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101883801 0895F0196A

1. PLATES LEVEL Figure 21 Figure 22 Be sure battery hold down bracket is properly tightened Torque to 15 25 106 1 7 2 9 A loose hold down bracket may allow the battery to become damaged from vibration or jarring A hold down bracket that is too tight may buckle or crack the battery case If battery appears weak have it charged by a trained mechanic The battery should never be left dis charged any longer than absolutely necessary do not leave discharged overnight BATTERY ELECTRIC VEHICLE 1 BATTERY EXPLOSIVE GASES DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE TOOLS WIRES AND METAL OBJECTS CAN CAUSE SPARKS WHEN SHORTED ACROSS A BATTERY FOLLOW ALL INSTRUCTIONS CARE FULLY WHEN DEALING WITH BATTERIES e VENTILATE WHEN CHARGING AN ENCLOSED SPACE POISON CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING ANTIDOTES EXTERNAL FLUSH WITH WATER FOR 15 MINUTES CALL PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOWED WITH MILK OF MAGNESIA OR VEGETABLE OIL CALL PHYSICIAN IMMEDIATELY EYES FLUSH WITH WATER FOR 15 MINUTES CALL PHYSICIAN IMMEDIATELY A WARNING ALWAYS WEAR SAFETY GLASSES OR EYE PROTECTION WHEN SERVICING VEHICLE e ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL CONNECTI
2. 88 om Front Wheel Tread ome Pag em oan 98 38 1 2 98 38 112 RaarWhaal Tread seve i 206 kg 203 Weight Electric without batteries 4 495 68 Waiqht Gascline dry 8833 I 1 24 1824 1824 14824 14 24 KPH Forward 1215 1245 1275 1215 12 15 Clearance Circle 17767 are ore Are Braking Distance at 19 KPH 12 27 1 4 14 4 14 42708 14 4276 14 34 CLUB CAR LIMITED LIFETIME WARRANTY FOR 1996 FLEET GOLF CARS IN THE UNITED STATES AND CANADA 1 WARRANTY CLUB CAR INC CLUB 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 1996 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 stat ed below LIMITED LIFETIME WARRANTY The golf car frame excluding the front and rear bumper mounts the rack and pinion steerin
3. of the switch to run the vehicle in the forward direction or push down the R reverse side of the switch to run the vehicle in reverse When the switch is positioned with neither side down the vehicle is in the neutral position and the vehicle will not run if the accelerator is depressed See Figure 6 NOTE e 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 word GO molded into it See Figure 7 e THE OPERATION OF THE ACCELERATOR PEDAL DIFFERS FROM THAT AN AUTO MOBILE WHEN THE KEY SWITCH IS ON AND THE SHIFT LEVER IS IN EITHER FOR WARD 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 IS DEPRESSED SPEED WILL INCREASE UNTIL FULL SPEED IS REACHED WHEN THE ACCELERATOR IS RELEASED POWER WILL BE CUT OFF AND THE ENGINE OR MOTOR WILL STOP RUN NING POWERDRIVE SYSTEM 48 VEHICLES WITH REGENERATIVE BRAKING ONLY SEE PEDAL UP AND PEDAL DOWN MOTOR BRAKING OF PAGE 7 Figure 6 Figure 7 BRAKE PEDAL The brake pedal is the large pedal on the left with the word STOP molded into it See Figure 7 To slow or stop the vehicle depress the brake pedal with your right foot A WARNING e THE PARK BRAKE WILL RELEASE AUTOMATICALLY WHEN EITHER THE ACCELERA
4. Accelerator push rod pivots and shifter cable pivots 4 Front suspension 5 fittings Annually by Trained 5 Check fill drive unit to plug level Personnel Only 6 Inspect front wheel bearings Repack as necessary 7 Check fill transmission to plug level First Change 100 Hours 8 Change engine oil and oil filter Additional Change Every 400 Rounds or Every 200 Hours or Operation or Annually Whichever Comes First GASOLINE VEHICLES Recommended Lubricant Dry Moly Lube Club Car P N 1012151 Dry Moly Lube Club Car P N 1012151 Dry Moly Lube Club Car P N 1012151 Chassis Lube 67 liters 22 SAE 30 WT API Class SE SF or SG Oil or higher Chassis Lube 80 90 WT API Class GL 3 or 80 90 WT AGMA Class EP Gear Lube 97 liters 32 oz without filter 1 16 liter 38 oz with filter 1OW30 above 32 F 0 C or SAE 5W20 below 32 F 0 C API Class SE SF SG Oil or higher DS GAS OLINE YEH CLE LUBRICATION PONTS 16 20 PERIODIC LUBRICATION SCHEDULE ELECTRIC VEHICLES Regular Interval Service Recommended Lubricant Quarterly by Owner or 1 Brake shaft bearings Dry Moly Lube Club Car P N 1012151 Trained Personnel Only 2 Brake linkage and pivots Dry Moly Lube Club Car P N 1012151 3 Accelerator pivots Dry Moly Lube Club Car P N 1012151 4 Forward and reverse switch contacts and Charger Receptacle WD 40 5 Front suspension 5 fittings Chassis Lube Annually by Trai
5. CLUB CAR warranties Tires are warranted by their manufacturer Also exclud ed 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 DRIVE UNIT OR OTHER OPERATING SYSTEMS OF THE CAR TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKE WISE VOID IF THE CAR SHOWS INDICATIONS THAT REASONABLE OR NECESSARY MAIN TENANCE 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 MAN UALS 4 SOLE REMEDY CLUB CAR S ONLY LIABILITY UNDER THIS LIMITED WARRANTY OR IN ANY ACTION WHETHER BASED UPON WARRANTY CONTRACT NEGLIGENCE STRICT PRODUCT LIA BILITY 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 DEFEC TIVE REPLACEMENT SHALL MEAN FURNI
6. THE RESULTING ARCING AND BURNING COULD DAMAGE THE PLUG AND RECEPTACLE AND COULD CAUSE BATTER IES TO EXPLODE IF THE CHARGER MUST BE STOPPED DISCONNECT THE AC SUPPLY PLUG FROM THE WALL OUTLET BEFORE DISCONNECTING THE CHARGER DC OUT PUT PLUG 48 VOLT POWERDRIVE CHARGER WHEN THE CHARGER IS ON DISCONNECT THE DC OUTPUT PLUG FROM THE BATTERY RECEPTACLE SLOWLY JERKING OR PULLING THE PLUG OUT QUICKLY COULD CAUSE ARCING AND BURNING THAT COULD DAMAGE THE PLUG AND RECEPTACLE AND COULD CAUSE BATTERIES TO EXPLODE CAUTION e DO NOT BLOCK OR COVER SLOTS AND OPENINGS IN THE BACK AND BOTTOM OF CABINET THEY PROVIDE VENTILATION AND PROTECT THE CHARGER FROM OVER HEATING e DO NOT ALLOW CLOTHING BLANKETS OR OTHER MATERIAL TO COVER CHARGER e PROVIDE ADEQUATE VENTILATION FOR THE CHARGER e 36 VOLT ACCU POWER CHARGER DO NOT LEAVE DC PLUG PLUGGED IN WHILE UNAT TENDED FOR MORE THAN TWO 2 DAYS IN A ROW SEVERE OVERHEATING AND DAMAGE TO THE BATTERIES MAY RESULT IF THE CHARGER DOES NOT TURN OFF e 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 27 Battery Charger Electric Vehicle Continued 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 T
7. TO SERVICING ON GASOLINE VEHCLES DISCONNECT THE NEGATIVE BATTERY LEAD FIRST FOR ELEC TRIC VEHICLES SEE FIGURES 1 AND 2 e ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL CONNECTIONS e 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 INCREASES THE SPEED BEYOND THE FACTORY SPECIFICATIONS COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH DRL OMME T HER E DEC ONMECT HERE WERDRGBE SYSTEM 4 AND VOLT ELECTRIC VEHICLE POWERDRIVE 5 45 WITH REGENERATIVE BRARING Figure 1 Figure 2 DS GASOLINE VEHICLE FEATURE IDENTIFICATION T Pe ETE TTE 1 F pri P pasi ir ra am prr p rp M g Lur be L k Fr Halip HE h ip OhE Oar GOLF F OPERATING LAE ge HSTRUCTIONS SERIAL NUMBER LE oe ACCELERATOR PEDAL OL WARNING LIGHT BRAKE PEDAL PARK BRAKE PEDAL E ua manan lu kawa mbizi kam MANIFOLD AHD SERVICE MUFFLER LABEL ICH
8. TRAILER THAT HAS A LOAD RATING OF 544 KG 1200 LBS PER VEHICLE EXAMPLE A 2 CAR TRAILER SHOULD BE RATED AT 2 X 544 1088 KG 2 X 1200 2400 LBS NEVER TOW A VEHICLE BEHIND A PASSENGER VEHICLE OR TRUCK UNLESS IT IS ON AN APPROVED TRAILER THE VEHICLE SHOULD BE SECURELY TIED DOWN TO THE TRAILER WITH THE SHIFT LEVER IN NEUTRAL KEY SWITCH OFF AND THE PARK BRAKE FIRMLY DEPRESSED AND LOCKED WHEN TOWING A TRAILER NORMAL SPEED SHOULD BE REDUCED AND CARE SHOULD BE USED WHEN TURNING A CORNER DUE TO THE ADDED LENGTH OF THE TRAILER REMOVE THE VEHICLE S WINDSHIELD BEFORE TRANSPORTING IT ON A TRAILER 14 STORAGE GASOLINE VEHICLE To prepare your vehicle for extended off season storage 1 Store vehicle a place This will prevent self discharge of the battery If the battery appears to be weak have it charged using an automotive type 12 volt battery charger rated 10 amps or less 1 GASOLINE FLAMMABLE EXPLOSIVE DO SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE e NEVER ATTEMPT TO DRAIN GASOLINE WHEN THE ENGINE IS HOT OR WHILE IS RUNNING BE SURE TO CLEAN UP ANY SPILLED GASOLINE BEFORE OPERATING THE VEHICLE e STORE GASOLINE IN AN APPROVED GASOLINE CONTAINER ONLY STORE IN WELL VENTILATED AREA AWAY FROM SPARKS OPEN FLAMES HEATERS OR HEAT SOURCES DO NOT SERVICE REPAIR OR OPERATE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION ENGINE
