Club Car CARRYALL 252 2007, Owner'S Manual

Page 1: ...Owner s Manual 2007 Utility Vehicles Gasoline XRT 900 Turf 252 Carryall 252 ...

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Page 3: ... from the use of the material in this manual This manual contains proprietary information that is protected by copyright All rights are reserved No part 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 ch...

Page 4: ...at you ask them to 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 In the event that your Club Car vehicle needs repairs or service we recommend that your local authorized Club Car representative perform them For the name and address of the Club Car representative nearest you logon to our web si...

Page 5: ...t 16 Performance Inspection 17 Driving Instructions 18 Bed Latch 20 Prop Rod 20 Loading and Unloading 21 Towing with the Vehicle 22 Transporting on a Trailer 23 Storage 23 Maintenance 26 Periodic Service Schedule 26 Periodic Lubrication Schedule 28 Engine Oil 29 Fueling Instructions 31 Battery 32 Cleaning the Vehicle 34 Accessories 34 Subsequent Owner Registration 35 Vehicle Specifications 36 Rear...

Page 6: ...IL WARNING LAMP DRIVER PASSENGER WARNING DECAL FUEL GAUGE HOUR METER KEY SWITCH SERIAL NUMBER CRUSH AREA DECAL OPERATING INSTRUCTIONS BED LATCH WARNING DECAL VEHICLE LOADING DECAL BRAKE PEDAL ACCELERATOR PEDAL PARK BRAKE PEDAL DIRECTIONAL ARROW ON TIRE BED LOAD WARNING DECAL UNDERAGE WARNING DECAL ...

Page 7: ...GINE GASOLINE WARNING DECAL ON FRAME FRAME GROUND AND GOVERNOR WARNING DECAL ON FRAME TRAILER HITCH DECAL ON RECEIVER HITCH ON SEAT SUPPORT PANEL WINCH CABLE WARNING DECAL FOR VEHICLES WITH WINCH ACCESSORY TOP OF PASSENGER SIDE FENDER ROTATING PARTS DECAL DIODE WIRING DECAL ON FRAME ABOVE DIODE FORWARD REVERSE HANDLE ON DASH NEUTRAL LOCKOUT SWITCH DECAL ON NEUTRAL LOCKOUT BRACKET UNDER SEAT ...

Page 8: ...e from driver side only and not on public roads Keep entire body inside vehicle while moving Drive slowly in turns and straight up and down slopes Do not leave children unattended on vehicle Never operate under the influence of alcohol or drugs Use brakes to reduce speed when coasting downhill Never stand in front of or behind vehicle CCI 1019606 01 WARNING ROLLOVER OR FALLING OFF MAY CAUSE DEATH ...

Page 9: ...TARTER GENERATOR AND ENGINE GASOLINE WARNING DECAL ON FRAME FRAME GROUND AND GOVERNOR WARNING DECAL ON FRAME TRAILER HITCH DECAL ON SEAT SUPPORT PANEL WINCH CABLE WARNING DECAL FOR VEHICLES WITH WINCH ACCESSORY TOP OF PASSENGER SIDE FENDER ROTATING PARTS DECAL FORWARD REVERSE HANDLE ON DASH NEUTRAL LOCKOUT SWITCH DECAL ON NEUTRAL LOCKOUT BRACKET UNDER SEAT ...

Page 10: ...ve 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 Understand and become familiar with the DANGER WARNING and CAUTION statements and procedures it contains along with the safety de...

Page 11: ... safety 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 DANGER A DANGER indicates an immediate hazard that will result in severe personal injury or death ý WARNING A WARNING indicates an immediate hazard that could result in severe personal i...

Page 12: ...e unattended or servicing the vehicle set the park brake place the Forward Reverse handle in the NEUTRAL position turn the key switch to the OFF position and remove the key Chock the wheels when servicing the vehicle Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance severe personal injury or death Any modification or change to the vehicle ...

Page 13: ...arryall 252 vehicles Throughout this manual impor tant vehicle information and features are highlighted We urge the owner operator to read and understand this manual and to pay special attention to the features specific to his her vehicle s MODEL IDENTIFICATION The serial number of each vehicle is printed on a bar code decal mounted on the frame directly above the accelerator pedal Example AE0601 ...

