Transcription

1998CarryCarryall I,CarryCarryall II,CarryCarryall II Plus,and CarryCarryall VIVehicehicleslesManual Number 1019682-02ManualPrint Code 0897B1297A

WARNING THE ENGINE EXHAUST FROM THIS PRODUCT CONTAINSCHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSECANCER, BIRTH DEFECTS, OR OTHER REPRODUCTIVE HARM.

NOTICEThe Transportation and Utility Vehicle Limited Warranty appears on the last pages of this manual. No otherwarranties, express or implied, are contained herein. Please complete and return the warranty registrationcard included in this manual.Club Car is not liable for errors in this manual or for incidental or consequential damages that result from theuse of the material in this manual.This manual contains proprietary information that is protected by copyright. All rights are reserved. No part ofthis manual may be photocopied, reproduced, or translated to another language without the written consentof 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 obligationto make these changes on units previously sold.These vehicles are designed and manufactured for off-road use only. They do not conform to Federal MotorVehicle Safety Standards or EPA regulations and are not equipped for operation on public streets, roads, orhighways. 1997 Club Car, Inc.Club Car, Carryall, PowerDrive, PowerDrive Plus, Armorflex,and Tranquility are registered trademarks of Club Car, Inc.This manual effective August 18, 1997i

FOREWORDThank you for choosing Carryall. You have chosen the finest utility vehicle on the market; the vehicle mostwidely recognized as the industry leader in vehicle efficiency and long-lasting value. Please protect yourinvestment and ensure that your Carryall vehicle(s) provides years of reliable, superior performance by fillingout and returning your Warranty Registration Card (located between the last page and back cover of thismanual), and by reading and following the maintenance instructions in this manual.Your comfort and safety are important to us as well, so we urge you to read and follow the step-by-step operating instructions and safety procedures in this manual. These instructions must be followed in order to avoidthe risk of severe personal injury. If you rent or loan your vehicle to others, we recommend that you ask themto 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. Inthe event that your Carryall vehicle needs repairs or service, we recommend that your local authorized Carryall representative perform them. For the name and address of the Carryall representative nearest you, call706-863-3000, Ext. 2601. If you would prefer to write to us, direct your letter to: Club Car, Attention: ProductDevelopment Department, P.O. Box 204658, Augusta, Ga. 30917-4658 USA. Your local authorized Carryallrepresentative can also provide technical advice, parts, and service manuals.We hope you will consider this owner’s manual a permanent part of your Carryall vehicle. If you sell the vehicle, please include the manual so that the next owner will have the important operating, safety, and maintenance information it contains.ii

TABLE OF CONTENTSSafety Details.1General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Feature Identification - Carryall I, Carryall II, and Carryall Turf II Gasoline Vehicle . . . . . . . . . . . . . . . . .4Feature Identification - Carryall I and Carryall II Electric Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Feature Identification - Carryall II Plus (Gasoline) Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Feature Identification - Carryall VI Electric Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Feature Identification - Carryall VI Gasoline Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Pre-Operation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Controls - Carryall I, Carryall II, and Carryall VI Electric Vehicles;Carryall I, Carryall II, and Carryall Turf II Pedal Start Gasoline Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . .17Driving Instructions - Carryall I, Carryall II, and Carryall VI Electric Vehicles;Carryall I, Carryall II, and Carryall Turf II Pedal Start Gasoline Vehicles . . . . . . . . . . . . . . . . . . . . . . . . .23Controls - Carryall II Plus and Carryall VI Key Start Gasoline Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . .25Driving Instructions - Carryall II Plus and Carryall VI Key Start Gasoline Vehicles . . . . . . . . . . . . . . . . .29Bed Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Loading and Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Towing a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33Transporting on a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Storage - Gasoline Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35Storage - Electric Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37Periodic Service Schedule - Gasoline Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40Periodic Service Schedule - Electric Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42Periodic Lubrication Schedule - Gasoline Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Periodic Lubrication Schedule - Electric Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Liquid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47Tire Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47Engine Oil - Gasoline Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48Fueling Instructions - Gasoline Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48Battery - Gasoline Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49Batteries - Electric Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50Battery Charger - Electric Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52Cleaning The Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56Vehicle Controller - Electric Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56Accessories and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56Subsequent Owner Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56Vehicle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58iii

