Club Car Carryall 1 User manual

2002
Owner’s
Manual
Electric
Industrial
Truck
Carryall 1
Carryall 2
Carryall 6

P. O. Box 204658
Augusta, Georgia 30917-4658 USA
Telephone [phone]
Service Parts Fax [phone]
www.clubcar.com
2002 Carryall Electric Industrial Truck Owner’s Manual Page 1
©2001 Club Car, Inc.
Club Car, Carryall, PowerDrive, and ArmorFlex
are registered trademarks of Club Car, Inc.
This manual effective July 23, 2001.
NOTICE
The Club Car Limited Warranties for 2002 Transportation and Utility Vehicles, 2002 PowerDrive 8-Volt Batter-
ies, 2002 PowerDrive Battery Chargers, and 2002 Onboard Computers and Solid State Speed Controllers
appear on the last pages of this manual. No other warranties, express or implied, are contained herein. Your
authorized representative checked this vehicle before it was delivered to you and will provide you a copy of the
completed vehicle warranty registration form.
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.
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 changes to vehicles without obligation to make these changes on
units previously sold.
These vehicles do not conform to Federal Motor Vehicle Safety Standards for automobiles or to FMVSS 500
for low-speed vehicles, and are not equipped for operation on public streets, roads, or highways.

Page 2 2002 Carryall Electric Industrial Truck Owner’s Manual

2002 Carryall Electric Industrial Truck Owner’s Manual Page 3
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.
Your comfort and safety are important to us as well, so we urge you to read and follow the step-by-step oper-
ating instructions and safety precautions in this manual. These instructions must be followed 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.
Club Car products are backed by a customer support system designed to offer you fast, courteous service. In
the event that your Carryall 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 site at www.clubcar.com or call 1-800-ClubCar (258-2227) or 1-706-863-3000. If you would
prefer to write to us, direct your letter to: Club Car, Attention: Marketing Services, P.O. Box 204658, Augusta,
Georgia 30917-4658, U.S.A.Your local authorized Club Car representative 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 and keep it in the
storage tube provided for it on the passenger side dash. 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.

!WARNING
Rotating Parts
Practice Safety
Page 4 2002 Carryall Electric Industrial Truck Owner’s Manual
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.
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 life.

2002 Carryall Electric Industrial Truck Owner’s Manual Page 5
TABLE OF CONTENTS
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Vehicle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Vehicle Feature Identification – Carryall 1 and Carryall 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Vehicle Feature Identification – Carryall 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pre-Operation and Daily Safety Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Driving Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Bed Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Prop Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Loading and Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Towing with the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Transporting on a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Vehicle Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Periodic Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Periodic Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Cleaning the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Subsequent Owner Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Warranties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

General Information
Page 6 2002 Carryall Electric Industrial Truck Owner’s Manual
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%. The vehicle is not intended for use on public
streets, roads, or highways or for operation in flammable or explosive atmospheres.The charts that follow pro-
vide a complete listing of vehicle specifications and capacities.
Throughout this manual, important features unique to each model are highlighted. We urge the owner/opera-
tor to read and understand this manual, and to pay special attention to the features specific to their vehicle(s).
VEHICLE SPECIFICATIONS
SPECIFICATIONS
Carryall 1 Carryall 2 Carryall 6
POWER SOURCE
Drive motor : Direct drive, 48 volts DC, series wound, 3.1 hp • • •
Transaxle: Double reduction helical gear with 12.28:1 direct drive axle • • •
Electrical system: 48 volts DC, reduced speed reverse • • •
Batteries: High capacity, deep cycle, Trojan PowerDrive 8 volt, 117 min. capacity • • •
Charger: Automatic, 17 amp PowerDrive; UL and CSA listed • • •
STEERING/SUSPENSION/BRAKES
Steering: Self-adjusting rack and pinion • • •
Suspension: Front mono-leaf and rear multi-leaf springs with dual hydraulic shocks • • •
Brakes: Mechanical brake cable system to self-adjusting drum brakes on each rear wheel
with separate hand-operated park brake •
Brakes: Mechanical brake cable system to manually adjusted drum brakes on all four
wheels with separate hand-operated park brake ••
BODY/CHASSIS
Frame/chassis: Twin I-Beam welded aluminum • • •
Side and rear body: All aluminum • • •
Front body: ArmorFlex
®
•••
Front body finish: Matched paint finish over molded-in color • • •
Tires: 18 x 8.5 - 8 tubeless, 4 ply rated load range front and rear •
Tires: 18 x 8.5 - 8 tubeless, 6 ply rated load range front and rear • •
DIMENSIONS/WEIGHT
Overall length (Carryall 1 and 2: cargo bed; Carryall 6: flatbed configuration) 263 cm
(103.5 in.)
282 cm
(111 in.)
340 cm
(134 in.)
Overall width
122 cm
(48 in.)
127 cm
(50 in.)
125 cm
(49.3 in.)
Overall height (at steering wheel) 122 cm
(48 in.)
122 cm
(48 in.)
122 cm
(48 in.)
Wheelbase
166 cm
(65.5 in.)
197 cm
(77.5 in.)
250 cm
(98.5 in.)
Ground clearance
11 cm
(4.5 in.)
11 cm
(4.5 in.)
11 cm
(4.5 in.)
Specifications continued on next page . . .

