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Club Car CARRYALL I 1997, Owner'S Manual

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Club Car CARRYALL I 1997 Owner'S Manual Download Page 11

 

5

CARRY

ALL

ClubCar

®

Checking Engine Oil Level

 

Service

Regular Interval

Governor is factory adjusted for
12 - 14 mph max. Do not tamper with
adjustment. To do so:
1) will void the warranty; 2) may result in 
damage to the engine or components;
3) could result in severe personal injury.

WARNING

!

SAE 30 above 32

°

F (0ºC) or

SAE 5 W20 below 32

°

F (0

°

C)

Classification SE, SF, SG or Higher

*Whichever comes first

1. Check Oil Level

2. Oil and Filter Change

3. Check Condition and Clean

    Air Filter Element

4. Change Air Filter

5. Check Tire Pressure

6. Replace Fuel Filters

7. Check / Fill Drive Unit

8. Check / Fill Transmission

Monthly

First - 100 Hours

*Additional - Annually or 200 Hours

One Year Under Normal Use

Six Months Under Dusty Conditions

* Two Years or 300 Hours

Monthly (See Manual)

* Two Years or 300 Hours

* One Year or 150 Hours

* One Year or 150 Hours

WARNING

!

HOT manifold and muffler

can cause severe burns.

WARNING

!

Negative frame ground. Do not contact positive 

(+)

battery post or cable to frame as this can cause
battery explosion, electrical shocks, and burns.

DANGER

!

• Gasoline – extremely flammable.
• Keep heat, sparks and open flame away from fuel
   tank and fuel lines.
• Do not add fuel while engine is running or hot.
• Service by trained personnel.

!

WARNING

MOVING PARTS

DANGER / POISON

!

FLUSH EYES
IMMEDIATELY
WITH WATER

GET
MEDICAL
HELP
FAST

SULFURIC
ACID

CAN CAUSE
BLINDNESS OR
SEVERE BURNS

NO

• SPARKS
• FLAMES
• SMOKING

KEEP OUT OF THE REACH OF CHILDREN – DO NOT TIP – KEEP VENT CAPS TIGHT AND LEVEL

SHIELD
EYES

EXPLOSIVE

GASES CAN CAUSE
BLINDNESS OR INJURY

HOT MANIFOLD

AND MUFFLER

(ON ENGINE)

FRAME GROUND

WARNING

(ON FRAME)

CHOKE

BATTERY DANGER

LABEL

(ON BODY UNDER SEAT)

GASOLINE TANK

DANGER LABEL

(ON BODY UNDER SEAT)

PERIODIC SERVICE

SCHEDULE

(ON INTAKE BOX)

MOVING PARTS

WARNING LABEL

   (ON FRAME BESIDE FENDER)

F

N

R

FORWARD - REVERSE

LEVER

FORWARD - REVERSE

LEVER

Low
Level

Safe

Level

Full

Level

2

1

3

VEHICLE FEATURE IDENTIFICATION

Summary of Contents for CARRYALL I 1997

Page 1: ...1997 1997 Carryall Carryall Vehicles Vehicles Manual Number 101906302 Print Code 0796A00000 Club Car Club Car Owner s Manual Owner s Manual R R ...

Page 2: ......

Page 3: ...otocopied 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 are designed and manufactured for off road use onl...

Page 4: ... injury If you rent or loan your vehicle to others we recommend that you ask them to read this manual before they operate the vehicle Club Car products are backed by a customer support system designed to offer you fast courteous service In the event that your golf car needs repairs or services we recommend that your local authorized Club Car representative perform them For the name and address of ...

Page 5: ...Carryall II Gasoline Vehicles 21 Controls Carryall II Plus and Carryall VI Gasoline Vehicles 23 Driving Instructions Carryall II Plus and Carryall VI Gasoline Vehicles 27 Bed Latch 30 Loading and Unloading 30 Towing a Trailer 31 Transporting on a Trailer 32 Storage Gasoline Vehicle 33 Storage Electric Vehicle 34 Maintenance 35 Periodic Service Schedule Gasoline Vehicle 38 Periodic Service Schedule...