Practice Safety! WARNINGMoving PartsSafety signs like you see above may at first seem shocking, but their impact is mildcompared with the reality of severe personal injury.Your safety and satisfaction are of the utmost importance to Club Car. That is whywe urge you to study this owner’s manual, and to read, understand, and heed thewarnings 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 yourlife.iv

SAFETY DETAILSWARNING THIS OWNER’S MANUAL SHOULD BE READ COMPLETELY BEFORE ATTEMPTING TO DRIVEOR SERVICE THE VEHICLE. FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS MANUALCOULD RESULT IN PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.It is important to note that some vital statements throughout this manual and on the decals affixed to thevehicle are preceded by the words DANGER, WARNING, CAUTION, or NOTE. For your protection, we recommend that you take special notice of these safety procedures. Safety procedures are essential and mustbe followed.If any of the operation or warning decals on the vehicle become damaged, have been removed, or cannot beeasily read, they should be replaced immediately to avoid possible personal injury, property damage, ordeath. Contact your CARRYALL distributor/dealer.DANGER A DANGER INDICATES AN IMMEDIATE HAZARD WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH.WARNING A WARNING INDICATES AN IMMEDIATE HAZARD WHICH COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH.CAUTION A CAUTION INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN PRODUCT OR PROPERTY DAMAGE OR MINOR PERSONAL INJURY.NOTE A NOTE PROVIDES KEY INFORMATION TO MAKE PROCEDURES MORE EASILY UNDERSTOOD.1

GENERAL WARNINGSThe safety procedures listed must be followed whenever the vehicle is being operated, repaired, orserviced. Other specific warnings appear throughout this manual and on the vehicle.DANGER GASOLINE VAPORS - FLAMMABLE! EXPLOSIVE! DO NOT SMOKE. KEEP SPARKS ANDFLAMES AWAY FROM THE AREA OF THE VEHICLE. SERVICE ONLY IN WELL-VENTILATEDAREAS. BATTERY VAPORS - FLAMMABLE! EXPLOSIVE! DO NOT SMOKE. KEEP SPARKS ANDFLAMES AWAY FROM THE AREA OF THE VEHICLE. SERVICE ONLY IN WELL-VENTILATEDAREAS. DO NOT OPERATE GASOLINE VEHICLE IN ENCLOSED AREA WITHOUT PROPER VENTILATION. ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS, DEADLY POISON. A UTILITY VEHICLE WILL NOT PROVIDE PROTECTION FROM LIGHTNING, FLYING OBJECTS,OR OTHER STORM RELATED HAZARDS. IF CAUGHT IN A STORM WHILE DRIVING A CARRYALL UTILITY VEHICLE, EXIT THE VEHICLE AND SEEK SHELTER IN ACCORDANCE WITHAPPLICABLE SAFETY GUIDELINES FOR YOUR LOCATION.WARNING THE ENGINE EXHAUST FROM THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THESTATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS, OR OTHER REPRODUCTIVEHARM. ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THE VEHICLE. ANYONE DOINGEVEN SIMPLE REPAIRS OR SERVICE SHOULD FOLLOW THE PROCEDURES EXACTLY ASSTATED IN THIS MANUAL, AND OBEY ALL DANGERS, WARNINGS, AND CAUTIONS LISTED INTHIS MANUAL AS WELL AS THOSE AFFIXED TO THE VEHICLE. ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN SERVICING THEVEHICLE. WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES. ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICALCONNECTIONS. IMPROPER USE OF THE VEHICLE OR FAILURE TO PROPERLY MAINTAIN IT COULD RESULTIN DECREASED VEHICLE PERFORMANCE OR SEVERE PERSONAL INJURY. ANY MODIFICATION OR CHANGE TO THE VEHICLE WHICH AFFECTS THE STABILITY ORHANDLING OF THE VEHICLE, OR INCREASES MAXIMUM VEHICLE SPEED BEYOND FACTORYSPECIFICATIONS COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH. FOLLOW ALL PROCEDURES LISTED IN THIS MANUAL FOR LOADING AND UNLOADING THEVEHICLE. DO NOT EXCEED VEHICLE RATED WEIGHT CAPACITY.GASOLINE VEHICLES ONLY: TO AVOID UNINTENTIONALLY STARTING THE VEHICLE, BEFORE SERVICING ALWAYS:- DISCONNECT THE BATTERY CABLES, NEGATIVE (-) FIRST.- DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG. FRAME GROUND - DO NOT ALLOW TOOLS OR OTHER METAL OBJECTS TO CONTACT FRAMEWHEN DISCONNECTING BATTERIES OR OTHER ELECTRICAL WIRING. NEVER ALLOW APOSITIVE WIRE TO TOUCH THE VEHICLE FRAME, ENGINE, OR OTHER METAL COMPONENT.Warnings continued on next page.2