Accessories
2002 Carryall Electric Industrial Truck Owner’s Manual Page 7
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.
Front wheel tread
88 cm
(34.5 in.)
88 cm
(34.5 in.)
88 cm
(34.5 in.)
Rear wheel tread
98 cm
(38.5 in.)
98 cm
(38.5 in.)
98 cm
(38.5 in.)
Weight (standard electric industrial truck (without batteries)) 279 kg
(616 lb.)
326 kg
(718 lb.)
349 kg
(770 lb.)
Forward speed
19-24 km/h
(12-15 mph)
19-24 km/h
(12-15 mph)
19-24 km/h
(12-15 mph)
Curb clearance circle (diameter) 533 cm
(17 ft. 6 in.)
630 cm
(20 ft. 8 in.)
752 cm
(24 ft. 8 in.)
Turning radius per SAE J 695
257 cm
(101 in.)
305 cm
(120 in.)
366 cm
(144 in.)
Intersecting aisle clearance
183 cm
(72 in.)
196 cm
(77 in.)
228 cm
(89.8 in.)
Floorboard height
30 cm
(11.8 in.)
30 cm
(11.8 in.)
30 cm
(11.8 in.)
Load bed height
69 cm
(27 in.)
70 cm
(27.6 in.)
69 cm
(27 in.)
Seat height
72 cm
(28.4 in.)
73 cm
(28.7 in.)
72 cm
(28.4 in.)
Load bed size (box bed dimensions)
96 x 115 x 23 cm
(37.6 x 45.1
x 9.3 in.)
124 x 126 x
28 cm
48.8 x 49.8
x 10.9 in.)
179 x 115
x 23 cm
(70.5 x 45.1
x 9.3 in.)
Load bed size (flat bed dimensions) 91 x 112 cm
(35.8 x 44.3 in.)
119 x 126 cm
46.9 x 48.3 in.)
172 x 112 cm
(67.6 x 44.3 in.)
Maximum payload capacity (cargo load and gross trailer weight (level surface only)) 136 kg
(300 lb.)
363 kg
(800 lb.)
453 kg
(1000 lb.)
Maximum vehicle capacity (passengers, cargo load, and gross trailer weight) 363 kg
(800 lb.)
544 kg
(1200 lb.)
680 kg
(1500 lb.)
Maximum gross vehicle weight (fully loaded, accessories included) 815 kg
(1796 lb.)
1042 kg
(2298 lb.)
1202 kg
(2650 lb.)
Maximum drawbar pull
3728 N
(838 lb.)
3906 N
(878 lb.)
4083 N
(918 lb.)
Standard seating capacity (persons) 2 2 2
VIBRATION SPECIFICATIONS
Vibration at seat bottom
0.4 m/sec
3
0.4 m/sec
3
0.4 m/sec
3
Vibration at driver’s hands
1.5 to 2.1 m/sec
3
1.5 to 2.1 m/sec
3
1.5 to 2.1 m/sec
3
CLIMATIC EXTREMES
Operating temperature range
-20 to 40 °C
(4 to 104 °F)
-20 to 40 °C
(4 to 104 °F)
-20 to 40 °C
(4 to 104 °F)
LIQUID CAPACITIES
Transaxle (SAE 30 WT. API Class SE, SF, or SG oil or higher) .65 L (22 oz.) .65 L (22 oz.) .65 L (22 oz.)
TIRE PRESSURE
Front and rear
1.24-1.38 Bars
(18-20 psi)
2.07-2.34 Bars
(30-34 psi)
2.07-2.34 Bars
(30-34 psi)
SPECIFICATIONS
Carryall 1 Carryall 2 Carryall 6

