Club Car Carryall 500 User manual

Carryall
500/550/700
VehicleOwner'sManual
ElectricandGasoline
[Refertobackcoverforapplicablebuildcoderange]

NOTICE
Thismanualisvalidforvehiclesmanufacturedinthebuildcoderangeprovidedonthebackcoverofthismanual.Ifthe
vehiclebuildcodeisdifferentfromthatshownonthebackcoverofthismanual,pleasecontactyournearestdealerorgoto
www.clubcar.comtoretrievetheproperowner'smanualforthevehicle.SeealsoModelIdenticationinthismanual.
Warrantyinformationappearsattheendofthismanual.Nootherwarranties,expressorimplied,arecontainedherein.
Yourauthorizedrepresentativecheckedthevehiclebeforeitwasdeliveredtoyouandwillprovideyouacopyofthe
completedvehiclewarrantyregistrationform.
ClubCarisnotliableforerrorsinthismanualorforincidentalorconsequentialdamagesthatresultfromtheuseof
thematerialinthismanual.
Thismanualcontainsproprietaryinformationthatisprotectedbycopyright.Allrightsarereserved.Nopartofthismanual
maybephotocopied,reproduced,ortranslatedtoanotherlanguagewithoutthewrittenconsentofClubCar,LLC.
Theinformationcontainedinthisdocumentissubjecttochangewithoutnotice.ClubCarreservestherighttomakedesign
changestovehicleswithoutobligationtomakethesechangesonunitspreviouslysold.
Theseutilityvehiclesarefour-wheel,general-purposevehiclesintendedtotransportpeopleandcargoonimprovedor
groomedsurfaces.
ThesevehiclesdonotconformtoU.S.FederalMotorVehicleSafetyStandards(FMVSS)forautomobilesortoFMVSS500
forlow-speedvehicles,andarenotequippedforoperationonpublicstreets,roads,orhighways.
IfinEnglish,thismanualistheOriginalInstructionsprovidedbythemanufacturer.IfinanylanguageotherthanEnglish,
thismanualisatranslationoftheOriginalInstructions.
P .O.Box204658
Augusta,Georgia30917–4658USA
Telephone[phone]
ServicePartsFax706–855–7413
www.clubcar.com
Copyright©2013,2014,2015ClubCar,LLC
ClubCar,Tranquility,andArmorFlex
areregisteredtrademarksofClubCar,LLC
ThismanualeffectiveJune2015
Carryall500/550/700VehicleOwner'sManualPage1

FOREWORD
ThankyouforchoosingClubCar,thenamemostwidelyrecognizedastheindustryleaderinvehicleefciencyand
long-lastingvalue.Youhavechosenthenestutilityvehicleonthemarket.Pleaseprotectyourinvestmentand
ensurethatyourClubCarvehicle(s)providesyearsofreliable,superiorperformancebyreadingandfollowingthe
maintenanceinstructionsinthismanual.
Yourcomfortandsafetyareimportanttous,soweurgeyoutoreadandfollowthestep-by-stepoperatinginstructions
andsafetyproceduresinthismanual.Theseinstructionsmustbefollowedinordertoavoidtheriskofseverepersonal
injury.Ifyourentorloanyourvehicletoothers,werecommendthatyouaskthemtoreadthismanualbeforethey
operatethevehicle.
ClubCarproductsarebackedbyacustomersupportsystemdesignedtoofferyoufast,courteousservice.Intheevent
yourClubCarvehicleneedsrepairsorservice,pleasecontactyourlocalauthorizedClubCardealerordistributor,who
willbeabletoprovidetechnicaladvice,performwarrantywork,andsellpartsandservicemanuals.
TondyourlocalauthorizedClubCardealer,visitwww.clubcardealer.com,call1-800-ClubCar(258–2227),orscan
thisQuickResponse(QR)codetobetakentotheClubCardealerlocator.RefertoFigure1.DownloadaQRcode
readersuchasRedLaserorBarcodeScannertoyourcellphoneortablet.
Ifyouwouldprefertowritetous,directyourletterto:ClubCarLLC,Attention:MarketingServices,P .O.Box204658,
Augusta,Georgia30917-4658USA.
Wehopeyouwillconsiderthisowner’smanualapermanentpartofyourClubCarvehicle.Ifyousellthevehicle,
pleaseincludethemanualsothatthenextownerwillhavetheimportantoperating,safety,andmaintenance
informationitcontains.
DealerLocatorQRCode
3118
Figure1DealerLocatorQRCode
_
MAINTENANCEITEMS
BatteryTerminalProtectorSpray
CCPN1014305
DryMolyLube
CCPN1012151
ChassisLube
EPNLGIGrade2(commerciallyavailable)
EngineAirFilter(404cc)
CCPN102558201
DeionizerFilterReplacementCartridge(SPWS)
CCPN104005901
SparkPlugO.H.C.(404cc)
CCPN105017801
DeionizerFilterReplacementCartridge(non-SPWS)
CCPNAM10975
Page2Carryall500/550/700VehicleOwner'sManual

