Transportation vehicles electric and gasoline (80 pages)
Summary of Contents for Club Car CARRYALL I 1997
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Club Car Club Car Owner’s Manual Owner’s Manual 1997 1997 Carryall Carryall Vehicles Vehicles Manual Number: 101906302 Print Code: 0796A00000...
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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.
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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.
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 safey 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 warn- ings in this manual, as well as the safety decals on your vehicle, before operating the vehicle.
If any of the operation or warning decals 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 •...
GENERAL WARNINGS The safety procedures listed must be followed whenever the vehicle is being operated, repaired, or serviced. Other specific warnings appear throughout this manual and on the vehicle. DANGER • GASOLINE VAPORS - FLAMMMABLE! EXPLOSIVE! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE.
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General Warnings, Continued: WARNING ELECTRIC VEHICLES ONLY: • TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, DISCONNECT THE BATTERIES AS SHOWN (SEE FIGURES 1 AND 2) AND DISCHARGE THE CONTROLLER AS FOLLOWS: - TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD AND REVERSE SWITCH IN THE REVERSE POSITION.
CARRYALL I AND CARRYALL II GASOLINE OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS • Read owner’s manual prior to operation. • Study and understand controls. Be sure everyone is seated. • Before driving, read safety warnings located above pedals. • Make sure wheels are turned in desired direction. TILT BED VEHICLE LOADING •...
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VEHICLE FEATURE IDENTIFICATION GASOLINE TANK DANGER LABEL (ON BODY UNDER SEAT) • 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. DANGER •...
CARRYALL I AND CARRYALL II ELECTRIC OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS • Read owner’s manual prior to operation. • Study and understand controls. Be sure everyone is seated. • Before driving, read safety warnings located above pedals. • Make sure wheels are turned in desired direction. •...
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VEHICLE FEATURE IDENTIFICATION BATTERY DANGER LABEL (ON BODY UNDER SEAT) DANGER / POISON FLUSH EYES SULFURIC IMMEDIATELY WITH WATER ACID SHIELD • SPARKS CAN CAUSE EYES • FLAMES MEDICAL EXPLOSIVE BLINDNESS OR • SMOKING HELP GASES SEVERE BURNS CAN CAUSE FAST BLINDNESS OR INJURY KEEP OUT OF THE REACH OF CHILDREN –...
CARRYALL II PLUS (GASOLINE) OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS • Read owner's manual prior to operation. • Study and understand controls. Be sure everyone is seated. • Before driving, read safety warnings located above pedals. •To start engine: -Place shift lever in "N" - Neutral posistion. -Depress brake pedal.
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VEHICLE FEATURE IDENTIFICATION GASOLINE TANK DANGER LABEL (ON BODY UNDER SEAT) • Gasoline – extremely flammable. • Keep heat, sparks and open flame away from fuel tank and fuel lines. DANGER • Do not add fuel while engine is running or hot. •...
CARRYALL VI ELECTRIC VEHICLE LOADING LABEL VEHICLE LOADING • Vehicle rated capacity - 1500 lbs. on level surface - See Owner's manual. • Maximum cargo bed load - 1000 lbs. • No more than two people in front seat. • Cargo should be evenly spread over the floor of cargo bed as far forward as possible.
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VEHICLE FEATURE IDENTIFICATION OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS • Read owner’s manual prior to operation. • Study and understand controls. Be sure everyone is seated. • Before driving, read safety warnings located above pedals. • Make sure wheels are turned in desired direction. •...
CARRYALL VI GASOLINE VEHICLE LOADING LABEL VEHICLE LOADING • Vehicle rated capacity - 1500 lbs. on level surface - See Owner's manual. • Maximum cargo bed load - 1000 lbs. • No more than two people in front seat. • Cargo should be evenly spread over the floor of cargo bed as far forward as possible.
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VEHICLE FEATURE IDENTIFICATION OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS • Read owner's manual prior to operation. • Study and understand controls. Be sure everyone is seated. • Before driving, read safety warnings located above pedals. •To start engine: -Place shift lever in "N" - Neutral posistion. -Depress brake pedal.
