Club Car DS Gold Standard Owner'S Manual Download

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DS Gold Standard Remanufactured

Vehicle Owner’s Manual

Electric and Gasoline

[Refer to back cover for applicable build code range]

Summary of Contents for DS Gold Standard

Page 1: ...DS Gold Standard Remanufactured Vehicle Owner s Manual Electric and Gasoline Refer to back cover for applicable build code range ...

Page 2: ......

Page 3: ...right All rights are reserved No part of this manual may be photocopied reproduced or translated to another language without the written consent of Club Car The information contained in this document is subject to change without notice Club Car reserves the right to make design changes to vehicles without obligation to make these changes on units previously sold These vehicles do not conform to US...

Page 4: ...ocal authorized Club Car dealer or distributor who will be able to provide technical advice perform warranty work and sell parts and service manuals For the name and address of the authorized Club Car dealer and distributor nearest you logon to our web site at www clubcar com or call 1 800 ClubCar 258 2227 If you would prefer to write to us direct your letter to Club Car Attention Marketing Servic...

Page 5: ...wing 26 Transporting on a Trailer 27 Storage Electric Vehicles 27 Storage Gasoline Vehicles 29 Maintenance 31 Periodic Service Schedules 32 Periodic Lubrication Schedules 35 Batteries Electric Vehicles 37 Battery Charger Electric Vehicles 40 Battery Gasoline Vehicles 43 Engine Oil Gasoline Vehicles 45 Fueling Instructions Gasoline Vehicles 48 Cleaning the Vehicle 49 Accessories 49 Subsequent Owner...

Page 6: ...feature identification information For detailed information on specific features read the appropriate section in this manual ELECTRIC VEHICLE 2000A 1 2 1 101960601 Decal Rollover Warning on instrument panel 2 103783001 Decal Operating Instructions on steering wheel Page 4 DS Gold Standard Remanufactured Vehicle Owner s Manual ...

Page 7: ...4 1 2 1 101908601 Decal Tow Switch Warning on Tow Run switch plate under seat 3 Battery Charger Receptacle 2 101931501 Decal Component Cover Notice on electrical component cover 4 Forward Reverse Control DS Gold Standard Remanufactured Vehicle Owner s Manual Page 5 ...

Page 8: ... Off Key Switch above key switch 5 Park Brake Pedal 2 101960601 Decal Rollover Warning on instrument panel 6 Accelerator Pedal 3 103783002 Decal Operating Instructions on steering wheel 7 Serial Number 4 Low Oil Warning Light 8 Brake Pedal Page 6 DS Gold Standard Remanufactured Vehicle Owner s Manual ...

Page 9: ...rame near fuel tank 5 Fuel Shut Off Valve 2 101915201 Decal Frame Ground Governor Warning on vehicle frame near battery 6 Oil Fill 3 101960501 Decal Rotating Parts Hot Manifold Warning on engine starter generator and transaxle 7 Choke 4 Forward Reverse Control 8 Neutral Lockout Cam DS Gold Standard Remanufactured Vehicle Owner s Manual Page 7 ...

Page 10: ...n FOUR PASSENGER VEHICLE 317A 1 2 3 1 101705701 Decal Falling Off Warning on rear facing seat hand rail and or on back side of forward facing seat backs 3 Hand Holds 2 Hand Rail Page 8 DS Gold Standard Remanufactured Vehicle Owner s Manual ...

Page 11: ...n this manual Understand and become familiar with the DANGER WARNING and CAUTION statements and procedures it contains along with the safety decals that are affixed to your vehicle Take time to understand the language of safety It is a language that can save your life PROPOSITION 65 STATE OF CALIFORNIA WARNING This product contains or emits chemicals or substances that have been determined by the ...

Page 12: ... distributor dealer DANGER A DANGER indicates an immediate hazard that will result in severe personal injury or death WARNING A WARNING indicates an immediate hazard that could result in severe personal injury or death CAUTION A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury CAUTION A CAUTION without the safety alert symbol ind...

