Club Car Carryall 1 2007 Owner'S Manual Download Page 8

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Vehicle Feature Identification

Page 6

2007 Turf/Carryall Vehicle Owner’s Manual

ELECTRIC TURF 2/CARRYALL 2

DRIVER/PASSENGER WARNING DECAL

VEHICLE LOADING DECAL

CRUSH AREA

DECAL

BATTERY WARNING

LAMP

KEY SWITCH

BED LOAD WARNING DECAL

ACCELERATOR

PEDAL

BRAKE

PEDAL

PARK BRAKE

PEDAL

SERIAL

NUMBER

OPERATING INSTRUCTIONS

DECAL

Summary of Contents for Carryall 1 2007

Page 1: ...Owner s Manual 2007 Turf Carryall Vehicles Electric and Gasoline Turf 1 Carryall 1 Turf 2 Carryall 2 Carryall 2 Plus Turf 6 Carryall 6...

Page 2: ......

Page 3: ...rom 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 t...

Page 4: ...e name and address of the Club Car representative nearest you logon to our web site at www clubcar com or call 1 800 ClubCar 258 2227 If you would prefer to write to us direct your letter to Club Car...

Page 5: ...wing with the Vehicle 36 Transporting on a Trailer 36 Storage Electric Vehicles 37 Storage Gasoline Vehicles 38 Maintenance 41 Periodic Service Schedules 42 Periodic Lubrication Schedules 45 Vehicle C...

Page 6: ...cle Owner s Manual ELECTRIC TURF 1 CARRYALL 1 DRIVER PASSENGER WARNING DECAL VEHICLE LOADING DECAL CRUSH AREA DECAL BATTERY WARNING LAMP KEY SWITCH BED LOAD WARNING DECAL ACCELERATOR PEDAL BRAKE PEDAL...

Page 7: ...cle Owner s Manual Page 5 ELECTRIC TURF 1 CARRYALL 1 BED LATCH BATTERY DANGER DECAL ON BATTERY CAPS OR ON BODY UNDER SEAT CHARGER RECEPTACLE BED LATCH WARNING DECAL FORWARD REVERSE SWITCH ON DASH TOW...

Page 8: ...cle Owner s Manual ELECTRIC TURF 2 CARRYALL 2 DRIVER PASSENGER WARNING DECAL VEHICLE LOADING DECAL CRUSH AREA DECAL BATTERY WARNING LAMP KEY SWITCH BED LOAD WARNING DECAL ACCELERATOR PEDAL BRAKE PEDAL...

Page 9: ...TRAILER HITCH DECAL BED LATCH BATTERY DANGER DECAL ON BATTERY CAPS OR ON BODY UNDER SEAT CHARGER RECEPTACLE BED LATCH WARNING DECAL TOW SWITCH WARNING DECAL ON TOW SWITCH BRACKET UNDER PASSENGER SIDE...

Page 10: ...URY OR DEATH Bed can tip up unexpe ctedly Bed hold down CCI 101707801 BED LOAD WARNING DECAL DRIVER PASSENGER WARNING DECAL BATTERY CONDITION INDICATOR SERIAL NUMBER BATTERY WARNING LAMP CRUSH AREA DE...

Page 11: ...DEATH Bed can tip up unexpectedly Bed hold down CCI 101707801 ELECTRICAL COMPONENT MOUNTING PLATE NOTICE ON PLATE ONBOARD CHARGER AC CORD REEL BED BOLT WARNING DECAL ELECTRICAL COMPONENT COVER CAUTIO...

Page 12: ...a Can cau se sev ere inju ry Stay clea r whe n closing bed LOW OIL WARNING LAMP FUEL GAUGE HOUR METER SERIAL NUMBER PARK BRAKE PEDAL BRAKE PEDAL ACCELERATOR PEDAL FOR TURF 2 AND CARRYALL 2 VEHICLE LOA...

Page 13: ...0 P E N Crush area Can cause severe injury Stay clear when closing bed BED LATCH FUEL SHUT OFF VALVE FORWARD REVERSE HANDLE ON DASH CHOKE TRAILER HITCH DECAL TURF 2 AND CARRYALL 2 BED LATCH WARNING D...

