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Carryall 700 Owners Manual

1. 2822 Figure 18 Lubrication Points Electric Vehicles Page 44 CARRYALL 500 550 700 Vehicle Owner s Manual Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULE GASOLINE VEHICLES LUBRICATION SERVICE RECOMMENDED LUBRICANT POINTS REGULAR INTERVAL Semiannually by owner or trained technician or every 50 hours of operation whichever comes first Annually by trained technician only or every 100 hours of operation whichever comes first First change 100 hours additional change every 200 hours of operation or annually whichever comes first Brake pedal shaft bearings Brake linkage and pivots Accelerator pivot rod supports and shifter cable pivots Brake slides Transaxle Check fill to plug level Inspect front wheel bearings Repack as necessary 40 5 fl oz 1 2 L 10W 30 or Change engine oil 5W 30 grade SE or higher See also Figure 30 Page 62 Chassis Lube EP NLGI Grade 2 2 lt 2823 Figure 19 Lubrication Points Gasoline Vehicles CARRYALL 500 550 700 Vehicle Owner s Manual Dry Moly Lube CC PN 1012151 Dry Moly Lube CC PN 1012151 Dry Moly Lube CC PN 1012151 Dry Moly Lube CC PN 1012151 67 6 fl oz 2 L SAE 80W 90 API Class GL 5 Page 45 Batteries Electric Vehicles BATTERIES ELECTRIC VEHICLES See General Warnings on page 15 DANGER
2. Vehicle rated capacity 900 Ib 408 kg level surface only VEHICLE sp peii y Includes occupants and cargo load LOADING Maximum cargo load 500 Ib 227 kg Includes cargo bed load and optional equipment Read owner s manual vehicle combination rated capacity 900 Ib 408 kg and warnings on dash 2 101609401 Decal Crush Area Warning 101825101 Decal On Off Key Switch above key switch 102075801 Decal Young Driver Warning Includes vehicle rated capacity and gross trailer weight Decal Bed Loading Warning on cargo bed or seat 1 101553901 back ROLLOVER CAN CAUSE SERIOUS INJURY OR DEATH Place cargo forward in the cargo bed and distribute evenly side to side Secure load On uneven or steep terrain reduce speed and load Avoid stopping on or backing down steep hills Avoid top heavy loads AULA UTN 105046101 Decal Operating Instructions Decal 12V Accessory Fuse Block under front 7 105130101 bij y 105137103 105137103 Decal Vehicle Load 105163601 Decal 12V under front body 104026801 Decal Occupant Warning 10 105163701 Decal Ground under front body CARRYALL 500 550 700 Vehicle Owner s Manual Page 5 Safety Decal Identification ELECTRIC CARRYALL 500 AND 550 CONTINUED EXPOSURE TO WATER MAY DAMAGE ELECTRONIC COMPONENTS Do not operate vehicle without this cover properly installed AVOID FIRE HAZARD Do not direct water stream in
3. Gasoline 2407 Ib 1091 kg 907 Ib 411 kg Gasoline 2107 Ib 956 kg Gasoline 2107 Ib 956 kg Electric 1402 Ib 636 kg Gasoline 942 Ib 427 kg Electric 2302 Ib 1044 kg Gasoline 1842 Ib 836 kg Electric 2302 Ib 1044 kg Gasoline 1842 Ib 836 kg 2850 Figure 17 Vehicle Load Capacity CARRYALL 500 550 700 Vehicle Owner s Manual Electric 1475 Ib 669 kg Gasoline 993 Ib 450 kg Electric 2975 Ib 1349 kg Gasoline 2493 Ib 1130 kg Electric 2975 Ib 1349 kg Gasoline 2493 Ib 1130 kg Page 35 Towing with the Vehicle TOWING WITH THE VEHICLE 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 Maximum gross vehicle combination weight 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 can cause the vehicle to overturn possibly resulting in severe personal injury Stay clear from the area between the tow vehicle and the towed vehicle or trailer Because towing a vehicle or trailer can have an adverse effect on vehicle handling be especially cautio
4. Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries Charge batteries in a well ventilated area only Batteries emit hydrogen while being charged Hydrogen is an explosive gas and must never exceed a level of 2 of the air e Battery Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes External Flush with water Call a physician immediately nternal 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 or battery charger Wear a full face shield and rubber gloves when working on or near batteries Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Ensure battery connections are clean and properly tightened See Battery Care Vehicles Equipped with the Single Point Watering System SPWS on page 48 or Battery Care Vehicles Without the Single Point Watering System SPWS on page 49 Use only 4 gauge AWG wires with low resistance terminals to replace battery wir