Page 13: ...easy to read Only trained technicians should service or repair the vehicle or battery charger Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation Electric vehicles only Place Tow Run switch in the TOW position before disconnecting ...

Page 14: ...hten battery terminals to 80 in lb 9 N m 3 Coat terminals with Battery Terminal Protector Spray CC P N 1014305 to minimize corrosion 4 Connect the spark plug wire s to the spark plug s 1 2 3 5 6 4 TOW RUN WARNING 1 2 3 Viewed from driver side of vehicle 1 Place TOW RUN Switch in TOW before disconnecting or connecting battery cables 2 Remove negative battery cable 3 Remove positive battery cable Co...

Page 15: ...ECYCLING LEAD ACID BATTERIES WARNING Lead acid batteries contain lead Pb other metals acids and other compounds If improperly handled they can contaminate both water and soil causing environmental damage and personal injury Lead acid batteries are identified by the symbol shown below and should be properly recycled Figure 4 They cannot be disposed as municipal waste and must be collected separatel...

Page 16: ... bar code decal mounted either below the passenger side cup holder or above the accelerator or brake pedal Example PH0901 583947 Figure 6 The two letters 1 at the beginning of the serial number indicate the vehicle model The following four digits 2 indicate the model year and production week during which the vehicle was built The six digits 3 following the hyphen represent the unique sequential nu...

Page 17: ... committee feels necessary or appropriate CONTROLS AND INDICATORS See General Warnings on page 10 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 Do not shift the Forward Reverse handle or switch while the vehicle is moving To avoid injury to an unsuspecting passenger or damage to the veh...

Page 18: ...ARD side of the switch to operate the vehicle in the forward direction or push down the REVERSE side of the switch to operate the vehicle in reverse When the rocker switch is positioned in the NEUTRAL position with neither side down the vehicle will not operate if the accelerator pedal is pressed Figure 9 The reverse buzzer will sound as a warning when the Forward Reverse switch is in the REVERSE ...

Page 19: ...e When the key switch is in the ON position and the Forward Reverse handle or switch is in either in the FORWARD or REVERSE position pressing the 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 pressed speed will increase until full speed is reached When the accelerator is released pow...

Page 20: ...otor braking is automatically disengaged when vehicle speed slows below the programmed top speed See following WARNING Pedal Up Motor Braking When vehicle speed is above 11 mph 17 7 km h releasing the accelerator pedal will activate motor braking which slows the vehicle speed Once vehicle speed slows to below approximately 11 mph 17 7 km h with the accelerator pedal still released motor braking wi...

Page 21: ... power cord is disconnected 2 AC power to the charger is interrupted 3 automatic charger shut off occurs after 16 hours of operation 4 the charger malfunctions or 5 the wrong charger is used the warning light will indicate as follows The warning light will not illuminate if the charge is 90 or more complete The onboard computer will retain in memory the amount of charge needed to fully replenish t...

Page 22: ...ow 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 walk away braking motor braking function is operating Before Disconnecting or Connect...

Page 23: ...m in the MAINTENANCE position and the engine running the vehicle may move suddenly if the Forward Reverse handle is shifted or accidentally bumped To prevent this chock the front and rear wheels and firmly set the park brake before servicing or leaving the vehicle NOTE Be sure to return the cam to the OPERATE position after servicing the vehicle or it will not operate with the Forward Reverse hand...

Page 24: ...ver upon receiving your new vehicle s you should become familiar with its controls indicators and operation Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery Use the following checklist as a guide to inspect the vehicle This checklist should be used daily to ensure that the vehicle is in proper working condition and in conjunction with the Pe...

Page 25: ...ld come to a smooth straight stop within 14 feet 4 3 m If the pedal goes more than halfway to the floor or if the vehicle swerves or fails to stop within 14 feet 4 3 m have the brake system checked and adjusted as required Brake adjustment must be maintained so that the brake pedal cannot be pressed to the floor under any circumstance Park brake When latched the park brake should lock the wheels a...