9. automatic charger shut off occurs after 16 hours of oper ation or 4 the charger malfunctions the warning light will indicate as follows The warning light will not come on if the charge is 90 or more complete The on board computer will retain in memory the amount of charge needed to fully replenish the batteries and will com plete the charge during the next charge cycle When the charger is unplugged the warning light will come on and remain illuminated for 10 sec onds 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 come on and remain illuminated if the charger times out at 16 hours see charger manual and the batteries are not sufficiently charged This indicates an abnormal charge cycle The charger and batteries should be checked by your Club Car distributor dealer 11 Battery Warning Light continued e The warning light will come on 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 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
10. charger The rear seat should be propped open while charging the batteries 32 A WARNING SHOULD HAVE ITS OWN DEDICATED 15 20 SEPARATELY PROTECTED CIRCUIT BREAKER OR FUSE SINGLE PHASE BRANCH CIRCUIT IN ACCOR DANCE WITH ALL APPLICABLE ELECTRICAL CODES FOR THE LOCATION CAUTION e TURN OFF ALL ACCESSORIES POWERDRIVE SYSTEM 48 VEHICLES BEFORE CHARG ING BATTERIES CAUTION e IF USING AN ON BOARD 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 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 NOTES CAUTIONS AND WARNINGS AS WELL AS ALL INFORMATION NOTES CAUTIONS AND WARNINGS SPECIFIC TO THE POWER DRIVE CHARGER AND POWERDRIVE SYSTEM 48 IN THE BATTERY CHARGER SECTION OF THIS MANUAL PAGE 26 Figure 27 33 VEHICLE SPECIFICATIONS POWERDRIVE DS FARWAY i FAIRWAY SPECIFICATIONS OSGASOUNE SYSTEM48 WLLAGER WILLAGER ELECTRIC ELECTRIC GASOUNE ELECTRIC POWER SOURCE Enqgne 4 OHV 288666 9 0 hp rated single cylinder sir cocked preseure lubrication sy i i Drive Motor Direct Drive 48 volte DG Series Wound 3 1 hp I I Drive Motor Direct Drive DG Series
11. distributor or dealer or send the defective component freight pre paid tt WARRANTY ADMINISTRATION CLUB CAR INC 4152 Washington Road P O Box 204658 Augusta Georgia 30917 4658 6 DEFINITIONS For the purpose of this warranty an Original Retail Fleet Purchaser is the original purchaser of the golf car who 16 in the business of owning or operating golf courses and who purchases such golf for the purpose of renting it to golf players for use on such courses An Original Retail Fleet Lessee is the first end user of the golf car who is in the business of owning and operating golf courses and who leases such golf car for the purpose of renting it to golf players for use on such golf courses In the event the golf car is purchased or leased by any entity for the purpose of leasing it to an Original Retail Fleet Lessee then this limited warranty shall extend only to the first Original Retail Fleet Lessee and not to such entity or to any subsequent lessee of the golf car 7 DISCLAIMER THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND 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 EXCLUS
12. value Please protect your investment and ensure that your Club Car provides years of reliable superior performance by returning your Warranty Registration provided by your distributor dealer and by reading and following the maintenance instructions in this manual Your comfort and safety are important to us as well so we urge you to read and follow the step by step operating instructions and safety procedures in this manual These instructions must be followed in order to avoid the risk of severe personal injury If you rent or loan your vehicle to others rec ommend 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 ser vice In the event that your golf car needs repairs or services we recommend that your local authorized Club Car representative perform them For the name and address of the Club Car representative near est you call 706 863 3000 Ext 261 If you would prefer to write to us direct your letter to Club Car Attention Product Development Department 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 owner s manual a permanent part of your golf car If you sell the vehi cle please include the manual so that the next owner will have the important operating safety and maint
13. 8 inch and rotate it one half turn until it snaps into place See Figure 11 e BE SURE TO RETURN THE TO THE OPERATE POSITION AFTER SERVICING THE VEHICLE OR WILL NOT RUN WITH THE DIRECTION SELECTOR IN EITHER THE FOR WARD OR REVERSE POSITION A WARNING e WITH THE CAM IN THE SERVICE POSITION AND THE ENGINE RUNNING THE VEHICLE MAY MOVE SUDDENLY IF THE FORWARD REVERSE LEVER IS SHIFTED OR ACCIDEN TALLY BUMPED TO PREVENT THIS BLOCK THE FRONT AND REAR TIRES AND ALWAYS FIRMLY SET THE PARK BRAKE BEFORE SERVICING OR LEAVING THE VEHICLE CHOKE The choke is located on the seat support panel below and to the left of the driver s left knee See Fig ure 12 If the vehicle is hard to start in cool cold temperatures simply push in the choke cover with your left hand to activate it Hold it during start and release the choke cover after the engine starts and runs smoothly OIL LIGHT The DS Gasoline golf car is equipped with a low oil warning light located on the dash panel just above the steering column See Figure 13 If the oil warning light comes on oil should be checked and added to the engine as necessary before continuing to use the vehicle The vehicle should never be driven with the oil warning light remaining on If the oil warning light goes on and off you may proceed but oil should be added at the first opportunity If the oil level is correct and the light stays on have a trained mechanic check t
14. ATED AT THE HIGHEST POINT OF THE ROOF CONTACT A LOCAL HVAC ENGINEER A WARNING EACH CHARGER SHOULD HAVE ITS OWN DEDICATED 15 OR 20 AMPERE SEPARATELY PROTECTED CIRCUIT BREAKER OR FUSE SINGLE PHASE BRANCH CIRCUIT IN ACCOR DANCE WITH ALL APPLICABLE ELECTRICAL CODES FOR THE LOCATION 26 A WARNING DO NOT USE AN ADAPTOR 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 THE USE OF AN IMPROPER EXTENSION CORD COULD RESULT IN A FIRE OR AN ELEC TRICAL SHOCK ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THE CHARGER CON TACT 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 FLAMMA BLES 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 THAT COULD RESULT IN FIRE OR ELECTRICAL SHOCK 36 VOLT ACCU POWER CHARGER DO NOT DISCONNECT THE DC OUTPUT PLUG FROM THE BATTERY RECEPTACLE WHEN THE CHARGER IS ON
15. BEL MELDE VOLT ONLY 27 WARNING RESETORS CAUZE SEVERE BODY UNDER SEAT F FE EF gt 2 2 ass 2 LEVER Pa FORWARD REVERSE 0 SWITCH 5 46 VEHICLES WITH REGENERATIVE BRARAG ONLY CHARGER RECEPTACLE SPEED SWITCH CAUTION LABEL eo HOT OPERATE FEFECLE WITHOUT DD TER IH FLL rD G WATER ITOH SPEED SWITCH UNDER SEAT VOLT VEHICLE ONLY GENERAL INFORMATION There are four DS Golf Car models the DS gasoline powered vehicle the DS V Glide 36 volt electric powered vehicle the DS PowerDrive System 48 48 volt electric vehicle and the DS PowerDrive Sys tem 48 vehicle with regenerative braking Throughout this manual important features unique to each model are highlighted We urge the owner operator to read and understand this manual and to pay special attention to the features specific to his her vehicle MODEL IDENTIFICATION The serial number of your CLUB CAR is stamped on the data plate mounted on the frame directly above the accelerator pedal Example A9601 123456 for Electric or AG9601 123456 for Gasoline See Figure 3 ALWAYS MENTION THIS NUMBER WHEN ORDERING PARTS OR MAKING INQUIRIES IF THIS VEHICLE IS EQUIPPED AS A FA
16. E DJ LE LABEL AT TR WWE hd wan mawan lan AN OOM BODY WL ALL FOR WAR ORE YER SE DS ELECTRIC VEHICLE FEATURE IDENTIFICATION ROTE LET TE 45 11 prd bh T F L aa Fu Fagplan dr Fapa kdi u g L ur Fa m d lG p Lr bf plaa F Fr p Halip paud op pi p p Dhe ra r GOLF LABEL STANDARD POWERDRIVE OPERATING AND GLE VEHICLES RSTRUCTIONS LABEL SERIAL X a ACCELERATOR REG ENERATIVE PEDAL BRAKING VEHICLE ONLY E BRAKE PEDAL BATTERY WARNING LIGHT PARK BRAKE PEDAL ee els u nhik hiana am 1 zmay ku 1 m w DANGER LABEL LA
