed below Tires Visually inspect for wear damage and proper inflation
45. exercise due care in working on or around batteries 1999 DS Golf Car Electric Vehicle Owner s Manual 31 THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOT APPLY TO FAILURE DUE TO Abuse or neglect such as improper fluid levels loose wiring or rusted or corroded hardware Lack of proper maintenance as outlined in the electric vehicle owner s manual Damage caused by improper installation of the battery 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 and a battery charged by systems other than the CLUB CAR PowerDrive Charger 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 LIMITED TO LOSS OF USE OR REVENUE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS 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 WARRANTY LIMITATIONS CLUB liability shall be to replace a defective battery Replacement shall mean f
46. he charger DC plug into the vehicle receptacle The charger will turn on two to ten seconds later Figure 13 Page 22 When inserting the PowerDrive System 48 DC plug align the raised guide on the plug with the guide slot in the receptacle and push straight in slowly The PowerDrive Charger interacts with an onboard computer on the PowerDrive System 48 vehicle 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 lock out 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 lock out remains activated until the charger plug is disconnected from the vehicle Because of these unique features only PowerDrive System 48 vehicles are compatible with the PowerDrive Charger neither vehicles made by other manufacturers nor other Club Car models are 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 charg
47. he 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 either gasoline or electric vehicles without obligation to make these changes on units previously sold These vehicles are designed and manufactured for off road use only They 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 1998 Club Car Inc Club Car Armorflex PowerDrive and PowerDrive Plus are registered trademarks of Club Car Inc This manual effective July 27 1998 1999 DS Golf Car Electric Vehicle Owner s Manual i CLUB CAR LIMITED THREE YEAR WARRANTY FOR 1999 SINGLE GOLF CARS IN THE UNITED STATES AND CANADA 1 WARRANTY CLUB CAR INC CLUB CAR hereby warrants to the original retail purchaser that its new 1999 Model DS golf car purchased from CLUB CAR or an authorized distributor or dealer for use in the United States or Canada shall be free from defects in materials and workmanship under normal use and service as a golf car for the periods stated below 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
48. icle Specifications Continued on Next Page 26 1999 DS Golf Car Electric Vehicle Owner s Manual DS Electric Vehicle Specifications POWERDRIVE POWERDRIVE DS SPECIFICATIONS SYSTEM 48 PLUS 36 Volt Batteries High capacity deep cycle Trojan PowerDrive 8 volt 117 min capacity Batteries High capacity deep cycle Trojan 6 volt 115 capacity Charger Automatic 17 amp PowerDrive UL and CSA listed Charger Automatic 21 amp Accu Power 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 BODY CHASSIS Frame Chassis Twin welded aluminum Front and Rear Armorflex Finish Matched paint finish over molded in color Tires 18 00 x 8 50 8 00 tubeless 4 rated SEATING CAPACITY FUEL CAPACITY Standard Seating Capacity 2 persons Fairway Villager Seating Capacity 4 persons DIMENSIONS WEIGHT 91 1 2 91 1 2 91 1 2 Overall Length 232 cm 232 cm 232 cm 47 1 4 47 1 4 47 1 4 120 120 120 PERS 48 48 48 Overall Height At Steering Wheel 122
