OM, 1996 Carryall Gas/Electric (101883802-)

OM, 1996 Carryall Gas/Electric (101883802-)
Club Car
R
Owner’s Manual
1996
Carryall
Vehicles
Manual Number: 101883802
Print Code: 0895A00000
NOTICE
The Club Car Limited Warranty appears on the last page of this manual. No other warranties,
express or implied, are contained herein. Please complete and return the warranty registration card
included in this manual.
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 manual contains proprietary information that is protected by copyright. All rights are reserved. No
part of this manual may be photocopied, reproduced or translated to another language without the written consent of Club Car, Inc.
The information contained in this document is subject to change without notice.
Club Car reserves the right to make design changes to either gasoline or electric vehicles without obligation to make these changes on units previously sold.
These vehicles do not conform to Federal Motor Vehicle Safety Standards or EPA regulations. They
are not designed, manufactured, or equipped for operation on public streets, roads, or highways.
©1995 Club Car Inc.
This manual effective August 1, 1995.
i
FOREWORD
Thank you for choosing Club Car. You have chosen the finest utility vehicle on the market-- the vehicle most widely recognized as the industry leader in vehicle efficiency and long-lasting value. Please
protect your investment and ensure that your Club Car provides years of reliable, superior performance
by filling out and returning your Warranty Registration Card (located between the last page and
back cover of this manual), 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, we recommend that you ask them to read this manual before they operate the vehicle.
Club Car products are backed by a customer support system designed to offer you fast, courteous service. In the event that your utility vehicle 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 nearest 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 utility vehicle. If you sell the
vehicle, please include the manual so that the next owner will have the important operating, safety and
maintenance information it contains.
ii
TABLE OF CONTENTS
Safety Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
General Warnings
2
............................................................
Vehicle Feature Identification
...................................................
4
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pre-Operation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Performance Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Controls - Carryall-l Electric, Carryall II Electric, Carryall-VI Electric,
Carryall-l Gasoline, and Carryall-ll Gasoline Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Driving Instructions - Carryall-l Electric, Carryall II Electric, Carryall-VI Electric,
Carryall-l Gasoline, and Carryall-ll Gasoline Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Controls - Carryall-ll Plus and Carryall-VI Gasoline Vehicles
. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Driving Instructions - Carryall-ll Plus and Carryall-VI Gasoline Vehicles . . . . . . . . . . . . . . . . . . . 26
Loading and Unloading
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Transporting on a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Storage - Gasoline Vehicle
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Storage - Electric Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Periodic Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Periodic Lubrication Schedule – Gasoline Vehicle
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Periodic Lubrication Schedule – Electric Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Liquid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Engine Oil - Gasoline Vehicle
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fueling Instructions - Gasoline Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Battery - Gasoline Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Battery - Electric Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Battery Charger - Electric Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Vehicle Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Accessories and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Subsequent Owner Registration
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
iii
iv
Practice Safety
Safety signs like you see above may at first seem shocking, but their impact is
mild compared with the reality of severe personal injury.
Your safety and satisfaction are of the utmost importance to Club Car. That is why
we urge you to study this owner’s manual, and to read, understand, and heed the
warnings in this manual, as well as the safety signs on your vehicle, before operating the vehicle.
Take time to understand the language of safety. It is a language that can save your
life.
1
SAFETY DETAILS
WARNING
• THIS OWNER’S MANUAL SHOULD BE READ COMPLETELY BEFORE ATTEMPTING TO
DRIVE OR SERVICE THE VEHICLE.
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 protection, we recommend that you take special notice of these safety procedures. Safety procedures are
essential and must be followed.
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.
DANGER
• A DANGER INDICATES AN IMMEDIATE HAZARD WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH.
GENERAL WARNINGS
WARNING
The safety procedures listed must be followed whenever the vehicle is being repaired or ser• A WARNING
INDICATES
AN IMMEDIATE
HAZARDthis
WHICH
COULD
IN SEVERE PERviced.
Other specific
warnings
appear throughout
manual
andRESULT
on the vehicle.
SONAL INJURY OR DEATH.
MODEL IDENTIFICATION
CAUTION
• A CAUTION INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN
PRODUCT OR PROPERTY DAMAGE OR MINOR PERSONAL INJURY.
NOTE
• A NOTE PROVIDES KEY INFORMATION TO MAKE PROCEDURES EASILY UNDERSTOOD.
The serial number of your vehicle is stamped on the data plate mounted on the frame directly above
the accelerator pedal (Example: F9602-123456 for electric vehicles and FG9602-123456 for gasoline
vehicles).
DANGER
• GASOLINE VAPORS - FLAMMABLE - EXPLOSIVE - DO NOT SMOKE. KEEP SPARKS AND
FLAMES AWAY FROM THE AREA OF THE VEHICLE. SERVICE ONLY IN WELL-VENTILATED AREAS.
• BATTERY VAPORS - FLAMMABLE - EXPLOSIVE - DO NOT SMOKE. KEEP SPARKS AND
FLAMES AWAY FROM THE AREA OF THE VEHICLE. SERVICE ONLY IN WELL-VENTILATED AREAS.
2
DANGER
• DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER
VENTILATION. ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS,
DEADLY POISON.
• A UTILITY VEHICLE WILL NOT PROVIDE PROTECTION FROM LIGHTNING, FLYING
OBJECTS, OR OTHER STORM RELATED HAZARDS. IF CAUGHT IN A STORM WHILE DRIVING A UTILITY VEHICLE, EXIT THE VEHICLE AND SEEK SHELTER IN ACCORDANCE WITH
SAFETY GUIDELINES APPLICABLE TO YOUR LOCATION.
WARNING
• ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THE VEHICLE. ANYONE
DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD FOLLOW THE CORRECT PROCEDURES AND OBEY THE WARNINGS LISTED IN THIS MANUAL AS WELL AS THOSE IN THE
MAINTENANCE AND SERVICE MANUAL.
• ALWAYS WEAR SAFETY GLASSES OR EYE PROTECTION WHEN SERVICING THE VEHICLE.
• TURN KEY SWITCH TO “OFF”, REMOVE KEY, BLOCK TIRES, PLACE FORWARD/REVERSE
LEVER IN “NEUTRAL”, AND DISCONNECT BATTERY(IES) PRIOR TO SERVICING. (ON
GASOLINE VEHICLES, DISCONNECT THE NEGATIVE BATTERY LEAD FIRST, FOR ELECTRIC VEHICLES, SEE FIGURES 1 AND 2).
• ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL
CONNECTIONS.
• IMPROPER USE OF THE VEHICLE, OR FAILURE TO PROPERLY MAINTAIN IT, COULD
RESULT IN DECREASED VEHICLE PERFORMANCE OR SEVERE PERSONAL INJURY.
• FOLLOW ALL PROCEDURES LISTED IN THE MANUAL FOR LOADING AND UNLOADING
VEHICLE.
• 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.
• THE ENGINE EXHAUST FROM THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE
STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS, OR OTHER REPRODUCTIVE HARM.
Figure 1
Figure 2
3
Carryall-I & Carryall-II Gasoline
4
Vehicle Feature Identification
5
Carryall-I & Carryall-II Electric
6
Vehicle Feature Identification
7
Carryall-II Plus
8
Vehicle Feature Identification
9
Carryall-VI Electric
10
Vehicle Feature Identification
11
Carryall-VI Gasoline
12
Vehicle Feature Identification
13
Carryall-VI Gasoline
Vehicle Feature Identification
14
PRE-OPERATION CHECKLIST
Your vehicle has been thoroughly inspected and adjusted at the factory and also by your CLUB CAR
distributor/dealer. However, upon arrival of your
new vehicle(s), you should become familiar with its
controls and operation, and carefully inspect each
vehicle to be satisfied that it is in proper working
condition before accepting delivery.
NOTE
• ALWAYS MENTION THIS NUMBER WHEN
ORDERING SERVICE PARTS OR MAKING INQUIRIES (SEE FIGURE 3).
Use the following checklist as a guide to inspect
your new vehicle. Any problems should be corrected by only your CLUB CAR distributor/dealer or a trained mechanic.
Figure 3
• General: All parts should be in place and properly installed. Be sure that all nuts, bolts and screws
are tight. On the gasoline vehicle, check all hose clamps for tight fit as well as the starter belt for
tightness.
• Warning Labels: Check to ensure that all warning and operation labels are in place (See
Pages 4-14).
• Tires: Check for proper tire pressure (Tire Specifications, Page 39).
• Batteries - Electric Vehicle: Check the electrolyte to ensure that it is at its proper level (See Figure 32, Page 42). Check battery posts. Wires should be tight and free of corrosion. Charge batteries fully before first use of vehicle.
• Engine - Gasoline Vehicle: Check for proper engine oil level (See Engine Oil, Page 40).
• Fuel - Gasoline Vehicle: Check fuel level (See Fueling Instructions, Page 40).
PERFORMANCE INSPECTION
After you have familiarized yourself with the vehicle’s controls, and have read and understood the driving instructions, take the vehicle for a test drive. Check the following:
WARNING
• BE SURE THE PLASTIC HAS BEEN REMOVED FROM THE SEAT BOTTOM BEFORE OPERATING VEHICLE. FAILURE TO DO SO MAY RESULT IN A FIRE, PROPERTY DAMAGE,
PERSONAL INJURY, OR DEATH.
• Brakes: Be sure that the brakes work properly. On vehicles with rear brakes only, both rear wheels
should brake simultaneously. On vehicles with front and rear brakes, all four wheels should brake
simultaneously. The pedal should not go more than halfway to the floor. If it does, have the brakes
adjusted (Carryall I Gas and Electric have self-adjusting brakes; have brake system checked).
Performance Inspection, Continued:
• Park Brake: The park brake should lock the wheels when latched, and should release when either
the accelerator or brake pedal is depressed.
15
• 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 vehicle should come up smoothly to full speed. When the pedal is released, it should return to the original position and the engine or motor should stop, except Carryall-II Plus and Carryall VI, which
idle (See Controls, Page 23). The electric vehicle runs at reduced speed in reverse.
• Governor: Check the speed of the vehicle. The electric vehicles and the Carryall-l gasoline vehicle should run at 12-15 MPH (19-23 KPH) on a level surface. The Carryall-ll and Carryall-VI gasoline vehicle should run at 14-16 MPH (23-26 KPH) on a level surface. The Carryall-ll Plus gasoline vehicle should run at 17-18 MPH (27-29 KPH) 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.