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CARRYALL VI GASOLINE VEHICLE FEATURE IDENTIFICATION GASOLINE TANK DANGER LABEL (ON FRAME) • Gasoline – extremely flammable. WARNING HOT MANIFOLD • Keep heat, sparks and open flame away from fuel AND MUFFLER tank and fuel lines. DANGER • Do not add fuel while engine is running or hot. HOT manifold and muffler (ON ENGINE) •...
MODEL IDENTIFICATION The serial number of your CLUB CAR is printed on a bar code decal mounted on the frame directly above the accelerator pedal (Example: F9701-123456 for Electric or FG9701-123456 for Gasoline) (See Figure 3) .
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. Use the following checklist as a guide to inspect your new vehi- cle. Any problems should be corrected only by your CLUB CAR distributor/dealer or a trained technician. All vehicles: •...
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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. • 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.
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Forward/Reverse Control, Continued: NOTE • THE REVERSE BUZZER WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE. FIGURE 6 FIGURE 7 FIGURE 8 ACCELERATOR PEDAL The accelerator pedal is the pedal on the right, with the word GO molded into it (See Figure 6). NOTE •...
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BRAKE PEDAL The brake pedal is the large pedal on the left with the word STOP molded into it (See Figure 6). To slow or stop the vehicle, depress the brake pedal with your right foot (See Figure 7). PARK BRAKE PEDAL The park brake pedal is the small raised portion in the upper left corner of the brake pedal.
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Neutral Lock-out, Continued: NOTE • BE SURE TO RETURN THE CAM TO THE OPERATE POSITION AFTER SERVICING THE VEHI- CLE, OR IT WILL NOT RUN WITH THE FORWARD AND REVERSE SWITCH IN EITHER THE FORWARD OR REVERSE POSITION. 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 cover with your left hand to activate it.
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 30 minutes, have your Club Car distributor/ dealer check the vehicle for a possible battery or electrical system problem.
Driving Instructions - Carryall I Electric, Carryall II Electric, Carryall VI Electric, Carryall I Gasoline, and Carryall II Gasoline Vehicles, Continued: WARNING • STOP THE VEHICLE BEFORE SHIFTING THE FORWARD AND REVERSE LEVER. FAILURE TO DO SO MAY RESULT IN INJURY TO AN UNSUSPECTING PASSENGER AND (OR) DAMAGE TO THE VEHICLE.
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 •...
Controls - Carryall II Plus and Carryall VI Gasoline Vehicles, Continued: WARNING • BEFORE ALLOWING ANYONE TO DRIVE THE VEHICLE, BE SURE HE OR SHE IS 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.
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NOTE • THE OPERATION OF THE ACCELERATOR PEDAL DIFFERS FROM THAT OF AN AUTOMO- BILE. 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).
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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 15). To set park brake, depress the brake pedal firmly and tilt the park brake portion of the pedal forward with your foot (Figure 17).
the engine as necessary before continuing to use the vehicle. The vehicle should never be driven with the oil warning light remaining on. If the oil warning light goes on and off, you may proceed, but oil should be added at the first opportunity.
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Driving Instructions - Carryall II Plus and Carryall VI Gasoline Vehicles, Continued: 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. •...
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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. Driver should have both hands on the steering wheel. 5.
BED LATCH The Carryall I, Carryall II, and Carryall II Plus are equipped with a bed latch on the driver’s side of the vehicle as standard equipment (See Figure 22). To lift the bed, pull the latch handle toward the rear of the vehicle and lift the bed (See Figure 23).
SEAT BACK BED LATCH FIGURE 22 FIGURE 23 PROP PROP FIGURE 24 TOWING A TRAILER Because towing a trailer can have adverse effects on vehicle handling, be especially cautious when towing a trailer with a Carryall vehicle. Total vehicle capacity, including the tow vehicle load rating and the gross weight of the trailer should not exceed the weight specified in the WARNING below.
SHOULD BE RATED AT 2 X 1600 = 3200 LBS (2 X 727 = 1454 KG)) (2000 LBS (909 KG) FOR CAR- RYALL VI). • NEVER TOW A CLUB CAR VEHICLE BEHIND A PASSENGER VEHICLE OR TRUCK ON A PUB- LIC ROAD UNLESS IT IS ON AN APPROVED TRAILER.