49. ing the vehicle A WARNING e SURE THE PLASTIC HAS BEEN REMOVED FROM THE SEAT BOTTOM BEFORE OPERATING THE VEHICLE FAILURE TO DO SO MAY RESULT IN A FIRE PROPERTY DAMAGE PERSONAL INJURY OR DEATH PERFORMANCE INSPECTION After you have familiarized yourself with the vehicle s 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 your new vehicle Any problems should be corrected only by your Club Car distributor dealer or a trained technician All vehicles Brakes Be sure the brakes function properly When brake pedal is fully depressed under moderate pressure it should not go more than halfway to the floor and vehicle should come to a smooth straight stop within 14 feet If the pedal goes more than halfway to the floor or if the vehicle swerves or fails to stop within 14 feet have the brake system checked and adjusted as required Brake adjustment must be maintained so that the brake pedal cannot be depressed to the floor under any circumstances Park Brake When latched the park brake should lock the wheels and hold the vehicle stationary on incline of 20 or less It should release when either the accelerator or brake pedal is depressed Reverse Buzzer The reverse buzzer should sound as a warning when the vehicle is in reverse Steering The vehicle should be easy to steer and should not have any play in the steering wheel A
50. ing the vehicle firmly depress the park brake pedal until it locks This will prevent the vehicle from rolling 2 Turn the key switch to OFF and place the Forward Reverse handle in the NEUTRAL position Remove the key when the vehicle is not in use PowerDrive Plus 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 rolling at more than 1 or 2 mph unless the accelerator is depressed This prevents the possibility of a parked vehicle with the park brake disengaged rolling away too fast to be overtaken on foot See Zero Speed Detect on Page 6 12 1999 DS Golf Car Electric Vehicle Owner s Manual Towing TOWING A WARNING NEVER TOW THE VEHICLE ON PUBLIC STREETS OR HIGHWAYS USE ONLY APPROVED CLUB CAR TOW BARS TURN THE KEY SWITCH TO OFF AND PLACE THE FORWARD REVERSE SWITCH IN NEUTRAL BEFORE TOWING THE VEHICLE EXTREME CAUTION SHOULD BE USED WHEN TOWING ANY VEHICLE DO NOT EXCEED 5 MPH 8 KPH TOWING SPEED DO NOT ALLOW PEOPLE IN THE VEHICLES BEING TOWED AVOID SUDDEN STARTS SUDDEN STOPS AND TIGHT TURNS WHEN TOWING DO NOT TOW MORE THAN ONE CLUB CAR VEHICLE WITH ANOTHER CLUB CAR VEHICLE IF MORE THAN ONE VEHICLE MUST BE TOWED AN ADEQUATELY POWERED VEHICLE TRACTOR OR FULL SIZED TRUCK PROPERLY FITTED WITH A TOW HITCH HEIGHT OF 11 INCHES SHOULD BE USED ONLY HEAVY DUTY TOW BARS SHO
51. l circuitry and the functions of all components in both sys tems Therefore if any repair or servicing needs to be performed we recommend that it be performed by an authorized Club Car distributor dealer using Club Car OEM parts 1999 DS Golf Car Electric Vehicle Owner s Manual 17 Batteries BATTERIES Read DANGER and WARNING on page 3 DANGER BATTERY EXPLOSIVE GASES DO NOT SMOKE KEEP SPARKS AND FLAMES A SAFE DIS TANCE FROM THE VEHICLE TOOLS WIRES AND METAL OBJECTS CAN CAUSE SPARKS WHEN SHORTED ACROSS A BATTERY FOLLOW ALL INSTRUCTIONS CAREFULLY WHEN DEALING WITH 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 POISON CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING ANTIDOTES EXTERNAL FLUSH WITH WATER FOR 15 MINUTES 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 CAUTION ON ALL VEHICLES TURN OFF ALL ACCESSORIES BEFORE CHARGING BATTERIES NOTE e RECYCLE OR DISPOSE OF DISCARDED BATTERIES IN ACCORDANCE WITH LOCAL STATE AND FEDERAL REGULATIONS The batteries DS V Glide 36 Volt Electric Vehicles are 6 volts each Th
52. limited warranty This warranty gives you specific legal rights and you may also have other rights which vary from state to state 34 1999 DS Golf Car Electric Vehicle Owner s Manual Manual No 101993802 Edition Code 0698B0299A Golf Cars Electric Club Car Inc P O Box 204658 Augusta GA 30917 4658 CLUB CAR
53. n the seat support panel below and to the right of the driver s right knee Figure 5 Page 7 The F amp R handle has three distinct positions FORWARD REVERSE and NEUTRAL Rotate the handle to the FORWARD F position towards the driver to operate the vehicle in the forward direction Rotate the handle to the REVERSE R position towards the passenger to drive the vehicle in the reverse direction When the F amp R handle is in the straight up NEUTRAL N position the vehi cle will not run DS vehicles operate at reduced speed in reverse When the vehicle is in reverse the reverse warning buzzer will sound DS PowerDrive Plus The Forward Reverse F amp R rocker