Page 6: ...faction 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 warn ings in this manual as well as the safety decals on your vehicle before operating the vehicle Take time to understand the language of safety It is a language that can save your life WARNING Moving Parts Practice Safety ...

Page 7: ...nal injury property damage or death Contact your CLUB CAR distributor dealer THIS OWNER S MANUAL SHOULD BE READ COMPLETELY BEFORE ATTEMPTING TO DRIVE OR SERVICE THE VEHICLE FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS MANUAL COULD RESULT IN PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH A DANGER INDICATES AN IMMEDIATE HAZARD WHICH WILL RESULT IN SEVERE PER SONAL INJURY OR DEATH A WARNING INDICATES ...

Page 8: ...E DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD FOLLOW THE PROCEDURES EXACTLY AS STATED IN THIS MANUAL AND OBEY ALL DANGERS WARNINGS AND CAUTIONS LISTED IN THIS MANUAL AS WELL AS THOSE AFFIXED TO THE VEHICLE ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN SERVICING THE VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR E...

Page 9: ...RSE POSITION SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THE REVERSE WARNING BUZZER CAN NO LONGER BE HEARD WHEN THE BUZZER STOPS SOUNDING THE CONTROLLER IS DISCHARGED FIGURE 1 FIGURE 2 WARNING POS NEG POS NEG POS NEG POS NEG POS NEG POS NEG 1 2 5 6 4 3 FRONT OF CAR POWERDRIVE SYSTEM 48 CARRYALL I DISCONNECT HERE POS NEG POS NEG POS NEG POS NEG POS NEG POS NEG 1 2 5 4 3 FRONT O...

Page 10: ...pedal is depressed To stop release accelerator pedal and depress brake pedal After stopping firmly depress park brake until it locks Turn key to OFF position remove key and place shift lever in the straight up neutral position when not in use Pinch point WARNING WARNING Keep hands body and other persons away when closing bed L A T C H O P E N Read operating instructions before using vehicle Never ...

Page 11: ...ifold and muffler can cause severe burns WARNING Negative frame ground Do not contact positive battery post or cable to frame as this can cause battery explosion electrical shocks and burns DANGER Gasoline extremely flammable Keep heat sparks and open flame away from fuel tank and fuel lines Do not add fuel while engine is running or hot Service by trained personnel WARNING MOVING PARTS DANGER POI...

Page 12: ...dal is depressed To stop release accelerator pedal and depress brake pedal After stopping firmly depress park brake until it locks Turn key to OFF position remove key and place shift lever in the straight up neutral position when not in use Pinch point WARNING WARNING Keep hands body and other persons away when closing bed L A T C H O P E N Read operating instructions before using vehicle Never st...

Page 13: ...T CAPS TIGHT AND LEVEL SHIELD EYES EXPLOSIVE GASES CAN CAUSE BLINDNESS OR INJURY BATTERY DANGER LABEL ON BODY UNDER SEAT FUSE LINK CHARGER RECEPTACLE F N R FORWARD REVERSE LEVER FORWARD REVERSE LEVER Do not operate vehicle without this cover properly installed See vehicle Maintenance and Service Manual before servicing CAUTION ELECTRICAL COMPONENT COVER CAUTION CARRYALL II ONLY VEHICLE FEATURE IDE...

Page 14: ...rms legs feet and body inside vehicle Stop vehicle before changing direction Buzzer will sound in reverse Drive slowly in turns Drive slowly straight up and down slopes Set park brake before leaving vehicle Remove key when vehicle is not in use Place shift lever in neutral when vehicle is not in use WARNING Failure to follow these instructions can cause severe injury or death WARNING No persons in...

Page 15: ...s WARNING HOT manifold and muffler can cause severe burns WARNING Negative frame ground Do not contact positive battery post or cable to frame as this can cause battery explosion electrical shocks and burns DANGER Gasoline extremely flammable Keep heat sparks and open flame away from fuel tank and fuel lines Do not add fuel while engine is running or hot Service by trained personnel WARNING MOVING...