General Warnings, Continued:WARNINGELECTRIC VEHICLES ONLY: TO AVOID UNINTENTIONALLY STARTING THE VEHICLE, DISCONNECT THE BATTERIES ASSHOWN (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 THEREVERSE POSITION.- SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THEREVERSE WARNING BUZZER CAN NO LONGER BE HEARD. WHEN THE BUZZER STOPSSOUNDING, THE CONTROLLER IS DISCHARGED. CARRYALL I POWERDRIVE PLUS (MOTOR BRAKING) VEHICLES ONLY: PLACE THE TOW/RUN SWITCH IN THE TOW POSITION BEFORE DISCONNECTING BATTERIES.FRONT OF VEHICLEFRONT OF OS.POS.POS.#1NEG.NEG.#1#4#2DISCONNECT HEREDISCONNECT HERECARRYALL IPOWERDRIVE SYSTEM 48AND POWERDRIVE PLUSCARRYALL II AND CARRYALL VIPOWERDRIVE SYSTEM 48FIGURE 1FIGURE 23

CARRYALL I, CARRYALL II, AND CARRYALL TURF IIDRIVER/PASSENGERWARNING DECALOPERATING INSTRUCTIONSOFFONKEY SWITCHPINCH POINTDECALOIL WARNING LIGHTSERIALNUMBERTILT BEDWARNING LABELPARK BRAKEPEDALBED/LATCHWARNING LABELBRAKEPEDALVEHICLE LOADING DECAL(FOR CARRYALL I ONLY)(FOR CARRYALL II AND CARRYALL TURF II ONLY)4ACCELERATORPEDAL

GASOLINE VEHICLE FEATURE IDENTIFICATIONGASOLINE TANKDANGER LABEL(ON FRAME)F N RHOT MANIFOLD ANDMUFFLER LABEL(ON STARTER/GENERATORAND ENGINE)FORWARD - REVERSEHANDLELEVERALLCARRYBED LATCHCHOKEFRAME GROUNDWARNING LABEL(ON FRAME)PERIODIC SERVICESCHEDULE(ON INTAKE BOX)5

CARRYALL I AND CARRYALL II ELECTRICDRIVER/PASSENGERWARNING DECALOPERATING INSTRUCTIONSOFFONKEY SWITCHPINCH POINTDECALBATTERY WARNINGLIGHTBATTERY CONDITIONINDICATORSERIALNUMBERTILT BEDWARNING LABELBRAKEPEDALPARK BRAKEPEDALVEHICLE LOADING DECAL(FOR CARRYALL I ONLY)(FOR CARRYALL II ONLY)6BED/LATCHWARNING LABELACCELERATORPEDALREGENERATIVEBRAKING DECAL(POWERDRIVE PLUSVEHICLE ONLY)

TOW SWITCH WARNING DECAL(ON TOW SWITCH BRACKET UNDER SEAT)(ON POWERDRIVE PLUS VEHICLE ONLY)VEHICLE FEATURE!DANGER / POISONNOEXPLOSIVESHIELDEYES SPARKS FLAMES SMOKINGGASES CAN CAUSEBLINDNESS OR INJURYSULFURICACIDCAN CAUSEBLINDNESS ORSEVERE BURNSFLUSH EYESIMMEDIATELYWITH WATERGETMEDICALHELPFASTF N RKEEP OUT OF THE REACH OF CHILDREN – DO NOT TIP – KEEP VENT CAPS TIGHT AND LEVELFORWARD -- REVERSEREVERSEFORWARDLEVERHANDLEBATTERY DANGERLABEL(ON BODY UNDER SEAT)ALLCARRYBED LATCHFUSE LINKCHARGERRECEPTACLERESISTOR WARNING DECAL(ON POWERDRIVE PLUS 48 VOLT VEHICLE)WARNINGHOT RESISTORS (COILED WIRE) CAN CAUSE SEVERE BURNS.POTENTIOMETER CAUTION DECAL(ON WIPER SWITCH COVER INSIDEBATTERY COMPARTMENT)7