TABLEOFCONTENTS
TechnicalPublicationCustomerSatisfactionSurvey................................................................................................4
SafetyDecalIdentication.....................................................................................................................................5
PracticeSafety...................................................................................................................................................15
Proposition65–StateofCalifornia......................................................................................................................15
SafetyDetails.....................................................................................................................................................16
GeneralWarnings...............................................................................................................................................16
GeneralInformation............................................................................................................................................21
ModelIdentication.............................................................................................................................................22
ControlsandIndicators.......................................................................................................................................22
Pre-OperationandDailySafetyChecklist.............................................................................................................31
DrivingInstructions.............................................................................................................................................33
LoadingandUnloading.......................................................................................................................................36
VehicleLoadCapacities......................................................................................................................................36
TowingwiththeVehicle.......................................................................................................................................38
TransportingonaTrailer.....................................................................................................................................39
Storage–ElectricVehicles..................................................................................................................................39
Storage–GasolineVehicles................................................................................................................................41
Maintenance......................................................................................................................................................43
PeriodicServiceSchedules.................................................................................................................................44
PeriodicLubricationSchedules...........................................................................................................................47
Batteries–ElectricVehicles................................................................................................................................49
BatteryCharger,QuiQ™–ElectricVehicle...........................................................................................................53
SinglePointWateringSystem(SPWS).................................................................................................................59
Battery–GasolineVehicle..................................................................................................................................61
EngineOil–GasolineVehicle..............................................................................................................................63
FuelingInstructions–GasolineVehicle................................................................................................................66
CleaningtheVehicle...........................................................................................................................................67
Accessories........................................................................................................................................................68
SubsequentOwnerRegistration..........................................................................................................................68
VehicleSpecications.........................................................................................................................................69
Warranties..........................................................................................................................................................74
ECDeclarationofConformity..............................................................................................................................82
Carryall500/550/700VehicleOwner'sManualPage3

TechnicalPublicationCustomerSatisfactionSurvey
TECHNICALPUBLICATIONCUSTOMERSATISFACTIONSURVEY
Letyourvoicebeheard!
PleaseparticipateintheTechnicalPublicationcustomersatisfactiononlinesurvey.
Thissurveytakeslessthanveminutestocompleteandyourresponseswillhelpexaminecurrentperformance
andidentifyareasforfutureimprovement.
Ourtoppriorityistoprovidetimely,accurate,anduserfriendlymanuals.
Theonlinesurveycanbefoundathttp://bit.ly/1w9uFMhorusingtheQRCodebelow.
Figure2TechnicalPublicationCustomerSatisfactionOnlineSurvey
Page4Carryall500/550/700VehicleOwner'sManual