Page 16: ... in cargo bed VEHICLE LOADING LABEL TILT BED WARNING SAFETY WARNING LABEL PARK BRAKE PEDAL ACCELERATOR PEDAL SERIAL NUMBER BATTERY WARNING LIGHT BRAKE PEDAL DANGER POISON FLUSH EYES IMMEDIATELY WITH WATER GET MEDICAL HELP FAST SULFURIC ACID CAN CAUSE BLINDNESS OR SEVERE BURNS NO SPARKS FLAMES SMOKING KEEP OUT OF THE REACH OF CHILDREN DO NOT TIP KEEP VENT CAPS TIGHT AND LEVEL SHIELD EYES EXPLOSIVE ...

Page 17: ...ator pedal to increase speed Park brake will release when accelerator pedal is depressed To stop release accelerator pedal and depress brake pedal After stopping firmly depress park brake until it locks Turn key to OFF position remove key and place shift lever in the straight up neutral position when not in use OPERATING INSTRUCTIONS BED HOLD DOWN BOLT WARNING ELECTRICAL COMPONENT COVER CAUTION KE...

Page 18: ... No persons in cargo bed VEHICLE LOADING LABEL TILT BED WARNING SAFETY WARNING LABEL PARK BRAKE PEDAL ACCELERATOR PEDAL SERIAL NUMBER BRAKE PEDAL DANGER POISON FLUSH EYES IMMEDIATELY WITH WATER GET MEDICAL HELP FAST SULFURIC ACID CAN CAUSE BLINDNESS OR SEVERE BURNS NO SPARKS FLAMES SMOKING KEEP OUT OF THE REACH OF CHILDREN DO NOT TIP KEEP VENT CAPS TIGHT AND LEVEL SHIELD EYES EXPLOSIVE GASES CAN C...

Page 19: ... Turn key switch to START position and release To operate vehicle Be sure nothing is in your path Select vehicle direction by placing shift lever in desired position F Forward N Neutral R Reverse Park brake will release when accelerator pedal is pushed Slowly push accelerator pedal to increase speed Accelerator pedal must be released to shift vehicle to neutral To stop vehicle Release accelerator ...

Page 20: ...nually or 200 Hours One Year Under Normal Use Six Months Under Dusty Conditions Two Years or 300 Hours Monthly See Manual Two Years or 300 Hours One Year or 150 Hours One Year or 150 Hours WARNING HOT manifold and muffler can cause severe burns DANGER Gasoline extremely flammable Keep heat sparks and open flame away from fuel tank and fuel lines Do not add fuel while engine is running or hot Servi...

Page 21: ...ed Be sure that all nuts bolts and screws are tight On all gasoline vehicles check all hose clamps for tight fit as well as the starter belt for tight ness Warning Decals Check to ensure that all warning and operation decals are in place See Pages 4 through 14 Tires Check for proper tire pressure See Tire Capacities Page 45 Batteries electric vehicles Check electrolyte to ensure that it is at its ...

Page 22: ...celerator All Carryalls except the Carryall II Plus and gasoline powered Carryall VI 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 The electric vehicle should run at reduced speed in reverse Carryall II Plus and gaso...

Page 23: ... OR DEATH DUE TO UNSAFE SPEEDS DO NOT MODIFY OR CHANGE THE VEHICLE IN ANY WAY WHICH MIGHT AFFECT ITS STABIL ITY OR HANDLING OR INCREASE MAXIMUM VEHICLE SPEED BEYOND FACTORY SPECIFI CATIONS PROPERTY DAMAGE PERSONAL INJURY OR DEATH COULD RESULT DO NOT SHIFT THE FORWARD REVERSE SWITCH WHILE THE VEHICLE IS IN MOTION TO AVOID INJURY TO AN UNSUSPECTING PASSENGER OR DAMAGE TO THE VEHICLE ALWAYS BRING THE...

Page 24: ...CCELERATOR PEDAL DIFFERS FROM THAT OF AN AUTOMO BILE 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 P...

Page 25: ... inch 10 millime ters 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 for ward or reverse position To put the vehicle back into t...

Page 26: ...owerDrive 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 Power Drive on board computer BE SURE TO RETURN THE CAM TO THE OPERATE POSITION AFTER SERVIC...

Page 27: ...pletion as soon as possible The warning light will come on and remain illuminated if the charger times out at 16 hours see Power Drive Charger Owner Manual and the batteries are not sufficiently charged This indicates an abnor mal 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 connec...