switch is located in the same place as the Forward Reverse handle on all other DS models on the seat support panel below and to the right of the driver s right knee The FORWARD and REVERSE R positions are clearly marked on the F amp R rocker switch Push down the FORWARD F side of the switch to operate the vehicle in the forward direction or push down the REVERSE R side of the switch to run the vehicle in reverse When the F amp R rocker switch is positioned in NEUTRAL with neither side down the vehicle will not operate if the accelerator pedal is depressed Figure 6 Page 9 See following NOTE NOTE THE REVERSE BUZZER WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE ACCELERATOR PEDAL The accelerator pedal is the pedal on the right with the wo
54. on Marketing Services P O Box 204658 Augusta Ga 30917 4658 USA Your local authorized Club Car representative can also provide technical advice parts and service manuals We hope you will consider this owners manual a permanent part of your golf car If you sell the vehicle please include the manual so that the next owner will have the important operating safety and maintenance information it contains iv 1999 DS Golf Car Electric Vehicle Owner s Manual 5 2 General Warnings 0 3 Vehicle Feature Identification 0 4 General Information pete Hee teed 5 Model Identification aaa e a e A E eee eee 5 Safety Committe 55 5 euo Goce e etx nios Ead aiat hohe deh eel Saee ed batten nis 5 Pre Operation Checklist 9 6 GODLIOIS t 7 Driving Instr ctlons expri hee oe 11 TOWING 13 Transporting Trailer mh 13 ie 14 Maintenance vu sesto Lise eae Eis iecit ie EE prts 15 Daily Pre Operation Safety Checklist 22s 15 Periodic Service Schedule 9 15 Periodic Lubrication Schedule 5 16 Vehicle Capacities tdci hind aie X GERE Ua RR Rib RUNE RARE ERA ARCU Rr ae 17 Vehicle Gontroller sa eese beso Ru eie ua
55. or against defects in material and workmanship for a period of one year from the date of purchase This limited warranty covers materials 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 lubricants and 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 the battery charger onboard computer and solid state speed controller are covered under separate CLUB CAR warranties Tires are warranted by their manufacturer 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
56. ote that some vital statements throughout this manual and on the decals affixed to the vehicle are preceded by the words DANGER WARNING CAUTION or NOTE For your protection we rec ommend that you take special notice of these safety procedures Safety procedures are essential and must be followed Throughout this manual and on the operation and warning 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 repre sentation is stated or implied If any of the operation or warning decals on the vehicle become damaged have been removed or cannot be easily read they should be replaced immediately to avoid possible property damage personal injury or death Contact your Club Car distributor dealer A DANGER A DANGER INDICATES AN IMMEDIATE HAZARD WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH WARNING A WARNING INDICATES AN IMMEDIATE HAZARD WHICH COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH CAUTION A CAUTION INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN PRODUCT OR PROPERTY DAMAGE OR MINOR PERSONAL INJURY NOTE A NOTE PROVIDES KEY INFORMATION TO MAKE PROCEDURES MORE EASILY UNDERSTOOD OF VEHICLE V REMOVE NEGATIVE CABLE FIRST DISCONNECT THESE DISCONNECT THESE BATTERY CABLES BEFORE WORKING ON VEHICLE BATTERY CABLES BEFORE WORK
57. park plugs 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 controller are covered by separate CLUB CAR warranties Tires are warranted by their manufacturer 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 service 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 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 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