17. E OR REPAIR IN A WELL VENTILATED AREA ONLY e NEVER POUR GASOLINE INTO GAS TANK WHILE THE ENGINE IS HOT OR RUNNING e TO AVOID ELECTRIC ARC CAUSED BY STATIC ELECTRICITY THE FUEL STORAGE PUMP ING DEVICE MUST BE GROUNDED IF THE PUMP IS NOT GROUNDED THE VEHICLE MUST BE GROUNDED TO THE PUMP BEFORE AND DURING THE FUELING OPERATION e IF THE VEHICLE HAS AN ALL WEATHER ENCLOSURE INSTALLED THE GAS TANK MUST BE PROPERLY VENTED AS SHOWN IN FIGURE 20 e TO AVOID THE POSSIBILITY OF FIRE CLEAN UP ANY SPILLED GASOLINE BEFORE OPERATING VEHICLE e GASOLINE QUALITY AND CHEMICAL ADDITIVES CAN AFFECT VEHICLE PERFORMANCE WE DO NOT RECOMMEND GASOLINES THAT ARE BLENDED WITH ALCOHOL AVOID USING THESE FUELS WHENEVER POSSIBLE AVOID THE USE OF OXYGENATED FUELS WHENEVER POSSIBLE VEHICLES THAT WILL BE STORED FOR EXTENDED PERIODS SHOULD BE PREPARED FOR STORAGE AS OUTLINED IN THIS OWNER S MANUAL 23 Fueling Instructions Continued 1 Lift remove seat bottom 2 The fuel tank is located on passenger side of vehicle Remove fuel cap and fill the fuel tank with fresh unleaded gasoline only CAUTION e DO NOT OVERFILL FUEL TANK AVOID FUEL SPILLAGE 3 Replace fuel cap on tank being sure cap is tightened securely 4 Replace seat bottom BATTERY GASOLINE VEHICLE fa DANGER BATTERY EXPLOSIVE GASES DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE TOOLS WIRES AND METAL OBJECTS CAN CAUSE SPARKS WHEN
18. ESENTATION 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 INNO EVENT SHALL CLUB CAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAM AGES INCLUDING BUT NOT LIMITED TO LOSS RELATED TO PROPERTY OTHER THAN THE GOLF CAR LOSS OF USE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS 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 FACTORY SPECIFICA TIONS INCLUDING THOSE THAT AFFECT THE WEIGHT DISTRIBUTION STABILITY OR SPEED OF THE GOLF CAR CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH iii FOREWORD Thank you for choosing Club Car Whether you have chosen the DS Gasoline or DS Electric you have chosen the finest golf car on the market the golf car most widely recognized as the industry leader in vehicle efficiency and long lasting
19. H OFF AND REMOVE THE KEY WHEN LEAVING THE VEHICLE TO AVOID UNINTENTIONAL STARTING OR ROLLING OF THE VEHICLE KEY SWITCH The key switch is mounted on the dash to the right of the steering column See Figure 4 Page 8 It has two positions OFF and ON which are clearly labeled NOTE e KEY IS REMOVABLE IN THE OFF POSITION ONLY Figure 4 Figure 5 FORWARD REVERSE CONTROL DS Gasoline DS V Glide Electric and DS PowerDrive System 48 forward reverse shift lever is located the seat support panel below and to the right of the dri ver s right knee See Figure 5 The lever has three distinct positions F forward N neutral R reverse Rotate the lever towards the driver F forward to run the vehicle in the forward direction or towards the passenger R reverse to run the vehicle in reverse When the lever is in the straight up or N neutral position the vehicle will not run The engine on the DS Gasoline will stop if it is shifted to this position while running The DS Electric vehicle operates at reduced speed in reverse DS PowerDrive System 48 With Regenerative Braking The forward reverse shift switch is located in the same place as the forward reverse shift lever on all other DS models on the seat support panel below and to the right of the driver s right knee The For ward F and Reverse R positions are clearly marked on the switch Push down the F forward side
20. HICLE SHOULD ONLY BE DRIVEN IN SPECIFIED AREAS BY TRAINED PEOPLE TO AVOID BEING STRUCK DO NOT STAND IN FRONT OF OR BEHIND VEHICLE DO NOT DRIVE WHILE UNDER THE INFLUENCE OF ALCOHOL DRUGS OR MEDICA TIONS No one should drive the vehicle without first being instructed in the proper operation and use of the vehi cle 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 12 ensure safe operation of the vehicle follow exactly and order all of the procedures listed below Read and understand all instructions prior to driving the vehicle STARTING THE VEHICLE 1 Enter the vehicle Study and understand controls Be sure everyone is seated and holding onto seat handles or handrails Read safety warnings located above pedals Make sure wheels are turned in desired direction Turn key to ON position and be sure nothing is in your path Select direction by placing shift lever 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 is depressed speed will increase until full speed is reached Oe Se ety Operator must control speed when going downhill e Gasoline Vehicle Only Depress the brake pedal as necess
21. HROUGHOUT THE STORAGE PERIOD e SHORTLY AFTER CHARGING HAS BEGUN THE POWERDRIVE CHARGER WILL SHUT OFF 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 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 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 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 accor dance 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
22. INFORMATION MAKE PROCEDURES MORE EASILY UNDER STOOD The safety procedures listed must be followed whenever the vehicle is being operated repaired or ser viced Other specific warnings appear throughout this manual and on the vehicle GENERAL WARNINGS fa DANGER GASOLINE VAPORS FLAMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE SERVICE ONLY IN WELL VENTI LATED AREAS BATTERY VAPORS FLAMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE SERVICE ONLY IN WELL VENTI LATED AREAS e DO NOT OPERATE AN ENCLOSED AREA WITHOUT PROPER VENTILATION ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POISON e 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 SAFETY GUIDE LINES APPLICABLE TO YOUR LOCATION A WARNING e ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THE VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD FOLLOW THE CORRECT PROCE DURES AND OBEY THE WARNINGS LISTED IN THIS MANUAL AS WELL AS THOSE IN THE MAINTENANCE AND SERVICE MANUAL e ALWAYS WEAR SAFETY GLASSES OR EYE PROTECTION WHEN SERVICING THE VEHI CLE e TURN KEY SWITCH TO OFF REMOVE KEY BLOCK TIRES PLACE FORWARD REVERSE LEVER IN NEUTRAL AND DISCONNECT BATTERY IES PRIOR
23. IRWAY VILLAGER FOUR PASSENGER VEHICLE READ THE SPECIAL INSTRUCTIONS ON PAGES 32 33 SAFETY COMMITTEE If the golf 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 e Ensuring that proper warnings of driving hazards displayed and visible SIGNS SUCH AS STEEP HILL AND SHARP TURN ARE AVAILABLE FROM GOLF CAR MANUFACTURERS ASSOCIATION MEMBERS Who should and who should not drive golf cars Instructing first time drivers e Maintaining golf cars in a safe driving condition How various rules to be enforced The safety committee should include all these items and such others as the com mittee feels necessary or appropriate Figure 3 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 prop er working condition before accepting delivery Use the following checklist as a guide to inspect your new vehicle Any problems should be correct ed only by your CLUB CAR distributor dealer or a trained technician e General All the par
24. IVE AND SOLE REMEDY 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 INNO EVENT SHALL CLUB CAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL AGES INCLUDING BUT NOT LIMITED TO LOSS RELATED TO PROPERTY OTHER THAN THE GOLF CAR LOSS OF USE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitation of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state 9 INFORMATION For further information contact WARRANTY ADMINISTRATION CLUB CAR INC P O Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 10 WARNING ANY MODIFICATION OR ALTERATION OF ANY GOLF CAR BEYOND FACTORY SPECIFICA TIONS INCLUDING THOSE THAT AFFECT THE WEIGHT DISTRIBUTION STABILITY OR SPEED OF THE GOLF CAR CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH Ciub Car Club Car P O Box 2046658 Augusta Georgia 30917 4669 USA 706 863 3000 CLUB CAR INC 1995
