Club Car 1999, Owner'S Manual

Page 1: ...Manual Number 101993805 Edition Code 0898B0310A Tourall Resort Villager Trans Porter and Trans Sender Gasoline Vehicles 1999 Owner s Manual ...

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Page 3: ...1999 Transportation Gasoline Vehicle Owner s Manual i ...

Page 4: ...art of this manual may be photocopied 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 vehicles without obligation to make these changes on units previously sold These vehicles are designed and manufactured for off road use onl...

Page 5: ...ed in order to avoid the risk of severe personal 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 Carryall products are backed by a customer support system designed to offer you fast courteous service In the event that your vehicle needs repairs or service we recommend that your local authorized Carryall representa...

Page 6: ...rans Sender Gasoline Vehicle 8 Model Identification 10 Pre Operation Checklist 10 Controls 11 Driving Instructions 16 Loading and Unloading 18 Transporting on a Trailer 18 Storage 19 Maintenance 21 Daily Pre Operation Safety Checklist 21 Periodic Service Schedule 22 Periodic Lubrication Schedule 23 Vehicle Capacities 24 Engine Oil 24 Fueling Instructions 25 Battery 25 Cleaning the Vehicle 26 Acces...

Page 7: ...d 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 Understand and become familiar with the DANGER WARNING and CAUTION state ments and procedures it contains along with the safety decals that are affixed to your vehicle Take time to understand the language of safety It is a language that can save your...

Page 8: ...be replaced immediately to avoid possible personal injury property damage or death Contact your Carryall 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...

Page 9: ... AND OBEY ALL DANGER WARNING AND CAUTION STATEMENTS 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 ELECTRICAL CONNECTIONS IMPROPER MAINTENANCE OR USE OF THE VEHICLE COULD RESULT IN DECREASED V...

Page 10: ...icle Owner s Manual TOURALL GASOLINE VEHICLE KEY SWITCH SERIAL NUMBER BRAKE PEDAL OIL WARNING LIGHT PARK BRAKE PEDAL ARM RESTS HAND RAIL ACCELERATOR PEDAL PASSENGER WARNING LABEL ON REAR HANDRAIL FACING SEAT DRIVER PASSENGER WARNING LABEL OPERATING INSTRUCTIONS LABEL ...

Page 11: ...GASOLINE VEHICLE GASOLINE WARNING DECAL ON VEHICLE FRAME NEAR FUEL TANK MOVING PARTS AND HOT MANIFOLD DECAL ON STARTER GENERATOR AND ENGINE FRAME GROUND AND GOVERNOR WARNING DECAL ON VEHICLE FRAME NEAR BATTERY CHOKE F N R FORWARD REVERSE HANDLE OIL FILL NEUTRAL LOCK OUT CAM FUEL SHUT OFF VALVE ...

Page 12: ...rtation Gasoline Vehicle Owner s Manual RESORT VILLAGER GASOLINE VEHICLE ACCELERATOR PEDAL BRAKE PEDAL PARK BRAKE PEDAL OIL WARNING LIGHT SERIAL NUMBER KEY SWITCH DRIVER PASSENGER WARNING DECAL OPERATING INSTRUCTIONS DECAL PASSENGER WARNING DECAL ...

Page 13: ...ILLAGER GASOLINE VEHICLE OIL FILL CHOKE FORWARD REVERSE HANDLE FRAME GROUND AND GOVERNOR WARNING DECAL ON VEHICLE FRAME NEAR BATTERY GASOLINE WARNING DECAL ON VEHICLE FRAME NEAR FUEL TANK MOVING PARTS AND HOT MANIFOLD DECAL ON STARTER GENERATOR AND ENGINE NEUTRAL LOCKOUT CAM FUEL SHUT OFF VALVE ...

Page 14: ... Gasoline Vehicle Owner s Manual TRANS PORTER TRANS SENDER GASOLINE VEHICLE DRIVER PASSENGER WARNING DECAL VEHICLE LOADING DECAL ACCELERATOR PEDAL BRAKE PEDAL SERIAL NUMBER PARK BRAKE PEDAL OPERATING INSTRUCTIONS KEY SWITCH OIL WARNING LIGHT GAS VEHICLE ...

Page 15: ...AND MUFFLER LABEL ON STARTER GENERATOR AND ENGINE CRUSH AREA DECAL FRAME GROUND WARNING DECAL ON FRAME BED BOLT WARNING DECAL CHOKE NEUTRAL LOCKOUT CAM PASSENGER WARNING DECAL GASOLINE TANK DANGER DECAL ON FRAME TILT BED WARNING DECAL PASSENGER WARNING DECAL FORWARD REVERSE HANDLE FUEL SHUT OFF VALVE TRANS PORTER VEHICLE TRANS SENDER VEHICLE ...

Page 16: ...n with the Periodic Service Schedule on page 22 Any problems should be corrected by your Carryall distributor dealer or a trained technician only See following WARNING General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tight Check all hose clamps for tight fit as well as the starter belt for tightness Warning Decals Check to ensure that all w...