Page 14: ...either a two position key switch or a three position key switch Turf 252 and Car ryall 252 vehicles have a two position key switch and are referred to as pedal start The XRT 900 has a three position key switch and is referred to as key start The key switch 1 is mounted on the dash to the right of the steering column Figure 3 Pedal start vehicle The key switch has two positions OFF and ON which are...

Page 15: ...on Pedal start vehicle The engine will not run when the handle is in the NEUTRAL position Key start vehicle The engine will idle while in the NEUTRAL position See following NOTE NOTE Key start vehicle The engine will stop running if the accelerator is pressed while the Forward Reverse handle is in the NEUTRAL position HEADLAMP CONTROL The headlamp switch 3 is located on the instrument panel to the...

Page 16: ...the fuel level in the vehicle The hour meter should be used by the trained technician to track vehicle usage and determine when periodic service procedures are required See Periodic Service Schedule on page 26 ACCELERATOR PEDAL The accelerator pedal is the pedal on the right with the word GO molded into it Figure 4 The operation of the accelerator pedal differs from that of an automobile Pedal sta...

Page 17: ...y and tilt the park brake portion of the pedal forward Figure 6 ý WARNING The park brake will release automatically when either the accelerator or brake pedal is pressed The park brake has multiple locking positions and should be firmly pressed and locked to prevent the vehicle from rolling CHOKE The choke is located on the seat support panel below and to the left of the driver s left knee Figure ...

Page 18: ...ay move suddenly if the Forward Reverse handle is shifted or accidentally bumped To prevent this chock the front and rear wheels and firmly set the park brake before servicing or leaving the vehicle NOTE Pedal start vehicle Be sure to return the switch to the OPERATE position after servicing the vehi cle or it will not run with the Forward Reverse handle in either the FORWARD or REVERSE posi tion ...

Page 19: ...trained technician Forward Reverse shifter Check for proper operation See Controls and Indicators on page 12 Brakes Be sure the brakes function properly When brake pedal is fully pressed under moderate pres sure it should not go more than halfway to the floor and vehicle should come to a smooth straight stop If the brake pedal goes more than halfway to the floor or if the vehicle swerves or fails ...

Page 20: ...help prevent the possibility of serious injury keep entire body inside the vehicle To help prevent overturning the vehicle drive slowly in turns To help prevent overturning the vehicle drive slowly straight up and down slopes Avoid driving the vehicle on slopes exceeding 20 incline Avoid stopping a loaded vehicle on a hill If a loaded vehicle must be stopped on a hill avoid sudden starts or rollin...

Page 21: ... place the Forward Reverse handle in desired position F forward or R reverse A buzzer will sound as a warning when the vehicle is in the REVERSE position 4 8 Release brake pedal and slowly press accelerator pedal The park brake will release automatically and the vehicle will start to move As the accelerator pedal is pressed speed will increase until full speed is reached See following WARNING and ...

Page 22: ...urn the fuel shut off valve to the closed OFF position when the vehicle is not in use Figure 11 See also Figure 19 Page 32 BED LATCH See General Warnings on page 10 The vehicle is equipped with a bed latch on the driver side of the vehicle Figure 9 and an automatically engaging prop rod Figure 10 To lift the bed pull the latch handle toward the rear of the vehicle and lift the bed To close the bed...

Page 23: ...ARNING Firmly engage the park brake before loading the vehicle Do not allow riders in the cargo bed Reduce vehicle load and speed when driving up or down slopes or on uneven terrain Do not exceed the rated capacity of the vehicle Rated capacity is for level surfaces only Overloading can affect vehicle handling or cause component failure resulting in loss of control of vehicle and possible severe p...

Page 24: ...standard vehicle with a cab accessory weighing 235 lb 107 kg must reduce its maximum pay load capacity by 235 lb 107 kg to 465 lb 119 kg TOWING WITH THE VEHICLE ý WARNING Do not tow a vehicle or trailer on public streets or highways Normal vehicle operating speed should be reduced when towing Extreme caution should be used when towing Do not allow riders in the vehicle or trailer being towed Total...