25. Maintenance Continued A WARNING 18 ALWAYS WEAR SAFETY GLASSES OR EYE PROTECTION WHEN SERVICING THE VEHI CLE DO NOT WEAR LOOSE CLOTHING OR JEWELRY RINGS WATCHES CHAINS ETC WHILE SERVICING THE VEHICLE ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL CONNECTIONS TURN KEY SWITCH TO OFF REMOVE THE KEY PLACE FORWARD REVERSE LEVER IN NEUTRAL POSITION AND BLOCK TIRES PRIOR TO SERVICING MOVING PARTS DO NOT ATTEMPT TO SERVICE GASOLINE VEHICLE WHILE THE ENGINE IS RUNNING HOT DO NOT ATTEMPT TO SERVICE HOT ENGINE MOTOR RESISTORS OR EXHAUST SYSTEM ATTEMPTING TO DO SO COULD CAUSE SEVERE BURNS REMOVE THE SPARK PLUG WIRE AND DISCONNECT THE BATTERY TO AVOID UNIN TENTIONAL STARTING OF THE ENGINE WHEN SERVICING THE GASOLINE VEHICLE DISCONNECT THE BATTERIES BEFORE SERVICING THE ELECTRIC VEHICLE SEE FIG URES 14 AND 15 DEL ONME T HERE es eee eee PO WERDRIVE SYSTEM 46 AND VELDE 36 WOLT ELECTRIC VEHICLE POWERDRIVE SYST EH 45 WITH REGENERATIVE BRAKING Figure 14 Figure 15 PERIODIC SERVICE SCHEDULE Regular Interval Daily Service by owner Weekly Service By Owner Monthly Service By Owner Quarterly Service By Owner or Trained Personnel Semi Annual Service by Trained Personnel Only Every 100 Rounds or every 50 hours of operation Annual Service by Trained Personnel Only Every 200 Rounds or Every 100 Hours of Operation First Change 100 Hours Additional Ch
26. ND 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 optional equipment and accessories fuses filters decals spark plugs lubricants the front body rear body 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 expo sure or ordinary wear and tear Batteries the battery charger on board 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 or neglect Transportation expenses for warranty service are also excluded from this warranty Limited Warranty Continued 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 MODIFICATION OF THE SPEED GOVERNOR BRAKI
27. NG SYSTEM STEERING DRIVE UNIT OR OTHER OPERATING SYSTEMS OF THE CAR TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKE WISE VOID IF THE CAR SHOWS INDICATIONS THAT REASONABLE OR NECESSARY MAIN TENANCE 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 MAN UALS 4 SOLE REMEDY CLUB CAR S ONLY LIABILITY UNDER THIS LIMITED WARRANTY OR IN ANY ACTION WHETHER BASED UPON WARRANTY CONTRACT NEGLIGENCE STRICT PRODUCT LIA BILITY 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 DEFEC TIVE REPLACEMENT SHALL MEAN FURNISHING DURING THE APPLICABLE LIMITED WAR RANTY PERIOD A NEW GOLF CAR OR FACTORY RECONDITIONED VEHICLE OR COMPONENT THEREOF WHICH IS IDENTICAL OR REASONABLY EQUIVALENT TO THE WARRANTED PROD UCT 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 com ponent to an authorized CLUB CAR
28. ON DURING STORAGE THIS IS TO PREVENT UNINTENTIONAL STARTING OF THE VEHICLE 15 Storage of Gasoline Vehicle Continued 4 Increase pressure to 20 psi 5 Grease front suspension and do all quarterly periodic lubrication See Periodic Lubrication Schedule under Periodic Service Schedule Page 19 6 Thoroughly clean front body rear body seats engine compartment and underside of vehicle 7 Do notlatch the park brake Block tires to prevent the vehicle from rolling TO RETURN THE STORED VEHICLE TO SERVICE 1 Restore fuel system to operation 1 1 Remove plug from the fuel tank vent nipple and reconnect fuel vent line to tank 1 2 Place the Foward and Reverse Lever in the NEUTRAL position and the neutral lock out cam in the SERVICE position Crank the engine until fuel is pumped into the carburetor and fuel lines and the engine starts Turn engine off and return neutral lock out cam to the OPERATE position 2 Readjust tire pressure to 12 14 psi 3 Perform the Pre Operation Checklist See pages 6 and 7 e WHEN RUNNING THE ENGINE FOR THE FIRST TIME AFTER STORAGE IT MAY SMOKE EXCESSIVELY DUE TO THE OIL ADDED TO THE ENGINE IN PREPARATION FOR STOR AGE STORAGE ELECTRIC VEHICLE A WARNING e TURN KEY SWITCH OFF REMOVE KEY AND LEAVE THE FORWARD REVERSE LEVER IN NEUTRAL POSITION DURING STORAGE THIS IS TO PREVENT UNINTENTIONAL STARTING OF THE VEHICLE e DO NOT ATTEMPT TO CHARGE FROZEN BATTERIES
29. ONS CAUTION e TURN OFF ALL ACCESSORIES ON ALL VEHICLES BEFORE CHARGING BATTERIES The batteries in DS V Glide 36 Volt Electric Vehicles are 6 volts each The batteries in PowerDrive System 48 Electric Vehicles are 8 volts each Both the 6 and 8 volt batteries are deep cycle batteries specially built for electric vehicle application 25 Batteries Electric Vehicles Continued Automotive 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 bat teries restrict vehicle with new batteries to 36 holes of use between charges in the first two months of operation Batteries should be fully charged before first use of new vehicle and before releasing vehi cle for use each day Battery Care To keep batteries in good working condition follow this maintenance program regular basis 1 The batteries should be clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water Rinse solution off batteries NOTE Do not allow this solution to enter the battery Be sure terminals are tight Let the terminals dry and then spray them with CLUB CAR battery protector spray Part No 1014305 2 The water level in the batteries should be checked weekly See Figure 22 Page 25 for proper level Add water only after charging unless the water level is below t
30. OR BATTERIES WITH BULGED CASES DISCARD BATTERY FROZEN BATTERIES CAN EXPLODE CAUTION e BATTERIES INA LOW STATE OF CHARGE WILL FREEZE AT LOW TEMPERATURES e WHEN WASHING VEHICLE DO NOT DIRECT WATER STREAM AT THE SPEED SWITCH e IF BATTERY WIRE TERMINALS ARE DAMAGED OR CORRODED THEY SHOULD BE REPLACED OR CLEANED AS NECESSARY FAILURE TO DO SO MAY CAUSE THEM TO OVERHEAT DURING OPERATION 1 Fully charge batteries See Battery Electric Vehicle Page 25 2 Wash off any corrosion around the terminals with a solution of baking soda and water then rinse NOTE 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 16 3 Store cool dry place This will prevent self discharge of the batteries 4 Adjust tire pressure to 20 psi 5 Grease front suspension and do all quarterly periodic lubrication See Periodic Lubrication Schedule under Periodic Service Schedule Page 19 6 Thoroughly clean front body rear body seats battery compartment and underside of vehicle 7 notlatch the park brake Block tires to prevent the vehicle from rolling 8 Keep batteries fully charged during storage See Battery Electric Vehicle Page 25 Recharge 36 volt vehicles with Accu Power battery chargers every 6 8 weeks as necessary Leave PowerDrive System 48 vehicles with PowerDrive chargers plugged in during storage The PowerDrive stor
31. Owner s Manual 1996 DS Golf Car Qasoline Electric Manual Number 191863691 EdRion Code 0895F0196A WARNING e THE ENGINE EXHAUST FROM THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM Club Car Limited Warranty appears the pages following this notice the Limited Lifetime Fleet Warranty appears on the last pages of this manual No other warranties express or implied are contained herein Your authorized representative checked this vehicle before it was delivered to you and will provide you with a completed warranty registration card 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 Per formance Requirements for Golf Cars This standard which promotes safety in the design application and operation of golf cars defines a golf car as a vehicle used to convey a person or persons and equipment to play the game of golf in an area designated as a golf course Throughout this manual the words golf car and vehicle are used interchangeably This manual contains proprietary information that is protected by copyright All rights are reserved No part of this manual may be photocopied reproduced or translated to another lan
32. PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POISON e KEEP GASOLINE OUT OF THE REACH OF CHILDREN e DO NOT SIPHON GASOLINE FROM THE VEHICLE A WARNING e DO ATTEMPT TO CHARGE A BATTERY IF IT IS FROZEN OR IF THE CASE IS BULGED DISCARD BATTERY FROZEN BATTERIES CAN EXPLODE CAUTION e BATTERIES IN A LOW STATE OF CHARGE WILL FREEZE AT LOW TEMPERATURES 2 Drain carburetor and seal the fuel tank 2 1 Place the Foward and Reverse Lever in the NEUTRAL position and the neutral lock out cam in the SERVICE position Disconnect the fuel line from the fuel pump and run the engine until fuel remaining in the carburetor and fuel lines is used up and the engine stalls Return the neutral lock out cam to OPERATE position 2 2 Loosen do not remove the carburetor drain screw and drain fuel remaining in bowl into a small container then pour the fuel from the container into vehicle fuel tank 2 3 Reconnect fuel line to fuel pump 2 4 Disconnect fuel vent line from fuel tank vent nipple 2 6 Plug the fuel tank vent nipple so that it is air tight We recommend using a slip on vinyl cap 3 To protect the engine remove the spark plug and pour 1 2 ounce of SAE 10 weight oil into the engine through the spark plug hole Rotate the 5 crank shaft several times and then re install the spark plug A WARNING e TURN KEY SWITCH OFF REMOVE KEY AND LEAVE THE FORWARD REVERSE LEVER IN NEUTRAL POSITI
33. R THE VEHICLE S RECEPTACLE DO NOT USE A CHARGER IF e THE PLUG IS TOO LOOSE OR DOES MAKE GOOD CONNECTION e THE PLUG AND RECEPTACLE FEEL HOTTER THAN NORMAL DURING CHARGE e THE PLUG PINS POWERDRIVE SYSTEM 48 OR BLADES 36 VOLT ACCU POWER RECEPTACLE CONTACTS ARE BENT OR CORRODED e THE PLUG RECEPTACLE OR CORDS ARE CUT WORN HAVE ANY EXPOSED WIRES ARE DAMAGED IN ANY WAY USING THE CHARGER WITH ANY OF THE ABOVE SYMPTOMS COULD RESULT IN A FIRE PROPERTY DAMAGE PERSONAL INJURY OR DEATH THE DC CHARGER CORD AND PLUG ARE WEAR ITEMS AND MUST BE REPLACED WHEN WORN OR DAMAGED Figure 23 Figure 24 29 Plug and Receptacle If the charger plug becomes difficult to insert or disconnect the receptacle contacts should be light ly sorayed with WD 40 brand spray lubricant The plug should then be inserted and removed sever al times to ensure ease of insertion ease of removal and good electrical contact NOTE IF 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 vehi cle is equipped with a receptacle fuse link Figure 25 V Glide 36 volt vehicle or Figure 26 Pow erDrive System 48 vehicle If the portable charger does come on when the vehicle is placed charge visually inspect the fuse link Figure 25 Figure 26 A WA
34. RNING e IF THE 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 CLEANING The vehicle is equipped with an Armorflex front body and rear body Use only mild dishwashing liq soap with a sponge or soft cloth for normal cleaning CAUTION e IF A PRESSURE WASHER IS USED DO NOT EXCEED 500 PSI Minor scratches or blemishes in the front body or the rear body can be buffed out using most com mercially available polishing compounds and polishes The seats of the vehicle will last longer with proper cleaning Mild soap or detergent with a sponge or soft cloth for normal cleaning is recommended For stubborn or imbedded dirt a soft bristle brush may be used 30 Do notuse harsh detergents cleaning solvents the front body the body 1 seat Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible stains Use commercial automotive products because the finish on the vehicle is the same as the finish on today s automobiles VEHICLE CONTROLLERS ELECTRIC VEHICLE The DS Electric vehicle is equipped with either a Solid State Speed Controller PowerDrive System 48 and PowerDrive System 48 with Regenerative Braking or a V Glide Speed Controller 36 Volt Vehicle In order to properly service and maintain the Solid State Controll
35. SHING DURING THE APPLICABLE LIMITED WAR RANTY PERIOD A NEW GOLF CAR OR FACTORY RECONDITIONED VEHICLE OR COMPONENT THEREOF WHICH IS IDENTICAL OR REASONABLY EQUIVALENT TO THE WARRANTED PROD UCT 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 com ponent to an authorized CLUB CAR distributor or dealer or send the defective component freight pre paid to WARRANTY ADMINISTRATION CLUB CAR INC 4152 Washington Road P O Box 204658 Augusta Georgia 30917 4658 6 DISCLAIMER 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 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 IS THE EXCLUSIVE AND SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER REPR
36. SHORTED ACROSS A BATTERY FOLLOW ALL INSTRUCTIONS CARE FULLY WHEN DEALING WITH BATTERIES e VENTILATE WHEN CHARGING AN ENCLOSED SPACE e POISON CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING ANTIDOTES EXTERNAL FLUSH WITH WATER FOR 15 MINUTES CALL PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOWED WITH MILK OF MAGNESIA OR VEGETABLE OIL CALL PHYSICIAN IMMEDIATELY EYES FLUSH WITH WATER FOR 15 MINUTES CALL PHYSICIAN IMMEDIATELY A WARNING DO NOT JUMP START VEHICLE TO CHARGE BATTERY USE AN AUTOMOTIVE TYPE 12 VOLT CHARGER RATED 10 AMPS OR LESS ALWAYS WEAR SAFETY GLASSES OR EYE PROTECTION WHEN SERVICING VEHICLE ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL CONNECTIONS The battery in the DS Gasoline Vehicle is a 12 volt low maintenance battery that requires infrequent watering Figure 21 Any corrosion around the positive or negative terminals should be washed off with a solution of baking soda and water Rinse solution off the battery Be sure terminals are tight Let the terminals dry and then spray them with CLUB CAR battery terminal spray Club Car Part No 1014305 CAUTION 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 24 WATER LEvEL ATLEAST 12
37. THE VEHICLE IS NOT SPECIALLY EQUIPPED FOR HANDICAPPED PERSONS BE SURE ALL PERSONS CAN PROPERLY OPERATE VEHICLE PRIOR TO ALLOWING THEM TO DRIVE THE VEHICLE FOR NIGHT USE VEHICLE MUST BE EQUIPPED WITH HEADLIGHTS TAILLIGHTS AND REFLECTORS STOP VEHICLE BEFORE SHIFTING THE FORWARD REVERSE LEVER FAILURE TO DO SO MAY RESULT IN INJURY TO AN UNSUSPECTING PASSENGER AND OR DAMAGE TO THE VEHICLE BUZZER WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE WHEN DRIVING THE VEHICLE OPERATE THE VEHICLE FROM THE DRIVER S SEAT ONLY REMAIN SEATED IN A MOVING VEHICLE AND HOLD TO SEAT HANDLES OR HANDRAILS AT ALL TIMES TO PREVENT FALLS DRIVER SHOULD KEEP BOTH HANDS ON STEERING WHEEL AT ALL TIMES KEEP ALL BODY PARTS INSIDE THE VEHICLE TO PREVENT THEM FROM GETTING CAUGHT BETWEEN THE VEHICLE AND THE GROUND OR OTHER OBJECTS DRIVE SLOWLY IN TURNS AND DRIVE STRAIGHT UP OR DOWN SLOPES TO PREVENT OVERTURNING OF THE VEHICLE VEHICLE SHOULD NOT BE DRIVEN ON SLOPES EXCEEDING 20 OF GRADE AVOID SUDDEN STARTS STOPS AND ABRUPT TURNS TO AVOID INJURY TO AN UNSUS PECTING PASSENGER AND OR DAMAGE TO THE VEHICLE 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 ON PUBLIC ROADS THE VEHICLE 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 VE
38. TOR OR BRAKE PEDAL IS DEPRESSED THE PARK BRAKE HAS MULTIPLE LOCKING POSITIONS AND SHOULD BE FIRMLY PRESSED TO PREVENT THE VEHICLE FROM ROLLING 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 See Figure 8 To set the park brake depress the brake pedal firmly and tilt the park brake portion of the pedal forward with your foot See Figure 9 Figure 8 Figure 9 GASOLINE VEHICLE ONLY NEUTRAL LOCK OUT The vehicle has a neutral lock out circuit that prevents the driver from starting the vehicle in NEUTRAL If the vehicle is started in forward or reverse and then shifted to neutral the engine will stop running Neutral Lock out Continued For the convenience of the trained mechanic there is a neutral lock out cam located on the back of the forward reverse lever If the neutral lock out cam is pulled out approximately 10 millimeters 3 8 inch and then rotated one half turn until it snaps into place the vehicle will be in the SERVICE position See Figure 10 This will allow the mechanic to run the engine in NEUTRAL for certain maintenance pro cedures With the cam in this position the vehicle will not operate if the forward reverse lever is placed in either the forward or reverse position To put the vehicle back into the OPERATE position pull the cam out approximately 10 millimeters 8
