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Summary of Contents for Club Car Carryall 294D
- Page 1 2006 Carryall 294 and 294 SE Vehicles Gasoline and Diesel Owner’s Manual Carryall 294 Carryall 294D Carryall 294 SE Carryall 294D SE business...
- 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 We hope you will consider this owner’s manual a permanent part of your Club Car vehicle. If you sell the vehi- cle, please include the manual so that the next owner will have the important operating, safety, and mainte- nance information it contains.
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Page 5: Table Of Contents
TABLE OF CONTENTS Vehicle Feature Identification ........................Safety Details ............................13 General Warnings ............................14 General Information ........................... 16 Model Identification ............................ 16 Controls and Indicators ..........................16 Roll-over Protective Structure and Safety Belts ..................21 Seat Latch and Adjustment ........................22 Pre-Operation and Daily Safety Checklist .................... -
Page 6: Vehicle Feature Identification
Vehicle Feature Identification CARRYALL 294 GASOLINE VEHICLE UNDERAGE WARNING DECAL CERTIFICATION NOTICE AND WARNING DECAL BED LOAD WARNING DECAL DRIVER/PASSENGER WARNING DECAL ROTATING PARTS WARNING DECAL (ON PASSENGER-SIDE VEHICLE FRAME) SERIAL NUMBER DECAL BED LATCH (ON REAR RECEIVER HITCH) WARNING DECAL CRUSH AREA DECAL (ON DRIVER-SIDE AND PASSENGER-SIDE) - Page 7 Vehicle Feature Identification CARRYALL 294 GASOLINE VEHICLE GASOLINE WARNING DECAL OPERATING (ON PASSENGER SIDE SEAT SUPPORT) INSTRUCTIONS (ON PANEL BETWEEN SEATS OR ON OPTIONAL CONSOLE/CUP HOLDER) HOT SURFACE WARNING DECAL (ON UNDERSIDE OF BOTH SEATS) WINCH CABLE WARNING DECAL (FOR VEHICLES WITH WINCH ACCESSORY) FRAME GROUND WARNING DECAL (ON FRONT BODY) (ON VEHICLE FRAME)
- Page 8 Vehicle Feature Identification CARRYALL 294D DIESEL VEHICLE UNDERAGE WARNING DECAL CERTIFICATION NOTICE AND WARNING DECAL BED LOAD WARNING DECAL DRIVER/PASSENGER WARNING DECAL ROTATING PARTS DECAL (TOP OF PASSENGER-SIDE VEHICLE FRAME) SERIAL NUMBER TRAILER HITCH CRUSH AREA DECAL DECAL DECAL (ON DRIVER-SIDE...
- Page 9 Vehicle Feature Identification CARRYALL 294D DIESEL VEHICLE DIESEL WARNING DECAL (ON PASSENGER-SIDE SEAT SUPPORT) OPERATING INSTRUCTIONS (ON PANEL BETWEEN ROTATING PARTS SEATS OR ON WARNING DECAL OPTIONAL CONSOLE/CUP HOLDER) HOT MANIFOLD WARNING DECAL (ON ENGINE VALVE COVER) WINCH CABLE WARNING DECAL...
- Page 10 Vehicle Feature Identification CARRYALL 294 SE GASOLINE VEHICLE UNDERAGE CERTIFICATION WARNING DECAL NOTICE AND WARNING DECAL BED LOAD WARNING DECAL ROTATING PARTS WARNING DECAL DRIVER/PASSENGER WARNING (ON PASSENGER-SIDE DECAL VEHICLE FRAME) SERIAL NUMBER DECAL FALLING OFF WARNING DECAL (ON REAR RECEIVER HITCH) BED LATCH WARNING DECAL CRUSH AREA DECAL...
- Page 11 Vehicle Feature Identification CARRYALL 294 SE GASOLINE VEHICLE GASOLINE WARNING DECAL (ON PASSENGER SIDE SEAT SUPPORT) OPERATING INSTRUCTIONS (ON STEERING WHEEL) HOT SURFACE WARNING DECAL (ON UNDERSIDE OF BOTH SEATS) ROTATING PARTS WARNING DECAL (INSIDE ENGINE COMPARTMENT) FRAME GROUND WARNING DECAL WINCH CABLE WARNING DECAL (ON VEHICLE FRAME) (FOR VEHICLES WITH WINCH ACCESSORY)
- Page 12 Vehicle Feature Identification CARRYALL 294D SE DIESEL VEHICLE UNDERAGE CERTIFICATION WARNING DECAL NOTICE AND WARNING DECAL BED LOAD WARNING DECAL ROTATING PARTS DRIVER/PASSENGER WARNING WARNING DECAL DECAL (ON PASSENGER-SIDE VEHICLE FRAME) SERIAL NUMBER DECAL (ON REAR RECEIVER HITCH) FALLING OFF WARNING DECAL...