SafetyDecalIdentication
SAFETYDECALIDENTIFICATION
Thefollowingpagescontainsafetydecalinformation.Fordetailedinformationonspecicfeatures,readthe
appropriatesectioninthismanual.
ELECTRICCARRYALL500
_
2852
1
54
2
7
3
8
6
9
1101553901Decal,BedLoadingWarning(oncargobedorseat
back)6105130101Decal,12VAccessoryFuseBlock(underfront body)
2101609401Decal,CrushAreaWarning(behindseat,near
cargobed)7105137106Decal,VehicleLoad
3101825101Decal,On/OffKeySwitch(abovekeyswitch)8105163601Decal,12V(+)(underfrontbody)
4104026801Decal,OccupantWarning9105163701Decal,Ground(underfrontbody)
5105046101Decal,OperatingInstructions
Carryall500/550/700VehicleOwner'sManualPage5

SafetyDecalIdentication
ELECTRICCARRYALL550
_
2873
1
65
2
8
3
9
7
10
4
1101553901Decal,BedLoadingWarning(oncargobedorseat
back)6105046101Decal,OperatingInstructions
2101609401Decal,CrushAreaWarning7105130101Decal,12VAccessoryFuseBlock(underfront
body)
3101825101Decal,On/OffKeySwitch(abovekeyswitch)8105137103Decal,VehicleLoad
4102075801Decal,Y oungDriverWarning9105163601Decal,12V(+)(underfrontbody)
5104026801Decal,OccupantWarning10105163701Decal,Ground(underfrontbody)
Page6Carryall500/550/700VehicleOwner'sManual

SafetyDecalIdentication
ELECTRICCARRYALL500AND550,CONTINUED
_
2853
CC I 102 9 67 60 1
WARNING
!
•Re placeme nt ba ttery wires mus t be 4-ga uge (AWG) with low-resistance terminals
equivalent to fa ctory-ins talled wires.
• Ens ure tha t battery conne ctions a re clea n and prope rly tightene d. S e e owner’s manual.
AVOID FIRE HAZARD
42
1
3
5
6
7
8
11011553Decal,TrailerHitchT ongueWeightNotice(on
trailer/receiverhitch)5102967601Decal,4GaugeWireWarning(onframeabove electricalcomponentmountingplate)
2102459301Decal,BedLatchWarning6105124701Decal,DoNotUseasGround(onframeabove
electricalcomponentmountingplate)
3102518301Decal,ComponentCoverNotice(onelectrical
componentcover)7105130001Decal,48VAccessoryFuseBlock(onelectrical componentmountingplate)
4102845101Decal,T owSwitchWarning(onT ow/Runswitch
plate,underseat)8105163701Decal,Ground(onelectricalcomponentmounting plate)
Carryall500/550/700VehicleOwner'sManualPage7

SafetyDecalIdentication
ELECTRICCARRYALL700
_
2854
1
54
2
7
3
8
6
9
1101553901Decal,BedLoadingWarning(oncargobedorseat
back)6105130101Decal,12VAccessoryFuseBlock(underfront body)
2101609401Decal,CrushAreaWarning(behindseat,near
cargobed)7105151501Decal,VehicleLoad
3101825101Decal,On/OffKeySwitch(abovekeyswitch)8105163601Decal,12V(+)(underfrontbody)
4104026801Decal,OccupantWarning9105163701Decal,Ground(underfrontbody)
5105046101Decal,OperatingInstructions
Page8Carryall500/550/700VehicleOwner'sManual