58. rd GO molded into it Figure 7 Page 9 See fol lowing NOTE NOTE THE OPERATION OF THE ACCELERATOR PEDAL DIFFERS FROM THAT OF AUTOMOBILE WHEN THE KEY SWITCH IS ON AND THE FORWARD REVERSE HANDLE IS IN EITHER FORWARD OR REVERSE DEPRESSING THE ACCELERATOR PEDAL WILL AUTOMATICALLY RELEASE THE PARK BRAKE AND START THE VEHICLE MOVING IN THE DIRECTION SELECTED FORWARD OR REVERSE AS THE ACCELERATOR PEDAL 15 DEPRESSED SPEED WILL INCREASE UNTIL FULL SPEED IS REACHED WHEN THE ACCELERATOR IS RELEASED POWER WILL BE CUT OFF AND THE MOTOR WILL STOP RUNNING e POWERDRIVE PLUS VEHICLES ONLY SEE PEDAL UP AND PEDAL DOWN MOTOR BRAKING ON PAGE 7 BRAKE PEDAL The brake pedal is the large pedal on the left with the word STOP molded into it Figure 7 Page 9 To slow or stop the vehicle depress the brake pedal with your foot Figure 8 Page 9 PARK BRAKE 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 Page 9 To set the park brake depress the brake pedal firmly and tilt the park brake portion of the pedal forward with your foot Figure 9 Page 9 See following WARNING WARNING THE PARK BRAKE WILL RELEASE AUTOMATICALLY WHEN EITHER THE ACCELERATOR OR BRAKE PEDAL IS DEPRESSED THE PARK BRAKE HAS MULTIPLE LOCKING POSITIONS AND SHOULD BE FIRMLY PRESSED AND LOCKED TO PREVENT
59. re used in the manner for which they were designed See following WARNING A WARNING TINTED WINDSHIELDS AND WEATHER PROOF ENCLOSURES WILL NOT PROTECT OCCUPANTS FROM FLYING OBJECTS GOLF BALLS ACCESSORY EQUIPMENT Accent Striping Rear View Mirror Differential Guard Custom Club Decals Glove Box Hour Meter Number Decals Performance Grade Tires Information Holder Canopy Standard Tread Tires Beverage Cooler Rear Rain Curtain Extra Traction Tires Extra Two bag Attachment Weather proof Enclosure DC to DC Converter Sand Bunker Rake Kit Tinted Split Windshield Chrome Hub Wheel Covers Golf Club and Ball Cleaner Tinted Snap on Windshield Chrome Sport Wheel Covers Battery Indicator Adjustable Seat Back Trailer Hitch Ashtray Sand Bottle Divot Repair Kit Uncommon Key Switch Club Protector Turn Signals for vehicles Permanent Tow Bar for Multiple 3 75 hp Electric Motor with lights Vehicle Towing factory installed PowerDrive System 48 vehicle only Sand Basket and Divot 3 5 hp Electric Motor V Glide Lighting Package headlights Bucket Repair Kit 36 Volt vehicle only taillights brake lights and horn Temporary Tow Bar for Single Onboard Tow Bar Onboard Charger with Rewind Cord Vehicle Towing SUBSEQUENT OWNER REGISTRATION In the event a vehicle is bought as a used vehicle from another individual or from a
60. rs from the date of purchase and repair labor costs for a period of one year from the date of purchase Such repair labor shall be performed only by CLUB CAR at its facility in Augusta Georgia or by an authorized distributor dealer Purchaser shall be responsible for all freight costs to and from CLUB facility For further information or to present a warranty claim contact Warranty Administration CLUB CAR INC P O Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 WARRANTY EXCLUSIONS THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOT APPLY TO a Normal maintenance services such as preventive maintenance checks and tightening loose wire connections b Parts such as diodes and fuses which are vulnerable to electrical overloads including lightning beyond the control of CLUB CAR and c Charger DC cord set with plug which is a wear item and subject to user abuse Any warranty service which includes labor must be performed by CLUB CAR or by an authorized distributor dealer FOR REPAIRS MADE BY QUALIFIED TECHNICIANS OTHER THAN CLUB CAR S FACTORY TECHNICIANS OR AN AUTHORIZED DISTRIBUTOR DEALER CLUB CAR WILL PROVIDE ONLY THE REPLACEMENT PARTS OR COMPONENTS 32 1999 DS Golf Car Electric Vehicle Owner s Manual THIS POWERDRIVE CHARGER IS INTENDED BE USED BY PERSONS KNOWLEDGEABLE WITH THE CHARGER AND PROPER CHARGING PRACTICES AND ONLY ON CLUB CAR POWERDRIVE SYSTEM 48 VEHICLES ANY OTHER USE RENDERS THE LIMITED WARRANT
