Club Car Carryall 1 Owner's Manual
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Club Car Carryall 1 Owner's Manual

Electric industrial truck
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Carryall 1
Carryall 2
Carryall 6
E
lectric
2002
I
ndustrial
T
ruck
Owner' s
Manual

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Summary of Contents for Club Car Carryall 1

  • Page 1 Carryall 1 Carryall 2 Carryall 6 lectric 2002 ndustrial ruck Owner’ s Manual...
  • Page 3 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.
  • Page 4 Page 2 2002 Carryall Electric Industrial Truck Owner’s Manual...
  • Page 5 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 Carryall vehicle(s) provides years of reliable, superior performance by read- ing and following the maintenance instructions in this manual.
  • Page 6 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 before operating the vehicle, we urge you to review the information in this manual.

  • Page 7: Table Of Contents

    Vehicle Feature Identification – Carryall 1 and Carryall 2 ....... .

  • Page 8: General Information

    General Information GENERAL INFORMATION There are three electric Carryall models: the Carryall 1, Carryall 2, and Carryall 6. The Carryall electric industrial truck is produced for commercial use; it has been designed for transportation of cargo and passengers in both indoor and outdoor settings. Its construction allows for operation on turf, paved, and prepared surfaces on inclines not to exceed 20%.

  • Page 9: Accessories

    (30-34 psi) ACCESSORIES There is a complete line of accessory equipment available from Club Car and our dealers. Care should be taken that these accessories are properly installed by trained technicians, and they are used in the manner for which they were designed. See following WARNING.
  • Page 10 • If the vehicle is equipped with an electric powered bed lift, remove the bed before servicing the bed lift system. ACCESSORY EQUIPMENT ACCESSORY Carryall 1 Carryall 2 Carryall 6 3-sided enclosure • •...

  • Page 11: Model Identification

    NOTE: Always have the vehicle serial number at hand when ordering parts or making inquiries. The specifications decal containing the CE mark is located on the frame below the dash and directly above the brake pedal. See Vehicle Feature Identification beginning on page 18. Club Car SERIAL NUMBER FA0201-123456...
  • Page 12 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 property damage, personal injury, or death. Contact your Club Car dealer. ∆...
  • Page 13 Driving Instruction Warnings - Be sure all passengers are capable of securing themselves in a moving Carryall vehicle before allowing them to ride in one. - Be sure all persons can properly operate the vehicle prior to allowing them to drive the vehicle.
  • Page 14 Loading and Unloading Warnings LOADING AND UNLOADING WARNINGS The following warnings should be observed when loading and unloading the vehicle. See Loading and Unloading on page 30. ∆ WARNING • Follow all procedures listed in this manual for loading and unloading the vehicle. Do not exceed vehicle rated weight capacity.
  • Page 15 • Reduce normal driving speed when transporting a Club Car vehicle on a trailer. • Never tow a Club Car vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer.
  • Page 16 Storage Warnings STORAGE WARNINGS The following warnings should be observed when preparing a vehicle for storage. See Storage on page 31. ∆ WARNING • Turn the key switch OFF, remove the key, and leave the Forward/Reverse handle in the NEUTRAL position during storage. This is to prevent unintentionally starting the vehicle or a fire hazard.
  • Page 17 ∆ WARNING • Only trained technicians should repair or service the charger. Contact a Club Car dealer. • Each charger should have its own dedicated, separately protected (circuit breaker or fuse), single phase branch circuit, in accordance with all applicable electrical codes for the location.
  • Page 18 Maintenance Warnings • Install surge arrestors on incoming AC power lines. Surge arrestors will help protect electrical/electronic components in the charger and on the vehicle from all but direct or very close lightning strikes. MAINTENANCE WARNINGS The following warnings should be observed when performing maintenance. See Maintenance on page 36. ∆...
  • Page 19 Maintenance Warnings Figure 2 Carryall 1 PowerDrive Battery Configuration Figure 3 Carryall 2 and 6 PowerDrive Battery Configuration 2002 Carryall Electric Industrial Truck Owner’s Manual Page 17...