- Page 13 Vehicle Feature Identification CARRYALL 294D SE DIESEL VEHICLE DIESEL WARNING DECAL (ON PASSENGER-SIDE SEAT SUPPORT) OPERATING ROTATING PARTS INSTRUCTIONS WARNING DECAL (ON STEERING WHEEL) (IN ENGINE COMPARTMENT) HOT MANIFOLD WARNING DECAL (ON ENGINE VALVE COVER) HOT SURFACE WARNING DECAL (ON COOLANT PIPES AND...
- Page 14 Page 12 2006 Carryall 294/294 SE Gasoline and Diesel Vehicle Owner’s Manual...
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Page 15: Safety Details
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. ý... -
Page 16: General Warnings
• A Club Car vehicle will not provide protection from lightning, flying objects, or other storm- related hazards. If caught in a storm while driving a Club Car vehicle, exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location. - Page 17 General Warnings ý WARNING • Only trained technicians should service or repair the vehicle. Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair. The appropriate instructions must be used when performing maintenance, service, or accessory installation.
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Page 18: General Information
The fuel tank must be removed to view this decal. See following NOTE. NOTE: Have the vehicle serial number available when ordering parts or making inquiries. Club Car SERIAL NUMBER GC0601-123456... - Page 19 Forward/Reverse handle. See WARNING and CAUTION beginning on page 17. Club Car vehicles operate at a reduced speed in reverse. The reverse buzzer will sound as a warning when the Forward/Reverse handle is in the REVERSE position.
- Page 20 Controls and Indicators WARNING WARNING START Figure 4 Instrument Panel – Gasoline Vehicles WARNING WARNING PREHEAT START Figure 5 Instrument Panel – Diesel Vehicles Page 18 2006 Carryall 294/294 SE Gasoline and Diesel Vehicle Owner’s Manual...
- Page 21 Controls and Indicators ACCELERATOR PEDAL The accelerator pedal (1) is the pedal on the right (Figure 6). With the engine running and the Forward/Reverse handle in the FORWARD or REVERSE position, vehicle speed will increase as the accelerator pedal is pressed. When the accelerator pedal is released, it will return to the original position and the engine will idle.
- Page 22 If the warning light comes on, stop the vehicle and allow it to idle for approxi- mately five minutes before stopping the engine. Contact a Club Car dealer/distributor or a trained technician. See following WARNING.
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Page 23: Roll-Over Protective Structure And Safety Belts
WARNING • The ROPS must be properly installed before operating the vehicle. Club Car strongly urges that the vehicle’s occupants be properly restrained at all times with the safety belts provided. Pregnant woman: Consult your doctor for specific recommendations. The safety belt should be worn securely and as low as possible over the hips and not on the waist. -
Page 24: Seat Latch And Adjustment
• The Club Car vehicle is not designed to meet child seat compatibility requirements. Children requiring a child safety seat must not ride on the vehicle. Comply with state and local laws pertaining to child safety. -
Page 25: Pre-Operation And Daily Safety Checklist
5. Install seat in the vehicle. See preceding WARNING “Make sure seat hinges and latch...”. PRE-OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new vehicle(s), you should become familiar with its controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery. -
Page 26: Driving Instructions
Use the following checklist as a guide to inspect the vehicle and check daily for proper operation. Any prob- lems should be corrected by a Club Car dealer/distributor or a trained technician. • Forward/Reverse shifter: Check for proper operation. See Controls and Indicators on page 16. - Page 27 WARNING • The vehicle is not specially equipped for handicapped persons: - Be sure all passengers are capable of securing themselves in a moving Club Car 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 28 Driving Instructions 3. Study and understand controls. 4. Be sure all passengers are seated with safety belt fastened and holding on to hand holds. Driver should have both hands on the steering wheel. 5. Make sure wheels are turned in desired direction and nothing is in your path. 6.