CONTROLS - CARRYALL-I ELECTRIC, CARRYALL-II ELECTRIC,
CARRYALL-VI ELECTRIC, CARRYALL-I GASOLINE AND
CARRYALL-II GASOLINE VEHICLES
KEY SWITCH
The key switch is mounted on the dash to the right of the steering column (See Figure 4). It has two
positions, OFF and ON, which are clearly labeled.
DANGER
• DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER
VENTILATION. GASOLINE ENGINES PRODUCE CARBON MONOXIDE GAS WHICH IS AN
ODORLESS, DEADLY POISON.
WARNING
• BEFORE ASSIGNING THE VEHICLE TO A DRIVER, MAKE SURE THE DRIVER IS FAMILIAR
WITH ALL CONTROLS AND OPERATING INSTRUCTIONS 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 THE FACTORY SPECIFICATIONS. PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH COULD RESULT.
• DO NOT SHIFT FORWARD/REVERSE LEVER WHILE THE VEHICLE IS IN MOTION. ALWAYS
BRING THE VEHICLE TO A FULL STOP BEFORE SHIFTING LEVER TO AVOID INJURY
TO AN UNSUSPECTING PASSENGER OR DAMAGE TO THE VEHICLE. BUZZER(S) WILL
SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE.
• DEPRESS THE BRAKE PEDAL FIRMLY UNTIL STOPPED. SET THE PARK BRAKE, TURN
KEY SWITCH “OFF” AND REMOVE THE KEY WHEN LEAVING THE VEHICLE TO AVOID
UNINTENTIONAL STARTING OR ROLLING OF THE VEHICLE.
16
FORWARD/REVERSE CONTROL
The forward/reverse shift lever is located below and to the right of the driver’s right knee on the seat
NOTE
• KEY IS REMOVABLE IN THE “OFF” POSITION ONLY.
Figure 4
Figure 5
support panel (See Figure 5). The lever has three distinct positions: F (forward), N (neutral), and R
(reverse). Rotate the lever towards the driver, to F (forward), to run the vehicle in the forward direction, or towards the passenger, to 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 in the Carryall-l and Carryallll gasoline vehicles will stop if shifted to this position while it is running. The electric vehicle operates
at reduced speed in reverse.
ACCELERATOR PEDAL
NOTE
• THE REVERSE BUZZER(S) WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN
REVERSE.
The accelerator pedal is the pedal on the right with the word GO molded into it (See Figure 6, Page
18).
Accelerator, Continued:
NOTE
• THE OPERATION OF THE ACCELERATOR PEDAL DIFFERS FROM THAT OF AN AUTOMOBILE. WHEN THE KEY SWITCH IS “ON”, AND THE SHIFT LEVER IS IN EITHER FORWARD OR REVERSE, DEPRESSING THE ACCELERATOR PEDAL WILL AUTOMATICALLY
RELEASE THE PARK BRAKE AND START THE VEHICLE MOVING IN THE DIRECTION
SELECTED (FORWARD OR REVERSE). AS THE ACCELERATOR PEDAL 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 RUNNING.
17
BRAKE PEDAL
Figure 6
Figure 7
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.
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
7). 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 8).
Figure 8
WARNING
• THE PARK BRAKE WILL RELEASE AUTOMATICALLY WHEN EITHER THE ACCELERATOR OR BRAKE PEDAL IS DEPRESSED. THE PARK BRAKE HAS MULTIPLE LOCKING
POSITIONS AND SHOULD BE FIRMLY PRESSED TO PREVENT THE VEHICLE FROM
ROLLING.
CARRYALL GASOLINE VEHICLES ONLY:
NEUTRAL LOCK-OUT
This 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
when the accelerator pedal is depressed.
For the convenience of the trained mechanic, there is a neutral lock-out cam (yellow knob) located on
the back of the forward/reverse lever inside engine compartment. 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 9). This will allow the mechanic to run the
engine in NEUTRAL for certain maintenance procedures. 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 (3/8 inch) and
rotate it one-half turn until it snaps into place (See Figure 10).
18
Figure 9
Figure 10
NOTE
• BE SURE TO RETURN THE CAM TO THE OPERATE POSITION AFTER SERVICING THE
VEHICLE, OR IT WILL NOT RUN WITH THE FORWARD AND REVERSE LEVER IN EITHER
THE FORWARD OR REVERSE POSITION.
WARNING
• WITH THE CAM IN THE SERVICE POSITION AND THE ENGINE RUNNING, THE VEHICLE
MAY MOVE SUDDENLY IF THE FORWARD/REVERSE LEVER IS SHIFTED OR ACCIDENTALLY 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 Figure 11). If the vehicle is hard to start in cool or cold temperatures, simply push in the choke button with
your left hand to activate it. Hold it during start up and release the choke button after the engine starts
and runs smoothly.
Figure 11
Figure 12
OIL LIGHT
The vehicle is equipped with a low oil warning light, located on the dash panel just above the steering
column (See Figure 12). If the oil warning light comes on, oil level should be checked and oil added,
if necessary, to the engine 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
19
Oil Light, Continued:
should be added at the first opportunity. If the oil level is correct and the light stays on, have a trained
mechanic check the vehicle.
WARNING
• FAILURE TO ADD OIL IMMEDIATELY WHEN LIGHT STAYS ON MAY RESULT IN PERMANENT
ENGINE DAMAGE.
ELECTRIC VEHICLES ONLY:
BATTERY WARNING LIGHT
PowerDrive System 48 vehicles, including all electric Carryall models, feature 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.
When the vehicle is in operation, the warning light will come on and remain illuminated if:
• Batteries voltage drops below 48 when there is no load on the batteries (the vehicle is stopped and
there are no accessories on).
• Batteries have discharged to less than 25% of rated capacity.
If the warning light comes on when the vehicle is operating, there should enough power remaining to
drive the vehicle for approximately 30 minutes. However, the vehicle should be charged at the first
opportunity. If the warning light comes on and the vehicle is unable to operate for 1/2 hour, have your
Club Car distributor/dealer check the vehicle for a possible battery or electrical system problem.
When the batteries receive an incomplete charge because 1) the DC power cord is disconnected, 2)
AC power to the charger is interrupted, 3) automatic charger shut-off occurs after 16 hours of operation, or 4) the charger malfunctions, 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 complete the charge during the next charge cycle.
• When the charger is unplugged, the warning light will come on and remain illuminated for 10 seconds if the charge is less than 90% complete but the vehicle has enough power for approximately
thirty minutes of operation. This will alert the operator that the vehicle may be used, but that it must
be charged to completion as soon as possible.
• The warning 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.
• 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 - CARRYALL-I ELECTRIC, CARRYALL-II
ELECTRIC, CARRYALL-VI ELECTRIC, CARRYALL-I GASOLINE
AND CARRYALL-II GASOLINE VEHICLES
No one should drive the vehicle without first being instructed in the proper operation and use of the vehicle’s controls. An experienced operator should accompany each first-time driver on a test drive
before allowing him (her) to operate the vehicle alone. Only licensed drivers should be allowed to drive
this vehicle.
20
To ensure safe operation of the vehicle, follow exactly, and in order, all of the procedures listed below.
Read and understand all instructions prior to driving the vehicle.
WARNING
• BEFORE ASSIGNING THE VEHICLE TO A DRIVER, MAKE SURE THE DRIVER IS FAMILIAR
WITH ALL CONTROLS AND OPERATING PROCEDURES BEFORE ALLOWING THE VEHICLE
TO BE DRIVEN.
• THE VEHICLE IS NOT SPECIALLY EQUIPPED FOR HANDICAPPED PERSONS. BE SURE ALL
PERSONS CAN PROPERLY OPERATE VEHICLE PRIOR TO ALLOWING THEM TO DRIVE
VEHICLE.
• DO NOT ALLOW PASSENGERS IN THE CARGO BED. NO MORE THAN TWO PEOPLE
SHOULD BE ON THE VEHICLE AT ONE TIME.
• 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(S) 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 ON TO SEAT HANDLES OR
HANDRAILS AT ALL TIMES TO PREVENT FALLS.
• KEEP ALL BODY PARTS INSIDE THE VEHICLE TO PREVENT THEM FROM GETTING
CAUGHT BETWEEN THE VEHICLE AND THE GROUND OR OTHER OBJECTS.
• WHEN LOADED, DRIVE SLOWLY IN TURNS AND DRIVE STRAIGHT UP OR DOWN SLOPES
TO PREVENT OVERTURNING OF THE VEHICLE.
• AVOID STOPPING ON HILLS WHEN LOADED. WHEN STOPPED ON A HILL, AVOID SUDDEN
STARTS OR ROLLING BACKWARDS AND STOPPING SUDDENLY. THIS CAN CAUSE THE
VEHICLE TO OVERTURN OR FLIP OVER BACKWARDS.
• VEHICLE SHOULD NOT BE DRIVEN ON SLOPES EXCEEDING 20% OF GRADE.
• AVOID SUDDEN STARTS, STOPS, AND TIGHT TURNS TO AVOID INJURY TO AN UNSUSPECTING PASSENGER AND DAMAGE TO THE VEHICLE.
• TO AVOID THE POSSIBILITY OF LOSING CONTROL OR OVERTURNING OF THE VEHICLE,
REDUCE SPEED FOR DRIVING CONDITIONS SUCH AS WET GRASS OR ROUGH TERRAIN.
• DO NOT USE ON PUBLIC ROADS. THIS VEHICLE IS NOT DESIGNED OR INTENDED FOR
STREET USE AND SHOULD NOT BE LICENSED FOR USE ON PUBLIC ROADS.
• VEHICLES SHOULD ONLY BE DRIVEN IN SPECIFIED AREAS BY TRAINED DRIVERS.
• TO AVOID BEING STRUCK, DO NOT STAND IN FRONT OF OR BEHIND VEHICLE.
• DO NOT DRIVE WHILE UNDER THE INFLUENCE OF ALCOHOL, DRUGS, OR MEDICATIONS.
• OPERATOR MUST CONTROL SPEED WHEN GOING DOWNHILL.
• GASOLINE VEHICLE ONLY: DEPRESS THE BRAKE PEDAL AS NECESSARY AND DEPRESS
THE ACCELERATOR PEDAL PARTIALLY WHEN DESCENDING A HILL. PARTIALLY
DEPRESSING THE ACCELERATOR WILL CAUSE THE ENGINE GOVERNOR TO CONTROL
DOWNHILL SPEED.
21
Driving Instructions, Continued:
STARTING THE VEHICLE
1. Be sure load, if any, is secure.
2. Enter the vehicle.
3. Study and understand controls.
4. Be sure everyone is seated and holding onto seat handles or handrails. The driver should have
both hands on the steering wheel.