Accessories
Page 8 2002 Carryall Electric Industrial Truck Owner’s Manual
∆
WARNING
• Custom cab assemblies, weatherproof enclosures, door kits, and tinted windshields will not
protect occupants from flying objects.
• If the vehicle has a portable refreshment center option installed in the bed, it must be removed
before unlatching and lifting the bed.
• 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 •••
3.75 HP electric motor • • •
Accent stripe •••
Ambulance kit ••
Ashtray •••
Battery capacity indicator • • standard
Bed mat •••
Cab assembly •••
Communication display module • • •
Custom van box •••
DC converter • standard
Differential guard •••
Electric lift ••
Fold-down seat ••
Glove box with lock • • •
Heavy-duty front bumper • standard standard
Hour meter •••
Lighting package • standard
Mirror, sport •
Mirror, west coast style • • •
Portable refreshment center • •
Radio/beverage holder • • •
Safety strobe light •••
Stake side kit •••
Tires: 6-ply premium and extra traction • • •
Toolbox (cargo bed and flatbed) • •
Trailer hitch • standard •
Turn signals •••
Wheel covers •••
Windshield, safety glass with wiper • • •
Windshield, tinted fold-down • • •
Windshield, tinted one-piece • • •

Model Identification
2002 Carryall Electric Industrial Truck Owner’s Manual Page 9
MODEL IDENTIFICATION
The serial number (1) of the vehicle is printed on a bar code decal mounted on the frame directly above the
accelerator pedal (Example: FA0201-123456) (Figure 1, Page 9) . There is also a second serial number decal
mounted on the front body frame behind the center dash panel. The center dash panel must be removed to
view this decal.
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.
SAFETY SYMBOLS
∆
Safety alert
Reverse (Forward/Reverse handle)
Forward (Forward/Reverse handle)
Neutral (Forward/Reverse handle)
Emergency stop switch
Horn
Light switch (Carryall 6 only)
Front of vehicle (illustration reference only)
SAFETY DETAILS
∆
WARNING
• 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.
Figure 1 Serial Number Decal
Cl b
GO
GO
SERIAL NUMBER
FA0201-123456
P O BOX 204658
AUGUSTA GA 30917
Club Car
R
1

Driving Instruction Warnings
Page 10 2002 Carryall Electric Industrial Truck Owner’s Manual
It is important to note that some vital statements throughout this manual and on the decals affixed to the vehi-
cle are preceded by the words DANGER, WARNING, or CAUTION. For your protection, we recommend that
you take special notice of these safety precautions. Safety precautions are essential and must be followed.
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.
∆ DANGER
•A DANGER indicates an immediate hazard that will result in severe personal injury or death.
∆
WARNING
•A WARNING indicates an immediate hazard that could result in severe personal injury or
death.
∆
CAUTION
•A CAUTION indicates hazards or unsafe practices that could result in minor personal injury or
product or property damage.
The safety precautions listed must be followed whenever the vehicle is being operated, repaired, or serviced.
Vehicle feature identification information is also included on pages 18 through 21.
The following pages contain DANGER/WARNING/CAUTION statements for operation and maintenance for
this vehicle. Other warnings for specific procedures appear throughout this manual and on the vehicle.
Descriptions of vehicle features and operating instructions follow these warning statements.
DRIVING INSTRUCTION WARNINGS
The following warnings should be observed when driving the vehicle. See Driving Instructions on page 26.
∆
DANGER
•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 with applicable safety guidelines for your location.
∆
WARNING
•Only licensed drivers should be allowed to drive this vehicle.
•Before allowing anyone to drive the vehicle, make sure the driver is familiar with all controls
and operating procedures.
•No more than two people (one person per seat) should be on the vehicle at one time.
•Do not leave children unattended on vehicle.
•Do not allow riders in the cargo bed.
•The vehicle is not specially equipped for handicapped persons:

Driving Instruction Warnings
2002 Carryall Electric Industrial Truck Owner’s Manual Page 11
- 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.
•For night use, the vehicle must be equipped with headlights, taillights, and reflectors.
•To avoid being struck, do not stand in front of or behind the vehicle.
•Operate the vehicle from the driver seat only. A seat switch, located under the driver seat, will
prevent operation of vehicle when seat is unoccupied.
•To prevent falls from the vehicle, remain seated in a moving vehicle and hold on to armrest or
handrails at all times. Driver should keep both hands on the steering wheel when the vehicle
is in motion.
•To prevent the possibility of serious injury, keep entire body inside the vehicle.
•Release the accelerator pedal, then depress the brake pedal firmly until the vehicle stops. To
avoid unintentionally starting or rolling the vehicle, or when leaving the vehicle:
- Set the park brake.
- Place the Forward/Reverse handle in NEUTRAL.
- Turn the key switch to OFF and remove the key.
•Stop the vehicle before shifting the Forward/Reverse handle. Failure to do so may result in
injury to inattentive passengers and (or) damage to the vehicle.
•To prevent overturning the vehicle, drive slowly around turns.
•To prevent overturning the vehicle, drive slowly straight up and down slopes, never across
them. 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 rolling backwards and stopping suddenly. Failure to heed this warning could
result in overturning the vehicle.
•To avoid possible injury to inattentive passengers and (or) damage to the vehicle, avoid
sudden starts, sudden stops, and abrupt turns.
•To avoid the possibility of losing control of or overturning the vehicle, reduce speed for
adverse driving conditions such as wet grass or rough terrain.
•Do not use the vehicle on public roads. It is neither designed nor intended for street use and
should not be licensed for use on public roads.
•The vehicle should be driven by trained drivers in specified areas only.
•Do not drive while under the influence of alcohol, drugs, or medications.
•Use brakes to reduce speed when coasting downhill.
•Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle
performance or severe personal injury.

Loading and Unloading Warnings
Page 12 2002 Carryall Electric Industrial Truck Owner’s Manual
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.
•Firmly engage the park brake before loading the vehicle.
•Do not allow riders in the cargo bed.
•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 personal injury.
•Vehicle load and speed must be reduced when driving up or down slopes or on uneven
terrain.
•Reduce speed and avoid sudden stops when backing up. Failure to do so may cause the
vehicle to overturn or flip over backwards.
•Do not load the tailgate. The tailgate should be in the upright position and latched securely
while the vehicle is in motion.
•To avoid shifting the vehicle load and possibly overturning the vehicle, avoid sudden starts,
sudden stops, and abrupt turns. The cargo’s center of gravity may affect the handling,
steering, and braking of the vehicle.
•To prevent cargo from shifting and possibly injuring a passenger or affecting the vehicle’s
handling, cargo should be evenly spread over the floor of the cargo bed as far forward as
possible and well secured.
•Exercise caution when operating in high winds; vehicle can become unstable under certain
loading conditions.
•Avoid top-heavy loads. The center of gravity of a load should never exceed 38 cm (15 inches)
above the bottom of the cargo bed.
•Always unload cargo bed before raising vehicle with a lift, hoist, or jack.