61. rtant 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 MODEL IDENTIFICATION The serial number of your Club Car is printed on a bar code decal mounted on the frame directly above the accelerator pedal Example A9901 123456 Figure 3 Page 5 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 access it See following NOTE NOTE ALWAYS HAVE THE VEHICLE SERIAL NUMBER AT HAND WHEN ORDERING PARTS OR MAKING INQUIRIES IF THE VEHICLE IS EQUIPPED AS A FAIRWAY VILLAGER FOUR PASSENGER VEHICLE READ THE SPECIAL INSTRUCTIONS BEGINNING ON PAGE 25 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 Where golf cars should be driven Ensuring that proper warnings of driving hazards are displayed and visible Who should and who should not drive golf cars Instructing first time drivers Maintaining golf cars in a safe driving condition How various rules are to be enforced The safety committee should include all these items and such others as the committee feels necessary or appropriate SER
62. s released System is activated only when tow switch is in the RUN position When towing vehicle tow switch must be in the TOW position PARK BRAKE PEDAL ES oes ELNDNESS OR MOTOR BRAKING DECAL KEEP OUT OF THE REACH OF CHILDREN DO NOT TIP KEEP VENT CAPS TIGHT AND LEVEL POWERDRIVE PLUS VEHICLES ONLY A WARNING 33330 01104 RESISTOR WARNING DECAL ON BODY UNDER SEAT ON V GLIDE 36 VOLT VEHICLE ON BODY UNDER ACCESS PANEL ON POWERDRIVE PLUS VEHICLE FORWARD REVERSE HANDLE POWERDRIVE SYSTEM 48 AND V GLIDE 36 VOLT VEHICLES 5 A LL CHARGER RECEPTACLE FORWARD REVERSE TOW SWITCH WARNING DECAL POWERDRIVE PLUS VEHICLES ONLY PLUS ON TOW SWITCH BRACKET UNDER SEAT VEHICLES ONLY WARNING VEHICLE PLACE TOW SWITCH IN e DO 50 COULD RESULT IN DAMAGE NOTI CE id DO NOT DIRECT WATER TOWING TO VEHICLE OR BATTERY EXPLOSION STREAM AT THIS SWITCH 1016109 01 EXTENDED STORAGE SERVICING POTENTIOMETER CAUTION DECAL Kopie a iru ON WIPER SWITCH COVER INSIDE BATTERY COMPARTMENT 4 1999 DS Golf Car Electric Vehicle Owner s Manual General Information GENERAL INFORMATION There are three electric DS Golf Car models the DS V Glide 36 volt vehicle the DS PowerDrive System 48 48 volt electric vehicle and the DS PowerDrive Plus 48 volt vehicle Throughout this manual impo
63. spectively installed in its new electric vehicle equipped with the PowerDrive System 48 purchased from CLUB CAR or authorized distributor or dealer will be free from defects in materials and workmanship for a period of four years or 800 rounds from the date of purchase whichever event first occurs subject to the terms and conditions contained herein This limited warranty only covers defects in materials and workmanship for a period of four years or 800 rounds from the date of purchase whichever event first occurs The terms of this four year or 800 round limited warranty shall be as follows Free replacement with respect to parts and labor within four years or 800 rounds from date of purchase whichever event first occurs The Computer or Controller should be returned to CLUB CAR or an authorized distributor or dealer with evidence of proof of purchase date and number of rounds freight prepaid CLUB CAR reserves the right to 1999 DS Golf Car Electric Vehicle Owner s Manual 33 test any Computer returned for warranty and to verify number of rounds played by accessing information contained in the Computer In the event the vehicles are used for purposes other than golf the warranty will be four years or 16 000 energy units as recorded by the Computer whichever event first occurs For further information or to submit a warranty claim contact WARRANTY ADMINISTRATOR CLUB CAR INC 4152 Washington Road P O Box 204658 Augusta G
64. tated below LIMITED LIFETIME WARRANTY The golf car frame excluding the front and rear bumper mounts the rack and pinion steering gearbox unit and the suspension system defined as the shock absorbers shock mounts A plates leaf springs shackles and associated hardware are warranted with respect to parts and labor against defects in materials and workmanship for the lifetime of the vehicle 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 transmission torque converter drive and driven unitized transaxle starter generator transaxle electric vehicle and electric motor are warranted with respect to parts and labor against defects in materials and workmanship for a period of three years 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 with respect to parts and labor against defects in materials and workmanship for a period of two years from the date of purchase while owned by the Original Retail Fleet Purchaser or in the possession of the Original Retail Fleet Lessee LIMITED ONE YEAR WARRANTY All original equipment options and accessories supplied by Club Car are warranted with respect to parts and lab