5. Read safety warnings located above pedals.
6. Make sure wheels are turned in the desired direction.
7. Turn the key to the ON position and be sure nothing is in your path.
8. Select direction by placing shift lever in desired position (F = forward or R = reverse).
9. Slowly depress accelerator pedal. The park brake will release automatically and the vehicle will
start to move. As the accelerator pedal is depressed, speed will increase until full speed is reached.
WARNING
• OPERATOR MUST CONTROL SPEED WHEN GOING DOWNHILL.
• GASOLINE VEHICLE ONLY: DEPRESS THE BRAKE PEDAL AS NECESSARY AND PARTIALLY DEPRESS THE ACCELERATOR PEDAL TO CONTROL SPEED WHEN DESCENDING
A HILL. PARTIALLY DEPRESSING THE ACCELERATOR WILL CAUSE THE ENGINE GOVERNOR TO CONTROL DOWNHILL SPEED.
STOPPING THE VEHICLE
To stop the vehicle, release the accelerator pedal fully and depress the brake pedal with your right foot
until the vehicle comes to a complete stop.
WARNING
• DRIVING THROUGH WATER MAY AFFECT THE BRAKES. CHECK THEIR EFFECTIVENESS 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
• WHEN STOPPED ON A HILL, USE THE BRAKE PEDAL TO HOLD YOUR POSITION. DO NOT
USE THE ACCELERATOR PEDAL.
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. Place shift lever in the NEUTRAL position and turn key switch to OFF. This prevents unintentional
starting of the vehicle. Remove the key when the vehicle is not is use.
22
CONTROLS - CARRYALL-II PLUS AND CARRYALL-VI GASOLINE
VEHICLES
DANGER
• DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER
VENTILATION. GASOLINE ENGINES PRODUCE CARBON MONOXIDE GAS, WHICH IS
AN ODORLESS, DEADLY POISON.
WARNING
• BEFORE ASSIGNING THE VEHICLE TO A DRIVER, MAKE SURE THE DRIVER IS FAMILIAR
WITH ALL CONTROLS AND OPERATING INSTRUCTIONS 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 THE FACTORY SPECIFICATIONS. PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH COULD RESULT.
• DO NOT SHIFT FORWARD/REVERSE LEVER WHILE THE VEHICLE IS IN MOTION. ALWAYS
BRING THE VEHICLE TO A FULL STOP BEFORE SHIFTING LEVER TO AVOID POSSIBLE
INJURY TO AN UNSUSPECTING PASSENGER, AND (OR) DAMAGE TO THE VEHICLE.
BUZZER(S) WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE.
• DEPRESS THE BRAKE PEDAL FIRMLY UNTIL STOPPED. SET THE PARK BRAKE, TURN KEY
SWITCH “OFF”, AND REMOVE THE KEY WHEN LEAVING THE VEHICLE. THIS WILL PREVENT 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 13, Page 24).
It has three positions, OFF, ON, and START, which are clearly labeled.
NOTE
• KEY IS REMOVABLE IN THE “OFF” POSITION ONLY.
To start the vehicle, turn the key past the ON position to the START position and hold until the engine
is running smoothly. Release the key and it will return to the ON position.
FORWARD/REVERSE CONTROL
The forward/reverse shift lever is located below and to the right of the driver’s right knee on the seat
support panel (See Figure 14, Page 24). The lever has three (3) distinct positions: F (forward), N (neutral), and R (reverse). Rotate the lever towards the driver, F (forward), to run the vehicle in the forward
direction, or towards the passenger, R (reverse), to run the vehicle in reverse. When the lever is in the
straight up, or N (neutral) position, the vehicle will idle.
23
Forward and Reverse Control, Continued:
Figure 13
Figure 14
ACCELERATOR PEDAL
NOTE
The accelerator pedal is the pedal on the right with the word GO molded into it (See Figure 15).
• THE ENGINE WILL STOP RUNNING IF THE ACCELERATOR IS DEPRESSED WHILE THE
BRAKE
PEDAL
FORWARD/REVERSE
LEVER IS IN THE NEUTRAL POSITION.
The
brakeREVERSE
pedal is theBUZZER(S)
large pedal WILL
on the SOUND
left with the
STOP molded
intoTHE
it (See
Figure 15).
• THE
AS word
A WARNING
WHEN
VEHICLE
IS INTo
slowREVERSE.
or stop the vehicle, depress the brake pedal with your right foot.
PARK BRAKE PEDAL
The park brake pedal is the small raised portion in the upper left corner of the brake pedal with the word
PARK molded into it (See Figure 16). The words PARK BRAKE are marked on top of the pedal.
NOTE
• THE OPERATION OF THE ACCELERATOR PEDAL DIFFERS FROM THAT OF AN AUTOMOBILE.
• WHEN THE ENGINE IS RUNNING, AND THE SHIFT LEVER IS IN EITHER FORWARD OR
REVERSE, DEPRESSING THE ACCELERATOR PEDAL WILL AUTOMATICALLY RELEASE
THE PARK BRAKE AND START THE VEHICLE MOVING IN THE SELECTED DIRECTION
(FORWARD OR REVERSE). AS THE ACCELERATOR PEDAL IS DEPRESSED, SPEED WILL
INCREASE UNTIL FULL SPEED IS REACHED. WHEN THE ACCELERATOR PEDAL IS
RELEASED, IT WILL RETURN TO THE ORIGINAL POSITION AND THE ENGINE WILL DROP
BACK TO IDLE.
Figure 15
24
Figure 16
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 17).
NEUTRAL LOCK-OUT
For the convenience of the trained mechanic,
there is a neutral lock-out cam (yellow knob)
located on the back of the forward/reverse lever
inside engine compartment. 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 SERFigure 17
VICE position (See Figure 18, Page 26). This will
allow the mechanic to run the engine for certain maintenance procedures. With the cam in this position, the vehicle will not operate if the forward/reverse lever is placed in the forward or reverse posi-
WARNING
• THE PARK BRAKE WILL AUTOMATICALLY RELEASE WHEN EITHER THE ACCELERATOR OR BRAKE PEDAL IS DEPRESSED. THE PARK BRAKE HAS MULTIPLE LOCKING
POSITIONS AND SHOULD BE FIRMLY PRESSED TO PREVENT THE VEHICLE FROM
ROLLING.
tion. To put the vehicle back into the OPERATE position, pull the cam out approximately 10 millimeters (3/8 inch) and rotate it one-half turn until it snaps into place (See Figure 19, Page 26).
CHOKE
The choke is located on the seat support panel and to the left of the driver’s left knee (See Figure 20,
Page 26). If the vehicle is hard to start in cool or cold temperatures, simply push in the choke button
Choke, Continued:
with your left hand to activate it. Hold it during start up and release the choke button after the engine
NOTE
• BE SURE TO RETURN CAM TO THE OPERATE POSITION AFTER SERVICING THE VEHICLE, OR IT WILL NOT RUN WITH THE FORWARD/REVERSE LEVER IN THE FORWARD OR
THE REVERSE POSITION.
WARNING
• WITH THE CAM IN THE SERVICE POSITION AND THE ENGINE RUNNING, THE VEHICLE
MAY MOVE SUDDENLY IF THE FORWARD/REVERSE LEVER IS SHIFTED OR ACCIDENTALLY BUMPED. TO PREVENT THIS, BLOCK THE FRONT AND REAR TIRES AND ALWAYS
FIRMLY SET THE PARK BRAKE BEFORE SERVICING OR LEAVING THE VEHICLE.
starts and runs smoothly.
OIL LIGHT
25
The vehicle is equipped with a low oil warning light, located on the dash panel just above the steering
column (See Figure 21). If the oil warning light comes on, oil level should be checked and oil added,
if necessary, to the engine before continuing to use the vehicle. The vehicle should never be driven with
Figure 18
Figure 19
the oil warning light remaining on. If the oil warning light goes on and off, you many 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 the vehicle.
DRIVING INSTRUCTIONS - CARRYALL-II PLUS AND CARRYALL-VI
GASOLINE VEHICLES
WARNING
• FAILURE TO ADD OIL IMMEDIATELY WHEN LIGHT STAYS ON MAY RESULT IN PERMANENT
ENGINE DAMAGE.
Figure 20
Figure 21
No one should drive the vehicle without first being instructed in the proper operation and use of the vehicle’s controls. An experienced operator should accompany each first-time driver on a test drive
before he or she is allowed to operate the vehicle alone. Only licensed drivers should be allowed to
drive the vehicle.
To ensure safe operation of the vehicle, follow all of the procedures listed below exactly and in
order. Read and understand all instructions prior to driving the vehicle.
26
Driving Instructions, Continued:
STARTING THE VEHICLE
1. Be sure load, if any, is secure.
WARNING
• BEFORE ASSIGNING THE VEHICLE TO A DRIVER, MAKE SURE THE DRIVER IS FAMILIAR
WITH ALL CONTROLS AND OPERATING PROCEDURES BEFORE ALLOWING THE VEHICLE
TO BE DRIVEN.
• THE VEHICLE IS NOT SPECIALLY EQUIPPED FOR HANDICAPPED PERSONS. BE SURE ALL
PERSONS CAN PROPERLY OPERATE VEHICLE PRIOR TO ALLOWING THEM TO DRIVE
VEHICLE.
• DO NOT ALLOW PASSENGERS IN THE CARGO BED. NO MORE THAN TWO PEOPLE
SHOULD BE ON THE VEHICLE AT ONE TIME.
• 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(S) WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE.
WHEN DRIVING THE VEHICLE:
• OPERATE THE VEHICLE FROM THE DRIVER’S SIDE ONLY.
• REMAIN SEATED IN A MOVING VEHICLE AND HOLD ON TO SEAT HANDLES OR
HANDRAILS AT ALL TIMES TO PREVENT FALLS.
• KEEP ALL BODY PARTS INSIDE THE VEHICLE TO PREVENT THEM FROM GETTING
CAUGHT BETWEEN THE VEHICLE AND THE GROUND OR OTHER OBJECTS.
• WHEN LOADED, DRIVE SLOWLY IN TURNS AND DRIVE STRAIGHT UP OR DOWN SLOPES
TO PREVENT OVERTURNING OF THE VEHICLE.
• DO NOT DRIVE VEHICLE ON SLOPES EXCEEDING 20% OF GRADE.