Towing Warnings
2002 Carryall Electric Industrial Truck Owner’s Manual Page 13
TOWING WARNINGS
The following warnings should be observed when towing the vehicle. See Towing with the Vehicle on
page 30.
∆
WARNING
•Never 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.
•Total vehicle capacity, including the tow vehicle load rating and the gross weight of the
vehicle or trailer being towed should not exceed the weight previously specified.
•Do not allow riders in the vehicle or trailer being towed.
•Avoid sudden starts, sudden stops, and tight turns when towing.
•Avoid stopping on a hill when towing. If you must stop on a hill, avoid sudden starts, or rolling
backwards and stopping suddenly. Failure to heed this warning could cause the vehicle to
overturn, possibly resulting in severe personal injury.
TRANSPORTING ON A TRAILER WARNINGS
The following warnings should be observed when transporting the vehicle on a trailer. See Transporting on
a Trailer on page 30.
∆
WARNING
•Do not allow riders in the trailer being towed.
•Avoid sudden starts, sudden stops, and tight turns when towing a trailer.
•Avoid stopping on a hill when towing. If you must stop on a hill, avoid sudden starts, or rolling
backwards and stopping suddenly. Failure to heed this warning could cause the vehicle to
overturn, possibly resulting in severe personal injury.
•For use on public roads, the trailer must meet all governmental requirements such as
taillights, brake lights, etc.
•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.
•The vehicle to be transported should be tied securely to the trailer, with the park brake firmly
depressed and locked, the Forward/Reverse handle in NEUTRAL, and the key switch OFF.
•Because of the added length of the trailer, use caution when making turns.
•Never transport the vehicle on a trailer with a load in the vehicle cargo bed.
•Remove the vehicle windshield before transporting on a trailer.

Storage Warnings
Page 14 2002 Carryall Electric Industrial Truck Owner’s Manual
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.
•Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the
batteries. Frozen batteries can explode.
BATTERY WARNINGS
The following warnings should be observed when working with batteries. See Batteries on page 32.
∆
DANGER
•Battery –Explosive gases! Do not smoke! Keep sparks and flames away from vehicle and
service area. Tools, wires, and metal objects can cause sparks when shorted across a battery.
Follow all instructions carefully when dealing with batteries.
•Poison! Contains acid! Causes severe burns –avoid contact with skin, eyes, or clothing.
Antidotes:
- External: Flush with water for 15 minutes. Call a physician immediately.
- Internal: Drink large quantities of milk or water followed with milk of magnesia or vegetable
oil. Call a physician immediately.
- Eyes: Flush with water for 15 minutes. Call a physician immediately.
∆
WARNING
•Wear safety glasses or approved eye protection when servicing the vehicle. Wear a full face
shield and rubber gloves when working with batteries.
•Use insulated tools when working around batteries or electrical connections.
BATTERY CHARGER WARNINGS
The following warnings should be observed when using the battery charger. See Battery Charger on
page 33.
∆
DANGER
•Batteries emit hydrogen while being charged. Hydrogen is an explosive gas. If the vehicle is
equipped with a weatherproof enclosure, it should be unzipped and pulled back while
batteries are being charged. This is to avoid the accumulation of hydrogen gas inside the
enclosure.
•Charge batteries in a well-ventilated area only. To prevent a buildup of explosive gas,
hydrogen level in the air must never exceed a level of 2%. The total volume of air in the
building must be changed five times per hour. Exhaust fans should be located at the highest
point of the roof. Contact a local HVAC engineer.