Page 26: ...face DRIVING INSTRUCTIONS WARNING Only licensed drivers should be allowed to drive the vehicle If renting or loaning the vehicle make sure the driver is familiar with all controls and operating procedures before allowing the 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 properl...

Page 27: ... sure everyone is seated and holding onto seat hand holds or handrails 3 Read safety and information decals located on the vehicle 4 Make sure wheels are turned in desired direction 5 Turn the key to the ON position and make sure nothing is in your path 6 Select direction by placing the Forward Reverse handle or switch in desired position F forward or R reverse A buzzer will sound as a warning whe...

Page 28: ...This prevents the possibility of a parked vehicle with the park brake disengaged rolling away too fast to be overtaken on foot Gasoline vehicles only Turn the fuel shut off valve to the closed OFF position when the vehicle is not in use TOWING WARNING Do not tow the vehicle on public streets or highways Use only approved Club Car tow bars Turn the key switch to the OFF position and place the Forwa...

Page 29: ...opping on a hill when towing If you must stop on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning could cause the vehicle to overturn possibly resulting in severe personal injury When towing on a trailer normal road speed of the tow vehicle should be reduced Because of the added length of the trailer use caution when making turns Remove the vehicle...

Page 30: ...witch remains in the RUN position rather than in the TOW position required for all other vehicles 4 Batteries should be clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse solution off batteries Do not allow this solution to enter the batteries Let the terminals dry and then coat them w...

Page 31: ...able will not come into contact with battery terminal RETURNING THE STORED ELECTRIC VEHICLE TO SERVICE 1 If necessary connect batteries See Connecting the Batteries Electric Vehicles on page 13 2 Fully charge batteries WARNING Do not attempt to charge frozen batteries or batteries with bulged cases Discard the battery Frozen batteries can explode 3 Adjust tires to recommended tire pressure See Veh...

Page 32: ...drain screw and drain fuel remaining in bowl into a small clean container then pour the fuel from the container into vehicle fuel tank Tighten the carburetor drain screw 2 3 Disconnect fuel vent line from fuel tank vent nipple 2 4 Plug the fuel tank vent nipple so that it is air tight We recommend using a slip on vinyl cap 3 Disconnect battery and spark plug wire s See Disconnecting the Battery Ga...

Page 33: ...vely for a short time when it is run for the first time after storage 5 Adjust tires to recommended tire pressure See Vehicle Specifications on page 50 6 Perform the Pre Operation and Daily Safety Checklist on page 22 MAINTENANCE See General Warnings on page 10 To ensure trouble free vehicle performance it is very important to follow an established preventive maintenance program Regular and consis...

Page 34: ...ts to contact frame when disconnecting batteries or other electrical wiring Never allow a positive wire to touch the vehicle frame engine or other metal component PERIODIC SERVICE SCHEDULES See General Warnings on page 10 WARNING Service repairs and adjustments must be made per instructions in the maintenance and service manual If any problems are found during scheduled inspection or service do no...

Page 35: ...chedule Check brake cables for damage replace if necessary Brake system Check brake cable equalizer adjustment adjust if necessary Electrical wiring and connections Check for tightness and damage Forward Reverse switch Check condition of contacts and wire connections Make sure connections are tight Front wheel alignment and camber Check and adjust as required See Steering and Front Suspension in t...

Page 36: ...nt Suspension in the maintenance and service manual Electrical wiring and connections Check for tightness and damage Check brake shoes replace if necessary Lubricate brake slides See Periodic Lubrication Schedules on page 35 Check brake cables for damage replace if necessary Semiannual service by trained technician only every 50 hours of operation or every 100 rounds for golf cars Brake system Che...