Page 25: ...e lights etc Do not tow a Club Car vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer The vehicle to be transported should be tied securely to the trailer with the Forward Reverse handle in the NEUTRAL position the key switch in the OFF position and the park brake firmly engaged Because of the added length of the trailer use caution when making turns D...

Page 26: ...otive type 12 volt battery charger rated at 10 amps or less 3 Drain carburetor and seal the fuel tank 3 1 Place the Forward Reverse handle in the NEUTRAL position Turn the fuel shut off valve to the closed OFF position Figure 11 and run the engine until fuel remaining in the carburetor and fuel lines is depleted and the engine stalls 3 2 Loosen but do not remove the carburetor drain screw and drai...

Page 27: ...revent the vehicle from rolling RETURNING THE STORED VEHICLE TO SERVICE 1 Restore fuel system to operation Figure 19 Page 32 1 1 Remove plug from the fuel tank vent 1 2 Connect vent tube to fuel tank vent 2 Connect battery cables positive cable first and tighten terminals to 12 ft lb 16 N m 3 Completely open the fuel shut off valve Figure 12 Make sure the valve is fully open A partially closed fue...

Page 28: ...ervicing the vehicle Turn the key switch to the OFF position remove the key place the Forward Reverse handle in the NEUTRAL position and chock the wheels prior to servicing Moving parts Do not attempt to service vehicle while the engine is running Do not work on vehicle powertrain or under the cargo bed when it is loaded Turn the fuel shut off valve to the closed OFF position Figure 11 Page 24 Hot...

Page 29: ...from casing check electrolyte level See Battery on page 32 Front wheel alignment and camber Check and adjust if necessary See Section 7 Steering and Front Suspension in the appropriate maintenance and service manual Electrical wiring and connections Check for tightness and damage Brake system Check brake shoes replace if necessary See Section 6 Park Brake System in the appropriate maintenance and ...

Page 30: ... Front suspension 5 fittings Chassis Lube EP NLGI Grade 2 Brake slides Dry Moly Lube CCI P N 1012151 Annually by trained technician only or every 100 hours of operation whichever comes first Check fill unitized transaxle to plug level 27 oz 0 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 Chassis Lube EP NLGI Grade 2 First chang...

Page 31: ...ess the engine compartment 3 Disconnect the battery cables negative cable first See WARNING To avoid unintentionally start ing on page 10 4 Position a pan designed for oil changes under the front drain plug Figure 15 5 Use a 14 mm socket or wrench to remove the drain plug turning it counterclockwise and allow the engine oil to drain into the pan See following WARNING ý WARNING Do not attempt to ch...

Page 32: ...t the filter port oil into the drain pan Dispose of used oil according to the environmental laws and regulations for your area 10 Use a clean rag and wipe the oil filter mounting bracket surface clean where the oil filter gasket seats 11 Install a new oil filter CCI P N 1016467 onto the engine oil filter port Apply a light coat of white lithium NLGI Number 2 grease Dow Corning BR2 Plus or equivale...

Page 33: ...he engine is hot or while it is running To avoid electric arc caused by static electricity the fuel storage pumping device must be grounded If the pump is not grounded the vehicle must be grounded to the pump before and during the fueling operation If the vehicle has an all weather enclosure installed be sure the fuel tank is properly vented as shown Figure 19 To avoid the possibility of fire clea...

Page 34: ...nd metal objects can cause sparks when shorted across a battery Follow all instructions carefully when working with batteries Charge battery in a well ventilated area only Battery Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes External Flush with water Call a physician immediately Internal Drink large quantities of milk or water followed with milk of ma...

Page 35: ...ll line Replace battery cell caps 6 Clean both battery terminals with a solution of baking soda and water 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse thoroughly Do not allow this solution to enter the battery Tighten battery terminals to 12 ft lb 16 N m Let the terminals dry and then spray them with Battery Terminal Protector Spray CCI P N 1014305 See following CAUTION ý CAUTION If ...