39. TOW THE VEHICLE ON PUBLIC STREETS OR HIGHWAYS e USE ONLY APPROVED CLUB CAR TOW BARS TURN KEY SWITCH TO OFF AND PLACE SHIFT LEVER IN NEUTRAL BEFORE TOWING VEHICLE EXTREME CAUTION SHOULD BE USED WHEN TOWING ANY VEHICLE DO NOT EXCEED 8 KPH 5 MPH TOWING SPEED DO NOT ALLOW PEOPLE IN THE VEHICLES BEING TOWED AVOID SUDDEN STARTS STOPS AND TIGHT TURNS WHEN TOWING DO NOT TOW MORE THAN ONE 1 VEHICLE WITH ANOTHER CLUB CAR IF MORE THAN ONE VEHICLE MUST BE TOWED A PROPERLY FITTED VEHICLE WITH A TOW HITCH HEIGHT OF 11 INCHES SHOULD BE USED ONLY HEAVY DUTY TOW BARS SHOULD BE USED FOR MULTI VEHICLE TOWING NEVER TOW MORE THAN FIVE 5 VEHICLES AT ONE TIME POWERDRIVE SYSTEM 48 VEHICLE WITH REGENERATIVE BRAKING ONLY KEY SWITCH MUST BE OFF BEFORE VEHICLE CAN BE TOWED VEHICLE WILL NOT ROLL OTHERWISE All vehicles are equipped with both front and rear tow bar attaching points A light duty tow bar is avail able for break down towing and single vehicle towing A heavy duty tow bar and an on board tow bar are available for multi vehicle towing Observe all of the above warnings when towing TRANSPORTING ON A TRAILER If your vehicle must be transported over long distances or on public highways it should be done on approved trailer observing all the following warnings 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
40. Wound 2 97 hp Drive Drive 48 Series Wound 3 2 hp i Regenerative Braking Vehicles I Fuel System Side draft carburetor with float bowl fixad jeta fuel filter 2 i and impulse fuel i Gaenor Automatic ground speed sensin internally geared im 4 tranemiasion i ignition Transistor electronic ignition with electronic APM limiter Tranemission Fully ynchronizedforwazt and reverse with neutral 5 forward 1 037 reverse i Drive Unit Double reckction helical gear with 12 261 direct dive ade I Electrical Syatem 48 volta DC reduced Electical 38 volte reduced speed reverse 5 Electical System 12 volte 325 cold cranking amp battery and 35 amp charging capacity capacity Trojan Bolt 110 min capacity reverse Batteries High capacity Trojan 105 107 min capacity Charger Automatic 17 emp aed GSA approved 5 Charger Automate 21 Accu Power UL and CSA approved I i I Torque CGonverter Autometic varible speed dry type STEERINGISUSPENSION Steering Se adjusting rack and pinion 5 Suspenskomn Front and rear tapered springs with d
41. age charge feature will automatically charge the batteries as needed See Bat tery Electric Vehicle Page 25 e A POWERDRIVE SYSTEM 48 VEHICLE WILL NOT OPERATE WHILE PLUGGED TO CHARGER To Return the Stored Vehicle to Service 1 Fully charge batteries See Battery Electric Vehicle Page 25 e POWERDRIVE SYSTEM 48 VEHICLES WILL NOT REQUIRE CHARGING IF THEY REMAINED PLUGGED IN DURING STORAGE 2 Readjust tire pressure to 18 20 psi 3 Perform the Pre Operation Checklist See pages 6 and 7 MAINTENANCE GENERAL INFORMATION To ensure trouble free vehicle performance it is very important to follow an established preventive maintenance program regularly scheduled service even though the vehicle is functional Regular and consistent vehicle maintenance can prevent the vehicle down time and expensive repairs that result from neglect Any vehicle not functioning correctly should be removed from use until it is properly repaired This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions Contact your local CLUB CAR distributor dealer to perform all repairs and semi annual and annual peri odic service A WARNING e ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THE VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD FOLLOW THE CORRECT PROCE DURES AND OBEY THE WARNINGS LISTED IN THIS MANUAL AS WELL AS THOSE IN THE MAINTENANCE AND SERVICE MANUAL 17
42. ange Every 400 Rounds or Every 200 Hours or Operation or Annually Whichever Comes First WARNING Service Check steering and linkages Check brake operation Check to be sure all warning labels are in place Pages 3 4 Check tires for wear and damage Check engine for proper operation Check accelerator governor linkage for free movement and return Check reverse warning buzzer for proper operation Check engine air intake screen to be sure it is not clogged Check to be sure park brake latches and releases properly Check charger plug and receptacle for damage and snug fit Charge batteries after each use Check fuel tank lines cap pump and carburetor for fuel leakage Check speed of vehicle Clean battery terminals and wash dirt off battery case s Wash engine battery compartment and underside of vehicle Check all electrical wires and ground wires for tightness or damage Inspect vehicle for loose hardware and tighten as required Check battery electrolyte level Check all daily items listed above Check exhaust system for leaks Check brake pedal for play Check tire pressure and adjust Capacities Page 22 Check brake cables for damage and replace as required Check all daily and weekly items listed above Lubricate as shown in lubrication chart on Page 20 21 or 22 Check air intake hose for leaks Check engine oil level Check resistor assembly for broken coils or loose connections PowerDrive Regenerative Braking Vehicle
43. ary and partially depress the accel erator when descending a hill With the accelerator pedal partially depressed the engine governor will cause the engine to control downhill speed PowerDrive System 48 Vehicle with Regenerative Braking Only Pedal Down Pedal Up Motor Braking may be used to control speed when going downhill See Performance Inspection Page 6 STOPPING THE VEHICLE A WARNING e DRIVING THROUGH WATER MAY AFFECT THE BRAKES CHECK THEIR EFFECTIVE NESS BY DEPRESSING THE BRAKE PEDAL GENTLY IF THE VEHICLE DOES NOT SLOW DOWN AT THE NORMAL RATE CONTINUE TO DEPRESS THE BRAKES UNTIL THEY DRY OUT AND NORMAL PERFORMANCE RETURNS CAUTION e WHEN STOPPED ON A HILL USE THE BRAKE PEDAL TO HOLD YOUR POSITION DO NOT USE THE ACCELERATOR PEDAL To stop the vehicle release the accelerator pedal and depress the brake pedal with your right foot until the vehicle comes to a complete stop PARKING AND LEAVING THE VEHICLE 1 After stopping 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 shift lever in the NEUTRAL position Remove the key when the vehicle 16 not in use e Regenerative Braking Vehicles Only When the vehicle is in use with the key switch the zero speed detect function will resist vehicle rolling See Zero Speed Detect Page 7 13 TOWING A WARNING e NEVER
44. ave your SAFETY DETAILS WARNING e THIS OWNER S MANUAL SHOULD BE READ COMPLETELY BEFORE ATTEMPTING TO DRIVE OR SERVICE THE VEHICLE FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS MANUAL COULD RESULT IN SEVERE PERSONAL INJURY PROPERTY DAMAGE OR DEATH It is important to note that some vital statements throughout this manual and on the labels affixed to the vehicle are preceded by the words DANGER WARNING CAUTION or NOTE For your protec tion we recommend that you take special notice of these safety procedures Safety procedures are essential and must be followed Throughout this manual and on the labels affixed to the vehicle the words golf and vehicle are used interchangeably Golf is defined in the Notice of this manual and no other representation is stated or implied If any of the labels on the vehicle become damaged have been removed or cannot be easily read they should be replaced immediately to avoid possible personal injury property damage or death Contact your CLUB CAR distributor dealer 1 DANGER e A DANGER INDICATES AN IMMEDIATE HAZARD WHICH WILL RESULT IN SEVERE PER SONAL INJURY OR DEATH WARNING WARNING INDICATES AN IMMEDIATE HAZARD WHICH COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH CAUTION CAUTION INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN PRODUCT OR PROPERTY DAMAGE OR MINOR PERSONAL INJURY e NOTE PROVIDES KEY
45. d as stated in this Owner s Manual with the fol lowing exceptions A WARNING e PREVENT POSSIBLE INJURY UNSUSPECTING PASSENGER OR DAMAGE THE VEHICLE AVOID SUDDEN STARTS STOPS AND ABRUPT TURNS e SLOWER SPEEDS SHOULD BE OBSERVED WHEN FOUR PASSENGERS ARE IN THE VEHICLE PASSENGERS SHOULD HOLD ON TO SEAT HANDLES OR HAND RAILS AT ALL TIMES SEE FIGURE 27 PAGE 33 e DO NOT LEAVE CHILDREN UNATTENDED ON REAR SEAT WHILE VEHICLE IS MOVING e NO MORE THAN FOUR PASSENGERS SHOULD BE ON THE VEHICLE AT ONE TIME e KEEP ALL BODY PARTS INSIDE THE VEHICLE TO PREVENT THEM FROM GETTING CAUGHT BETWEEN THE VEHICLE AND THE GROUND OR OTHER OBJECTS MAINTENANCE Refer to Pages 19 22 for periodic service schedule and periodic lubrication schedule e IF THE VEHICLE IS CONSTANTLY HAULING HEAVY LOADS THE PREVENTIVE MAINTE NANCE PROCEDURES SHOULD BE PERFORMED MORE OFTEN THAN RECOMMENDED IN THE SERVICE SCHEDULES AND LUBRICATION SCHEDULE STORAGE COMPARTMENT There is an enclosed storage compartment underneath the rear seat with 06 cu m 2 cu ft of storage area Access the storage compartment by lifting the rear seat ELECTRIC FAIRWAY VILLAGER An optional on board charger is available for the Fairway Villager electric 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