Page 28: ... TO PREVENT OVERTURNING OF THE VEHICLE DRIVE SLOWLY IN TURNS TO PREVENT OVERTURNING OF THE VEHICLE DRIVE SLOWLY STRAIGHT UP AND DOWN SLOPES DO NOT DRIVE THE VEHICLE ON SLOPES EXCEEDING 20 INCLINE AVOID STOPPING A LOADED VEHICLE ON A HILL IF A LOADED VEHICLE MUST BE STOPPED ON A HILL AVOID SUDDEN STARTS OR ROLLING BACKWARDS AND STOPPING SUDDENLY FAILURE TO HEED THIS WARNING COULD RESULT IN OVERTURN...

Page 29: ... GOING DOWNHILL GASOLINE VEHICLE ONLY DEPRESS THE BRAKE PEDAL AS NECESSARY AND PARTIALLY DEPRESS THE ACCELERATOR WHEN DESCENDING A HILL WITH THE ACCELERATOR PEDAL PARTIALLY DEPRESSED THE GOVERNOR WILL CAUSE THE ENGINE TO ASSIST THE BRAKES IN CONTROLLING DOWNHILL SPEED DRIVING THROUGH WATER MAY AFFECT THE BRAKES AFTER DRIVING THROUGH WATER CHECK EFFECTIVENESS OF THE BRAKES BY GENTLY DEPRESSING THE ...

Page 30: ... FAMILIAR WITH ALL CONTROLS AND OPERATING PROCEDURES DO NOT TAMPER WITH THE GASOLINE VEHICLE 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 MIGHT AFFECT ITS STABIL ITY OR HANDLING OR INCREASE MAXIMUM VEHICLE SPEED BEYOND ...

Page 31: ...ORIGINAL POSITION AND THE ENGINE WILL DROP BACK TO IDLE FIGURE 13 FIGURE 14 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 FIGURE 15 FIGURE 16 NOTE Vehicle rated capacity 800 lbs on level surface See Owner s manual Maximum cargo bed load ...

Page 32: ...put the vehicle back into the OPERATE position pull the cam out approximately 3 8 inch 10 millimeters and rotate it one half turn until it snaps into place See Fig ure 19 See WARNING and NOTE below Choke The choke is located on the seat support panel below and to the left of the driver s left knee See Figure 20 If the vehicle is hard to start in cool or cold temperatures simply push in the choke c...

Page 33: ...ensure safe operation of the vehicle follow exactly and in order all of the following procedures Read and understand all instructions prior to driving the vehicle See WARNINGS at top of page 28 FAILURE TO ADD OIL IMMEDIATELY WHEN THE OIL WARNING LIGHT STAYS ON MAY RESULT IN PERMANENT ENGINE DAMAGE FIGURE 18 FIGURE 19 FIGURE 20 FIGURE 21 CAUTION NEUTRAL FORWARD SERVICE POSITION NEUTRAL FORWARD OPER...

Page 34: ... GROUND OR OTHER OBJECTS TO PREVENT OVERTURNING OF THE VEHICLE DRIVE SLOWLY IN TURNS TO PREVENT OVERTURNING OF THE VEHICLE DRIVE SLOWLY STRAIGHT UP AND DOWN SLOPES DO NOT DRIVE THE VEHICLE ON SLOPES EXCEEDING 20 INCLINE AVOID STOPPING A LOADED VEHICLE ON A HILL IF A LOADED VEHICLE MUST BE STOPPED ON A HILL AVOID SUDDEN STARTS OR ROLLING BACKWARDS AND STOPPING SUDDENLY FAILURE TO HEED THIS WARNING ...

Page 35: ...elerator pedal and depress the brake pedal with your right foot until the vehicle comes to a complete stop PARKING AND LEAVING THE VEHICLE 1 After stopping the vehicle firmly depress the park brake pedal until it locks This will prevent the vehicle from rolling 2 Turn the key switch to OFF and place the shift lever in the NEUTRAL position Remove the key when the vehicle is not in use IF THE ACCELE...