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Page 29: Bed Latch And Prop Rod
Bed Latch and Prop Rod Under most circumstances the driver will not need to do anything to engage the AWD system; however, the front differential may become locked (rotate at the same speed regardless of the terrain) under certain condi- tions. -
Page 30: Front Shock Absorbers
Front Shock Absorbers Figure 10 Bed Latch Figure 11 Prop Rod ý WARNING • For vehicles with cargo beds, remove all cargo before raising the bed or servicing the vehicle. If the vehicle is equipped with a prop rod, ensure that it is securely engaged. Do not close bed until all persons are clear of cargo bed area. -
Page 31: Towing With The Vehicle
Towing another Club Car vehicle or a trailer can have adverse effects on vehicle handling. Be especially cau- tious when towing other equipment with a Club Car vehicle. See the preceding chart for vehicle capacities. -
Page 32: Transporting On A Trailer
• For use on public roads, the trailer must meet all federal, state, and local requirements such as taillights, brake lights, etc. • Never tow a Club Car vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer. - Page 33 Storage ý WARNING • Turn the key switch to the OFF position, 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. • Gasoline vehicles only: Turn fuel shut-off valve to the closed (OFF) position (Figure 12, Page 31).
- Page 34 4.3. Disconnect the fuel vent line from the fuel tank vent nipple (Figure 34, Page 47). 4.4. Plug the fuel tank vent nipple so that it is air tight. Club Car recommends using a slip-on vinyl cap. 5. Remove both spark plugs and pour 1/2 ounce (14.2 mL) of SAE 10 weight oil through each of the two spark plug holes.
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Page 35: Maintenance
Any vehicle not functioning correctly should not be used 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 dealer/distributor for repairs and semiannual and annual periodic service. ý... -
Page 36: Periodic Service Schedule
Periodic Service Schedule ý WARNING • To help avoid unintentionally starting the vehicle: - Disconnect battery cables, negative (–) cable first (Figure 1, Page 13). - Gasoline vehicles only: Disconnect the spark plug wires from the spark plugs. • If wires are removed or replaced make sure wiring and wire harness are properly routed and secured. - Page 37 Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Daily service by owner Check engine oil level; add if necessary. or trained technician See Engine Oil Level Check on page 39. Engine Diesel vehicles: Check engine coolant; add if necessary. See Engine Coolant Level Check on page 45.
- Page 38 (or every 100 hours of operation, Gasoline vehicles: Inspect, clean, and whichever comes first) gap spark plug; replace if necessary. See authorized Club Car dealer or trained technician for service. Engine Diesel vehicles: Check the v-belt for proper tension or damage. Adjust or replace if necessary.
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Page 39: Periodic Lubrication Schedule
Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Gasoline vehicle: First change 20 hours – Diesel vehicle: Gasoline vehicles: 1 qt.-25 oz. (1.7 L) First change 50 hours – with filter Change engine oil and oil filter additional change for both Diesel vehicles: 3 qt. -
Page 40: Brake Fluid Reservoir
Brake Fluid Reservoir FLOORBOARD Figure 16 Lubrication Points – Diesel Vehicles BRAKE FLUID RESERVOIR Ful l Lev el Safe Le vel Lev el Figure 17 Brake Fluid and Coolant Access Door Figure 18 Brake Fluid Reservoir The brake fluid reservoir (1) is located under the dashboard (Figure 17). Raise the access panel located on top of the dashboard to check the brake fluid level. -
Page 41: Engine Oil
Engine Oil BRAKE FLUID Brake fluid level should be within 1/4-inch (6 mm) from the top of the reservoir (Figure 18). Also, brake fluid should be clean with no residue in the bottom of the reservoir or other evidence of contamination. ý... - Page 42 Engine Oil Full Level Full Safe Level Level Safe Level Level Level Figure 19 Engine Oil Level Check – Gasoline Vehicles Figure 20 Engine Oil Level Check – Diesel Vehicles ENGINE OIL AND FILTER CHANGE Engine oil and oil filter should be changed after the first 20 hours of operation (gasoline) or 50 hours of oper- ation (diesel).
- Page 43 Engine Oil 7. Use a socket- or box-end (do not use an open-end) wrench to replace the oil drain plug. Turn the plug clockwise and tighten to 29 ft-lb (40 N·m) for gasoline vehicles, 31 ft-lb (42 N·m) for diesel vehicles. Figure 21 Engine Oil Drain Plug and Pan –...
- Page 44 Engine Oil NOTE: An oil drip guard can be used to prevent excess oil from dripping onto the engine base plate. Use an empty quart (one liter) container and cut the bottom off at an angle, then slide the open area of the container up and under the oil filter before removal.
- Page 45 Engine Oil NOTE: Use only Club Car oil filters designed for your engine. 6. Tighten the oil filter by hand 2/3 turn after gasket contact. Do not use a band wrench or channel lock pliers. Engine Oil Filling 1. Add engine oil; use a funnel or pour spout to direct the oil into the opening (Figure 26 or Figure 27). With filter change, the engine requires 1 qt.-25 oz.