5. Do not ride in cargo bed GND 2 105163701 101609401 VEHICLE Vehicle rated capacity 1200 Ib 544 kg on level surface only Includes occupants and cargo load ROLLOVER CAN CAUSE SERIOUS INJURY OR DEATH LOADING Maximum cargo load 800 Ib 363 kg Place cargo forward in the cargo bed and distribute Includes cargo bed load and optional equipment evenly side to side Secure load iRecdiownens manual Vehicle combination rated capacity 1500 Ib 680 kg nun even or pet nic ierit Asl load x Mi inctudes venicte rated capacity and gross frsllerwelght Avoidtop heavyloads Decal Bed Loading Warning on cargo bed or seat Decal 12V Accessory Fuse Block under front 1 101553901 105130101 back body Decal Crush Area Warning behind seat near 7 2 101609401 7 105137106 Decal Vehicle Load cargo bed 105137106 3 101825101 Decal On Off Key Switch above key switch 105163601 Decal 12V under front body 104026801 Decal Occupant Warning 105163701 Decal Ground under front body Page 4 CARRYALL 500 550 700 Vehicle Owner s Manual ELECTRIC CARRYALL 550 Unintended vehicle movement may cause severe injury or death Before using vehicle read owner s manual and vehicle safety warnings Before leaving vehicle Engage park brake to lock wheels Place vehicle in NEUTRAL Turn key to OFF and remove key EU UM
6. 3 conductor 1 5mm minimum rated appropriately for industrial use The cord countries set must be terminated on one end with a grounding type input connector appropriate for use in the country of destination and on the other end an output grounding type IEC 60320 C14 plug CARRYALL 500 550 700 Vehicle Owner s Manual Page 55 Single Point Watering System SPWS CHARGER TROUBLESHOOTING INSTRUCTIONS See General Warnings on page 15 If a fault occurs count the number of red flashes on the charger between pauses and refer to the table below RED FLASHES CAUSE SOLUTION Battery High Voltage Ensure battery set is rated 48 volts and composed of 24 cells See Charger Maintenance and Service Manual If not replace with correct battery set Reset charger interrupt AC power for 15 seconds Battery Low Voltage Ensure battery set is rated 48 volts and composed of 24 cells Also check the voltage of each individual battery See Charger Maintenance and Service Manual If not replace with correct battery set Reset charger interrupt AC power for 15 seconds Charge Time out caused by battery Check for loose or corroded connections pack not reaching required voltage Check for old or defective batteries See Charger output was reduced due to high Charger Maintenance and Service Manual temperatures Operate charger at a lower ambient temperature Check Battery battery could not be trickle Check for shorted or damaged cells See Charger
7. 6 ply rated load range front and rear Tires Turf 23 x 10 5 12 tubeless 4 ply rated load range front and rear 0 Tires All Terrain 22 x 11 10 tubeless 6 ply rated load range front and rear DIMENSIONS WEIGHT Overall length Standard boxbed configuration 118 in 299 7 cm 118 in 299 7 cm 139 3 in 358 8 cm Add for Heavy Duty Bumper 1 8 in 4 5 cm 1 8 in 4 5 cm 1 8 in 4 5 cm Overall width 50 3 in 127 7 cm 50 3 in 127 7 cm 50 3 in 127 7 cm with mirrors 62 6 in 159 0 cm 62 6 in 159 0 cm 62 6 in 159 0 cm Overall height At steering wheel Front wheel tread 36 6 in 92 9 cm 36 6 in 92 9 cm 36 6 in 92 9 cm Rear wheel tread 39 5 in 100 3 cm 39 5 in 100 3 cm 39 5 in 100 3 cm Weight Standard electric vehicle curb weight 1393 Ib 632 kg 1402 Ib 636 kg 1475 Ib 669 kg 15 to 17 mph 15 to 17 mph 15 to 17 mph Ground clearance 5 6 in 14 2 cm 6 in 15 2 cm 5 6 in 14 2 cm Maximum forward speed 24 to 27 km h 24 to 27 km h 24 to 27 km h Outside clearance circle diameter 248 5 in 631 2 cm 268 in 680 7 cm 253 5 in 643 8 cm Turning radius per SAE J 695 119 3 in 302 9 cm 126 5 in 321 3 cm 122 5 in 311 1 cm Intersecting aisle clearance 94 in 238 7 cm 91 2 in 231 6 cm 80 5 in 204 4 cm Floorboard height 12 5 in 31 7 cm 15 in 38 1 cm 12 5 in 31 7 cm Load bed height 29 5 in 74 9 cm 31 6 in 80 2 cm 29 5 in 74 9 cm 44 2 x 47 5 10 5 44 2x47 5x 1