CARRYALL II PLUS KEY STARTOFF ON STARTKEY SWITCHDRIVER/PASSENGERWARNING DECALOPERATING INSTRUCTIONSPINCH POINTDECALOIL WARNING LIGHTSERIALNUMBERTILT BEDWARNING LABELPARK BRAKEPEDALBRAKEPEDALACCELERATORPEDALVEHICLE LOADING DECALBED/LATCHWARNING LABEL8

VEHICLE FEATURE IDENTIFICATIONGASOLINE TANKDANGER LABEL(ON FRAME)F N RHOT MANIFOLD ANDMUFFLER LABEL(ON STARTER/GENERATORAND ENGINE)FORWARD - REVERSEHANDLELEVERALLCARRYII PlusBED LATCHCHOKEFRAME GROUNDWARNING LABEL(ON FRAME)PERIODIC SERVICESCHEDULE(ON INTAKE BOX)9

CARRYALL VI ELECTRIC VEHICLEDRIVER/PASSENGERWARNING DECALSERIALNUMBERBATTERY WARNINGLIGHTTILT BEDWARNING LABELACCELERATORPEDALBATTERYCONDITIONINDICATORCARR YALL-VIPARK BRAKEPEDALBRAKEPEDALBATTERY DANGERLABEL(ON FRAME)!DANGER / POISONNOSHIELDEYESEXPLOSIVEGASES CAN CAUSEBLINDNESS OR INJURY SPARKS FLAMES SMOKINGSULFURICACIDCAN CAUSEBLINDNESS ORSEVERE BURNSFLUSH EYESIMMEDIATELYWITH WATERGETMEDICALHELPFASTKEEP OUT OF THE REACH OF CHILDREN – DO NOT TIP – KEEP VENT CAPS TIGHT AND LEVELVEHICLE LOADING DECAL10

FEATURE IDENTIFICATIONBED HOLDDOWN BOLTSOPERATINGINSTRUCTIONSOFFONKEY SWITCHALL-VICARRYELECTRICAL COMPONENTMOUNTING PLATE NOTICE(ON PLATE)F N RBED BOLTWARNING LABELFORWARD - REVERSEHANDLELEVERELECTRICAL COMPONENTCOVER CAUTION(ON COVER)ON-BOARDCHARGERAC CORD REEL11

CARRYALL VI GASOLINEDRIVER/PASSENGERWARNING DECALSERIALNUMBERCARPARK BRAKEPEDAL12R YALL-VITILT BEDWARNINGBRAKEPEDALVEHICLE LOADING DECALACCELERATORPEDAL

VEHICLE FEATURE IDENTIFICATIONOFF - ON - STARTLABEL(AT KEY SWITCH)OPERATINGINSTRUCTIONSOFF ON STARTBED HOLDDOWN BOLTSALL-VICARRYCHOKEF N RFORWARD - REVERSEHANDLELEVERBED HOLD DOWN BOLTWARNING13

CARRYALL VI GASOLINEVEHICLE FEATURE IDENTIFICATIONGASOLINE TANKDANGER LABEL(ON FRAME)HOT MANIFOLD ANDMUFFLER LABEL(ON STARTER/GENERATORAND ENGINE)CARR YALL-VIPERIODIC SERVICESCHEDULE(ON INTAKE BOX)FRAME GROUND/GOVERNORWARNING (ON FRAME)14