SafetyDecalIdentication
ELECTRICCARRYALL700,CONTINUED
_
2855
CC I 102 9 67 60 1
WARNING
!
•Re placeme nt ba ttery wires mus t be 4-ga uge (AWG) with low-resistance terminals
equivalent to fa ctory-ins ta lled wires.
• Ens ure tha t battery conne ctions a re clea n and prope rly tightene d. S e e owner’s manual.
AVOID FIRE HAZARD
3
1
2
4
5
6
7
11011553Decal,TrailerHitchT ongueWeightNotice(on
trailer/receiverhitch)5105124701Decal,DoNotUseasGround(onframeabove electricalcomponentmountingplate)
2102518301Decal,ComponentCoverNotice(onelectrical
componentcover)6105130001Decal,48VAccessoryFuseBlock(onelectrical componentmountingplate)
3102845101Decal,T owSwitchWarning(onT ow/Runswitch
plate,underseat)7105163701Decal,Ground(onelectricalcomponentmounting plate)
4102967601Decal,4GaugeWireWarning(onframeabove
electricalcomponentmountingplate)
Carryall500/550/700VehicleOwner'sManualPage9

SafetyDecalIdentication
GASOLINECARRYALL500
_
2856
1
65
2
7
8
3
4
1101553901Decal,BedLoadingWarning(oncargobedorseat
back)5104026801Decal,OccupantWarning
2101609401Decal,CrushAreaWarning(behindseat,near
cargobed)6105046101Decal,OperatingInstructions
3101825101Decal,On/OffKeySwitch(abovekeyswitch)
(pedal-startvehicles)7105137102Decal,VehicleLoad(two-wheelbrakevehicles)
4101825102Decal,On/Off/StartKeySwitch(abovekeyswitch)
(key-startvehicles)8105137106Decal,VehicleLoad(four-wheelbrakevehicles)
Page10Carryall500/550/700VehicleOwner'sManual

SafetyDecalIdentication
GASOLINECARRYALL550
_
2874
1
76
2
8
3
4
5
1101553901Decal,BedLoadingWarning(oncargobedorseat
back)5102075801Decal,YoungDriverWarning
2101609401Decal,CrushAreaWarning(behindseat,near
cargobed)6104026801Decal,OccupantWarning
3101825101Decal,On/OffKeySwitch(abovekeyswitch)
(pedal-startvehicles)7105046101Decal,OperatingInstructions
4101825102Decal,On/Off/StartKeySwitch(abovekeyswitch)
(key-startvehicles)8105137103Decal,VehicleLoad
Carryall500/550/700VehicleOwner'sManualPage11

SafetyDecalIdentication
GASOLINECARRYALL500AND550,CONTINUED
_
2857
8
7
3
1
5
4
2
6
11011553Decal,TrailerHitchT ongueWeightNotice(on
trailer/receiverhitch)5102459301Decal,BedLatchWarning
2101915201Decal,FrameGround/GovernorWarning(on
vehicleframenearbattery)6103205501Decal,Maintenance/OperateWarning(on Maintenance/Operateswitchplate,underseat)
3101960501Decal,RotatingParts/HotManifoldWarning(on
starter/generator)7105082301Decal,GasolineFuelWarning(onfueltank)
4102345901Decal,DiodeWarning(nearbattery)8105084701Decal,GasolineFuelWarning(atfuelll)
Page12Carryall500/550/700VehicleOwner'sManual

SafetyDecalIdentication
GASOLINECARRYALL700
_
2858
1
65
2
7
3
4
1101553901Decal,BedLoadingWarning(oncargobedorseat
back)5104026801Decal,OccupantWarning
2101609401Decal,CrushAreaWarning(behindseat,near
cargobed)6105046101Decal,OperatingInstructions
3101825101Decal,On/OffKeySwitch(abovekeyswitch)7105151501Decal,VehicleLoad
4101825102Decal,On/Off/StartKeySwitch(abovekeyswitch)
(key-startgasolinevehiclesonly)
Carryall500/550/700VehicleOwner'sManualPage13

SafetyDecalIdentication
GASOLINECARRYALL700,CONTINUED
_
2859
7
6
3
1
2
5
4
11011553Decal,TrailerHitchT ongueWeightNotice(on
trailer/receiverhitch)5103205501Decal,Maintenance/OperateWarning(on Maintenance/Operateswitchplate,underseat)
2101915201Decal,FrameGround/GovernorWarning(on
vehicleframenearbattery)6105082301Decal,GasolineFuelWarning(onfueltank)
3101960501Decal,RotatingParts/HotManifoldWarning(on
starter/generator)7105084701Decal,GasolineFuelWarning(atfuelll)
4102345901Decal,DiodeWarning(nearbattery)
Page14Carryall500/550/700VehicleOwner'sManual