  • Page 20: Vehicle Feature Identification - Carryall 1 And Carryall 2

    Vehicle Feature Identification CARRYALL 1 AND CARRYALL 2 WARNING ROLLOVER OR FALLING OFF MAY CAUSE DEATH. OPERATING INSTRUCTIONS • Before using vehicle, read operating instructions. OPERATING INSTRUCTIONS • Remain seated and hold on to seat handle while moving. • Read Owner’s Manual and safety warnings located on dash panel prior to driving.
  • Page 21 CRUSH AREA Crush area. Can cause severe injury. Stay clear when closing bed. STAY CLEAR CCI 1016094-01 CARRYALL 1 AND 2 VEHICLE IDENTIFICATION KEY (17) Battery danger decal (1) Serial number (9) Accelerator pedal (on body under seat) (2) Battery warning light...

  • Page 22: Vehicle Feature Identification - Carryall 6

    Vehicle Feature Identification CARRYALL 6 WARNING OPERATING INSTRUCTIONS ROLLOVER OR FALLING OFF MAY CAUSE DEATH. • Before using vehicle, read operating instructions. • Read Owner’s Manual and safety warnings located on dash panel prior to driving. • Remain seated and hold on to seat handle while moving. •...
  • Page 23 Vehicle Feature Identification CARRYALL 6 DANGER / POISON FLUSH EYES SULFURIC IMMEDIATELY WITH WATER ACID SHIELD • SPARKS CAN CAUSE EYES • FLAMES BLINDNESS OR MEDICAL EXPLOSIVE • SMOKING HELP SEVERE BURNS GASES CAN CAUSE FAST BLINDNESS OR INJURY KEEP OUT OF THE REACH OF CHILDREN – DO NOT TIP – KEEP VENT CAPS TIGHT AND LEVEL WARNING FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SEVERE INJURY OR DEATH.

  • Page 24: Controls And Indicators

    (REVERSE). Rotate the handle towards the driver (FORWARD) to operate the vehicle in the forward direction, or towards the passenger (REVERSE) to operate the vehicle in reverse. When the handle is in the straight up position (NEUTRAL) the vehicle will not operate. Club Car vehicles operate at reduced speed in reverse.
  • Page 25 Controls and Indicators ACCELERATOR PEDAL The accelerator pedal is the pedal on the right with the word GO molded into it (Figure 7, Page 23). The operation of the accelerator pedal differs from that of an automobile. When the key switch is ON, the For- ward/Reverse handle is in either FORWARD or REVERSE, and the park brake is released, depressing the accelerator pedal will start the motor and the vehicle will begin moving in the direction selected.
  • Page 26 30 minutes. However, the vehicle should be charged at the first opportunity. If the warning light illuminates and the vehicle is unable to operate for 30 minutes, have your Club Car dealer check the vehicle for a possible battery or electrical system problem.

  • Page 27: Pre-Operation And Daily Safety Checklist

    Periodic Service Schedule on page 36. Any problems should be corrected by your Club Car distributor/dealer or a trained technician only. • General: All the parts should be in place and properly installed. Be sure all nuts, bolts, and screws are tight.

  • Page 28: Driving Instructions

    Use the following checklist as a guide to inspect your new vehicle and check daily for proper operation. Any problems should be corrected only by a Club Car dealer or a trained technician.

  • Page 29: Bed Latch

    Read DANGER and WARNING on page 9. The Carryall 1 and 2 are equipped with a bed latch (1) on the driver side of the vehicle as standard equipment (Figure 10, Page 28). To lift bed, pull latch handle toward back of the vehicle and lift the bed.

  • Page 30: Prop Rod

    The Carryall 1 and Carryall 6 are equipped with manual prop rods. To Raise the Bed Carryall 1 Only: When lifting the bed of a Carryall 1 vehicle, remove the prop rod from the clip (1) and insert into hole (2) in inner body (Figure 11, Page 29). See following DANGER.
  • Page 31 • Do not drop tilt bed; lower gently and keep entire body clear. Failure to follow these instructions could result in severe injury. • Keep hands clear of crush area between bed and seat back support. Figure 11 Carryall 1 Prop Rod Figure 12 Carryall 2 Prop Rod Figure 13 Carryall 6 Prop Rod 2002 Carryall Electric Industrial Truck Owner’s Manual...

  • Page 32: Loading And Unloading

    909 kg (2000 lb.) NOTE: A two-car trailer should be rated at 2 x 727 kg = 1454 kg (2 x 1600 lb. = 3200 lb.) for Carryall 1 and 2, or 2 x 909 kg = 1818 kg (2 x 2000 = 4000 lb.) for Carryall 6.