Page 37: ...151 Charger receptacle WD 40 Brake slides Dry Moly Lube CC P N 1012151 Semiannually by owner or trained technician every 50 hours of operation or 100 rounds of golf Front suspension 5 fittings Chassis Lube EP NLGI Grade 2 Annually by trained technician only every 100 hours of operation or 200 rounds of golf Check fill transaxle to plug level 7 22 oz 0 67 L SAE 30 WT API Class SE SF or SG Oil or hi...

Page 38: ...rs of operation or every 100 rounds of golf Brake slides Dry Moly Lube CC P N 1012151 Annually by trained technician only every 100 hours of operation or every 200 rounds of golf Check fill unitized transaxle to plug level 27 oz 0 8 L 80 90 WT API Class GL 3 or 80 90 WT AGMA Class EP Gear Lube First change 100 hours additional change every 200 hours of operation or every 400 rounds of golf or annu...

Page 39: ...ld never be used in electric vehicles New batteries will not deliver their full capabilities until they have been discharged and recharged 20 to 50 times To obtain the maximum service life from new batteries restrict electric vehicles with new batteries to 36 holes of use between charges in the first two months of operation Batteries should be fully charged before first use of new vehicle before f...

Page 40: ...Y Suspended matter Trace Total solids 100 0 Organic and volatile matter 50 0 Corrosion of positive plates Ammonia 8 0 Slight self discharge of both plates Antimony 5 0 Self discharge reduces life lower on charge voltage Arsenic 0 5 Self discharge can form poisonous gas Calcium 40 0 Increase of positive plate shedding Chloride 5 0 Loss of capacity in plates greater loss in positive plates Copper 5 ...

Page 41: ...o inner hold downs to 115 in lb 13 N m and tighten the retaining nuts on the two outer hold downs to 55 in lb 6 2 N m The terminal connections should be clean and tight and any worn insulation or frayed wires should be replaced Tighten battery terminals to proper torque See Connecting the Batteries Electric Vehicles on page 13 See following WARNING WARNING If battery wire terminals are damaged or ...

Page 42: ...ed 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...

Page 43: ...nto the receptacle Figure 22 Page 42 Do not pull on the DC cord Figure 23 Page 42 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 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 g...

Page 44: ...have been used for only a short period 9 holes of golf or 10 minutes The charger is automatic and will turn off when batteries are fully charged If the charger does not seem to be operating properly or if the batteries seem weak contact your local Club Car distributor dealer PLUG AND RECEPTACLE The charger cord plug and receptacle are wear items and should be inspected daily Visually inspect them ...

Page 45: ...ectrical problem and correct it before replacing the fuse Contact your nearest Club Car distributor dealer BATTERY GASOLINE VEHICLES See General Warnings on page 10 DANGER Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or nea...

Page 46: ...inals should be washed off with a solution of baking soda and water 1 cup 237 mL per gallon 3 8 L of water Rinse solution off the battery Do not allow this solution to enter battery Be sure terminals are tight Let the terminals dry and then spray them with Battery Terminal Protector Spray CC P N 1014305 See Connecting the Battery Gasoline Vehicles on page 12 See preceding WARNING and following WAR...

Page 47: ...surface when checking oil Do not overfill with oil ENGINE OIL LEVEL CHECK 1 Remove the oil level dipstick from the oil filler tube and wipe oil off dipstick 1 Figure 27 See following CAUTION CAUTION Do not remove dipstick while engine is running 2 Check oil by fully inserting the dipstick into the oil filler tube 2 and immediately removing it 3 If the oil level is at or below the low level mark on...

Page 48: ...ng it counterclockwise and allow the engine oil to drain into the pan See following WARNING WARNING Do not attempt to change engine oil when the engine is hot or even warm Engine oil can cause skin burns Wear safety glasses or approved eye protection when servicing the vehicle Wear rubber gloves when handling oil drain plug oil filter and oil drain pan 6 Clean the oil drain plug threads with solve...

Page 49: ...se a clean rag and wipe the oil filter mounting bracket surface clean where the oil filter gasket seats 11 Coat new oil filter gasket with clean engine oil and install the oil filter onto the engine oil filter port Figure 30 NOTE Use only Club Car oil filters CC P N 103887901 designed for this engine 12 Hand tighten 2 3 to 3 4 turn after filter gasket contacts mounting surface 13 Remove the dipsti...