8. Operating Instructions cargo bed Decal On Off Key Switch above key switch 101825101 7 105137102 Decal Vehicle Load two wheel brake vehicles pedal start vehicles e 105137106 Decal Vehicle Load four wheel brake vehicles Decal On Off Start Key Switch above key switch 101825102 key start vehicles CARRYALL 500 550 700 Vehicle Owner s Manual Page 9 Safety Decal Identification GASOLINE CARRYALL 550 Unintended vehicle movement may cause severe injury or UNINTENDED MOVEMENT ROLLOVER OR FALLING OUT CAN CAUSE SERIOUS INJURY OR DEATH death Before using vehicle read owner s manual and vehicle Vehicle to be operated by licensed and authorized persons only Remain fully seated while moving safety warnings S Use in authorized areas only Do not operate on public roads Hold on and keep entire body inside vehicle while moving Before leaving vehicle One 1 person per bucket seat maximum Never attempt jumps and avoid extreme braking in reverse Engage park brake to lock wheels Two 2 persons per bench seat maximum Do not leave children unattended in vehicle at any time Place vehicle in NEUTRAL Operate from driver s seat only Children requiring a child safety seat must not ride in vehicle Turn key to OFF and remove key Do not start vehicle until all occupants are fully seated Never operate under the influence of alcohol or drugs 046 Drive slowly in turns and straight up and down
9. bte PEEL bI itid icu Re PE uetus AT 78 CARRYALL 500 550 700 Vehicle Owner s Manual Page 3 Safety Decal Identification SAFETY DECAL IDENTIFICATION The following pages contain safety decal information For detailed information on specific features read the appropriate section in this manual ELECTRIC CARRYALL 500 Unintended vehicle movement may cause severe injury or UNINTENDED MOVEMENT ROLLOVER OR FALLING OUT CAN CAUSE SERIOUS INJURY OR DEATH death Before using vehicle read owner s manual and vehicle Vehicle to be operated by licensed and authorized persons only Remain fully seated while moving safety warnings z Use in authorized areas only Do not operate on public roads Hold on and keep entire body inside vehicle while moving Before leaving vehicle One 1 person per bucket seat maximum Never attempt jumps and avoid extreme braking in reverse Engage park brake to lock wheels Two 2 persons per bench seat maximum Do not leave children unattended in vehicle at any time Place vehicle in NEUTRAL Operate from driver s seat only Children requiring a child safety seat must not ride in vehicle Turn key to OFF and remove key DS not kan oceans ae fully Never operate under the influence of alcohol or drugs 000 0 S E eee HT 103028601 12V 105163601 12V ACC QE EIE Use BLOCK CN or B TETTE
10. charged up to minimum voltage Maintenance and Service Manual Over Temperature Charger shut down due to Check for dirty obstructed or damaged cooling fins high internal temperature Clean if necessary and ensure sufficient cooling air flow Reset charger interrupt AC power for 15 seconds Charger Internal Fault Reset charger interrupt AC power for 15 seconds Return to qualified service depot if fault persists SINGLE POINT WATERING SYSTEM SPWS CAUTION Water the batteries only AFTER charging Use water that meets the quality standards shown on page 46 Maximize battery life by removing ions and heavy metals from water with the use of a deionizer See Water Quality on page 46 WATERING BATTERIES WITH THE SPWS Checking the Water Flow Rate 1 Connect the water hose with the built in screen filter 2 to the water faucet 1 Figure 22 See following CAUTION CAUTION Make sure the screen filter is clean Do notuse alonger garden hose than provided with the System 20 feet or 6 meters as a decrease in water pressure can overfill the batteries and damage the refill system 2 Before screwing the hose end assembly 3 onto the opposite end of the water hose check the screen filter 4 inside the end of the assembly to make sure it is clean Figure 22 3 Connect the purger 5 to the female coupler 8 on the end of the hose end assembly Figure 23 Page 56 CARRYALL 500 550 700 Vehicle Owner s Manua