Page 36: ...F A TRAILER MAXIMUM SUM OF THE GROSS WEIGHT AND TONGUE WEIGHT OF TRAILER 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 THE TONGUE WEIGHT OF ANY TRAILER SHOULD NEVER EXCEED 150 LBS 68 KG OVERLOADING CAN AFFECT VEHICLE HANDLING OR CAUSE COMPONENT FAILURE RESULTING IN LOSS OF CONTROL OF VEHICLE AND POSSIBLE SEVERE PER...

Page 37: ...Brakes should be released to allow the chocks to absorb the load of the trailer After the tires have been chocked engage the park brake FIGURE 22 FIGURE 23 FIGURE 24 NEVER TOW THE VEHICLE ON PUBLIC STREETS OR HIGHWAYS NORMAL VEHICLE OPERATING SPEED SHOULD BE REDUCED WHEN TOWING A TRAILER EXTREME CAUTION SHOULD BE USED WHEN TOWING A TRAILER TOTAL VEHICLE CAPACITY INCLUDING TOW VEHICLE LOAD AND GROS...

Page 38: ...ULD CAUSE THE VEHICLE TO OVERTURN POSSIBLY RESULTING IN SEVERE PERSONAL INJURY NORMAL VEHICLE OPERATING SPEED SHOULD BE REDUCED WHEN TOWING A TRAILER 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 1600 LBS 727 KG CARRYALL I II AND II PLUS PER VEHICLE TO BE TOWED EXAM...

Page 39: ...ip 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 crank shaft several times and then re install the spark plug 5 Inflate tires to rated capacities See Tire Specifications Page 45 GASOLINE FLAMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE NEVER AT...

Page 40: ... Operation Checklist See pages 15 and 16 STORAGE ELECTRIC VEHICLE 1 Unload the vehicle completely so that only minimum vehicle weight will be on the tires 2 Fully charge batteries See Batteries Electric Vehicle Page 48 WHEN RUNNING THE ENGINE FOR THE FIRST TIME AFTER STORAGE IT MAY SMOKE EXCESSIVELY FOR A SHORT WHILE DUE TO THE OIL ADDED TO THE ENGINE IN PREPARA TION FOR STORAGE TURN THE KEY SWITC...

Page 41: ...re to rated capacities See Tire Specifications Page 45 3 Perform the Pre Operation Checklist See pages 15 and 16 MAINTENANCE GENERAL INFORMATION To ensure trouble free vehicle performance it is very important to follow an established preventive mainte nance program regularly scheduled service even though the vehicle is functional Regular and consistent vehicle maintenance can prevent vehicle down ...

Page 42: ...GINE MOTOR OR EXHAUST SYSTEM ATTEMPTING TO DO SO COULD CAUSE SEVERE BURNS BE SURE ALL PERSONS ARE CLEAR OF THE REAR OF THE VEHICLE WHEN LIFTING A CARGO 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 AND LIFTING THE BED DO NOT REMOVE PROP ROD OR CLOSE BED UNTIL ALL PERSONS ARE CLEAR OF THE BED AREA ...

Page 43: ... LONGER BE HEARD WHEN THE BUZZER STOPS SOUNDING THE CONTROLLER IS DISCHARGED 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 FIGURE 25 FIGURE 26 WARNING NOTE POS NEG POS NEG POS NEG POS NEG POS NEG POS NEG 1 2 5 6 4 3 FRONT OF CAR POWERDRIVE SYSTEM 48 CARRY...

Page 44: ...stem Check air filter element clean as necessary Engine cooling air intake Check for clogging clean as necessary Fuel System Check fuel tank lines cap pump and carburetor for fuel leakage Park Brake Check for proper operation See Page 16 Reverse Warning Buzzer Check for proper operation See NOTE Page 18 Steering and linkages Check for proper operation See Performance Inspec tion Page 16 Tires Chec...

Page 45: ...or proper operation adjust as necessary See NOTE Page 18 Accelerator governor linkage and cables Check for proper operation adjust as necessary Steering Lubricate per Gas Vehicle Lubrication Chart on Page 43 General Vehicle Lubricate per Gas Vehicle Lubrication Chart on Page 43 Check all daily weekly and monthly items listed above Semi annual Service by Trained Mechanic Only Every 50 hours of oper...