Page 14: ...ush area Can cause severe injury Stay clea r whe n clos ing bed 2 LOW OIL WARNING LAMP FUEL GAUGE HOUR METER SERIAL NUMBER PARK BRAKE PEDAL BRAKE PEDAL ACCELERATOR PEDAL BED LOAD WARNING DECAL CRUSH A...

Page 15: ...F N R 2 2 PLUS BED LATCH FUEL SHUT OFF VALVE CHOKE TRAILER HITCH DECAL GASOLINEWARNING DECAL ON FRAME ROTATING PARTS AND HOT MANIFOLD DECAL ON STARTER GENERATOR AND ENGINE FRAME GROUND WARNING DECAL O...

Page 16: ...up unexpe ctedly Bed hold down CCI 101707801 FUEL SHUT OFF VALVE LOW OIL WARNING LAMP FUEL GAUGE HOUR METER SERIAL NUMBER ACCELERATOR PEDAL BRAKE PEDAL PARK BRAKE PEDAL LAMP SWITCH ROTATING PARTS AND...

Page 17: ...SEVERE INJURY OR DEATH Bed can tip up unexpectedly Bed hold down CCI 101707801 CARRYALL VI CCI 101621601 KEY SWITCH CARRYALL 6 KEY SWITCH TURF 6 OPERATING INSTRUCTIONS DECAL CARRYALL 6 BED HOLD DOWN...

Page 18: ...may at first seem shocking but their impact is mild compared with the reality of severe personal injury Your safety and satisfaction are of the utmost importance to Club Car That is why before operat...

Page 19: ...ates 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 i...

Page 20: ...th a prop rod ensure that it is securely engaged while bed is raised Do not close bed until all persons are clear of cargo bed area Keep hands clear of all crush areas Do not drop cargo bed lower gent...

Page 21: ...lus Electric Vehicle Figure 4 Carryall 6 IQ Plus Electric Vehicle FRONT OF VEHICLE AS SEEN FROM PASSENGER SIDE OF VEHICLE Remove negative cable first DISCONNECT BATTERY CABLES BEFORE WORKING ON VEHICL...

Page 22: ...ample EG0601 123456 Figure 5 There is also a second serial number decal mounted on the front body frame behind the center dash panel The center dash panel must be removed to view this decal See follow...

Page 23: ...ly Release the key and it will return to the ON position and the engine should idle NOTE The key can be removed only when the key switch is in the OFF position FORWARD REVERSE CONTROL Gasoline Vehicle...

Page 24: ...Controls and Indicators Page 22 2007 Turf Carryall Vehicle Owner s Manual Figure 6 Instrument Panel Gasoline Vehicles Figure 7 Instrument Panel Electric Vehicles 0 1 2 1 1 10 1 3 4 5 2 1 3 4 2...

Page 25: ...e FUEL GAUGE HOUR METER Gasoline Vehicles Only The gasoline vehicle is equipped with a fuel gauge hour meter 5 located on the instrument panel Figure 6 The fuel gauge allows the operator to monitor th...

Page 26: ...isplay Module which provides information on the condition of the vehicle and batteries BATTERY CONDITION INDICATOR Electric Carryall 6 Vehicles Only The battery condition indicator features a 10 bar L...

Page 27: ...below the programmed top speed Pedal Up Motor Braking IQ System vehicles When vehicle speed is above 11 mph 17 7 km h releasing the accelerator pedal will activate motor braking which slows the vehicl...

Page 28: ...Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning could result in a battery explosion or severe personal injury When the Tow Run switch is i...

Page 29: ...the battery cables are disconnected For Long Term Storage Place the Tow Run switch in the TOW position to turn off power to the vehicle electrical system thus preventing vehicle electrical components...

Page 30: ...ward Reverse handle is in either the FORWARD or REVERSE position and the accelerator pedal is pressed the engine will stop running WARNING With the switch in the MAINTENANCE position and the engine ru...

Page 31: ...ny problems should be corrected by a Club Car distributor dealer or a trained technician General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tigh...