PracticeSafety
PRACTICESAFETY
399
Figure3PracticeSafety
Safetysignslikeyouseeabovemayatrstseemshocking,buttheirimpactismildcomparedwiththereality
ofseverepersonalinjury.
Yoursafetyandsatisfactionareoftheutmostimportancetous.Thatiswhybeforeoperatingthevehicle,weurge
youtoreviewtheinformationinthismanual.UnderstandandbecomefamiliarwiththeDANGER,WARNING,and
CAUTIONstatementsandproceduresitcontains,alongwiththesafetydecalsthatareafxedtoyourvehicle.
Taketimetounderstandthelanguageofsafety.Itisalanguagethatcansaveyourlife.
PROPOSITION65–STATEOFCALIFORNIA
WARNING
•Thisproductcontainsoremitschemicalsorsubstancesthathavebeendeterminedbythestateof
Californiatocausecancerandbirthdefectsorotherreproductiveharm.
Carryall500/550/700VehicleOwner'sManualPage15

SafetyDetails
SAFETYDETAILS
WARNING
•Thisowner’smanualshouldbereadcompletelybeforeattemptingtodriveorservicethevehicle.
Failuretofollowtheinstructionsinthismanualcanresultinpropertydamage,severepersonal
injury,ordeath.
Itisimportanttonotethatsomevitalstatementsthroughoutthismanualandonthedecalsafxedtothevehicleare
precededbythewordsDANGER,WARNING,orCAUTION.Foryourprotection,werecommendthatyoutakespecial
noticeofthesesafetyprecautions.Safetyprecautionsareessentialandmustbefollowed.
Ifanyoftheoperationorsafetydecalsonthevehiclebecomedamaged,havebeenremoved,orcannotbeeasily
read,theyshouldbereplacedimmediatelytoavoidpossiblepropertydamage,personalinjury,ordeath.Contactyour
distributor/dealer.
DANGER
•ADANGERindicatesanimmediatehazardthatwillresultinseverepersonalinjuryordeath.
WARNING
•AWARNINGindicatesanimmediatehazardthatcanresultinseverepersonalinjuryordeath.
CAUTION
•ACAUTIONwiththesafetyalertsymbolindicatesahazardorunsafepracticethatcanresultin
minorpersonalinjury.
CAUTION
•ACAUTIONwithoutthesafetyalertsymbolindicatesapotentiallyhazardoussituationthatcanresult
inpropertydamage.
GENERALWARNINGS
Thefollowingsafetystatementsmustbeheededwheneverthevehicleisbeingoperated,repaired,orserviced.See
SafetyDecalIdenticationonpage5.Otherspecicsafetystatementsappearthroughoutthismanualandon
thevehicle.
Page16Carryall500/550/700VehicleOwner'sManual