11. including accessories before raising the bed or servicing the vehicle If the vehicle is equipped with a prop rod ensure that it is securely engaged while bed is raised Do not close bed until all persons are clear of cargo bed area Keep hands clear of all crush areas Do not drop cargo bed lower gently and keep entire body clear Failure to heed this warning can result in severe personal injury or death Only trained technicians should service or repair the vehicle or battery charger Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation Electric vehicles only Ensure battery connections are clean and properly tightened See Battery Care Vehicles Equipped with the Single Point Watering System SPWS on page 48 or Battery Care Vehicles Without the Single Point Watering System SPWS on page 49 Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning can result in a battery explosion or severe personal injury To avoid unintentionally starting an electric vehicle disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 17 Gasoline vehicles only To avoid unintentionally starting a gasoline vehicle disconnect the battery and spark plu
12. Never operate under the influence of alcohol or drugs 5046 Drive slowly in turns and straight up and down slopes EROU UA TAN 105086101 y grup ALLELUIA LT 1 040260 CEID C Riding in cargo bed can cause severe injury or death Do not ride in cargo bed CCI 101553901 101609401 Vehicle rated capacity 1500 Ib 680 kg on level surface only VEHICLE suco pellen y Includes occupants and cargo load ROLLOVER CAN CAUSE SERIOUS INJURY OR DEATH LOADING Maximum cargo load 1000 Ib 454 kg Place cargo forward in the cargo bed and distribute Includes cargo bed load and optional equipment evenly side to side Secure load Read owner s manual Vehicle combination rated capacity 1500 Ib 680 kg venicia rated capacity and gross Waller weight Avoid top heavy loads Decal Bed Loading Warning on cargo bed or seat 1 101553901 back 5 104026801 Decal Occupant Warning Decal Crush Area Warning behind seat near 2 101609401 catio bed 105046101 Decal Operating Instructions 101825101 Decal On Off Key Switch above key switch 105151501 Decal Vehicle Load Decal On Off Start Key Switch above key switch 4 101825102 key start gasoline vehicles only 105151501 Page 12 CARRYALL 500 550 700 Vehicle Owner s Manual Safety Decal Identification GASOLINE CARRYALL 70
13. SHALL BE VOID IF THE VEHICLE IS ABUSED OR USED IN AN UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY INCLUDING BUT NOT LIMITED TO MODIFICATION OF THE SPEED GOVERNOR BRAKING SYSTEM STEERING TRANSAXLE OR OTHER OPERATING SYSTEMS OF THE VEHICLE TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS 4 HOW TO MAKE A WARRANTY CLAIM To make a warranty claim under this limited warranty you must present the vehicle or defective component to an authorized CLUB CAR dealer CARRYALL 500 550 700 Vehicle Owner s Manual Page 77 EC Declaration of Conformity EC DECLARATION OF CONFORMITY When properly configured the vehicle complies with the listed Directives Declaration of Conformity Model Model Code Number ME 104030201 Carryall 500 Electric 104030501 Carryall 500 Gas 104030701 Carryall 550 Electric 104030801 Carryall 550 Gas 104030901 Carryall 700 Electric 104031201 Carryall 700 Gas Serial numbers 1401000001 and greater Model Name Four wheel vehicles in the above series that bear the CE mark fulfill all the relevant provisions of the following Directives Enspricht den Bestimmungen Conforme Aux Directives Conforme Con Las Directivas Voldoet aan Richtlijnen De Acordo com Directiva Conforme Alla Direttiva Opfylder folgende direktiver Upptyller foljande direktiv 2006 42 EC Machinery 2006 66 EC Batteries and Accumulators and Waste Batteries and Accumulators 20