Battery Charger Warnings
2002 Carryall Electric Industrial Truck Owner’s Manual Page 15
∆
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.
•Be sure wire connections at the receptacle and fuse link are clean and tight.
•Have worn, cut, or damaged power cords or wires replaced immediately.
•Do not expose charger to rain or any liquid. Keep the charger dry.
•Do not use near fuels, grain dust, solvents, thinners, or other flammables. Chargers can ignite
flammable materials and vapors.
•Connect the charger AC supply cord to a properly grounded, three-wire outlet of the proper
voltage and frequency as shown on the charger.
•Do not use an adapter to plug the charger with a three-prong plug into a two-prong outlet.
Improper connection of the equipment-grounding conductor can result in a fire or an
electrical shock.
•An extension cord or electrical outlet must accept a three-prong plug. Extension cord should
be a three-wire No. 14 SWG (British Standard Wire Gauge), or No. 12 AWG (American Wire
Gauge), and be as short as possible. The use of improper extension cord could result in fire or
an electrical shock.
•Do not operate the charger if it has received a sharp blow, was dropped, or otherwise
damaged in any way.
•Never push objects of any kind into the charger through cabinet slots. They may touch
dangerous voltage points or cause an electrical short circuit that could result in fire or
electrical shock.
•Do not connect a stationary charger to the receptacle if the charger cord, plug, or the vehicle
receptacle is broken, damaged in any manner, or does not make a good electrical connection.
Fire or personal injury can result. Have a qualified technician repair or replace it immediately.
•Do not pull on the charger DC cord (Figure 16, Page 34). Do not twist, rock, or bend the plug.
To disconnect the plug from the receptacle, grasp the plug, not the cord, and slowly pull it
straight out of the receptacle (Figure 15, Page 34).
•When the charger is on, the charger DC cord may be disconnected from the vehicle receptacle
slowly. Jerking or pulling the DC cord out quickly could cause arcing and burning that could
damage the plug and receptacle and could cause batteries to explode.
•Do not use a charger if the following conditions exist:
- The plug is too loose or does not make a good connection.
- The plug and receptacle feel hotter than normal during charge.
- The plug pins or contacts are bent or corroded.
- The plug, receptacle or cords are cut, worn, have any exposed wires, or are damaged in any
way.
•Using a charger with any of the above symptoms could result in fire, property damage,
personal injury, or death.
∆ CAUTION
•Do not block or cover slots and openings in the back and bottom of charger cabinet. They
provide ventilation and protect the charger from overheating.
•Do not allow clothing, blankets, or other material to cover the charger.
•Provide adequate ventilation for the charger.
•Turn off all vehicle accessories before charging batteries.

Maintenance Warnings
Page 16 2002 Carryall Electric Industrial Truck Owner’s Manual
•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.
∆ DANGER
•Battery vapors –Flammable! Explosive! Do not smoke. Keep sparks and flames away from the
vehicle and service area. Service only in well-ventilated areas.
∆ WARNING
•Only trained technicians should repair or service the vehicle. Anyone doing even simple
repairs or service should follow the procedures exactly as stated in this manual, and follow all
DANGER, WARNING, and CAUTION precautions listed in this manual as well as those affixed
to the vehicle.
•Do not modify or change the vehicle in any way that may affect its stability or handling, or
increase maximum vehicle speed beyond factory specifications. Severe personal injury or
death could result.
•When servicing the vehicle:
- Chock the wheels.
- Place the Forward/Reverse handle in NEUTRAL.
- Turn the key switch to OFF and remove the key.
- Disconnect the battery cables as shown (1) (Figure 2, Page 17 and Figure 3, Page 17),
negative (–) cable first.
- When reconnecting batteries, secure protective rubber boots (2) over battery terminals.
•To avoid unintentionally starting the vehicle, disconnect the batteries as shown and discharge
the controller as follows:
- Turn the key switch to ON and place the Forward/Reverse handle in the REVERSE position.
- Slowly depress the accelerator pedal and keep it depressed until the reverse warning buzzer
can no longer be heard. When the buzzer stops sounding, the controller is discharged.
•If any problems are found during scheduled inspection or service, do not operate the vehicle
until repairs are made. Failure to make necessary repairs could result in fire, property
damage, severe personal injury, or death.
•Be sure all persons are clear of the vehicle when lifting a cargo bed equipped with a tailgate
ramp.
•Do not remove prop rod or close bed until all persons are clear of the bed area. Lower the bed
gently, keeping entire body clear. Do not drop the bed. Failure to follow these instructions
could result in severe personal injury.
•Do not work on vehicle powertrain or under the cargo bed when it is loaded.
•Hot! Do not attempt to service hot motor. Attempting to do so can cause severe burns.