Page 17: ... released it should return to the original position and the engine should stop Both the electric and gasoline vehicles should run at a reduced speed when in reverse Accelerator for Trans Porter Trans Sender and Resort Villager vehicles After starting the engine the vehicle should accelerate smoothly to full speed as the accelerator pedal is depressed When the accelerator pedal is released it shoul...

Page 18: ...D REVERSE CONTROL The Forward Reverse shift handle is located on the seat support panel Figure 4 Page 12 The handle has three distinct positions F forward N neutral and R reverse Rotate the handle towards the driver F for ward to operate the vehicle in the FORWARD direction or towards the passenger R reverse to operate the vehicle in REVERSE Tourall When the handle is in the straight up or N neutr...

Page 19: ...E WILL STOP RUNNING IF THE ACCELERATOR IS DEPRESSED WHILE THE FORWARD REVERSE HANDLE IS IN THE NEUTRAL POSITION THE REVERSE BUZZER S WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE THE OPERATION OF THE ACCELERATOR PEDAL DIFFERS FROM THAT OF AN AUTOMOBILE TOURALL WHEN THE KEY SWITCH IS ON AND THE FORWARD REVERSE HANDLE IS IN EITHER FORWARD OR REVERSE DEPRESSING THE ACCELERATOR PEDAL WILL AUT...

Page 20: ...ition Trans Porter Trans Sender and Resort Villager vehicles When the cam is in the SERVICE posi tion it will allow the mechanic to run the vehicle in FORWARD REVERSE or NEUTRAL for certain maintenance and or repair functions However if the Forward Reverse handle is in either FORWARD or REVERSE and the accelerator is depressed the engine will stop running To put the cam back into the OPERATE posit...

Page 21: ...umn Figure 12 Page 15 If the oil warning light comes on oil should be checked and added to the engine as neces sary before continuing to use the vehicle The vehicle should never be driven when the oil warning light remains on If the oil warning light goes on and off the vehicle may be driven but oil should be added at the first opportunity If the oil level is correct and the light stays on have a ...

Page 22: ...SEATED AND HOLD ON TO SEAT HAN DLES OR HANDRAILS AT ALL TIMES DRIVER SHOULD KEEP BOTH HANDS ON THE STEER ING WHEEL WHEN THE VEHICLE IS IN MOTION TO PREVENT THE POSSIBILITY OF SERIOUS INJURY KEEP ENTIRE BODY INSIDE VEHICLE DO NOT LEAVE CHILDREN UNATTENDED IN THE VEHICLE TO PREVENT VEHICLE FROM OVERTURNING DRIVE SLOWLY IN TURNS TO PREVENT VEHICLE FROM OVERTURNING DRIVE SLOWLY STRAIGHT UP AND DOWN SL...

Page 23: ...rse 5 3 Release brake pedal and slowly depress accelerator pedal The park brake will release automati cally and the vehicle will start to move As the accelerator pedal is depressed speed will increase until full speed is reached See following WARNING and NOTE STOPPING THE VEHICLE See following WARNING and CAUTION VEHICLE OPERATOR MUST CONTROL SPEED WHEN GOING DOWNHILL DEPRESS THE BRAKE PEDAL AS NE...

Page 24: ...ROSS WEIGHT AND TONGUE WEIGHT OF A TRAILER THE TONGUE WEIGHT OF ANY TRAILER SHOULD NEVER EXCEED 150 LBS 68 KG MAXIMUM RATED CAPACITY FOR TRANS PORTER TRANS SENDER VEHICLES IS 1500 LBS 680 KG MAXIMUM RATED CAPACITY FOR RESORT VILLAGER IS 1500 LBS 680 KG MAXIMUM RATED CAPACITY FOR TOURALL IS 800 LBS 363 KG OVERLOADING CAN AFFECT VEHICLE HANDLING OR CAUSE COMPONENT FAILURE RESULTING IN LOSS OF CONTRO...

Page 25: ...09 KG PER TRANS PORTER TRANS SENDER EXAMPLE A TRAILER TO CARRY TWO RESORT VILLAGERS SHOULD BE RATED AT 2 X 1600 3200 LB 2 X 727 1454 KG NEVER TOW A CARRYALL VEHICLE BEHIND A PASSENGER VEHICLE OR TRUCK ON A PUBLIC ROAD UNLESS IT IS ON AN APPROVED TRAILER THE VEHICLE TO BE TOWED SHOULD BE TIED SECURELY TO THE TRAILER WITH THE FORWARD REVERSE HANDLE IN NEUTRAL THE KEY SWITCH OFF AND THE PARK BRAKE FI...

Page 26: ...se front suspension and do all other semiannual periodic lubrication See Periodic Lubrication Schedule Page 23 7 Thoroughly clean front body rear body seats cargo bed engine compartment and underside of vehicle 8 Do not latch the park brake Chock wheels to prevent the vehicle from rolling TO RETURN THE STORED VEHICLE TO SERVICE 1 Restore fuel system to operation 1 1 Remove plug from the fuel tank ...