GENERAL INFORMATIONThere are three Carryall models, the Carryall I, Carryall II, and Carryall VI, that are available with either gasoline or electric power. Carryall I electric with regenerative motor braking is also available. The Carryall IIPlus and Carryall Turf II are available with gasoline power only. Throughout this manual, important featuresunique to each model are highlighted. We urge the owner/operator to read and understand this manual, andto pay special attention to the features specific to his/her vehicle(s).MODEL IDENTIFICATIONThe serial number of your Carryall vehicle is printed on a bar code decal mounted on the frame directlyabove the accelerator pedal (Example: F9801-123456 for Electric or FG9801-123456 for Gasoline) (See Figure 3). There is also a second serial number decal mounted on the front body frame behind the center dashpanel. The center dash panel must be removed to access it.NOTE ALWAYS HAVE THE VEHICLE SERIAL NUMBER AT HAND WHEN ORDERING PARTS OR MAKING INQUIRIES. SEE FIGURE 3.SERIAL NUMBERDECALSERIAL NUMBERClub CarRP O BOX 204658AUGUSTA GA 30917GOF9801-123456This vehicle is covered by one or more of thefollowing U.S. Patents as applicable: D271008D292899, 4343503, 4539162, 4637270, 48218274826467, 5042519, 5083736 and otherpatents pendings.ClubFIGURE 3PRE-OPERATION CHECKLISTYour Carryall vehicle(s) has been thoroughly inspected and adjusted at the factory, and also by your Carryalldealer. However, upon arrival of your new Carryall vehicle(s), you should become familiar with its controlsand operation, and carefully inspect each vehicle to be satisfied that it is in proper working condition beforeaccepting delivery.Use the following checklist as a guide to inspect your new vehicle, and in conjunction with the Periodic Service Schedules (pages 40-44). Any problems should be corrected only by your Carryall dealer or a trainedtechnician. General: All the parts should be in place and properly installed. Be sure that all nuts, bolts, and screwsare tight. On all gasoline vehicles, check all hose clamps for tight fit as well as the starter belt for tightness. Warning Decals: Check to ensure that all warning and operation decals are in place (See Pages 4through 14). Tires: Check for proper tire pressure (See Tire Capacities, Page 47).15

Pre-Operation Checklist, Continued: Batteries (electric vehicles): Check electrolyte to ensure that it is at its proper level (See Figure 37,Page 50). Check battery posts. Wires should be tight and free of corrosion. Charge batteries fullybefore first use of vehicle. Multi-Step Potentiometer (Carryall I electric vehicles): Be sure potentiometer (wiper switch) cover isproperly secured prior to operating the vehicle. Engine (gasoline vehicle): Check for proper engine oil level (See Engine Oil, Page 48). Fuel (gasoline vehicle): Check fuel level (See Fueling Instructions, Page 48).WARNING BE SURE THE PLASTIC HAS BEEN REMOVED FROM THE SEAT BOTTOM BEFORE OPERATING THE VEHICLE. FAILURE TO DO SO MAY RESULT IN A FIRE, PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.PERFORMANCE INSPECTIONAfter you have familiarized yourself with the vehicle’s controls and have read and understood the drivinginstructions, take the vehicle for a test drive. Use the following checklist as a guide to inspect your new vehicle. Any problems should be corrected only by your Carryall dealer or a trained technician.All vehicles: Brakes: Be sure the brakes function properly. When brake pedal is fully depressed under moderatepressure, it should not go more than halfway to the floor, and vehicle should come to a smooth, straightstop; Carryall I vehicles should stop within 14 feet, and all other Carryall vehicles should stop within 16feet. If the brake pedal goes more than halfway to the floor, or if the vehicle swerves or fails to stopwithin the appropriate braking distance for your vehicle (see preceding sentence), have the brake system checked and adjusted as required. Brake adjustment must be maintained so that the brake pedalcannot be depressed to the floor under any circumstances. Park Brake: When latched, the park brake should lock the wheels and hold the vehicle stationary (onincline of 20% or less). It should release when either the accelerator or brake pedal is depressed. Reverse Buzzer: The reverse buzzer should sound as a warning when the vehicle is in reverse. Steering: The vehicle should be easy to steer and should not have any play in the steering wheel. Accelerator:All Carryalls except the Carryall II Plus with key start and gasoline powered Carryall VI: With thekey switch ON and the forward and reverse switch in the FORWARD position; as the accelerator pedalis depressed, the engine or motor should start and the vehicle should accelerate smoothly to fullspeed. When the pedal is released it should return to the original position and the engine or motorshould stop. All Carryall vehicles should run at reduced speed in reverse.Carryall II Plus with key start and gasoline powered Carryall VI: After starting engine with the keyswitch, the vehicle should accelerate smoothly to full speed as the accelerator pedal is depressed.When the accelerator pedal is released it should return to the original position and engine should idle. Governor (gasoline vehicles): Check maximum speed of the vehicle. All electric Carryalls and thegasoline powered Carryall I and Carryall Turf II should run at 12-15 MPH (19-24 KPH) on a level surface. The Carryall II and Carryall VI gasoline powered vehicles should run at 14-16 MPH (23-26 KPH)on a level surface. The Carryall II Plus should run at 17-18 MPH (27-29 KPH) on a level surface. AllCarryall vehicles should run at reduced speed in reverse. General: Listen for any unusual noises such as squeaks or rattles. Check the vehicle ride and performance. Have a CLUB CAR distributor/dealer or a trained mechanic investigate anything unusual.16