• OPERATOR MUST CONTROL SPEED WHEN GOING DOWNHILL. DEPRESS THE BRAKE
PEDAL AS NECESSARY AND DEPRESS THE ACCELERATOR PARTIALLY WHEN DESCENDING A HILL. PARTIALLY DEPRESSING THE ACCELERATOR WILL CAUSE THE ENGINE
GOVERNOR TO CONTROL DOWNHILL SPEED.
• AVOID STOPPING ON HILLS WHEN LOADED. WHEN STOPPED ON A HILL, AVOID SUDDEN
STARTS OR ROLLING BACKWARDS AND STOPPING SUDDENLY. THIS CAN CAUSE THE
VEHICLE TO OVERTURN OR FLIP OVER BACKWARDS.
• AVOID SUDDEN STARTS, STOPS AND TIGHT TURNS TO AVOID INJURY TO AN UNSUSPECTING PASSENGER AND DAMAGE TO THE VEHICLE.
• TO AVOID THE POSSIBILITY OF LOSING CONTROL OR OVERTURNING OF THE VEHICLE,
REDUCE SPEED FOR DRIVING CONDITIONS SUCH AS WET GRASS OR ROUGH TERRAIN.
• DO NOT USE ON PUBLIC ROADS. THIS VEHICLE IS NOT DESIGNED OR INTENDED FOR
STREET USE AND SHOULD NOT BE LICENSED FOR USE ON PUBLIC ROADS.
• VEHICLES SHOULD ONLY BE DRIVEN IN SPECIFIED AREAS BY TRAINED DRIVERS.
• TO AVOID BEING STRUCK, DO NOT STAND IN FRONT OF OR BEHIND VEHICLE.
• DO NOT DRIVE WHILE UNDER THE INFLUENCE OF ALCOHOL, DRUGS, OR MEDICATIONS.
27
2. Enter vehicle.
3. Study and understand controls.
4. Be sure everyone is seated and holding onto seat handles or handrails. The driver should have
both hands on the steering wheel.
5. Read safety warnings located above pedals.
6. Place shifter in neutral position.
7. Make sure wheels are turned in desired direction.
8. Be sure nothing is in your path.
9. Depress and hold brake pedal.
10. Turn key all the way to the START position and release after engine is started. Engine will idle.
11. While keeping brake engaged, select direction of travel by placing shifter lever in desired position
(F = forward or R = reverse).
12. Release brake completely, and then slowly depress the accelerator pedal. As the accelerator is
depressed, speed will increase until full speed is reached.
STOPPING THE VEHICLE
To stop the vehicle, release the accelerator pedal and then depress the brake pedal with your right foot
until the vehicle comes to a complete stop.
NOTE
• IF THE ACCELERATOR PEDAL IS DEPRESSED WHILE SHIFTER IS IN NEUTRAL, OR IF YOU
TRY TO SHIFT FROM FORWARD TO REVERSE WHILE THE ACCELERATOR PEDAL IS
DEPRESSED, THE ENGINE WILL SHUT OFF. TO KEEP THE ENGINE RUNNING, THE
ACCELERATOR PEDAL MUST BE RELEASED COMPLETELY BEFORE SHIFTING THE
VEHICLE TO NEUTRAL OR FROM FORWARD TO REVERSE.
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.
WARNING
• DRIVING THROUGH WATER MAY AFFECT THE BRAKES. CHECK THEIR EFFECTIVENESS 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
• WHEN STOPPED ON A HILL, USE THE BRAKE PEDAL TO HOLD YOUR POSITION. DO NOT
USE THE ACCELERATOR PEDAL.
2. Place shift lever in the straight up NEUTRAL position, turn key to OFF. Engine will shut off.
Remove key when the vehicle is not in use.
LOADING AND UNLOADING
Center cargo in the cargo bed as far forward as possible and secure.
28
WARNING
• FIRMLY ENGAGE THE PARK BRAKE PRIOR TO LOADING.
• DO NOT ALLOW PEOPLE IN THE CARGO BED.
• DO NOT EXCEED THE VEHICLE’S RATED CAPACITY: 800 LBS (363 KG) FOR THE CARRYALL-I, 1200 LBS (544 KG) FOR THE CARRYALL-II AND CARRYALL-II PLUS, AND 1500 LBS
(680 KG) FOR THE CARRYALL-VI. THIS INCLUDES ALL PASSENGERS, THE LOAD IN THE
CARGO BED, AND THE GROSS WEIGHT AND TONGUE WEIGHT OF A TRAILER: MAXIMUM
300 LBS (136 KG) FOR THE CARRYALL-I, 800 LBS (363 KG) FOR THE CARRYALL-II AND
CARRYALL-II PLUS, AND 1000 LBS (454 KG) FOR THE CARRYALL-VI. TONGUE WEIGHT OF
ANY TRAILER SHOULD NOT EXCEED 150 LBS (68 KG). OVERLOADING CAN CAUSE
LOSS OF VEHICLE CONTROL AND SEVERE PERSONAL INJURY BY CAUSING A VEHICLE
COMPONENT TO FAIL OR BY AFFECTING THE VEHICLE’S HANDLING.
• VEHICLE LOAD AND SPEED MUST BE REDUCED WHEN DRIVING UP OR DOWN SLOPES
OR ON UNEVEN TERRAIN. RATED CAPACITY IS FOR LEVEL SURFACES ONLY.
• REDUCE SPEED AND AVOID SUDDEN STOPS WHEN BACKING UP. FAILURE TO DO SO
MAY CAUSE THE VEHICLE TO OVERTURN OR FLIP OVER BACKWARDS.
• DO NOT LOAD TAILGATE. TAILGATE SHOULD BE IN UPRIGHT POSITION AND LATCHED
SECURELY WHILE VEHICLE IS IN MOTION.
• MAKE STARTS, STOPS AND TURNS IN A SMOOTH MANNER TO AVOID SHIFTING THE
VEHICLE’S LOAD OR OVERTURNING THE VEHICLE. THE CARGO’S CENTER OF GRAVITY
MAY AFFECT THE HANDLING, STEERING AND BRAKING OF THE VEHICLE.
• SECURE LOOSE CARGO TO KEEP IT FROM SHIFTING, WHICH COULD AFFECT THE
VEHICLE’S HANDLING AND (OR) INJURE THE DRIVER OR PASSENGER.
• AVOID TOP HEAVY LOADS. THE CENTER OF GRAVITY OF A LOAD SHOULD NEVER
EXCEED 15 INCHES (38 CENTIMETERS) ABOVE THE CARGO BED BOTTOM.
TOWING
Towing, Continued:
WARNING
• NEVER OPERATE THE VEHICLE ON PUBLIC STREETS OR HIGHWAYS.
• EXTREME CAUTION SHOULD BE USED WHEN TOWING A TRAILER.
• TOTAL VEHICLE CAPACITY, INCLUDING TOW VEHICLE LOAD AND GROSS TRAILER
WEIGHT, MUST NOT EXCEED 800 LBS (363 KG) FOR THE CARRYALL-I, 1200 LBS (544 KG)
FOR THE CARRYALL-II AND CARRYALL-II PLUS, AND 1500 LBS (680 KG) FOR THE CARRYALL-VI.
• DO NOT EXCEED TONGUE WEIGHT OF 150 LBS (68 KG) FOR ANY CARRYALL VEHICLE.
• DO NOT ALLOW PEOPLE IN THE VEHICLES OR IN THE TRAILER BEING TOWED.
29
When towing a trailer with the vehicle, extra caution should be observed due to the trailer’s adverse
WARNING
CONTINUED:
• AVOID STOPPING ON HILLS WHEN LOADED. WHEN STOPPED ON A HILL, AVOID SUDDEN
STARTS OR ROLLING BACKWARDS AND STOPPING SUDDENLY. THIS CAN CAUSE THE
VEHICLE TO OVERTURN OR FLIP OVER BACKWARDS.
• AVOID SUDDEN STARTS, STOPS, AND TIGHT TURNS WHEN TOWING.
• SLOWER SPEEDS SHOULD BE OBSERVED WHEN TOWING A TRAILER.
effects on the handling of the vehicle. Total vehicle capacity, including tow vehicle load and gross trailer weight should not exceed weight specified in WARNING on Page 29. The tongue weight should not
exceed 150 Ibs (68 kg). Parking the vehicle with a trailer on a hill should be avoided. If you must park
on a hill, apply the brakes and have someone block the tires of the trailer. Brakes should be released
to allow the blocks to absorb the load of the trailer. After the tires have been blocked, engage the park
brake.
TRANSPORTING ON A TRAILER
If your vehicle must be transported over long distances or on public highways, it should be done on an
approved trailer. Observe all the following warnings:
STORAGE - GASOLINE VEHICLE
WARNING
• FOR USE ON PUBLIC ROADS, THE TRAILER MUST MEET ALL FEDERAL, STATE, AND
LOCAL REQUIREMENTS SUCH AS TAILLIGHTS, BRAKE LIGHTS, ETC.
• ALWAYS USE AN APPROVED TRAILER THAT HAS A LOAD RATING OF 1200 LBS (544 KG)
PER VEHICLE (EXAMPLE: A 2-VEHICLE TRAILER SHOULD BE RATED AT 2 X 1200 = 2400
LBS (2 X 544 = 1088 KG).
• 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 COMPLETELY
DEPRESSED AND LOCKED.
• WHEN TOWING A TRAILER, SPEED SHOULD BE REDUCED. DUE TO THE ADDED LENGTH
OF THE TRAILER, CARE SHOULD BE USED WHEN TURNING A CORNER.
• NEVER TRANSPORT THE VEHICLE ON A TRAILER WITH A LOAD IN THE VEHICLE’S
CARGO BED.
• REMOVE THE VEHICLE’S WINDSHIELD BEFORE TRANSPORTING A VEHICLE ON A TRAILER.
30
To prepare your vehicle for extended storage:
1. Completely unload the vehicle so that only minimum vehicle weight will be placed on the tires.
2. Store vehicle in a cool 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 at 10
amps or less before storage.
3. Drain carburetor and seal the fuel tank.
DANGER
• GASOLINE - FLAMMABLE - EXPLOSIVE - DO NOT SMOKE. KEEP SPARKS AND FLAMES
AWAY FROM THE AREA OF THE VEHICLE.
• NEVER ATTEMPT TO DRAIN OR POUR GASOLINE WHEN THE ENGINE IS HOT OR WHILE
RUNNING. BE SURE TO CLEAN UP ANY SPILLED GASOLINE BEFORE OPERATING THE
VEHICLE.
• STORE GASOLINE IN AN APPROVED GASOLINE CONTAINER ONLY. STORE IN A WELLVENTILATED AREA AWAY FROM SPARKS, OPEN FLAMES, HEATERS, OR HEAT SOURCES.