Page 36: ... the maintenance and service man ual See following NOTE NOTE Dispose of waste water properly 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 club car com and clicking the Dealer Locator link Care should be taken that these access...

Page 37: ...N Use of the winch for an extended period of time could discharge the battery Keep winch operations as short as possible and drive the vehicle for several minutes after the winch operation to recharge the battery 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...

Page 38: ...ed drum brakes on each wheel with automatic release park brake BODY CHASSIS Frame Chassis Twin I Beam welded aluminum Side and rear body All aluminum with a powder coated steel box bed Front body ArmorFlex Front body finish Matched paint finish over molded in color Tires Heavy Duty All Terrain tubeless 6 ply rated Turf tubeless 4 ply rated 22 x 11 00 x 10 in 23 x 10 50 x 12 in DIMENSIONS WEIGHT Ov...

Page 39: ...ce only 900 lb 408 kg Bed load capacity level surface only 500 lb 227 kg Standard seating capacity 2 LIQUID CAPACITIES Engine crankcase without filter 32 oz 95 liters Engine crankcase with filter 38 oz 1 12 liters Unitized transaxle 27 oz 8 liters Fuel tank 7 gallons 26 5 liters TIRE PRESSURE Off road tread 14 18 psi 97 1 24 Bars Turf tread 18 20 psi 1 24 1 38 Bars SPECIFICATIONS XRT 900 TURF 252 ...

Page 40: ... personal injury or death NOTE The rear fender with the warning decal should be installed on the passenger side of the vehicle The decal should be plainly visible when the cargo bed is raised 3 Position a fender in the vehicle align the hole in the fender with the slot in the frame as shown and install bolt 1 large flat washers 2 and locknut 3 Figure 22 Finger tighten only at this time Figure 22 I...

Page 41: ...arge flat washers 2 small flat washers 4 and locknuts 3 in the front mount ing bracket holes 7 Install bolt 1 large flat washer 2 small flat washer 4 and locknut 3 in the top mounting bracket hole as shown Figure 23 8 Tighten mounting hardware at both front mounting bracket holes then both top mounting bracket holes to 35 in lb 4 0 N m 9 Repeat steps 3 8 for the other rear fender 10 Lower cargo be...

Page 42: ... will be severely compromised The optional turf tire is not directional and installation is dictated only by correct wheel position not tire direction 1 Slightly loosen the lug nuts on all four wheels 2 Raise one end of the vehicle until the tires are off the ground by approximately six inches See following WARNING ý WARNING Lift only one end of a vehicle at a time Before lifting set the park brak...

Page 43: ...er plug and receptacle brake shoes belts brushes bushings engine mounts mats and pads maintenance adjustments cosmetic deterioration and items which deteriorate or fail due to exposure or ordinary wear and tear Batteries battery charger onboard computer and solid state speed controller are covered under separate CLUB CAR warranties Also excluded from any CLUB CAR warranty is damage to a vehicle or...

Page 44: ... ANY KIND AND NO REPRESENTATIVE EMPLOYEE OR DEALER OF CLUB CAR HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY 7 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 I...

Page 45: ...arranty services or repairs will be provided at all of our distribution centers that are franchised to service the subject engines or equipment 6 The engine or equipment owner will not be charged for diagnostic labor that is directly associated with diagnosis of a defective emission related warranted part provided that such diagnostic work is performed at a warranty station 7 CLUB CAR is liable fo...

Page 46: ...stem having optimum ignition timing characteristics The carburetors have been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system Maintenance and Warranty Proper maintenance is necessary to ensure that your engine will continue to have low emis sion levels Those items identified by the Periodic Maintenance Chart are ne...

Page 47: ...ty of Illustrations 4 Periodic Service and Periodic Lubrication Schedules Poor Fair Average Good Excellent Comments Suggestions In order to help us better serve you please rate this publication in the following catgories Your Comments Are Appreciated Please select your category Distributor Dealer Individual Owner Club Car Associate Representative Technician Golf Course Superintendent Other _______...

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Page 52: ...b Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Intl l 1 706 863 3000 Fax 1 706 863 5808 Publication Part Number 103218315 Edition Code 0706B0706A ...