65. teries BATTERY CHARGER DANGER BATTERIES EMIT HYDROGEN WHILE BEING CHARGED HYDROGEN IS AN EXPLOSIVE GAS IF THE VEHICLE IS EQUIPPED WITH A WEATHERPROOF ENCLOSURE IT SHOULD BE UNZIPPED AND PULLED BACK WHILE BATTERIES ARE BEING CHARGED THIS IS TO AVOID THE ACCUMULATION OF HYDROGEN GAS INSIDE THE ENCLOSURE THE CHARGING AREA MUST BE VENTILATED HYDROGEN LEVEL IN THE AIR MUST NEVER EXCEED 2 THE TOTAL VOLUME OF AIR IN THE BUILDING MUST BE CHANGED FIVE TIMES PER HOUR EXHAUST FANS SHOULD BE LOCATED AT THE HIGHEST POINT OF THE ROOF CONTACT A LOCAL HVAC ENGINEER 1999 DS Golf Car Electric Vehicle Owner s Manual 19 Battery Charger A WARNING 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 OUTLET 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 AND BE AS SHORT AS POSSIBLE THE USE OF IMPROPER EXTENSION CORD COULD RESULT IN FIRE OR AN ELECTRICAL SHOCK ONLY TRAINED TECHNICIA
66. the warning light will indicate as follows The warning light will not come on 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 1999 DS Golf Car Electric Vehicle Owner s Manual 9 Controls When the charger is unplugged the warning light will come on and remain illuminated for 10 seconds if the charge is less than 90 complete but the car has enough power to complete 36 holes of golf This will alert the fleet operator that the car may be used but that it must be charged to completion as soon as possible The warning light will repeatedly illuminate for 10 seconds with 4 second intervals if the charger times out at 16 hours see charger manual and the batteries are not sufficiently charged This indicates an abnormal charge cycle Charger and batteries should be checked by your Club Car distributor dealer The warning light 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 light will go out when AC power is restored POWERDRIVE PLUS VEHICLES ONLY Tow Run Switch WARNING TO AVOID POSSIBLE BATTERY EXPLOSION THE TOW RUN SWITCH MUST BE IN THE TOW POSITION BEFORE DISCONNECTING OR CONNECTING BATTERY WIRES WHEN THE TOW RUN SWITCH IS IN THE TOW POSITIO
67. thorized 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 verify number of rounds played by accessing information contained in the PowerDrive amp System 48 Onboard Computer In the event the vehicles are used for purposes other than golf the warranty will be four years or 16 000 energy units as recorded on the Onboard Computer whichever event first occurs ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL BE VOID AND EXCLUDED SUBSEQUENT TO ONE YEAR FROM THE DATE OF PURCHASE THE REPLACEMENT OF THE BATTERY IS THE EXCLUSIVE REMEDY UNDER THIS WRITTEN WARRANTY OR ANY IMPLIED WARRANTY 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 LIMITED WARRANTY LIMITED WARRANTY EXCLUSIONS Without limiting the generality of the foregoing in any way and as part of its limited warranty exclusion CLUB CAR does not warrant that its battery is suitable for use in any application other than in its golf car As in the use of any battery a prudent owner will read and study the charger owners manual the electric car owner s manual the operator instructions and the battery warning labels and will