GeneralWarnings
DANGER
•Battery–Explosivegases!Donotsmoke.Keepsparksandamesawayfromthevehicleandservice
area.Ventilatewhenchargingoroperatingvehicleinanenclosedarea.Wearafullfaceshieldand
rubbergloveswhenworkingonornearbatteries.
•Gasoline–Flammable!Explosive!Donotsmoke.Keepsparksandamesawayfromthevehicleand
servicearea.Serviceonlyinawell-ventilatedarea.
•Donotoperateengineinanenclosedareawithoutproperventilation.Theengineproducescarbon
monoxide,whichisanodorless,deadlypoison.
•Thevehiclewillnotprovideprotectionfromlightning,yingobjects,orotherstorm-relatedhazards.If
caughtinastormwhiledrivingaClubCarvehicle,exitthevehicleandseekshelterinaccordancewith
applicablesafetyguidelinesforyourlocation.
WARNING
•Followtheproceduresexactlyasstatedinthismanual,andheedallDANGER,WARNING,and
CAUTIONstatementsinthismanualaswellasthoseonthevehicleandbatterycharger.
•Donotleavechildrenunattendedinvehicleatanytime.
•Priortoleavingthevehicleunattendedorservicingthevehicle,settheparkbrake,placethe
Forward/ReversehandleorswitchintheNEUTRALposition,turnthekeyswitchtotheOFFposition,
andremovethekey.Chockthewheelswhenservicingthevehicle.
•Improperuseofthevehicleorfailuretoproperlymaintainitcanresultindecreasedvehicle
performance,severepersonalinjury,ordeath.
•Anymodicationorchangetothevehiclethataffectstheelectricalsystem,stabilityorhandlingof
thevehicle,orincreasesmaximumvehiclespeedbeyondfactoryspecications,canresultinsevere
personalinjuryordeath.
•Checkthevehicleforproperlocationofallvehiclesafetyandoperationdecalsandmakesuretheyare
inplaceandareeasytoread.
•Forvehicleswithcargobeds,removeallcargo(includingaccessories)beforeraisingthebedor
servicingthevehicle.Ifthevehicleisequippedwithaproprod,ensurethatitissecurelyengaged
whilebedisraised.Donotclosebeduntilallpersonsareclearofcargobedarea.Keephandsclearof
allcrushareas.Donotdropcargobed;lowergentlyandkeepentirebodyclear.Failuretoheedthis
warningcanresultinseverepersonalinjuryordeath.
•Onlytrainedtechniciansshouldserviceorrepairthevehicleorbatterycharger.Anyonedoingeven
simplerepairsorserviceshouldhaveknowledgeandexperienceinelectricalandmechanicalrepair.
Theappropriateinstructionsmustbeusedwhenperformingmaintenance,service,oraccessory
installation.
Electricvehiclesonly:
•Ensurebatteryconnectionsarecleanandproperlytightened.SeeBatteryCare–VehiclesEquipped
withtheSingle-PointWateringSystem(SPWS)onpage51orBatteryCare–VehiclesWithoutthe
Single-PointWateringSystem(SPWS)onpage52.
•PlaceTow/RunswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failureto
heedthiswarningcanresultinabatteryexplosionorseverepersonalinjury.
•Toavoidunintentionallystartinganelectricvehicle,disconnectthebatteriesanddischargethe
controller.SeeDisconnectingtheBatteries–ElectricVehiclesonpage19.
WARNINGCONTINUEDONNEXTPAGE
Carryall500/550/700VehicleOwner'sManualPage17

GeneralWarnings
WARNING
Gasolinevehiclesonly:
•Toavoidunintentionallystartingagasolinevehicle,disconnectthebatteryandsparkplugwire.See
Side-PostBattery:DisconnectingtheBattery-GasolineVehiclesonpage19.
SeeTop-PostBattery:DisconnectingtheBattery-GasolineVehiclesonpage20.
•Frameground–Donotallowtoolsorothermetalobjectstocontactframewhendisconnectingbattery
cablesorotherelectricalwiring.Donotallowapositivewiretotouchthevehicleframe,engine,or
anyothermetalcomponent.
Allvehicles:
•Wearsafetyglassesorapprovedeyeprotectionwhenservicingthevehicleorbatterycharger.Weara
fullfaceshieldandrubbergloveswhenworkingonornearbatteries.
•Donotwearlooseclothingorjewelrysuchasrings,watches,chains,etc.,whenservicingthe
vehicleorbatterycharger.
•Useinsulatedtoolswhenworkingnearbatteriesorelectricalconnections.Useextremecautionto
avoidshortingofcomponentsorwiring.
Page18Carryall500/550/700VehicleOwner'sManual