• SERVICE OR REPAIR ONLY IN A WELL-VENTILATED AREA.
• DO NOT SERVICE, REPAIR, OR OPERATE IN AN ENCLOSED AREA WITHOUT PROPER
VENTILATION. ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS,
DEADLY POISON.
• KEEP GASOLINE OUT OF THE REACH OF CHILDREN.
• DO NOT SIPHON GASOLINE FROM THE VEHICLE.
WARNING
• 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.
• DO NOT ATTEMPT TO CHARGE A BATTERY IF IT IS FROZEN OR IF THE CASE IS BULGED.
DISCARD BATTERY. FROZEN BATTERIES CAN EXPLODE.
CAUTION
• BATTERIES IN A LOW STATE OF CHARGE WILL FREEZE AT LOW TEMPERATURES.
3.1. Disconnect fuel line from the inlet side of the fuel pump.
3.2. Place the Foward and Reverse Lever in the NEUTRAL position and the neutral lock-out cam
in the SERVICE position. 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.
3.3. 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.
Storage - Gasoline Vehicle, Continued:
31
3.4. Reconnect fuel line to fuel pump.
3.5. Disconnect fuel vent line from fuel tank vent nipple.
3.6. Plug the fuel tank vent nipple so that it is air tight. We recommend using a slip-on vinyl cap.
4. To protect the engine, remove the spark plug and pour 1/2 ounce of SAE 10 weight oil into the
engine through the spark plug hole. Rotate the engine’s crankshaft several times and then re-install
the spark plug.
5. Inflate tires to rated capacities (Tire Specifications, Page 39).
6. Grease front suspension and do all quarterly periodic lubrication (See Periodic Lubrication
Schedule, Page 37).
7. Thoroughly clean front body, cargo bed, seats, engine compartment, and underside of vehicle.
8. Do not latch 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 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 OPERATE position.
2. Readjust tire pressure (Tire Specifications, Page 39).
3. Perform the Pre-Operation Checklist before returning the vehicle to service (See page 15).
NOTE
• WHEN RUNNING THE ENGINE FOR THE FIRST TIME AFTER STORAGE, IT MAY SMOKE
EXCESSIVELY DUE TO THE OIL ADDED TO THE ENGINE.
STORAGE - ELECTRIC VEHICLE
WARNING
• 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.
• DO NOT ATTEMPT TO CHARGE FROZEN BATTERIES OR BATTERIES WITH BULGED
CASES. DISCARD BATTERIES. FROZEN BATTERIES CAN EXPLODE.
CAUTION
• BATTERIES IN A LOW STATE OF CHARGE WILL FREEZE AT LOW TEMPERATURES.
• WHEN WASHING VEHICLE, DO NOT DIRECT WATER STREAM AT THE CHARGER RECEPTACLE.
• IF BATTERY WIRE TERMINALS ARE DAMAGED OR CORRODED, REPLACE OR CLEAN
THEM AS NECESSARY.
32
1. Completely unload the vehicle so that only minimum vehicle weight will be placed on the tires.
2. Fully charge batteries (See Battery - Electric Vehicle, Page 42).
3. 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 BATTERY TERMINAL SPRAY, CLUB CAR PART NO. 1014305.
4. Store in a cool, dry place. This will prevent self discharge of the batteries.
5. Leave PowerDrive System 48 vehicles with PowerDrive chargers plugged in during storage. The
PowerDrive storage charge feature will automatically charge the batteries as needed (See Battery - Electric Vehicle, Page 42).
6. Inflate tires to rated capacities (Tire Specifications, Page 39).
7. Grease front suspension and do all quarterly periodic lubrication (See Periodic Lubrication
Schedule, Page 38).
8. Thoroughly clean front body, cargo bed, seats, battery compartment and underside of vehicle.
9. Do not latch park brake. Block tires to prevent the vehicle from rolling.
TO RETURN THE STORED VEHICLE TO SERVICE
1. Make sure batteries are fully charged (See Battery - Electric Vehicle, Page 42).
2. Readjust tire pressure (Tire Specifications, Page 39).
3. Perform the Pre-Operation Checklist (See Page 15).
MAINTENANCE
GENERAL INFORMATION
To ensure trouble-free vehicle performance, it is very important to follow an established preventive
maintenance program (regularly scheduled services), even though the vehicle is functional. Regular
and consistent vehicle maintenance can prevent 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 the semi-annual and
annual periodic service.
WARNING
• ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THE VEHICLE. ANYONE
DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD FOLLOW THE CORRECT PROCEDURES AND OBEY THE WARNINGS LISTED IN THIS MANUAL AS WELL AS THOSE IN THE
MAINTENANCE AND SERVICE MANUAL.
33
Maintenance General Information, Continued:
WARNING
CONTINUED:
• ALWAYS WEAR SAFETY GLASSES OR EYE PROTECTION WHEN SERVICING THE VEHICLE.
• DO NOT WEAR LOOSE CLOTHING OR JEWELRY, SUCH AS RINGS, WATCHES, CHAINS,
ETC., WHEN SERVICING THE VEHICLE.
• ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL
CONNECTIONS.
• TURN KEY SWITCH “OFF”, REMOVE 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 UNINTENTIONAL STARTING OF THE ENGINE WHEN SERVICING THE GASOLINE VEHICLE.
• DISCONNECT THE BATTERIES BEFORE SERVICING THE ELECTRIC VEHICLE (SEE FIGURES 22 AND 23).
• BE SURE ALL PERSONS ARE CLEAR OF THE REAR OF THE VEHICLE WHEN LIFTING THE
BED EQUIPPED WITH A TAILGATE RAMP.
• IF THE VEHICLE HAS A PORTABLE REFRESHMENT CENTER OPTION INSTALLED IN
THE BED, IT MUST BE REMOVED BEFORE UNLATCHING BED LATCH AND LIFTING BED.
• DO NOT REMOVE PROP ROD OR CLOSE BED UNTIL ALL PERSONS ARE CLEAR OF
BED AREA. LOWER BED GENTLY, KEEPING ALL BODY PARTS CLEAR. DO NOT DROP
BED. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SEVERE PERSONAL
INJURY.
• IF VEHICLE IS EQUIPPED WITH AN ELECTRIC POWERED OR HYDRAULIC LIFT BED,
REMOVE BED BEFORE SERVICING THE BED LIFT SYSTEM.
• HYDRAULIC SYSTEM IS UNDER PRESSURE, AND A FACE SHIELD SHOULD BE WORN
WHEN SERVICING. EXTREME CARE SHOULD BE EXERCISED WHEN SERVICING THE
HYDRAULIC SYSTEM.
• DO NOT WORK ON THE POWERTRAIN OR UNDER CARGO BED WHILE BED OR BOX IS
LOADED.
NOTE
• IF THE VEHICLE IS CONSTANTLY HAULING HEAVY LOADS OR HAULING A TRAILER,
THESE PREVENTIVE MAINTENANCE PROCEDURES SHOULD BE PERFORMED MORE
OFTEN THAN RECOMMENDED IN THE PERIODIC SERVICE SCHEDULE.
34
Figure 22
Figure 23
BED LATCH
The Carryall-l, Carryall-ll, and Carryall-ll Plus
are equipped with a bed latch on the driver’s
side of the vehicle as standard equipment (See
Figure 24). To lift bed, push latch handle toward
the rear of the vehicle and lift bed (See Figure
25).
To close bed, Iower bed gently (do not drop)
until bed latch engages.
Figure 24
WARNING
• KEEP HANDS AND FINGERS CLEAR OF PINCH POINTS BETWEEN THE BED AND THE
SEAT BACK SUPPORT.
NOTE
• THE CARRYALL-II GAS AND CARRYALL-II PLUS ARE EQUIPPED WITH AN AUTOMATICALLY ENGAGING PROP ROD, UNLESS EQUIPPED WITH HYDRAULIC BED LIFT OPTION
(SEE FIGURE 26). AN ELECTRIC BED LIFT IS STANDARD ON CARRYALL II ELECTRIC.
Figure 25
Figure 26
35
PERIODIC SERVICE SCHEDULE
36
PERIODIC LUBRICATION SCHEDULE - GASOLINE VEHICLE
Regular
Interval
ENGINE
OIL
Service
- GASOLINE
VEHICLES
Recommended Lubricant
Even though
the
lightshaft
on bearings
the dash should warn you ifDry
your
oilLube
is getting
low,
engine
oil
Quarterly
by Owner
or low oil warning
1. Brake
Moly
- Club Car
P/N
1012151
level
should
be
checked
monthly
(See
Figure
29).
Trained Personnel Only
2. Brake linkage and pivots
Dry Moly Lube - Club Car P/N 1012151
FUELING INSTRUCTIONS - GASOLINE VEHICLES
3. Accelerator push rod pivots
and shifter cable pivots
For all gasoline vehicles except Carryall-VI:
4. Front suspension (5 fittings)
Dry Moly Lube - Club Car P/N 1012151
Chassis Lube
1. Lift and remove seat bottom from vehicle.
2. The fuel tank is located on passenger side of vehicle. Remove fuel cap and fill the fuel tank with
Annually
by Trained
Check/fill drive unit to plug level
fresh
unleaded gasoline5.only.
Personnel Only
.67 liters (22 oz.) SAE 30 WT. API
Class SE, SF, or SG Oil or higher
3. Replace fuel cap on tank,
beingfront
surewheel
cap bearings
is tightened securely to tank. Chassis Lube
6. Inspect
(Repack as necessary)
4. Replace seat bottom.
For Carryall-VI:
7. Check/fill transmission to plug level
80-90 WT. API Class GL-3 or 80-90 WT.
AGMA Class
EP refueling.
Gear Lube
1. Unlatch access door in the cargo bed of the vehicle and open completely
before
2. The fuel tank is located on passenger side of vehicle. Remove fuel cap and fill the fuel tank with
First Change 100 Hours 8. Change engine oil and oil filter
.97 liters (32 oz.) without filter; 1.16 liter
fresh unleaded gasoline only.
Additional Change - Every 200
(38 oz.) with filter. 10W30 above 32°F
Hours
or
Operation
or
(0°C)
SAE 5W20 below 32°F (0°C) API
3. Replace fuel cap on tank, being sure cap is tightened securely to or
tank.
Annually Class SE, SF, SG Oil or higher
Whichever
Comes
First door and secure latches.