Page 46: ... Replace Front Wheel Bearings Inspect and check for free play repack with chassis lube and adjust as necessary Starter Generator Check brush length remove excess carbon dust replace as necessary Unitized Transaxle Check fill transaxle to plug level See Gas Vehicle Lubrication Chart on Page 43 General Vehicle Lubricate per Gas Vehicle Lubrication Chart on Page 43 Check all daily weekly monthly quar...

Page 47: ... Check maximum speed of vehicle See Performance Inspection Page 16 Check all daily items listed above Monthly Service by Owner or Trained Mechanic Batteries Wash battery tops with baking soda water solution Brake System Check for proper operation See Performance Inspec tion Page 16 Check brake pedal free play Adjust as necessary See Carryall Maintenance Service Manual Check brake cables for damage...

Page 48: ...rvice by Trained Mechanic Only Every 100 hours of operation Accelerator Switch Continuously Variable Potentiometer Check for proper operation remove cover and inspect for wear and damage See Carryall Maintenance Service Manual Batteries Perform discharge test Motor Check motor brushes replace as necessary Front Wheel Bearings Inspect and check for free play repack with chassis lube and adjust as n...

Page 49: ...ings 4 Chassis Lube Annually by Trained Technician Only Every 100 hours of operation Check fill unitized transaxle to plug level 5 27 oz 8 liter 80 90 WT API Class GL 3 or 80 90 WT AGMA Class EP Gear Lube Inspect front wheel bearings Repack as necessary 6 Chassis Lube First Change 100 Hours Additional Change Every 200 Hours of Operation or Annually Whichever Comes First Change engine oil and oil f...

Page 50: ...ar Part No 1012151 Accelerator pivots 3 Dry Moly Lube Club Car Part No 1012151 Forward and reverse switch contacts and charger receptacle 4 WD 40 Front Suspension 5 fittings 5 Chassis Lube Anually by Trained Technician Only Every 100 hours of operation Check fill transaxle to plug level 6 22 oz 67 liter SAE 30 WT API Class SE SF or SG Oil or higher Inspect front wheel bearings Repack as necessary ...

Page 51: ...i 110 124 kPa 18 20 psi 124 138 kPa Carryall II 30 34 psi 207 234 kPa 30 34 psi 207 234 kPa Carryall II Plus 30 34 psi 207 234 kPa N A Carryall VI 30 34 psi 207 234 kPa 30 34 psi 207 234 kPa TO CHECK ENGINE OIL THE ENGINE MUST BE IN LEVEL POSITION REMOVE THE OIL LEVEL DIPSTICK FROM THE OIL FILLER TUBE AND WIPE OIL FROM IT WITH A CLEAN DRY CLOTH OR PAPER TOWEL CHECK OIL BY INSERTING THE DIPSTICK FU...

Page 52: ...VENTILATED AREA ONLY NEVER ATTEMPT TO POUR GASOLINE INTO THE FUEL TANK WHEN THE ENGINE IS HOT OR WHILE IT IS RUNNING TO AVOID ELECTRIC ARC CAUSED BY STATIC ELECTRICITY THE FUEL STORAGE PUMP ING DEVICE MUST BE GROUNDED IF THE PUMP IS NOT GROUNDED THE VEHICLE MUST BE GROUNDED TO THE PUMP BEFORE AND DURING THE FUELING OPERATION IF THE VEHICLE HAS AN ALL WEATHER ENCLOSURE INSTALLED THE GAS TANK MUST B...

Page 53: ...AUSE SPARKS WHEN SHORTED ACROSS A BATTERY FOLLOW ALL INSTRUCTIONS CAREFULLY WHEN WORKING WITH BATTERIES CHARGE BATTERY IN A WELL VENTILATED AREA ONLY POISON CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING ANTIDOTES EXTERNAL FLUSH WITH WATER FOR 15 MINUTES CALL A PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOWED WITH MILK OF MAGNESIA OR VEGET...

Page 54: ...ehi cle for use each day DO NOT ALLOW BAKING SODA SOLUTION TO ENTER THE BATTERIES IF BATTERY WIRE TERMINALS ARE DAMAGED OR CORRODED THEY SHOULD BE REPLACED OR CLEANED AS NECESSARY FAILURE TO DO SO MAY CAUSE THEM TO OVER HEAT DURING OPERATION BATTERY EXPLOSIVE GASSES DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE TOOLS WIRES AND METAL OBJECTS CAN CAUSE SPARKS WHEN SHORTED ACR...