Page 50: ...ded the vehicle must be grounded to the pump before and during the fueling operation If the vehicle has an all weather enclosure installed be sure the fuel tank is properly vented as shown Figure 32 To avoid the possibility of fire clean up any spilled fuel before operating the vehicle CAUTION Use unleaded gasoline only Whenever possible avoid using oxygenated and blended fuels Do not use any fuel...

Page 51: ...ossible stains The seats of the vehicle will last longer with proper cleaning Use a solution of 10 liquid soap and warm water applied with a soft cloth For imbedded dirt a soft bristle brush may be used For heavy soiling difficult stains or scratches blemishes or other body damage see the appropriate maintenance and service manual NOTE Dispose of waste water properly ACCESSORIES There is a complet...

Page 52: ... sensing internally geared in unitized transaxle Ignition Transistor electronic ignition with electronic RPM limiter Transaxle Double reduction helical gear with 12 3 1 direct drive axle Unitized transaxle Fully synchronized forward and reverse with neutral and reduced speed reverse 11 8 1 forward 17 1 1 reverse Torque converter Automatic variable speed dry type Electrical system 48 volts DC reduc...

Page 53: ...1 kg 633 lb 287 kg Forward speed 12 15 mph 19 24 km h Curb clearance circle diameter 17 ft 6 in 533 cm Braking distance at 12 mph 19 km h 14 ft 427 cm Standard seating capacity 2 2 4 4 LIQUID CAPACITIES Transaxle 22 oz 0 67 L 22 oz 0 67 L Engine crankcase without filter 32 oz 0 95 L Engine crankcase with filter 38 oz 1 12 L Unitized transaxle 27 oz 0 8 L Fuel tank 7 gallons 26 5 L TIRE PRESSURE Fr...

Page 54: ...anty are all fuses filters decals except safety decals lubricants routine wear items such as the charger plug and receptacle engine mounts mats pads spark plugs light bulbs brake shoes belts brushes bushings drive buttons cosmetic deterioration and items that deteriorate fade or fail due to exposure or ordinary wear and tear The provisions of this limited warranty shall not apply to failure due to...

Page 55: ...of at no cost to the purchaser during the applicable limited warranty period CLUB CAR reserves the right to test and recharge any component returned for adjustment If CLUB CAR elects to repair the vehicle or component it may provide factory reconditioned parts or components All parts and components replaced under warranty shall become the property of CLUB CAR DISCLAIMER THIS LIMITED WARRANTY IS EX...

Page 56: ... USA 706 863 3000 WARNING Any modification or change to the vehicle that affects the electrical system stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications could result in severe personal injury or death Page 54 DS Gold Standard Remanufactured Vehicle Owner s Manual ...

Page 57: ...00 CLUB CAR EXPLANATION OF EMISSION CONTROL WARRANTY 1 WARRANTY CLUB CAR warrants to the ultimate purchaser and each subsequent purchaser that the SORE and related emissions equipment is designed built and equipped so as to conform with all applicable California environmental emission regulations and free from defects in materials and workmanship that cause the failure of a warranted part to be id...

Page 58: ... a component that has a factory installed and properly operating adjustment limiting device is still eligible for warranty coverage The following emission warranty parts list are covered SYSTEMS COVERED PARTS DESCRIPTION Fuel Metering Carburetor assembly fuel injection pump fuel injection nozzle fuel regulator Exhaust Catalytic Converter Exhaust Manifold Air Induction Air filter housing air filter...

Page 59: ...Warranties DS Gold Standard Remanufactured Vehicle Owner s Manual Page 57 ...

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Page 64: ...Publication Part Number 103897209 Edition Code 0412B0412A This manual is valid for vehicles with build codes between 55775 and the one indicated at the top of this page 103897209 ...

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