46. depressed When the vehicle reaches approximately 15 mph the regenerative braking should engage and moderate vehicle speed between 15 and 18 mph depending upon the grade of the hill CONTROLS DANGER e DO NOT OPERATE GASOLINE VEHICLE AN ENCLOSED AREA WITHOUT PROPER VENTILATION GASOLINE ENGINES PRODUCE CARBON MONOXIDE GAS WHICH IS AN ODORLESS DEADLY POISON A WARNING e THE ENGINE EXHAUST FROM THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS OR OTHER REPRODUC TIVE HARM 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 TAMPER WITH THE GASOLINE VEHICLE S GOVERNOR DOING SO WILL VOID THE WARRANTY AS WELL AS DAMAGE THE ENGINE AND OTHER COMPONENTS AND COULD RESULT IN PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO UNSAFE SPEEDS DO NOT MODIFY OR CHANGE THE VEHICLE IN ANY WAY WHICH MAY AFFECT THE STABILITY OR INCREASE THE SPEED BEYOND FACTORY SPECIFICATIONS PROPERTY DAMAGE PERSONAL INJURY OR DEATH COULD RESULT DO NOT SHIFT THE FORWARD REVERSE LEVER WHILE THE VEHICLE IS IN MOTION TO AVOID INJURY TO AN UNSUSPECTING PASSENGER OR DAMAGE TO THE VEHICLE ALWAYS BRING THE VEHICLE TO A FULL STOP BEFORE SHIFTING LEVER BUZZER WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE DEPRESS THE BRAKE PEDAL FIRMLY UNTIL STOPPED SET THE PARK BRAKE TURN KEY SWITC
47. driven drive unit starter generator 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 are warranted with respect to parts and labor against defects in materials and workmanship for a period of two years from the date of pur chase This limited warranty covers materials workmanship and repair labor cost as to those items specif ically 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 optional equipment and accessories fuses filters decals spark plugs lubricants the front body rear body 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 expo sure or ordinary wear and tear Batteries battery charger on board computer and solid state controller are covered by separate
48. ed Sport Wheel Vehicle Towing AM FM Stereo Cassette Radio Cover Permanent Tow Bar for Multiple with Clock e Glove Box Vehicle Towing factory installed e Hour Meter Ashtray On board Tow Bar Beverage Cooler Rear View Mirror ELECTRIC VEHICLES ONLY 3 75 hp Electric Motor Battery Indicator PowerDrive System 48 Vehi On board Charger with Rewind Cord cle Only 3 5 hp Electric Motor V Glide 36 Volt Vehicle Only GASOLINE VEHICLES ONLY e Fuel Guage A WARNING TINTED WINDSHIELDS WILL NOT PROTECT OCCUPANTS FROM FLYING OBJECTS GOLF BALLS Spark Arrestor Kit 31 SUBSEQUENT OWNER REGISTRATION In the event a vehicle is bought used from another individual or from a distributor dealer we strong ly 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 FAIRWAY VILLAGER The Fairway Villager is designed to provide a smooth and comfortable ride for four passengers and is offered in both gasoline and PowerDrive System 48 electric power configurations An optional 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 maintaine
49. enance information it contains TABLE OF CONTENTS galety 811 General 40 5 52250840 6 Vehicle Feature Identification r COME al uy uuu S D D ead 171 8101 1 86 11 21 2121 1414 Pre Operation Controls BD FINANCE ANAS Towing Transponng oma uhu Storages Gasoline kanes 8082 u muyu 12 16014116 Service Schedule iu a Periodic Lubrication Schedule Gasoline Vehicles Periodic Lubrication Schedule Electric Vehicles 5 ss uD Qa Engine Gasol
50. er Vehicle or the V Glide Speed Con troller Vehicle it is necessary to understand the electrical circuitry and the functions of all components in both systems 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 ACCESSORIES AND OPTIONS The vehicle is available with a complete line of optional equipment items and accessories These include a lighting kit horn taillight packages all weather enclosures etc Care should be taken that these accessories and options are properly installed by trained technicians and that they are used in the manner for which they were designed OPTIONAL EQUIPMENT ALL DS GOLF CARS e Canopy Clear or Tinted Snap On Wind shield Tinted Split Windshield Weather Proof Enclosure Adjustable Seat Back Information Holder Sweater Basket Extra Two Bag Attachment Bagwell Liner Snap on Tee Holder Sand Bottle Divot Repair Kit Custom Club Decals Accent Striping Scuff Guards Woodgrain Decal Power Rib Tires Extra Traction Tires 1 0 Numbers White Lighting Package High Low Chrome Hub Wheel Sand Basket and Divot Bucket Beam Headlights Taillights Covers Repair Kit Brake Lights and Horn e Chrome Sport Wheel Trailer Hitch e Deluxe Lighting Package with Covers e Temporary Tow Bar for Single Turn Signals e Ribb
51. g gear box 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 drive unit starter generator and electric motor are warranted with respect to parts and labor against defects in materials and work manship 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 are warranted with respect to parts and labor against defects in materials and workmanship for a period of two years from the date of pur chase while owned by the Original Retail Fleet Purchaser or in the possession of the Original Retail Fleet Lessee This limited warranty covers materials workmanship and repair labor cost as to those items specifi cally 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 A
52. guage without the writ ten 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 oblig ation 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 or EPA regulations and are not equipped for operation on public streets roads or highways 1995 Club Car Inc This manual effective August 1 1995 CLUB CAR LIMITED THREE 3 YEAR WARRANTY FOR 1996 INDI VIDUAL GOLF IN THE UNITED STATES AND 1 WARRANTY CLUB CAR INC CLUB CAR hereby warrants to the original retail purchaser that its new 1996 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 ser vice as a golf car for the periods stated below subject to the provisions limitations and exclusions con tained in this limited warranty LIMITED THREE YEAR WARRANTY The golf car frame excluding the front and rear bumper mounts rack and pinion steering gearbox unit suspension system defined as the shock absorbers shock mounts A plate leaf springs shackles and associated hardware gasoline engine transmission torque converters drive and
53. he 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 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 15 25 in lbs 1 7 2 8 N m The terminal connections should be clean and tight and any worn insulation or frayed wires should be replaced Torque battery terminals to 90 100 in lbs 10 11 3 N m CAUTION BATTERY WIRE TERMINALS ARE DAMAGED CORRODED THEY SHOULD BE 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 BATTERY CHARGER ELECTRIC VEHICLE 1 DANGER e BATTERIES EMIT HYDROGEN WHILE BEING CHARGED HYDROGEN IS EXPLO SIVE 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 ACCUMULATION OF HYDROGEN GAS INSIDE ENCLOSURE CHARGING AREAS MUST BE VENTILATED THE TOTAL VOLUME OF AIR IN THE BUILD ING MUST BE CHANGED FIVE 5 TIMES PER HOUR EXHAUST FANS SHOULD BE LOC
54. he vehicle A WARNING e FAILURE TO ADD OIL IMMEDIATELY WHEN OIL WARNING LIGHT STAYS ON MAY RESULT PERMANENT ENGINE DAMAGE POWERDRIVE SYSTEM 48 ELECTRIC VEHICLES ONLY BATTERY WARNING LIGHT The PowerDrive System 48 vehicle features a dash mounted warning light above steering column 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 System 48 on board computer 10 MEUTAAL FE LIT Fo POSITION Figure 10 Figure 11 12 Figure 13 When the vehicle is operation the warning light will come 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 rated 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 bat tery 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