Page 27: ...ar damage and proper inflation Exhaust system Check for leaks Forward Reverse shifter Check for proper operation See Controls Page 11 Fuel system Check fuel tank lines cap pump and carburetor for fuel leakage WHEN STARTING THE ENGINE FOR THE FIRST TIME AFTER IT HAS BEEN STORED IT MAY SMOKE EXCESSIVELY FOR A SHORT WHILE THIS IS DUE TO THE OIL THAT WAS ADDED TO THE ENGINE TO PREPARE IT FOR STORAGE I...

Page 28: ...nnual Service by Trained Mechanic Only Every 50 hours of operation Battery Clean terminals and wash dirt from casing Check electrolyte level See page 25 Front Wheel Alignment and Camber Check and adjust as required See Maintenance Service Manual Section 7 Electrical wiring and connections Check for tightness and damage Brake System Check brake shoes replace if necessary Lubricate brake slides per ...

Page 29: ...uspension 5 fittings 4 Chassis Lube EP NLGI Grade 2 Brake slides 5 Dry Moly Lube Club Car Part No 1012151 Annually by Trained Technician Only Every 100 hours of operation Check fill unitized transaxle to plug level 6 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 7 Chassis Lube EP NLGI Grade 2 First Change 100 Hours Additi...

Page 30: ...4 psi 207 234 kPa Trans Porter 30 34 psi 207 234 kPa Trans Sender 30 34 psi 207 234 kPa TO CHECK ENGINE OIL THE VEHICLE MUST BE ON A LEVEL SURFACE REMOVE THE OIL LEVEL DIPSTICK FROM THE OIL FILLER TUBE AND WIPE OIL FROM STICK CHECK OIL BY FULLY INSERTING THE DIPSTICK INTO THE OIL FILLER TUBE AND IMMEDIATELY REMOVING IT AGAIN IF THE OIL LEVEL IS AT OR BELOW THE ADD MARK ON THE DIPSTICK GAUGE ADD OI...

Page 31: ...NDED TO THE PUMP BEFORE AND DURING THE FUELING OPERATION IF THE VEHICLE HAS AN ALL WEATHER ENCLOSURE INSTALLED THE GAS TANK MUST BE PROPERLY VENTED AS SHOWN FIGURE 17 PAGE 24 TO AVOID THE POSSIBILITY OF FIRE BE SURE TO CLEAN UP ANY SPILLED GASOLINE BEFORE OPERATING THE VEHICLE TO ALLOW FOR EXPANSION DO NOT FILL HIGHER THAN ONE INCH FROM TOP OF THE FUEL TANK AVOID FUEL SPILLAGE WHENEVER POSSIBLE AV...

Page 32: ... leave battery discharged overnight CLEANING THE VEHICLE Transportation vehicles are equipped with Armorflex front bodies and either Amorflex or all aluminum rear bodies Some models also have aluminum cargo beds Use only mild dishwashing liquid soap with a sponge or soft cloth for normal cleaning See following CAUTION and NOTE INTERNAL DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOWED WITH MILK OF ...

Page 33: ...r from a distributor dealer we strongly urge the new owner to reregister 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 GA 30917 4658 ATTN Vehicle Registration VEHICLE SPECIFICATIONS DISPOSE OF WASTE WATER PROPERLY CUSTOM CAB ASSEMBLIES WEATHERPROOF ENCLOSURES ...

Page 34: ...ITY FUEL CAPACITY Standard Seating Capacity persons 4 6 4 6 Fuel Tank 7 gallons 26 5 liters unleaded gasoline only DIMENSIONS WEIGHT Overall Length 100 254 cm 124 315 cm 134 340 cm 133 338 cm Overall Width 47 1 4 120 cm 47 1 4 120 cm 49 1 4 120 cm 49 1 4 120 cm Overall Height At Steering Wheel 48 122 cm 48 122 cm 48 122 cm 48 122 cm Wheelbase 65 1 2 166 cm 98 1 2 250 cm 98 1 2 250 cm 98 1 2 250 cm...

Page 35: ...d Bed Height Box bed inside dimensions 27 69 cm Load Bed Size Flat bed inside dimensions 35 3 4 x 44 1 4 91 x 112 cm Vehicle rated capacity Level surface only 800 lb 363 kg 1500 lb 680 kg 1500 lb 680 kg 1500 lb 680 kg SPECIFICATIONS Tourall Resort Villager Trans Porter Trans Sender ...

Page 36: ...alers or a service agency approved by CLUB CAR IF THE WARRANTY REGISTRATION FORM IS NOT COMPLETED AND RETURNED TO CLUB CAR AT THE TIME OF THE ORIGINAL RETAIL SALE PURCHASER MUST PROVIDE PROOF OF DATE OF PURCHASE WITH ANY WARRANTY CLAIM 2 EXCLUSIONS Excluded from any CARRYALL warranty are all fuses filters decals except safety decals spark plugs lubricants trim pieces seats routine wear items such ...

Page 37: ...ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REMEDY OF REPAIR OR REPLACEMENT OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE EXCLUSIVE AND SOLE REMEDY OF THE PURCHASER CLUB CAR...

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Page 40: ...Club Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Int l 1 706 863 3000 Fax 1 706 863 5808 ...