Carryall I Electric Vehicles with PowerDrive Plus (Motor Braking): Zero Speed Detect: With the vehicle parked on level ground, the Forward and Reverse Switch in anyposition and the park brake disengaged, place the tow/run switch in the RUN position and attempt topush the vehicle. It should resist rolling (moving at no more than 1 or 2 mph). A warning buzzer shouldsound two seconds after the vehicle begins to move. “Pedal Up” Motor Braking: Accelerate the vehicle to full speed and then release the acceleratorpedal. Motor braking should quickly and smoothly slow the vehicle to approximately 9 mph. Motor braking will disengage when vehicle slows to 9 mph. “Pedal Down” Motor Braking: Accelerate down an incline with the accelerator pedal depressed.When the vehicle reaches approximately 15 mph, motor braking should engage and moderate vehiclespeed between 15 and 16 mph, depending upon the grade of the hill.CONTROLS - CARRYALL I, CARRYALL II, AND CARRYALL VI ELECTRIC VEHICLES; CARRYALL I, CARRYALL II, AND CARRYALL TURF IIPEDAL START GASOLINE VEHICLESDANGER DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION. GASOLINE ENGINES PRODUCE CARBON MONOXIDE GAS, WHICH IS AN ODORLESS, DEADLY POISION.WARNING BEFORE ASSIGNING THE VEHICLE TO A DRIVER, MAKE SURE THE DRIVER IS FAMILIARWITH ALL CONTROLS AND OPERATING PROCEDURES BEFORE ALLOWING THE VEHICLE TOBE DRIVEN. DO NOT TAMPER WITH THE GASOLINE VEHICLE GOVERNOR. DOING SO WILL VOID THEWARRANTY, AS WELL AS DAMAGE THE ENGINE AND OTHER COMPONENTS, AND COULDRESULT 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 STABILITY OR HANDLING, OR INCREASE MAXIMUM VEHICLE SPEED BEYOND FACTORY SPECIFICATIONS. PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH COULD RESULT. DO NOT SHIFT THE FORWARD/REVERSE SWITCH WHILE THE VEHICLE IS IN MOTION. TOAVOID INJURY TO AN UNSUSPECTING PASSENGER OR DAMAGE TO THE VEHICLE, ALWAYSBRING THE VEHICLE TO A FULL STOP BEFORE SHIFTING THE SWITCH. A BUZZER WILLSOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE. RELEASE THE ACCELERATOR PEDAL AND THEN DEPRESS THE BRAKE PEDAL FIRMLYUNTIL THE VEHICLE STOPS. TO AVOID UNINTENTIONALLY STARTING OR ROLLING THEVEHICLE, SET THE PARK BRAKE, TURN THE KEY SWITCH TO OFF, AND REMOVE THE KEYWHEN LEAVING THE VEHICLE. DO NOT EXCEED VEHICLE RATED WEIGHT CAPACITY.KEY SWITCHThe key switch is mounted on the dash to the right of the steering column (See Figure 4, Page 18). It hastwo positions, OFF and ON, which are clearly labeled.NOTE THE KEY CAN BE REMOVED WHEN THE KEY SWITCH IS IN THE OFF POSITION ONLY.17