55. in the room five times per hour Consult a local HVAC engineer To charge batteries Insert the charger s DC plug into the vehicle s receptacle The charger will turn on two to ten seconds later Figure 23 Page 29 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 s owly e PowerDrive Charger interacts with an on board computer the PowerDrive System 48 Golf Car The computer records the amount of energy consumed during vehicle use While the charger 16 plugged the golf car s control circuit is locked out preventing operation of the vehi cle 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 on board 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 Bat
56. ine Venice A Fueling Instructions GaSoline Vehicle Ba lery Gasoline Venice Battery EICCIIG um aun ee rae Sat SDD use Battery Charger 2 Cleaning Vehicte Controllers ACCESSORIES and aa S bs guent Owner 52 11 12 27 93 20 28 patu Practice Safety Rotating Parts Safety signs like you see above may at first seem shocking but their impact is mild compared with the reality of severe personal injury Your safety and satisfaction are of the utmost importance to Club Car That is why before operating the vehicle urge you to review the information in this manual Understand and become familiar with the DANGER WARNING and CAUTION state ments 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 s
57. ned 6 Check fill drive unit to plug level 67 liters 22 02 SAE 30 WT API Personnel Only Class SE SF or SG Oil or higher 7 Inspect front wheel bearings Chassis Lube Repack as necessary POW ERDRIVE SYS 48 LUBRICATION POINTS Figure 17 21 5 Engine Crankcase without Filter Engine Crankcase with Filter Transmission Drive Unit Gasoline Tank Tire Pressure 22 GLIDE 36 YOLT LUBRICATION POINTS Figure 18 GASOLINE ELECTRIC 98 liters 32 02 1 16 liters 38 02 61 liters 20 02 67 liters 22 oz 67 liters 22 07 26 5 liters 7 U S gallons 12 14 psi 18 20 psi ENGINE OIL GASOLINE VEHICLE Even though the oil warning light on the dash should warn you if your oil is getting low engine oil level should be checked monthly See Figure 19 e ENGINE MUST BE IN LEVEL POSITION Remove oil level dipstick from the oil filler tube and wipe oil from it with a clean cloth or paper towel Check oil by inserting the dipstick fully into oil filler tube and immediately removing it again If oil level is at or below ADD mark on gauge add oil until level is between ADD and FULL safe level DO NOT OVERFILL Reinsert dipstick into oil filler tube Figure 19 Figure 20 FUELING INSTRUCTIONS GASOLINE VEHICLE fa DANGER e GASOLINE FLAMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE e SERVIC
58. s and V Glide 36volt Vehicles Only Check all daily weekly and monthly items listed above Check clean and adjust brake system Check front wheel alignment and camber adjust as necessary Test batteries Check battery electrolyte level Check spark plug wire and boot for damage and proper routing Check head and exhaust header pipe flange connection gasket for leaks Check starter generator belt tension and adjust as necessary Check condition of muffler Inspect drive belt replace as required Lubricate as shown on chart on Page 20 21 or 22 Check all wire insulation for cracks and worn insulation Check all daily weekly monthly and quarterly items listed above Check air filter every 6 months or 50 hours in dusty environment Inspect starter generator brush length blast with pressurized air to remove carbon Inspect spark plugs clean and regap Lubricate as shown on chart on Page 20 21 or 22 Check motor brushes and commutator Check accelerator switch adjustment Check all scheduled items listed above Replace fuel filters Change air filter Change engine oil and oil filter Elec e IF ANY PROBLEMS ARE FOUND DO NOT OPERATE VEHICLE UNTIL REPAIRS ARE MADE FAILURE MAKE NECESSARY REPAIRS COULD RESULT IN FIRE SEVERE PERSONAL INJURY PROPERTY DAMAGE OR DEATH 19 PERIODIC LUBRICATION SCHEDULE Regular Interval Service Quarterly by Owner or 1 Brake shaft bearings Trained Personnel Only 2 Brake linkage and pivots 3
59. teries should be put on charge even if they have been used for only a short period 9 holes of golf or 10 minutes The charger is automatic and will turn off when batteries are fully charged If the 28 charger does seem to operating properly if the batteries seem weak contact your local CLUB CAR distributor dealer NOTE When temperatures fall below 18 3 C 65 F batteries charged unheated areas should be placed on charge as soon after use as possible Batteries are warmest immediately after use and cold batteries require more time to fully charge A WARNING e SURE ALL WIRE CONNECTIONS AT THE RECEPTACLE AND THE FUSE LINK ARE CLEAN AND TIGHT e DO NOT ROCK OR BEND THE PLUG TO CONNECT THE CHARGER PLUG TO THE VEHI CLE RECEPTACLE GRASP THE PLUG HANDLE AND PUSH THE PLUG STRAIGHT INTO THE RECEPTACLE SEE FIGURE 23 e DO NOT PULL ON THE CORD SEE FIGURE 24 DO NOT TWIST ROCK OR BEND THE PLUG TO DISCONNECT THE CHARGER PLUG FROM THE VEHICLE RECEPTACLE GRASP THE PLUG BY THE HANDLE AND PULL THE PLUG STRAIGHT OUT OF THE RECEPTACLE e DO NOT CONNECT A PORTABLE 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 e FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE CHARGER CORD THE PLUG AND O
60. ts should be in place and properly installed Be sure that all nuts bolts and screws are tight On the DS Gasoline vehicle check all hose clamps for tight fit as well as the starter belt for tightness e Warning Labels Check to ensure that all warning and operation labels in place See Pages 3 and 4 e Tires Check for proper tire pressure See Capacities Page 22 DS Electric Batteries all models Check electrolyte to ensure that it is at its proper level See Figure 22 Page 25 Check battery posts Wires should be tight and free of corrosion Charge batteries fully before first use of vehicle DS V Glide Speed Switch Be sure speed switch cover is properly secured prior to operating the vehicle DS Gasoline Engine Check for proper engine oil level See Engine Oil Page 23 DS Gasoline Fuel Check fuel level See Fueling Instructions Page 23 A WARNING e BE SURE THE PLASTIC HAS BEEN REMOVED FROM THE SEAT BOTTOM BEFORE OPER ATING 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 dri ving instructions take the vehicle for a test drive Check the following All vehicles Brakes Be sure that the brakes function properly Both rear wheels should brake simultaneously The pedal should not go more than halfway to the floor If it does ha
61. ual hydraulic shocks Breakes Ouet rear wheel sel adusting brakes with cast iron and single brake pedal with autcnatic release park brake 5 I 5 I BODYIGHASSIS Frama Chassis Twin 1 welded aluminum I I Front and Rear Body Azmorilexib Body Finish Clear peotective coat over molded in coler I I 18 06 50 8 00 tubeless 4 ply rated SEATING CAPACITYFUEL CAPACITY Seating Capacity 2 persone z I Seating 4 persons Fuel Tank 26 5 liters 7 gal U S umeaded only DIMENSIONSAWEIGHT I 254 882 81 1 2 232 81 271 232 81 1 2 1 Overall Length a 12292 1 99 6 Overall Width 120 47 1 4 120 47 1 4 120 47 1 47 120 47 47 120 cm 47 1 47 Overall Height at Steering Wheel 122 1220 48 122 440 122 0 48 122 om 48 Ne Ground Clearance 11 11 114172 17 11 4 1 2 88 om BS cm
62. ve the brake system checked Park Brake The park brake should lock the wheels when latched and should release when either the accelerator or brake pedal is depressed Steering The vehicle should be easy to steer and should not have any play in the steering wheel Accelerator As the accelerator pedal is depressed the engine or motor should start and the vehi cle should come up smoothly to full soeed When the pedal is released it should return to the orig inal position and the engine or motor should stop The DS Electric vehicle runs at reduced speed in reverse DS Gasoline Governor Check the speed of the vehicle The vehicle should run at 19 24 KPH 12 15 MPH on a level surface 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 System 48 Vehicles with Regenerative Braking e Zero Speed Detect With the vehicle parked on level ground and the park brake disengaged turn the ignition key to the ON position and attempt to push the vehicle It should resist rolling with the forward and reverse switch in any position e Pedal Up Motor Braking Accelerate the vehicle to full speed and then release the accelerator pedal The vehicle should quickly and smoothly slow to approximately 9 mph e Pedal Down Motor Braking Accelerate down an incline with the accelerator pedal

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