68. tion to turn off power to the vehicle electrical system thus preventing vehicle electrical components from discharging the batteries DRIVING INSTRUCTIONS A WARNING IF RENTING OR LOANING THE VEHICLE MAKE SURE THE DRIVER IS FAMILIAR WITH ALL CONTROLS AND OPERATING PROCEDURES BEFORE ALLOWING THE VEHICLE TO BE DRIVEN NO MORE THAN TWO PEOPLE SHOULD BE ON THE VEHICLE AT ONE TIME 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 FOR NIGHT USE THE VEHICLE MUST BE EQUIPPED WITH HEADLIGHTS TAILLIGHTS AND REFLECTORS STOP THE VEHICLE BEFORE SHIFTING THE FORWARD REVERSE SWITCH FAILURE TO DO SO MAY RESULT IN INJURY TO AN UNSUSPECTING PASSENGER AND OR DAMAGE TO THE VEHICLE A BUZZER WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE WHEN DRIVING THE VEHICLE OPERATE THE VEHICLE FROM THE DRIVER SEAT ONLY TO PREVENT FALLS FROM THE VEHICLE REMAIN SEATED IN A MOVING VEHICLE AND HOLD ON TO SEAT HANDLES OR HANDRAILS AT ALL TIMES DRIVER SHOULD KEEP BOTH HANDS ON THE STEERING WHEEL WHEN THE VEHICLE IS IN MOTION TO PREVENT THE POSSIBILITY OF SERIOUS INJURY KEEP YOUR ENTIRE BODY INSIDE THE VEHICLE TO PREVENT OVERTURNING THE VEHICLE DRIVE SLOWLY IN TURNS TO PREVENT OVERTURNING THE VEHICLE DRIVE SLOWLY STRAIGHT UP AND DOWN SLOPES DO NOT DRIVE THE VEHICLE ON SLOPES EXCEEDING 20 INCLINE TO AVOID POSSIBLE INJURY TO AN U
69. ttery damaged by a defective charger 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 30 1999 DS Golf Car Electric Vehicle Owner s Manual ALSO EXCLUDED FROM THIS LIMITED WARRANTY ARE ANY AND ALL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE OR REVENUE LOSS OF TIME OR INCONVENIENCE SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS NOR EXCLUSIONS LIMITATIONS OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU WARRANTY LIMITATIONS CLUB CARS only liability under this warranty shall be to replace a defective battery Replacement shall mean furnishing a new or used battery 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 three year or 600 round limited warranty period whichever event first occurs except for labor or transportation expenses All batteries which are replaced under this limited warranty become the property of CLUB CAR Damage not resulting from a defect in materials or workmanship or which occurs due to abuse or neglect including failure to provide reasonable and necessary maintenance
70. urnishing a new battery or used battery 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 or 800 round limited warranty period whichever event first occurs except for labor or transportation expenses Damage not resulting from a defect in materials or workmanship or which occurs due to abuse or neglect including failure to provide reasonable and necessary maintenance accident or alteration is excluded from this limited warranty This warranty gives you specific legal rights and you may also have other rights which vary from state to state For further information or to submit a warranty claim contact Warranty Administrator CLUB CAR INC P O Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 CLUB CAR LIMITED FOUR YEAR WARRANTY FOR 1999 POWERDRIVEG BATTERY CHARGERS IN THE UNITED STATES AND CANADA CLUB CAR INC CLUB CAR warrants to the original retail purchaser that its new PowerDrive Charger purchased from CLUB CAR or an authorized distributor dealer for use in the United States or Canada will be free from defects in materials 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 covers defects in materials and workmanship for a period of four yea
71. y specifications including those that affect the weight distribution stability or speed of the golf car can cause serious personal injury or death 1999 DS Golf Car Electric Vehicle Owner s Manual FOREWORD Thank you for choosing Club Car the golf car most widely recognized as the industry leader in vehicle effi ciency and long lasting value You have chosen the finest golf car on the market Please protect your invest ment and ensure that your Club Car provides years of reliable superior performance by returning your Warranty Registration provided by your distributor dealer and by reading and following the maintenance instructions in this manual Your comfort and safety are important to us as well so we urge you to read and follow the step by step oper ating instructions and safety procedures in this manual These instructions must be followed in order to avoid the 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 golf car 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 call 706 863 3000 Ext 2601 If you would prefer to write to us direct your letter to Club Car Attenti

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