Page 55: ...laced Torque battery terminals to 90 100 in lbs 10 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 A BATTERY WATERING GUN IS AVAILABLE AT MANY AUTO PARTS DEALERS IF BATTERY WIRE TERMINALS ARE DAMAGED OR CORRODED THEY SHOULD BE REPLACED ...

Page 56: ...WAS DROPPED OR OTHERWISE DAMAGED IN ANY WAY NEVER PUSH OBJECTS OF ANY KIND INTO THE CHARGER THROUGH CABINET SLOTS THEY MAY TOUCH DANGEROUS VOLTAGE POINTS OR CAUSE AN ELECTRICAL SHORT CIR CUIT THAT COULD RESULT IN FIRE OR ELECTRICAL SHOCK 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 E...

Page 57: ... must be changed at least five times per hour Consult a local HVAC engineer If a vehicle s on board charger should become non functional an external stationary charger can be plugged into the vehicle charger receptacle to charge the batteries When an external stationary charger is used to charge the batteries the on board charger is by passed altogether See the WARNINGS on page 50 TO CHARGE BATTER...

Page 58: ...energy being returned to the batteries When the optimum amount of energy needed to replenish the batter ies 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 Power Drive Charger Neither vehicles made by other manufact...

Page 59: ... asphalt creosote paint or chewing gum should be removed immediately to pre vent possible stains Use commercial automotive products because the finish on the vehicle is the same as the finish on today s automobiles VEHICLE CONTROLLER ELECTRIC VEHICLE The Carryall electric vehicle is equipped with a Solid State Speed Controller In order to properly service and maintain the Solid State Controller Ve...

Page 60: ...ine Electric Gasoline Gasoline Electric Engine 4 cycle OHV 286 cc 9 0 hp rated single cylinder air cooled with pressure lubrication system Engine 4 cycle OHV 351 cc 11 0 hp rated single cylinder air cooled with pressure lubrication system Drive Motor Direct drive 48 volts DC series wound 3 1 hp Fuel System Side draft carburetor with float bowl fixed jets fuel filter and impulse fuel pump Governor ...

Page 61: ...se 65 1 2 166 cm 65 1 2 166 cm 77 1 2 197 cm 77 1 2 197 cm 77 1 2 197 cm 98 1 2 250 cm 98 1 2 250 cm Ground Clearance 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 11 cm Front Wheel Tread 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 88 cm Rear Wheel Tread 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 ...

Page 62: ...7 8 124x126 x 28 cm 48 3 4 x 49 3 4 x 10 7 8 124x126 x 28 cm 48 3 4 x 49 3 4 x 10 7 8 124x126 x 28 cm 64 3 16 x 44 x 18 1 2 163x112 x 47 cm 64 3 16 x 44 x 18 1 2 163x112 x 47 cm Load Bed Size Flat bed inside dimensions 35 3 4 x 44 1 4 91 x 112 cm 35 3 4 x 44 1 4 91 x 112 cm 46 7 8 x 48 5 16 119 x 126 cm 46 7 8 x 48 5 16 119 x 126 cm 46 7 8 x 48 5 16 119 x 126 cm 67 5 8 x 44 3 16 172 x 112 cm 67 5 ...

Page 63: ... OF THE ORIGINAL RETAIL SALE PURCHASER MUST PROVIDE PROOF OF DATE OF PUR CHASE WITH ANY WARRANTY CLAIM 2 EXCLUSIONS Excluded from any CLUB CAR warranty are all optional equipment and accessories fuses filters decals except safety decals spark plugs lubricants trim pieces seats routine wear items such as the charger plug and receptacle brake shoes belts brushes bushings engine mounts mats and pads ...

Page 64: ...IED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WAR RANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REMEDY OF REPAIR OR REPLACE MENT OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE EXCLUSIVE AND SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES...

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Page 68: ...Club Car Inc P O Box 204658 Augusta GA 30917 4658 ...

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