STORAGE - GASOLINE VEHICLE To prepare your vehicle for extended off season storage: 1. Unload the vehicle completely, 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 10 amps or less.
Storage - Gasoline Vehicle, Continued: 6. Grease front suspension and do all quarterly periodic lubrication (See Periodic Lubrication Sched- ule, Page 43). 7. Thoroughly clean front body, rear body, seats, cargo bed, engine compartment, and underside of vehi- cle. 8. Do not latch the park brake. Block tires to prevent the vehicle from rolling. TO RETURN THE STORED VEHICLE TO SERVICE: 1.
This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semi-annual and annual periodic ser- vice.
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Maintenance, Continued: WARNING • ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THE VEHICLE. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD FOLLOW THE PROCEDURES EXACTLY AS STATED IN THIS MANUAL, AND OBEY THE DANGERS, WARNINGS, AND CAUTIONS LISTED IN THIS MANUAL, AS WELL AS THOSE AFFIXED TO THE VEHICLE. •...
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WARNING ELECTRIC VEHICLES ONLY: • TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, DISCONNECT THE BATTERIES AS SHOWN (SEE FIGURES 25 AND 26) AND DISCHARGE THE CONTROLLER AS FOLLOWS: - TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD AND REVERSE SWITCH IN THE REVERSE POSITION.
PERIODIC SERVICE SCHEDULES WARNING • IF ANY PROBLEMS ARE FOUND, DO NOT OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE. FAILURE TO MAKE NECESSARY REPAIRS COULD RESULT IN FIRE, PROPERTY DAM- AGE, SEVERE PERSONAL INJURY, OR DEATH. • ALL SERVICE, REPAIRS, AND ADJUSTMENTS MUST BE MADE PER INSTRUCTIONS IN THE CARRYALL MAINTENANCE AND SERVICE MANUAL, PUBLICATION PART NO.
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PERIODIC SERVICE SCHEDULE - GASOLINE VEHICLE REGULAR INTERVAL SERVICE Wash battery top with baking soda/water solution Battery (See Page 47). Check brake cables for damage; replace as required. Check for proper operation (See Performance Inspec- Brake System tion, Page 16). Check brake pedal free play. Adjust as necessary (See Carryall Maintenance &...
PERIODIC SERVICE SCHEDULE - GASOLINE VEHICLE REGULAR INTERVAL SERVICE Check and adjust as required. See Carryall Mainte- Front Wheel Alignment and Camber nance & Service Manual. Check for cracks, wear, and glazing, replace if neces- sary. Starter/Generator Belt Semi-annual Service by Check belt tension, adjust as required.
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PERIODIC SERVICE SCHEDULE - ELECTRIC VEHICLE REGULAR INTERVAL SERVICE Accelerator Switch Check for proper operation (See Carryall Mainte- (Continuously Variable Potentiometer) nance and Service Manual). Batteries Charge batteries. Check for proper operation (See Performance Inspec- Brake System tion, Page 16). Adjust as necessary. Charger and Receptacle Check for damage and snug fit.
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PERIODIC SERVICE SCHEDULE - ELECTRIC VEHICLE REGULAR INTERVAL SERVICE Check specific gravity, electrolyte level, and on- Batteries charge voltage. Check for proper operation (See Performance Inspec- tion, Page 16). Check brake pedal free play. Clean, and adjust as necessary (See Carryall Maintenance &...
REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT PLACE Brake shaft bearings Dry Moly Lube - Club Car Part No. 1012151 Brake Linkage and Pivots Dry Moly Lube - Club Car Part No. 1012151 Quarterly by Owner Accelerator push rod pivots and Dry Moly Lube - Club Car Part No. 1012151...
REGULAR INTERVAL SERVICE PLACE RECOMMENDED LUBRICANT Brake shaft bearings Dry Moly Lube - Club Car Part No. 1012151 Brake Linkage and Pivots Dry Moly Lube - Club Car Part No. 1012151 Quarterly by Owner Accelerator pivots Dry Moly Lube - Club Car Part No. 1012151...