OFFONFIGURE 4FIGURE 5FORWARD/REVERSE CONTROLThe forward/reverse shift handle is located on the seat support panel, below and to the right of the driver’sright knee (See Figure 5). The lever has three distinct positions: F (forward), N (neutral), and R (reverse).Rotate the lever towards the driver, F (forward), to run the vehicle in the forward direction, or towards the passenger, R (reverse), to run the vehicle in reverse. When the lever is in the straight up, or N (neutral) position,the vehicle will not run. The engine in a gasoline powered Carryall I or Carryall II will stop if the vehicle isshifted to neutral while the engine is running. All 1998 Carryall vehicles run at reduced speed in reverse.Carryall I Electric with PowerDrive Plus (Motor Braking):The forward/reverse shift switch is located in the same place as the forward/reverse shift lever on all otherCarryall models; on the seat support panel below and to the right of the driver’s right knee. The Forward (F)and Reverse (R) positions are clearly marked on the switch. Push down the F (forward) side of the switch torun the vehicle in the forward direction, or push down the R (reverse) side of the switch to run the vehicle inreverse. When neither side of the switch is depressed, the vehicle is in the NEUTRAL position and the vehicle will not run if the accelerator pedal is depressed (See Figure 6). See NOTE below.NOTE THE REVERSE BUZZER WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE.ACCELERATOR PEDALThe accelerator pedal is the pedal on the right, with the word GO molded into it (See Figure 7).NOTE THE OPERATION OF THE ACCELERATOR PEDAL DIFFERS FROM THAT OF AN AUTOMOBILE. WHEN THE KEY SWITCH IS ON, AND THE SHIFTER HANDLE IS IN EITHER FORWARDOR REVERSE, DEPRESSING THE ACCELERATOR PEDAL WILL AUTOMATICALLY RELEASETHE PARK BRAKE AND START THE VEHICLE MOVING IN THE DIRECTION SELECTED (FORWARD OR REVERSE). AS THE ACCELERATOR PEDAL IS DEPRESSED, SPEED WILLINCREASE UNTIL FULL SPEED IS REACHED. WHEN THE ACCELERATOR IS RELEASED,POWER WILL BE CUT OFF AND THE ENGINE OR MOTOR WILL STOP RUNNING. CARRYALL I ELECTRIC WITH POWERDRIVE PLUS (MOTOR BRAKING) ONLY: SEE “PEDALUP”AND “PEDAL-DOWN” MOTOR BRAKING ON PAGE 17.18

BRAKE PEDALThe brake pedal is the large pedal on the left with the word STOP molded into it (See Figure 7). To slow orstop the vehicle, depress the brake pedal with your right foot (See Figure 8).FRFIGURE 6FIGURE 7FIGURE 8FIGURE 9PARK BRAKE PEDALThe park brake pedal is the small raised portion in the upper left corner of the brake pedal. It has the wordPARK molded into it and the words PARK BRAKE marked on top of it (See Figure 7). To set the park brake,depress the brake pedal firmly and tilt the park brake portion of the pedal forward with your foot (Figure 9).WARNING THE PARK BRAKE WILL RELEASE AUTOMATICALLY WHEN EITHER THE ACCELERATOR ORBRAKE PEDAL IS DEPRESSED. THE PARK BRAKE HAS MULTIPLE LOCKING POSITIONS ANDSHOULD BE FIRMLY PRESSED AND LOCKED TO PREVENT THE VEHICLE FROM ROLLING.GASOLINE VEHICLES ONLY:Neutral Lock-outThe gasoline vehicle has a neutral lock-out circuit that prevents the driver from starting the vehicle in NEUTRAL. If the vehicle is started in forward or reverse and then shifted to neutral, the engine will stop running.19

Neutral Lock-out, Continued:NEUTRALFORWARDSERVICE POSITIONFIGURE 10NEUTRALFORWARDOPERATE POSITIONFIGURE 11For the convenience of the trained mechanic, there is a neutral lock-out cam (yellow knob) located on theback of the forward/reverse switch, inside the engine compartment. If the neutral lock-out cam is pulled outapproximately 3/8 inch (10 millimeters) and then rotated one-half turn until it snaps into place, the cam will bein the SERVICE position (See Figure 10). This will allow the mechanic to run the engine in NEUTRAL forcertain maintenance procedures. With the cam in this position, the vehicle will not operat

positive wire to touch the vehicle frame, engine, or other metal component. warnings continued on next page. . neg. pos. neg. pos. pos. neg. pos. neg. pos. neg. #1 #2 #5 #4 #3 front of vehicle carryall ii and carryall vi powerdrive system 48 disconnect here #6. 4 operating instructions key switch serial number brake pedal