Page 32: ...park brake should lock the wheels and hold the vehicle stationary on an incline of 20 or less It should release when either the accelerator or brake pedal is pressed Reverse buzzer The reverse buzzer...

Page 33: ...e For ward Reverse handle in the FORWARD position the vehicle should accelerate smoothly to full speed as the accelerator pedal is pressed When the accelerator pedal is released it should return to th...

Page 34: ...kes to reduce speed when coasting downhill No one should drive the vehicle without first being instructed in the proper operation and use of the vehicle s controls An experienced operator should accom...

Page 35: ...NOTE Pedal start vehicle If the Forward Reverse handle or switch is shifted into the NEUTRAL posi tion power will be cut off and the engine will stop running Key start vehicle If accelerator pedal is...

Page 36: ...ard the rear of the vehicle and lift the bed To close the bed lower it gently until the bed latch engages DO NOT drop the bed WARNING Keep hands and fingers clear of crush area between the bed and the...

Page 37: ...ffect vehicle handling or cause component failure resulting in loss of control of vehicle and possible severe personal injury Reduce vehicle load and speed when driving up or down slopes or on uneven...

Page 38: ...ing Avoid stopping on a hill when towing If you must stop on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning could cause the vehicle to overturn poss...

Page 39: ...ttom before transporting on a trailer Gasoline vehicles only Turn the fuel shut off valve to the closed OFF position Figure 18 If the vehicle must be transported over long distances or on public highw...

Page 40: ...e from rolling 9 Keep batteries fully charged during storage Leave battery chargers plugged in during storage The onboard computer will automatically activate the charger when necessary If charger can...

Page 41: ...r and seal the fuel tank 3 1 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout cam in the MAINTENANCE position Turn the fuel shut off valve to the closed OFF position Fi...

Page 42: ...URNING THE STORED GASOLINE VEHICLE TO SERVICE 1 Restore fuel system to operation 1 1 Remove plug from the fuel tank vent Figure 33 Page 57 1 2 Connect vent tube to fuel tank vent 2 Connect battery cab...

Page 43: ...If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe persona...

Page 44: ...ERIODIC SERVICE SCHEDULES See General Warnings on page 17 WARNING Service repairs and adjustments must be made per instructions in the maintenance and service manual NOTE If the vehicle is constantly...

Page 45: ...comes first Brake system Check brake shoes replace if necessary or adjust as required See Section 6 Wheel Brake Assemblies in the appropriate maintenance and service manual Lubricate brake slides per...

Page 46: ...l See page 53 Front wheel alignment and camber Check and adjust if necessary See Section 7 Steering and Front Suspension in the appropriate maintenance and service manual Electrical wiring and connect...

Page 47: ...es first Brake pedal shaft bearings Dry Moly Lube CCI P N 1012151 Brake linkage and pivots Dry Moly Lube CCI P N 1012151 Accelerator pivot rod supports Dry Moly Lube CCI P N 1012151 Brake slides Dry M...

Page 48: ...sis Lube EP NLGI Grade 2 Brake slides Dry Moly Lube CCI P N 1012151 Annually by trained technician only or every 100 hours of operation whichever comes first Check fill unitized transaxle to plug leve...

Page 49: ...ntities of milk or water followed with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately WARNING Wear safety glasses or a...

Page 50: ...t Let the terminals dry and then spray them with Battery Terminal Protector Spray CCI P N 1014305 NOTE Dispose of waste water properly 2 The electrolyte level in the batteries should be checked weekly...

Page 51: ...es Chargers can ignite flammable materials and vapors Connect the charger AC supply cord to a properly grounded three wire outlet of the proper voltage and frequency as shown on the charger Do not use...

Page 52: ...rogram ammeter will drop to zero Charging will resume in a few moments ammeter returns to previous rate of charge Each electric vehicle is supplied with either a fully automatic stationary battery cha...

Page 53: ...ount of energy consumed during vehicle use While the charger is plugged in the vehicle s control circuit is locked out preventing operation of the vehicle as well as the possibility of subsequent dama...

Page 54: ...nsert or remove the receptacle contacts and plug terminals should be cleaned with a good electrical contact cleaner or lightly sprayed with WD 40 brand spray lubricant The plug should then be inserted...