14. 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 for damages to other engine or equipment components proximately caused by a covered failure under warranty of any warranted part 8 Throughout the engine or equipment warranty period stated above CLUB CAR will maintain a supply of warranted parts sufficient to meet the expected demand for such parts 9 Any replacement part may be used in the performance of any warranty maintenance or repairs and must be provided without charge to the owner Such use will not reduce the warranty obligations of CLUB CAR 10 Add on or modified parts that are not exempted by the Air Resources Board may not be used The use of any non exempted add on or modified parts by the ultimate purchaser will be grounds for disallowing a warranty claims CLUB CAR will not be liable to warrant failures of warranted parts caused by the use of a non exempted add on or modified part CLUB CAR its authorized dealers or a service agency approved by CLUB CAR ITEMS COVERED BY THIS WARRANT Y Page 76 CARRYALL 500 550 700 Vehicle Owner s Manual Warranties The repair or replacement of any warranted part otherwise eligible for warranty coverage may be exclud
15. automatically release the park brake and start the vehicle moving in the direction selected forward or reverse When the accelerator is released power will be cut off and the motor or engine will stop running Key start vehicles The engine must first be running before shifting the Forward Reverse handle and pressing the accelerator pedal Pressing the accelerator pedal will automatically release the park brake and start the vehicle moving in the direction selected When the accelerator is released the engine will idle See following WARNING and CAUTION WARNING Moving parts Keep clear of the engine compartment while the engine is running CAUTION Key start vehicles Do not rev the engine for long periods of time while the Forward Reverse handle is in the NEUTRAL position Failure to heed this caution can result in damage to the unitized transaxle Key start vehicles Do not shift the Forward Reverse handle while the accelerator pedal is pressed Shift the handle only when the vehicle is at a complete stop Failure to heed this caution can result in damage to the unitized transaxle Electric Vehicles Electric vehicles use a special electrical system which employs motor braking in some modes of operation In those modes the vehicle operates as follows Walk Away Braking This feature prevents the vehicle from rolling away uncontrolled should the driver park on a slope and leave the vehicle without locking the
16. following NOTE NOTE Properly recycle or dispose of used oil in accordance with local state and federal regulations 1 Full level 2 Safe level 3 Low level 2662 Figure 28 Engine Oil Level Check ENGINE OIL CHANGE Engine oil should be changed after the first 100 hours of operation After that it should be changed every 200 hours of operation or annually whichever comes first 1 Turn the key switch to the OFF position then remove the key Place the Forward Reverse handle in the NEUTRAL position Chock the front wheels 2 Access the engine compartment 3 Disconnect battery and spark plug wire See Disconnecting the Battery Gasoline Vehicles on page 17 Page 60 CARRYALL 500 550 700 Vehicle Owner s Manual Engine Oil Gasoline Vehicle 4 Position a pan designed for oil changes under the drain plug 1 Figure 29 1 Drain pan 2 Drain plug 2667 Figure 29 Engine Oil Drain Plug and Pan 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 WARNING Do not attempt to change engine oil when the engine is hot or even warm Engine oil can cause skin burns Wear safety glasses or approved eye protection when servicing the vehicle Wear rubber gloves when handling oil drain plug and oil drain pan 6 Clean the oil drain plug threads with solvent to remove oil and oil resi
17. following manufacturer s directions add a commercially available fuel stabilizer such as Sta Bil 3 2 Disconnect fuel vent line from fuel tank vent nipple 3 3 Plug the fuel tank vent nipple so that it is air tight We recommend using a slip on vinyl cap NOTE It is not necessary to drain the fuel line 4 Disconnect battery and spark plug wire See Disconnecting the Battery Gasoline Vehicles on page 17 5 Batteries should be clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water use 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse solution off batteries Do not allow this solution to enter the batteries Let the terminals dry and then coat them with Battery Terminal Protector Spray 6 To protect the engine remove spark plug and pour 0 5 fl oz 14 2 mL of SAE 10 weight oil into the engine through the spark plug hole Rotate engine crankshaft by hand several times and then install the spark plug and tighten it to 20 ft lb 27 N m 7 Adjust tires to recommended tire pressure See Vehicle Specifications on page 64 8 Perform semiannual periodic lubrication See Periodic Lubrication Schedules on page 44 9 Thoroughly clean front body rear body seats cargo bed engine compartment and underside of vehicle 10 Do not engage the park brake Chock the wheels to prevent the vehicle from rolling RETURNING THE STORED GASOLINE VEHICLE TO SERVICE 1 Restore fue