4. Close
access
BATTERY - GASOLINE VEHICLE
Figure 27
37
PERIODIC LUBRICATION SCHEDULE - ELECTRIC VEHICLE
Regular Interval
Service
Recommended Lubricant
Battery - Gasoline Vehicle, Continued:
The battery in the vehicle is a 12 volt, low maintenance battery that requires infrequent watering (See
Quarterly by Owner or
Figure 31).
Trained Personnel Only
1. Brake shaft bearings
Dry Moly Lube - Club Car P/N
1012151
Any corrosion around the positive (+) or negative (–) terminals should be washed off with a solution of
Dry
MolyLet
Lube
- Club
Car P/Ndry
2. Brake linkage
pivots Be sure terminals are
baking soda and water. Rinse solution
off theand
battery.
tight.
the
terminals
1012151
and then spray them with CLUB CAR battery protector, Part No.1014305.
Dry Moly
Lube(1.6/1.8
- Club Car
P/N A
Accelerator
pivots
Be sure the battery hold-down3.bracket
is properly
tightened. Torque to 14-16
in.lbs.
N-m).
1012151
loose hold-down bracket may allow the battery to become damaged from vibration or jarring. A holddown bracket that is too tight may
buckle or crack the battery case.
WD-40
4. Forward and reverse switch contacts
charger receptacle
BATTERY - ELECTRICand
VEHICLE
5. Front suspension (5 fittings)
Chassis Lube
The batteries in the PowerDrive System 48 Electric Vehicle are 8 volts each.
These batteries are deep cycle batteries, specially built for an electric vehicle application. Automotive
batteries should never be used. New batteries will not deliver their full range until they have been run
and recharged
To obtain
restrict
Annually
by Trainedfrom 20 to 50 times.
6. Check/fill
drive the
unit maximum
to plug levelservice life from
.67new
liters batteries,
(22 oz.) SAE
30 WT.vehiAPI
cle withOnly
new batteries to one hour of use between charges in the first two
months
oforoperation.
Personnel
Class
SE, SF,
SG Oil or higher
BATTERY CARE
7. Inspect front wheel bearings
Chassis Lube
(Repack
as necessary)
To keep batteries in good working
condition,
follow this maintenance program on a 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
Figure 28
38
LIQUID CAPACITIES
GASOLINE
ELECTRIC
Engine Crankcase
without Filter
.98 liters (32 oz.)
Engine Crankcase
with Filter
1.16 liters (38 oz.)
Transmission
.61 liters (20 oz.)
Drive Unit
.67 liters (22 oz.)
Gasoline Tank
26.5 liters (7 U.S. gallons)
.67 liters (22 oz.)
TIRE SPECIFICATIONS
Gasoline
Electric
Gasoline
(Heavy Load)
Electric
(Heavy Load)
Carryall-I
12-14 psi
18-20 psi
16-18 psi
20-22 psi
Carryall-II
30-34psi
30-34psi
40-45 psi
45-50 psi
Carryall-II Plus
30-34 psi
N/A
40-45 psi
45-50 psi
Carryall-VI
30-34 psi
30-34 psi
45-50 psi
45-50 psi
39
to enter the batteries.) Be sure terminals are tight. Let the terminals dry and then spray them with
CLUB CAR battery protector, Part No. 1014305.
2. The water level in the batteries should be checked weekly (See Figure 32 for proper level). Add
water only after charging unless the water level is below the top of the plates. In this case, add just
NOTE
• ENGINE MUST BE IN LEVEL POSITION. REMOVE OIL LEVEL DIPSTICK BY PULLING
FROM OIL FILLER TUBE AND WIPE OIL FROM IT WITH A CLEAN CLOTH OR PAPER
TOWEL. CHECK OIL BY INSERTING THE DIPSTICK FULLY INTO THE 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 WITH OIL. OVERFILLING WILL CAUSE ENGINE AND (OR) FUEL PROBLEMS.
REINSERT DIPSTICK INTO OIL FILLER TUBE.
Figure 29
Figure 30
DANGER
• GASOLINE - FLAMMABLE - EXPLOSIVE - DO NOT SMOKE. KEEP SPARKS AND FLAMES
AWAY FROM THE AREA OF THE VEHICLE.
• SERVICE OR REPAIR IN A WELL-VENTILATED AREA ONLY.
• NEVER POUR GASOLINE INTO GAS TANK WHILE ENGINE IS HOT OR RUNNING.
• TO AVOID ELECTRIC ARC CAUSED BY STATIC ELECTRICITY, THE FUEL
STORAGE/PUMPING DEVICE MUST BE GROUNDED. IF THE PUMP IS NOT GROUNDED,
THE VEHICLE MUST BE GROUNDED TO THE PUMP BEFORE AND DURING THE FUELING
OPERATION.
• IF THE VEHICLE HAS A CUSTOM CAB ASSEMBLY OR AN ALL-WEATHER ENCLOSURE
INSTALLED, THE GAS TANK MUST BE PROPERLY VENTED (AS SHOWN IN FIGURE 30).
BE SURE TO CLEAN UP ANY SPILLED GASOLINE BEFORE OPERATING THE VEHICLE.
CAUTION
• TO ALLOW FOR EXPANSION, DO NOT FILL HIGHER THAN ONE INCH FROM TOP OF
TANK.
40
enough water to cover the plates, charge and then check the level again. For maximum battery
life, add only distilled water to the batteries.
3. The hold-down brackets or 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
NOTE
• GASOLINE QUALITY AND CHEMICAL ADDITIVES CAN AFFECT VEHICLE PERFORMANCE.
WE DO NOT RECOMMEND GASOLINES BLENDED WITH ALCOHOL. AVOID THE USE OF
THESE FUELS WHENEVER POSSIBLE. VEHICLES THAT WILL BE STORED FOR EXTENDED PERIODS SHOULD BE PREPARED FOR STORAGE AS OUTLINED IN THIS OWNER’S
MANUAL.
tight, and any worn insulation or frayed wires should be replaced. Torque battery terminals to 90100 in.lbs. (10.2/11.3 N-m).
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
NOTE
• GASOLINE QUALITY AND CHEMICAL ADDITIVES CAN AFFECT VEHICLE PERFORMANCE.
WE DO NOT RECOMMEND GASOLINES BLENDED WITH ALCOHOL. AVOID THE USE OF
THESE FUELS WHENEVER POSSIBLE. VEHICLES THAT WILL BE STORED FOR EXTENDED PERIODS SHOULD BE PREPARED FOR STORAGE AS OUTLINED IN THIS OWNER’S
MANUAL.
GENERAL INFORMATION
Each electric vehicle is supplied with a PowerDrive battery charger, controlled by the vehicle’s on-board
computer, as standard equipment. The AC cord to each charger is to be connected to a source capable of supplying 10 amperes minimum per charger.
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 “SHORTED” ACROSS BATTERIES. FOLLOW ALL INSTRUCTIONS CAREFULLY WHEN DEALING WITH BATTERIES.
• VENTILATE WHEN CHARGING IN 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.
41
The battery charger must be grounded to reduce the risk of electrical shock. The charger is equipped
WARNING
• DO NOT JUMP START VEHICLE. TO CHARGE BATTERY, USE AN AUTOMOTIVE TYPE 12
VOLT BATTERY CHARGER RATED AT 10 AMPS OR LESS.
• ALWAYS WEAR SAFETY GLASSES OR EYE PROTECTION WHEN SERVICING THE VEHICLE.
• ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL
CONNECTIONS.
CAUTION
• IF BATTERY WIRE TERMINALS ARE DAMAGED OR CORRODED, CLEAN OR REPLACE
THEM AS NECESSARY. FAILURE TO DO SO MAY CAUSE THEM TO OVERHEAT DURING
OPERATION.
with an AC electric cord having an equipment grounding conductor and a grounding type plug and is
for use on a nominal 115 Volt, 60 Hertz circuit, unless noted otherwise on the charger. This plug must
be grounded to an appropriate dedicated receptacle that is properly installed and grounded in accordance with all codes and ordinances applicable to the location.
Do not use an extension cord with an on-board charger.
For stationary chargers, the use of an extension cord should be avoided. If an extension cord must be
used, use a three conductor No. 12 AWG heavy duty cord with a ground conductor in good electrical
condition and 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.
Figure 31
Figure 32
Ventilation fans should be located at the highest point in the room, and must be capable of changing
the total volume of air in the room five times per hour. Consult a qualified HVAC engineer.
Provide adequate ventilation for the charger. Keep all charger ventilation openings at least two
WARNING
• ALWAYS WEAR SAFETY GLASSES OR EYE PROTECTION WHEN SERVICING VEHICLE.
• ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL
CONNECTIONS.
42
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 “SHORTED” ACROSS BATTERIES. FOLLOW ALL INSTRUCTIONS CAREFULLY WHEN DEALING WITH BATTERIES.
• VENTILATE WHEN CHARGING IN 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.
CAUTION
• TURN OFF ALL ACCESSORIES ON VEHICLE BEFORE CHARGING BATTERIES.
inches away from the walls and others objects.
TO CHARGE BATTERIES
• Stationary Charger: Insert the charger’s DC plug into the vehicle’s receptacle (Figure 33). When
inserting the PowerDrive System 48 DC plug, align the raised guide on the plug with the guide
slot in the receptacle and push straight in slowly. The charger will turn on two to fifteen seconds
later.
• On-board Charger (Carryall VI): Connect the charger’s AC power cord to a properly wired 115
Volt, 60 Hertz outlet (See WARNING, Page 44). The charger will turn on two to fifteen seconds
later.
• The PowerDrive Charger interacts with an on-board computer on the PowerDrive System 48 vehicle. The computer records the amount of energy consumed during vehicle use and directs the
charger to replace exactly the amount of energy needed to replenish the batteries.
While the charger is plugged in, the vehicle’s control circuit is locked out, preventing operation of
the vehicle, as well as the possibility of consequent damage to the charger and the vehicle.
Once the lock-out is actuated, the charger turns on. The 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).
CAUTION
• 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.
43
As long as the charger is allowed to shut off by itself, the batteries will be fully charged. Overcharging
and undercharging will be prevented.
DANGER
• BATTERIES EMIT HYDROGEN WHILE BEING CHARGED. HYDROGEN IS AN EXPLOSIVE
GAS. IF THE VEHICLE IS EQUIPPED WITH A WEATHERPROOF ENCLOSURE OR CAB, IT
SHOULD BE OPENED TO ALLOW AIR TO CIRCULATE FREELY WHILE THE 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 BUILDING
MUST BE CHANGED FIVE TIMES PER HOUR. EXHAUST FANS SHOULD BE LOCATED AT
THE HIGHEST POINT OF THE ROOF. CONTACT A QUALIFIED HVAC ENGINEER.