Page 55: ...G Do not jump start a dead battery using another battery and jumper cables The battery in a Club Car gasoline vehicle is a 12 volt low maintenance battery that requires infrequent watering Figure 27 A...

Page 56: ...eration After that they should be changed every 200 hours of operation or annually whichever comes first 1 Turn the key switch to the OFF position then remove the key Place the Forward Reverse handle...

Page 57: ...lter prior to removing Position the port of the plastic container so oil will be directed into the oil pan Or make a drip guard by folding a piece of card board thin metal or plastic under the oil fil...

Page 58: ...STRUCTIONS GASOLINE VEHICLE See General Warnings on page 17 DANGER Turn the key switch to the OFF position before fueling Do not pour gasoline into the fuel tank when the engine is hot or while it is...

Page 59: ...lt in water damage and subsequent component failure Use non abrasive wax products Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible...

Page 60: ...before unlatching and lifting the bed If the vehicle is equipped with an electric powered lift bed remove the bed before servicing the bed lift system SUBSEQUENT OWNER REGISTRATION In the event a vehi...

Page 61: ...ke cable system to manually adjusted drum brakes on all four wheels Park brake is automatically released Self adjusting multi latch ratchet and pawl BODY CHASSIS Frame chassis Twin I Beam welded alumi...

Page 62: ...27 625 in 70 cm 27 in 69 cm Seat height 30 in 76 cm 30 25 in 77 cm 30 in 76 cm Load bed size Box bed dimensions 37 6 in x 45 1 in x 9 3 in 96 x 115 x 23 cm 48 8 in x 49 8 in x 10 9 in 124 x126 x 28 c...

Page 63: ...djusting rack and pinion Suspension Front mono leaf and rear multi leaf springs with dual hydraulic shocks Suspension Front and rear multi leaf springs with dual hydraulic shocks Brakes Mechanical bra...

Page 64: ...ed size Box bed dimensions 37 6 in x 45 1 in x 9 3 in 96 x 115 x 23 cm 48 8 in x 49 8 in x 10 9 in 124 x126 x 28 cm 48 8 in x 49 8 in x 10 9 in 124 x126 x 28 cm 64 2 in x 44 in x 18 5 in 163 x 112 x 4...

Page 65: ...te or fail due to exposure or ordinary wear and tear Batteries battery charger onboard computer and solid state speed controller are covered under separate CLUB CAR warranties Also excluded from any C...

Page 66: ...UB CAR INC CLUB CAR hereby warrants to the original retail purchaser that the new Trojan T 105 6 Volt Battery installed in its new electric utility vehicle purchased from CLUB CAR or an authorized dis...

Page 67: ...ailure to provide reasonable and necessary maintenance accident or alteration is excluded from this limited warranty Some states allow neither limitation on the duration of an implied warranty nor exc...

Page 68: ...excluded ALSO EXCLUDED FROM THIS LIMITED WARRANTY ARE ANY AND ALL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE OR REVENUE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOM...

Page 69: ...NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE...

Page 70: ...ARRANTY LIMITATIONS CLUB CAR s liability under this limited warranty or in any action whether based upon warranty contract negligence strict product liability or otherwise shall be the replacement or...

Page 71: ...application other than its PowerDrive System 48 PowerDrive Plus and IQ System products As in the use of any battery operated device a prudent owner will read and study the charger owner s manual the e...

Page 72: ...ations 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...

Page 73: ...anty services or repairs will be provided at all of our distribution centers that are franchised to service the subject engines or equipment 6 The engine or equipment owner will not be charged for dia...

Page 74: ...m having optimum ignition timing characteristics The carburetors have been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust...

Page 75: ...of Illustrations 4 Periodic Service and Periodic Lubrication Schedules Poor Fair Average Good Excellent Comments Suggestions In order to help us better serve you please rate this publication in the f...

Page 76: ...Club Car R NOTES...

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Page 80: ...Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Intl l 1 706 863 3000 Fax 1 706 863 5808 Publication Part Number 103218310 Edition Code 0706B07...

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