  • Page 33: Storage

    Storage STORAGE Read DANGER and WARNING on page 14. ∆ WARNING • Turn the key switch OFF, remove the key, and leave the Forward/Reverse switch/handle in the NEUTRAL position during storage. This is to prevent unintentionally starting the vehicle or a fire hazard.

  • Page 34: Batteries

    Batteries BATTERIES Read DANGER, WARNING, and CAUTION on page 14. NOTE: Recycle or dispose of discarded batteries in accordance with governmental regulations. Refer to appropriate maintenance and service manual when servicing batteries. The batteries in PowerDrive System 48 electric vehicles are 8-volt, deep-cycle batteries, specially built for electric vehicle application.

  • Page 35: Battery Charger

    Battery Charger 3. The hold-down 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. Tighten hold-down retaining nuts to 4.5 N·m (40 in-lb).
  • Page 36 The control circuit lockout remains activated until the charger plug is discon- nected from the vehicle. This vehicle is only compatible with a PowerDrive Charger. Other Club Car models or vehicles made by other manufacturers are not compatible.
  • Page 37 Batteries should be put on charge even if they have been used for only a short time, i.e., 10 minutes. The charger is automatic and will turn off when batteries are fully charged. If the charger does not seem to be operating properly, or if the batteries seem weak, contact a local Club Car dealer. PLUG AND RECEPTACLE The charger DC cord, plug, and receptacle are wear items and should be inspected daily.

  • Page 38: Maintenance

    Solid State Speed controller vehicle, it is necessary to understand the electrical circuitry and the functions of all components in the system. Therefore, if any repair or service is required, Club Car recom- mends that it be performed by an authorized Club Car dealer using Club Car OEM parts.
  • Page 39 Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Daily service by owner Batteries Charge batteries (after each use only). Weekly service by owner Check electrolyte level. Add water as necessary per Section 13 – Batteries in Batteries the appropriate maintenance and service manual.

  • Page 40: Periodic Lubrication Schedule

    Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE Read DANGER and WARNING on page 16. PERIODIC LUBRICATION SCHEDULE REGULAR INTERVAL SERVICE PLACE* RECOMMENDED LUBRICANT Semiannually by owner Brake pedal shaft bearings Dry Moly Lube (CCI 1012151) or trained technician (every Brake linkage and pivots Dry Moly Lube (CCI 1012151) 50 hours of operation) Accelerator pivot rod supports...

  • Page 41: Cleaning The Vehicle

    In the event a vehicle is bought used from another individual or from a dealer, we strongly urge the new owner to 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.

  • Page 42: Warranties

    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.
  • Page 43 , or IQ System™ purchased from CLUB CAR or an authorized distributor or dealer will be free from defects in material and workmanship and will provide 36-hole performance (60 minute discharge capacity) for a period of four years or 800 rounds, whichever first occurs, from the date of purchase subject to the terms and conditions contained herein.
  • Page 44 5) A battery damaged by a defective charger. Without limiting the generality of the foregoing in any way, and as part of its limited warranty exclusion, CLUB CAR does not warrant that its PowerDrive battery is suitable for use in any application other than in its products. As in the use of any battery, a prudent owner will read and study the charger owner’s manual, the electric vehicle owner’s manual, the operator...
  • Page 45 Limited Warranties expressed herein and any implied warranties null and void and same are hereby excluded. Without limiting the generality of the foregoing in any way, and as part of its limited warranty exclusion, CLUB CAR does not warrant that the PowerDrive or IQ Charger is suitable for use in any application other than its PowerDrive System 48, PowerDrive Plus, and IQ System products.
  • Page 46 4) Vehicles charged by systems other than the CLUB CAR PowerDrive Charger or CLUB CAR IQ Charger. Without limiting the generality of the foregoing in any way, and as part of its limited warranty exclusion, CLUB CAR does not warrant that the Computer or Controller is suitable for use in any application other than its PowerDrive System 48, PowerDrive Plus, and IQ System products.
  • Page 48 Manual No. 102252015 Edition Code 0801A00000 Carryall/Electric Club Car, Inc., P.O. Box 204658 Augusta, GA 30917-4658...

This manual is also suitable for:

Carryall 2Carryall 6

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