WARNING
• EACH CHARGER SHOULD HAVE ITS OWN DEDICATED 15 OR 20 AMPERE SEPARATELY
PROTECTED (CIRCUIT BREAKER OR FUSE) SINGLE PHASE BRANCH CIRCUIT, IN ACCORDANCE WITH ALL APPLICABLE ELECTRICAL CODES FOR THE LOCATION.
• INSTALL SURGE ARRESTORS ON INCOMING AC POWER LINES. SURGE ARRESTORS
WILL PROTECT ELECTRICAL/ELECTRONIC COMPONENTS IN THE CHARGER AND ON THE
VEHICLE FROM ALL BUT DIRECT OR VERY CLOSE LIGHTNING STRIKES.
• DO NOT USE AN ADAPTOR TO PLUG THE CHARGER WITH A THREE-PRONG PLUG INTO
A TWO-PRONG AC 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 FIRE OR AN ELECTRICAL SHOCK.
• ONLY TRAINED TECHNICIANS SHOULD SERVICE OR REPAIR THE CHARGER. CONTACT
YOUR NEAREST CLUB CAR DISTRIBUTOR/DEALER.
• DO NOT OPERATE THE CHARGER IF IT HAS RECEIVED A SHARP BLOW, WAS DROPPED,
OR OTHERWISE DAMAGED IN ANY WAY.
• HAVE WORN, CUT, OR DAMAGED POWER CORDS OR WIRES REPLACED IMMEDIATELY.
• DO NOT USE NEAR FUELS, GRAIN DUST, SOLVENTS, THINNERS OR OTHER FLAMMABLES. CHARGERS CAN IGNITE FLAMMABLE MATERIALS AND VAPORS.
• DO NOT EXPOSE TO RAIN OR ANY LIQUID. KEEP THE CHARGER DRY.
• NEVER PUSH OBJECTS OF ANY KIND INTO THE CHARGER THROUGH CABINET SLOTS.
THEY MAY TOUCH DANGEROUS VOLTAGE POINTS OR CAUSE AN ELECTRICAL SHORT
THAT COULD RESULT IN A RISK OF FIRE OR ELECTRICAL SHOCK.
• 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.
• DO NOT BY-PASS THE SENSE LEAD FUSE!
44
CAUTION
• DO NOT BLOCK OR COVER SLOTS AND OPENINGS IN THE BACK AND BOTTOM OF
CABINET. THEY PROVIDE VENTILATION AND PROTECT THE CHARGER FROM OVERHEATING.
• DO NOT ALLOW CLOTHING, BLANKETS, OR OTHER MATERIAL TO COVER CHARGER.
• PROVIDE ADEQUATE VENTILATION FOR THE CHARGER.
NOTE
• 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 (INCLUDES ALL 1995 AND
LATER ELECTRIC CARRYALL MODELS) THROUGHOUT THE STORAGE PERIOD.
• SHORTLY AFTER CHARGING HAS BEGUN, THE POWERDRIVE CHARGER WILL SHUT OFF
IN ORDER TO RUN A SELF-DIAGNOSTIC PROGRAM (AMMETER WILL DROP TO 0).
CHARGING WILL RESUME IN A FEW MOMENTS (AMMETER WILL RETURN TO CURRENT
RATE OF CHARGE).
• EXTREME HOT OR COLD TEMPERATURES CAN AFFECT THE LENGTH OF CHARGE.
• CHECK TO BE SURE THAT CHARGER HAS TURNED ON AND IS FUNCTIONING PROPERLY
BEFORE REPLACING BATTERIES THOUGHT TO BE DEAD.
• NEW BATTERIES WILL NOT DELIVER THEIR FULL RANGE UNTIL THE VEHICLE HAS
BEEN RUN AND RECHARGED FROM 20 TO 50 TIMES.
• VEHICLES SHOULD BE RESTRICTED TO BETWEEN 60 AND 70 ENERGY UNITS OF DISCHARGE BETWEEN CHARGES UNTIL THE BATTERIES HAVE BEEN PROPERLY SEASONED (20 TO 50 CHARGE CYCLES). FOR MAXIMUM BATTERY LIFE, CLUB CAR RECOMMENDS THAT ELECTRIC VEHICLES ALWAYS BE CHARGED AFTER 60 TO 70 ENERGY
UNITS OF DISCHARGE, OR EACH NIGHT, IN ORDER TO AVOID DEEP CYCLING OF THE
BATTERIES.
Batteries should be put on charge even if they have only been used for a short period (10 minutes).
Charger is automatic, and will turn off when batteries are fully charged. If charger does not seem to be
operating properly or the batteries seem weak, contact your nearest CLUB CAR Authorized Representative.
PLUG AND RECEPTACLE
If the charger plug becomes difficult to insert or remove, the receptacle contacts should be lightly
sprayed with WD-40® brand spray lubricant. Then the plug should be inserted and removed several
times to ensure ease of insertion, ease of removal and a good, firm electrical contact.
RECEPTACLE FUSE LINK
As an additional feature to protect the batteries and charging circuit from an overload when charging
with a stationary charger, the electric vehicle is equipped with a receptacle fuse link (See Figure 35).
If a stationary charger does not come on when the vehicle is placed on charge, visually inspect the fuse
link.
45
CLEANING
The vehicle is equipped with an Armorflex® front body and an all aluminum cargo bed. Use only mild
dish-washing liquid soap with a sponge or soft cloth for normal cleaning.
Minor scratches or blemishes in the front body or rear body can be buffed out using most commercially
CAUTION
• DO NOT CONNECT A STATIONARY CHARGER TO RECEPTACLE OF A VEHICLE EQUIPPED
WITH AN ON-BOARD CHARGER WHILE THE ON-BOARD CHARGER IS FUNCTIONING.
CHARGING OVERLOAD WILL DAMAGE THE ON-BOARD COMPUTER AND MAY CAUSE
BATTERY DAMAGE.
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.
Do not use harsh detergents or cleaning solvents on the front body or the seats.
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
All Carryall vehicles are equipped with a Solid State Speed Controller. In order to properly service and
maintain the Solid State Controller Vehicle, it is necessary to understand the electrical circuitry and the
functions of all components in the system. Therefore, if any repairs or service need be performed, we
recommend that they be performed by a CLUB CAR distributor/dealer using CLUB CAR OEM parts.
ACCESSORIES AND OPTIONS
The vehicle has a complete line of optional equipment items and accessories available. Contact your
distributor/dealer for an Optional Equipment book.
NOTE
• WHEN AIR TEMPERATURES FALL BELOW 18.3°C (65°F), BATTERIES CHARGED IN
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.
Care should be taken that these accessories and options are properly installed by trained technicians
and that the accessories are used for the purpose for which they were designed.
SUBSEQUENT OWNER REGISTRATION
46
WARNING
• BE SURE ALL WIRE CONNECTIONS AT THE RECEPTACLE AND THE FUSE LINK ARE
CLEAN AND TIGHT.
• DO NOT ROCK OR BEND THE PLUG. TO CONNECT THE CHARGER PLUG TO THE VEHICLE
RECEPTACLE, GRASP THE PLUG HANDLE, ALIGN RAISED PORTION OF PLUG WITH
RECESS IN RECEPTACLE, AND PUSH THE PLUG STRAIGHT INTO THE RECEPTACLE (SEE
FIGURE 33).
• DO NOT CONNECT A STATIONARY CHARGER TO THE RECEPTACLE IF THE CHARGER
CORD, PLUG OR THE VEHICLE RECEPTACLE IS BROKEN, DAMAGED IN ANY MANNER, OR
DOES NOT MAKE A GOOD ELECTRICAL CONNECTION. FIRE OR PERSONAL INJURY
CAN RESULT. HAVE IT REPLACED BY A QUALIFIED SERVICE PERSON IMMEDIATELY.
• FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE
CHARGER CORD, THE PLUG, AND (OR) THE VEHICLE’S RECEPTACLE.
• DO NOT PULL ON THE CORD (SEE FIGURE 34). 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 USE A CHARGER IF:
• THE PLUG IS TOO LOOSE OR DOES NOT MAKE A GOOD CONNECTION.
• THE PLUG AND RECEPTACLE FEEL HOTTER THAN NORMAL DURING CHARGE.
• THE PLUG PINS OR CONTACTS ARE BENT OR CORRODED.
• THE PLUG, RECEPTACLE OR CORDS ARE CUT, WORN, HAVE ANY EXPOSED WIRES OR
ARE DAMAGED IN ANY WAY.
USING THE CHARGER WITH ANY OF THE ABOVE SYMPTOMS COULD RESULT IN FIRE,
PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.
THE DC CHARGER CORD AND PLUG ARE WEAR ITEMS AND MUST BE REPLACED
WHEN WORN OR DAMAGED.
NOTE
• IF WARNING TAG HAS BEEN REMOVED FROM THE DC CORD OR IS DAMAGED, HAVE IT
REPLACED IMMEDIATELY.
Figure 33
Figure 34
47
In the event a vehicle is bought from a distributor/dealer, we strongly urge the new owner to
re-register the vehicle with Club Car. This will
enable us to contact you if the need arises.
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.
Figure 35
WARNING
• DO NOT BY-PASS THE SENSE LEAD FUSE!
• IF THE RECEPTACLE FUSE LINK IS BLOWN, DETERMINE THE SOURCE OF THE ELECTRICAL PROBLEM AND CORRECT IT BEFORE REPLACING THE FUSE. CONTACT YOUR
NEAREST CLUB CAR DISTRIBUTOR/DEALER.
48
WARNING
• CUSTOM CAB ASSEMBLIES, ALL-WEATHER ENCLOSURES, DOOR KITS, AND TINTED
WINDSHIELDS WILL NOT PROTECT OCCUPANTS FROM FLYING OBJECTS (GOLF BALLS,
ETC.).
49
SPECIFICATIONS
NOTE:
CLUB CAR, INC., RESERVES THE RIGHT TO CHANGE SPECIFICATIONS AND DESIGN OF EITHER GASOLINE OR
ELECTRIC VEHICLES AT ANY TIME WITHOUT NOTICE AND WITHOUT OBLIGATION TO MAKE THESE CHANGES ON
UNITS PREVIOUSLY SOLD.