Maintenance Warnings
2002 Carryall Electric Industrial Truck Owner’s Manual Page 17
Figure 2 Carryall 1 PowerDrive Battery Configuration
Figure 3 Carryall 2 and 6 PowerDrive Battery Configuration
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3
4
6
5
1
2
1
1
2
3
4
6
5
1
2

Vehicle Feature Identification
Page 18 2002 Carryall Electric Industrial Truck Owner’s Manual
CARRYALL 1 AND CARRYALL 2
L
A
T
C
H
0
P
E
N
Crusharea.
Cancause severe injury.
Stayclear when closing bed.
CLUB CAR
•Before using vehicle, read operating instructions.
•Remain seated and hold on to seat handle while moving.
•Do not start vehicle until all occupants are seated.
•One (1) person per seat maximum.
•Operate 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 102173301
WARNING
ROLLOVER OR FALLING OFF MAY CAUSE DEATH.
OPERATING INSTRUCTIONS
• Read Owner’s Manual and safety warnings located on dash panel prior to driving.
• Study and understand controls.
• Make sure wheels are turned in desired direction.
• Turn key to “ON”position and be sure nothing is in your path.
• While vehicle is stopped, select direction by placing
Forward/Reverse handle or switch in desired position:
Forward Neutral Reverse (Buzzer will sound)
• Release hand brake.
• Vehicle will start moving when accelerator pedal is depressed.
• Slowly depress accelerator pedal to increase speed.
• To stop, release accelerator pedal and depress brake pedal.
• After stopping, set hand brake.
• Place Forward/Reverse handle or switch in neutral position.
• Turn key “OFF”and remove key when not in use.
OPERATING INSTRUCTIONS
• Read Owner’s Manual and safety warnings located on dash panel prior to driving.
• Study and understand controls.
• Make sure wheels are turned in desired direction.
•Press emergency stop button, then return to upright position.
• Turn key to “ON”position and be sure nothing is in your path.
• While vehicle is stopped, select direction by placing
Forward/Reverse handle or switch in desired position:
Forward Neutral Reverse (Buzzer will sound)
• Release hand brake.
• Vehicle will start moving when accelerator pedal is depressed.
• Slowly depress accelerator pedal to increase speed.
• To stop, release accelerator pedal and depress brake pedal.
• After stopping, set hand brake.
• Place Forward/Reverse handle or switch in neutral position.
• Turn key “OFF”and remove key when not in use.
CCI 102173401
Riding in cargo bed
can cause severe injury
or death.
Do not ride in cargo bed.
WARNING
CCI 1015539-01
MAXIMUM TONGUE
WEIGHT –150 lb. (667 N)
CCI 1011553
NOTICE
CARRYALL 1
ELECTRIC
INDUSTRIAL TRUCK
Read Owner's Manual
and warnings on dash.
•Normal voltage—48 Volts.
•Tire pressure—18-24 PSI (1.24-1.38 Bars).
•Nominal Power—3.1 HP (2.31kw).
•Authorized max/min battery mass—360/400 lb. (163/181 kg).
•Duty cycle—30 min.
•Unladen vehicle mass—616 lb. (279 kg).
•Total battery mass—380 lb. (172 kg).
•Vehicle rated capacity—800 lb. (363 kg).
•Maximum cargo load—300 lb. (136 kg).
•Maximum trailer hitch supporting force—150 lb. (667 N).
•Maximum drawbar pull on trailer hitch—838 lb. (3728 N). CCI 102172501
CARRYALL 2
ELECTRIC
INDUSTRIAL TRUCK
Read Owner's Manual
and warnings on dash.
•Normal voltage—48 Volts.
•Tire pressure—30-34 PSI (2.07-2.34 Bars).
•Nominal Power—3.1 HP (2.31kw).
•Authorized max/min battery mass—360/400 lb. (163/181 kg).
•Duty cycle—30 min.
•Unladen vehicle mass—718 lb. (326 kg).
•Total battery mass—380 lb. (172 kg).
•Vehicle rated capacity—1200 lb. (544 kg).
•Maximum cargo load—800 lb. (363 kg).
•Maximum trailer hitch supporting force—150 lb. (667 N).
•Maximum drawbar pull on trailer hitch—878 lb. (3906 N). CCI 102172601
H
O
R
N
OFF ON
1
2
3
4
5
7
8
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6