18. gross vehicle combination weight must not be exceeded to maintain safe vehicle operation Refer to Figure 17 for the following specifications Page 34 CARRYALL 500 550 700 Vehicle Owner s Manual Vehicle Load Capacities Carryall 500 Ele and Carryall 500 Carryall 550 Electric Carryall 700 Electric Brake Gas Brake Gas Gas OIM Gas A Occupant Capacity Capacity 400 Ib 181 4000 181 kg 400 Ib 4001 181 kg kg 400 Ib 400 181 kg kg 500 Ib 500 226 kg kg B Cargo Capacity includes cargo bed load 800 Ib 363 kg 800 Ib 363 kg 500 Ib 227 kg 1000 Ib 454 kg and optional equipment 150 Ibf 667 N 150 Ibf 667 N 150 Ibf 667 N 150 Ibf 667 N D Maximum Gross Trailer Weight 1500 Ib 680 kg 1200 Ib 544 kg 900 Ib 408 kg 1500 Ib kg B Vehicle Rated A Vehicle Rated Capacity 1200 Ib 1200 544 kg kg 1200 Ib 544 kg 900 Ib 408 kg 1500 Ib 680 kg A B D not to exceed stated Vehicle To 1500 Ib 680 kg 1200 Ib 544 kg 900 Ib 408 kg 1500 Ib 680 kg Combination Rated Capacity C Maximum Trailer Tongue Weight Vehicle Weight A Vehicle Weight Maximum Gross Vehicle Weight A B D Vehicle Weight not to exceed stated Maximum Gross Vehicle Combination Weight Electric 1393 Ib 632 kg Gasoline 907 Ib 411 kg Electric 2593 Ib 1176 kg Gasoline 2107 Ib 956 kg Electric 2893 Ib 1312 kg
19. in place See Safety Decal Identification on page 4 Tires Visually inspect for wear damage and proper inflation on a daily basis See Vehicle Specifications on page 64 Battery ies Check electrolyte to ensure that it is at its proper level Figure 20 Page 50 or Figure 27 Page 59 Check battery posts Wires should be tight and free of corrosion On electric vehicles charge batteries fully before first use of vehicle Charger cord and plug electric vehicles Visually inspect for cracks loose connections and frayed wiring Engine gasoline vehicles Check for proper engine oil level See Engine Oil Gasoline Vehicle on page 60 Inspect air intake for blockage Fuel gasoline vehicles Check fuel level See Fueling Instructions Gasoline Vehicle on page 62 Check fuel tank fuel injector lines cap and pump for fuel leakage on a daily basis Performance Inspection Inspect as instructed See Performance Inspection on page 30 A WARNING Be sure the plastic has been removed from the seat bottom before operating the vehicle Failure to do so can result in a fire property damage personal injury or death CARRYALL 500 550 700 Vehicle Owner s Manual Page 29 Pre Operation and Daily Safety Checklist PERFORMANCE INSPECTION After you have familiarized yourself with the vehicle controls and have read and understood the driving instructions take the vehicle for a test drive Use the following checklis
20. model year See following NOTE NOTE Have the vehicle serial number available when ordering parts or making inquiries Build Code The build code 4 is a five digit number that appears on the vehicle serial number decal The build code exists to enable the user to identify the correct owner s manual for a vehicle This owner s manual is valid for the build code range indicated on the back cover of this owner s manual E SERIAL NUMBER 3 CC5819 123456 ASSEMBLED IN USA BC54679 2843 Figure 6 Serial Number Decal CONTROLS AND INDICATORS See General Warnings on page 15 WARNING Before allowing anyone to drive the vehicle make sure the driver is familiar with all controls and operating procedures Gasoline vehicles only Do not tamper with the governor Doing so will void the warranty as well as damage the engine and other components and can result in property damage personal injury or death due to unsafe speeds Page 20 CARRYALL 500 550 700 Vehicle Owner s Manual Controls and Indicators KEY SWITCH The key switch 1 is mounted on the dash to the right of the steering column Figure 7 or Figure 8 Each vehicle is equipped with either a two position key switch or a three position key switch All electric vehicles are equipped with a two position key switch Gasoline vehicles equipped with a two position key switch are referred to as pedal start Gasoline vehicles equipped with a three positio