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Page 46: Gearcase Lubrication
Gearcase Lubrication GEARCASE LUBRICATION NOTE: Dispose of used oil according to the environmental laws and regulations for your area. LUBRICATION LEVEL CHECK FOR FRONT DIFFERENTIAL, TRANSMISSION, AND REAR DIFFERENTIAL Each gearcase component is equipped with two oil port plugs (1 and 2) (Figure 30, Figure 31, and Figure 32). -
Page 47: Engine Coolant - Diesel Vehicles
Engine Coolant – Diesel Vehicles Rear differential: Clean and install the drain plug (2) and washer before filling the rear differential with new lubricant (Figure 32). Tighten the drain plug to 8 ft-lb (10.8 N·m). Use a funnel when filling the differential through the lubricant level indicator hole (1). -
Page 48: Air Intake System
3. Remove the air filter cartridge (1). See following NOTE. NOTE: The air filter cartridge is specifically designed for this engine. It only fits into the canister one way. Use only the Club Car part (CCI P/N 102498601) designed for this engine. Figure 33 Air Filter Cartridge Air Filter Installation 1. -
Page 49: Fueling Instructions
Fueling Instructions FUELING INSTRUCTIONS See General Warnings on page 14. ý DANGER • Turn key switch to the OFF position before fueling. • Never pour fuel into the fuel tank when the engine is hot or while it is running. •... - Page 50 Fueling Instructions DRAINING WATER FROM FUEL FILTER Diesel Vehicles Only Water should be drained from the fuel filter daily. The fuel filter is mounted on a plate by the lower seat support panel (Figure 36). 1. Position a pan under the fuel filter. 2.
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Page 51: Battery
ý WARNING • Do not jump-start a dead battery using another battery and jumper cables. The battery in a Club Car vehicle is a 12-volt, low-maintenance battery that requires infrequent checks (Figure 37). Electrolyte level should be checked semiannually. BATTERY... -
Page 52: Cleaning The Vehicle
(No. 00) steel wool. Club Car does not recommend any type of pressure washing or steam cleaning. Such a process will expose electrical components to moisture. Moisture entering electrical components can result in water damage and subsequent component failure. -
Page 53: Accessories
There is a complete line of accessory equipment available from Club Car and our dealers/distributors. You can obtain the name and phone number of your closest Club Car contact by visiting our web site at www.clubcar.com and clicking the “Dealer Locator” link. -
Page 54: Subsequent Owner Registration
In the event a vehicle is bought as a used vehicle, 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 of the vehicle to Club Car, Inc., P.O. - Page 55 Vehicle Specifications Carryall Carryall Carryall Carryall SPECIFICATIONS 294 SE 294 SE POWER SOURCE, Gasoline Diesel Gasoline Diesel Continued Brakes: Hydraulic brake system – brake pads and discs on each wheel with separate foot- • • • • operated park brake BODY/CHASSIS Frame/Chassis: Box tube aluminum •...
- Page 56 Vehicle Specifications Carryall Carryall Carryall Carryall SPECIFICATIONS 294 SE 294 SE LIQUID CAPACITIES, Gasoline Diesel Gasoline Diesel Continued 2 gal. (7.8 2.25 gal. Engine coolant: mixture of 55% propylene glycol and 45% water (8.5 L) Brake fluid: DOT 5 (silicone) brake fluid 8 oz.
- Page 57 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 58 To make a warranty claim under this limited warranty, you must present the vehicle or defective component to an authorized CLUB CAR dealer or send the defective component, freight prepaid, to WARRANTY SERVICES, CLUB CAR, INC., 4125 Washington Road, Evans, Georgia 30809, U.S.A., 706-863-3000.
- Page 59 TECHNICAL & CONSUMER INFORMATION (GASOLINE ENGINES) Carburetor Modification for High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions.
- Page 60 The emission control systems on your Honda engine were designed, built, and certified to conform with EPA and California emission regulations. We recommend replacement parts be purchased from Club Car, Inc.. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance.
- Page 61 5. 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. This warranty is applicable only where the California or U.S. EPA emission control system warranty regulation is in effect.
- Page 64 Publication Part Number 102907524 Edition Code 0805A00000 Club Car, Inc. www.clubcar.com P.O. Box 204658 Phone 1.706.863.3000 Augusta, GA 30917-4658 1.800.ClubCar Intl’l +1 706.863.3000 1.706.863-5808...
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