50
SPECIFICATIONS
SPECIFICATIONS
Carryall-I
Carryall-II
Carryall-I
I Plus
Carryall-VI
DIMENSIONS
Gasoline
Electric
Gasoline
Electric
Gasoline
Gasoline
Electric
Overall Length...Flatbed
254 cm
(100")
254 cm
(100")
282 cm
(111")
282 cm
(111")
282 cm
(111")
340 cm
(134")
340 cm
(134")
Overall Width
125 cm
(49-1/4")
125 cm
(49-1/4")
127 cm
(50")
127 cm
(50")
127 cm
(50")
125 cm
(49-1/4")
125 cm
(49-1/4")
Overall Height at Steering Wheel
122 cm
(48")
122 cm
(48")
122 cm
(48")
122 cm
(48")
122 cm
(48")
122 cm
(48")
122 cm
(48")
Wheelbase
166 cm
(65-1/2")
166 cm
(65-1/2")
197 cm
(77-1/2")
197 cm
(77-1/2")
197 cm
(77-1/2")
250 cm
(98-1/2")
250 cm
(98-1/2")
Ground Clearance
11 cm
(4-1/2")
11 cm
(4-1/2")
11 cm
(4-1/2")
11 cm
(4-1/2")
11 cm
(4-1/2")
11 cm
(4-1/2")
11 cm
(4-1/2")
Front Wheel Tread
88 cm
(34-1/2")
88 cm
(34-1/2")
88 cm
(34-1/2")
88 cm
(34-1/2")
88 cm
(34-1/2")
88 cm
(34-1/2")
88 cm
(34-1/2")
Rear Wheel Tread
98 cm
(38-1/2")
98 cm
(38-1/2")
98 cm
(38-1/2")
98 cm
(38-1/2")
98 cm
(38-1/2")
98 cm
(38-1/2")
98 cm
(38-1/2")
240 kg
(530 lbs.)
Weight...Electric (without batteries)
Weight...Gasoline (dry)
298 kg
(658 lbs.)
289 kg
(637 lbs.)
340 kg
(749 lbs.)
348 kg
(768 lbs.)
350 kg
(772 lbs.)
405 kg
(893 lbs.)
Forward Speed KPH (MPH)
19-23
(12-15)
19-23
(12-15)
19-23
(14-16)
19-23
(14-16)
27-29
(17-18)
23-26
(14-16)
19-23
(12-15)
Clearance Circle (diameter)
533 cm
(17' 6")
533 cm
(17' 6")
630 cm
(20' 8")
630 cm
(20' 8")
630 cm
(20' 8")
752 cm
(24' 8")
752 cm
(24' 8")
Braking Distance at 19 KPH (12 MPH)
427 cm
(14')
427 cm
(14')
488 cm
(16')
488 cm
(16')
488 cm
(16')
488 cm
(16')
488 cm
(16')
Braking Distance at 29 KPH (18 MPH)
Turning Radius per SAE J 695
173 cm
(5' 8")
173 cm
(5' 8")
257 cm
(8' 5")
257 cm
(8' 5")
257 cm
(8' 5")
328 cm
(10' 9")
328 cm
(10' 9")
Intersecting Aisle Clearance
183cm
(72")
183cm
(72")
196 cm
(77")
196 cm
(77")
196 cm
(77")
228 cm
(89-3/4")
228 cm
(89-3/4")
Floorboard Height
30 cm
(11-3/4")
30 cm
(11-3/4")
30 cm
(11-3/4")
30 cm
(11-3/4")
30 cm
(11-3/4")
30 cm
(11-3/4")
30 cm
(11-3/4")
Load Bed Height
69 cm
(27")
69 cm
(27")
70 cm
(27-5/8")
70 cm
(27-5/8")
70 cm
(27-5/8")
69 cm
(27")
69 cm
(27")
Load Bed Size...(Box Bed I.D. Dimensions)
96 cm x
115 cm x
23 cm
(37-5/8"
x 45-1/8"
x 9-1/4")
96 cm x
115 cm x
23 cm
(37-5/8"
x 45-1/8"
x 9-1/4")
124 cm x
126 cm x
28 cm
(48-3/4"
x 49-3/4"
x
10-7/8")
124 cm x
126 cm x
28 cm
(48-3/4"
x 49-3/4"
x
10-7/8")
124 cm x
126 cm x
28 cm
(48-3/4"
x 49-3/4"
x
10-7/8")
163 cm x
112 cm x
47 cm
(64-3/16"
x 44" x
18-1/2")
163 cm x
112 cm x
47 cm
(64-3/16"
x 44" x
18-1/2")
Load Bed Size...(Flatbed I.D. Dimensions)
91 cm x
112 cm
(35-3/4"
x
44-1/4")
91 cm x
112 cm
(35-3/4"
x
44-1/4")
119 cm x
126 cm
(46-7/8"
x
48-5/16")
119 cm x
126 cm
(46-7/8"
x
48-5/16")
119 cm x
126 cm
(46-7/8"
x
48-5/16")
172 cm x
112 cm
(67-5/8"
x
44-3/16")
172 cm x
112 cm
(67-5/8"
x
44-3/16)
Vehicle Rated Capacity (level surface only) in kilograms (pounds)
363
(800)
363
(800)
544
(1200)
544
(1200)
544
(1200)
680
(1500)
680
(1500)
Seat Height
76 cm
(30")
76 cm
(30")
77 cm
(30-1/4")
77 cm
(30-1/4")
77 cm
(30-1/4")
76 cm
(30")
76 cm
(30")
51
CLUB CAR LIMITED WARRANTY FOR 1996 CARRYALL VEHICLES
IN THE UNITED STATES AND CANADA
1. WARRANTY:
CLUB CAR, INC. (“CLUB CAR”) hereby warrants to the original retail purchaser that its new 1996 Model Carryall
vehicle purchased from CLUB CAR or an authorized distributor/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 utility vehicle for the periods stated below, subject to the provisions, limitations and exclusions contained in this limited warranty.
LIMITED ONE (1) YEAR WARRANTY:
The engine assembly, motor, transmission assembly, drive unit assembly, main frame assembly, hydraulic
dump kit, Custom Cab assembly and doors, Driving Range Protective Enclosure and Portable Refreshment Center are warranted with respect to parts and labor against defects in materials and workmanship for a period of one
year from the date of purchase.
LIMITED NINETY (90) DAY WARRANTY:
All remaining components of the vehicle not specified otherwise are warranted with respect to parts and labor
against defects in materials and workmanship for a period of ninety days from the date of purchase.
This limited warranty covers materials, workmanship and repair labor costs as to those items specifically listed
above for the periods specified. Such repair labor shall be performed only by CLUB CAR, its authorized dealers,
or a service agency approved by CLUB CAR.
IF THE WARRANTY REGISTRATION FORM IS NOT COMPLETED AND RETURNED TO CLUB CAR AT
THE TIME OF THE ORIGINAL RETAIL SALE, PURCHASER MUST PROVIDE PROOF OF DATE OF PURCHASE WITH ANY WARRANTY CLAIM.
2. EXCLUSIONS:
Excluded from any CLUB CAR warranty are all fuses; filters; decals; spark plugs; lubricants; the front 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; items which deteriorate
or fail due to exposure or ordinary wear and tear. Batteries, battery charger, on-board computer, and the solidstate speed controller are covered by separate Club Car warranties. Tires are warranted by their manufacturer.
Also excluded from any CLUB CAR warranty is damage to a vehicle or component resulting from a cause
other than a defect including unreasonable or unintended strain or use, improper installation of accessories, installation of parts or accessories that are not original equipment, overloading, accident, alteration, abuse or neglect.
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 VEHICLE 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 VEHICLE TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR
SPECIFICATIONS. THE WARRANTY IS LIKEWISE VOID IF THE VEHICLE SHOWS INDICATIONS THAT REASONABLE OR NECESSARY MAINTENANCE AS OUTLINED IN THE OWNER’S MANUAL AND MAINTENANCE AND SERVICE MANUAL WAS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED
IN SUCH MANUALS.
4. SOLE REMEDY:
CLUB CAR’S ONLY LIABILITY UNDER THIS LIMITED WARRANTY, OR IN ANY ACTION WHETHER BASED
UPON WARRANTY, CONTRACT, NEGLIGENCE, STRICT PRODUCT LIABILITY OR OTHERWISE, IS LIMITED
TO THE REPLACEMENT OR REPAIR, AT CLUB CAR’S OPTION, OF A VEHICLE OR COMPONENT THEREOF THAT CLUB CAR DEEMS TO BE DEFECTIVE. REPLACEMENT SHALL MEAN FURNISHING, DURING THE
APPLICABLE LIMITED WARRANTY PERIOD, A NEW OR FACTORY RECONDITIONED VEHICLE OR COMPONENT THEREOF WHICH IS IDENTICAL OR REASONABLY EQUIVALENT TO THE WARRANTED PRODUCT OR COMPONENT AT NO COST TO THE PURCHASER. REPAIR SHALL MEAN REMEDYING A DEFECT
IN THE VEHICLE OR COMPONENT THEREOF AT NO COST TO THE PURCHASER DURING THE APPLICABLE LIMITED WARRANTY PERIOD. IF CLUB CAR ELECTS TO REPAIR THE VEHICLE, 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 vehicle or defective component to an
authorized CLUB CAR distributor/dealer or send the defective component, freight prepaid, to WARRANTY
ADMlNlSTRATION, 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 VEHICLE OR COMPONENT THEREOF IS THE EXCLUSIVE AND SOLE REMEDY OF THE
PURCHASER. CLUB CAR MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND, AND NO
REPRESENTATIVE, EMPLOYEE, DISTRIBUTOR OR DEALER OF CLUB CAR HAS THE AUTHORITY TO
MAKE OR IMPLY ANY REPRESENTATION, PROMISE, OR AGREEMENT WHICH IN ANY WAY VARIES THE
TERMS OF THIS WARRANTY.
7. NO CONSEQUENTIAL DAMAGES:
IN NO EVENT SHALL CLUB CAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES
INCLUDING, BUT NOT LIMITED TO, LOSS RELATED TO PROPERTY OTHER THAN THE VEHICLE, LOSS OF
USE, LOSS OF TIME, INCONVENIENCE, OR ANY OTHER ECONOMIC LOSS.
Some states allow neither limitations on the duration of an implied warranty nor exclusions or limitations of incidental or consequential damages. Therefore, the above limitations or exclusions may not apply to you.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to
state.
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 VEHICLE BEYOND FACTORY SPECIFICATIONS, INCLUDING THOSE THAT AFFECT THE WEIGHT, WEIGHT DISTRIBUTION, STABILITY, OR SPEED OF THE VEHICLE, CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH.
Club Car, Inc.
P.O. Box 204658
Augusta, GA 30917-4658
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