FUELING INSTRUCTIONS - GASOLINE VEHICLE DANGER • GASOLINE - FLAMMABLE! EXPLOSIVE! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE. • SERVICE OR REPAIR IN WELL VENTILATED AREA ONLY. • NEVER ATTEMPT TO POUR GASOLINE INTO THE FUEL TANK WHEN THE ENGINE IS HOT OR WHILE IT IS RUNNING.
(1 cup per gallon of water), and then the baking soda solution rinsed off the battery. Do not allow the solution to get into the battery. Be sure terminals are tight. Let the terminals dry and then spray them with CLUB CAR battery terminal spray (Club Car Part No.1014305). See CAUTION at top of page 48.
Battery - Gasoline Vehicle, Continued: CAUTION • 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.
(NOTE: Do not allow this solution to enter the battery). Be sure terminals are tight. Let the terminals dry and then spray them with CLUB CAR battery protector spray (Club Car Part No. 1014305). 2. The water level in the batteries should be checked weekly (See Figure 32, Page 47, for proper level).
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WARNING • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THE CHARGER. CONTACT YOUR NEAREST CLUB CAR DISTRIBUTOR/DEALER. • EACH CHARGER SHOULD HAVE ITS OWN DEDICATED 15 OR 20 AMPERE SEPARATELY PRO- TECTED (CIRCUIT BREAKER OF FUSE) SINGLE PHASE BRANCH CIRCUIT, IN ACCORDANCE WITH ALL APPLICABLE ELECTRICAL CODES FOR THE LOCATION.
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CAUTION • DO NOT BLOCK OR COVER SLOTS AND OPENINGS IN THE BACK AND BOTTOM OF CHARGER CABINET. THEY PROVIDE VENTILATION AND PROTECT THE CHARGER FROM OVERHEATING. • DO NOT ALLOW CLOTHING, BLANKETS, OR OTHER MATERIAL TO COVER THE CHARGER. •...
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Because of these unique features, only PowerDrive System 48 vehicles are compatible with the Power- Drive Charger (Neither vehicles made by other manufacturers, nor other Club Car models are compatible). As long as the charger is allowed to shut off by itself, the batteries will be fully charged. Overcharging and undercharging will normally be prevented.
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 repair or servicing needs to be performed, we recommend that it be performed by an authorized Club Car distributor/dealer using CLUB CAR OEM parts.
In the event a vehicle is bought used from another individual or 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.
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Carryall SPECIFICATIONS Carryall I Carryall II Carryall VI II Plus STEERING/SUSPENSION/BRAKES, continued: Gasoline Electric Gasoline Electric Gasoline Gasoline Electric Brakes: Mechanical brake cable system to self-adjusting drum brakes on • each rear wheel. Park brake is automatically released. Self-adjusting multi- •...
Carryall SPECIFICATIONS Carryall I Carryall II Carryall VI II Plus DIMENSIONS/WEIGHT, continued: Gasoline Electric Gasoline Electric Gasoline Gasoline Electric 27” 27” 27 5/8” 27 5/8” 27 5/8” 27” 27” Load Bed Height: Box bed inside dimensions. (69 cm) (69 cm) (70 cm) (70 cm) (70 cm)
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UNITED STATES AND CANADA 1. WARRANTY: CLUB CAR, INC. (“CLUB CAR”) hereby warrants to the original retail purchaser that its new 1997 Model Car- ryall vehicle purchased from CLUB CAR or an authorized distributor/dealer for use in the United States or...
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CLUB CAR’S ONLY LIABILITY UNDER THIS LIMITED WARRANTY, OR IN ANY ACTION WHETHER BASED UPON WARRANTY, CONTRACT, NEGLIGENCE, STRICT PRODUCT LIABILITY OR OTHER- WISE, IS LIMITED TO THE REPAIR OR REPLACEMENT, AT CLUB CAR’S OPTION, OF A VEHICLE OR COMPONENT THEREOF THAT CLUB CAR DEEMS TO BE DEFECTIVE. REPLACEMENT SHALL MEAN...
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Club Car, Inc. P.O. Box 204658 Augusta, GA 30917-4658...
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