21. or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries DANGER CONTINUED ON NEXT PAGE Page 50 CARRYALL 500 550 700 Vehicle Owner s Manual Battery Charger QuiQ Electric Vehicle DANGER The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the charging area must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas can result in an explosion If equipped with a cab do not charge the vehicle batteries with the cab closed The cab should have windows or doors open when batteries are being charged An accumulation of hydrogen gas can result in an explosion Risk of electric shock Connect charger power cord to an outlet that has been properly installed and grounded in accordance with all local codes and ordinances A grounded outlet is required to reduce risk of electric shock do not use ground adapters or modify plug Do not touch uninsulated portion of output connector or uninsulated battery terminals Disconnect the AC supply before making or breaking the connections to the battery Do not open or disassemble char
22. slopes ER A ATTI 0504601 y gt up 2 Riding in cargo bed can cause severe injury ordeath Do not ride in cargo bed CCI 101553901 101609401 YOUNG DRIVERS OR PASSENGERS INCREASE CHANCE OF SERIOUS INJURY OR DEATH All occupants must be able to hold on and place both feet flat on the floorboard with their backs against the seat backs Children requiring a child safety seat must not ride in vehicle valid driver s license is required fo operate this vehicle 22207580 Vehicle rated capacity 900 Ib 408 kg on level surface only VEHICLE n dieu d y Includes occupants and cargo load ROLLOVER CAN CAUSE SERIOUS INJURY OR DEATH LOADING Maximum cargo load 500 Ib 227 kg Place cargo forward in the cargo bed and distribute Includes cargo bed load and optional equipment gvenly Side to side secure oad Sooda A Roag owners manual Vehicle combination rated capacity 900 Ib 408 kg stopping On or backing n Seep Includes raten capacity gross traller weight Avoidtop heavyloads T Decal Bed Loading Warning on cargo bed or seat 1 101553901 back 5 102075801 Decal Young Driver Warning Decal Crush Area Warning behind seat near 2 101609401 104026801 Decal Occupant Warning cargo bed Decal On Off Key Switch above key switch 3 101825101 7 105046101 Decal Operating Inst
23. step 13 12 To keep batteries fully charged during storage 12 1 Plug the battery charger into the car Leave battery chargers plugged in during storage The charger will automatically activate when necessary 12 2 Check the electrolyte level and charger function monthly to ensure that proper operation is maintained CAUTION Be sure to check the batteries and charger monthly to maintain correct battery water level and to ensure the charger is operating correctly during storage 13 If disconnecting the batteries for storage disconnect B negative battery cable and secure it in a way that ensures the cable will not come into contact with battery terminal RETURNING THE STORED ELECTRIC VEHICLE TO SERVICE 1 If necessary connect batteries See Connecting the Batteries Electric Vehicles page 17 2 Fully charge batteries WARNING Do not attempt to charge frozen batteries or batteries with bulged cases Discard the battery Frozen batteries can explode 3 Adjust tires to recommended tire pressure See Vehicle Specifications Electric Vehicles on page 64 4 Perform the Pre Operation and Daily Safety Checklist on page 29 and the Performance Inspection on page 30 STORAGE GASOLINE VEHICLES See General Warnings on page 15 DANGER Do not attempt to drain fuel when the engine is hot or while it is running e Be sure to clean up any spilled gasoline before operating the vehicle Store fu
24. such as rings watches chains etc when servicing the vehicle or battery charger Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Do not cover the charger cooling fins Do not allow clothing blankets or other material to cover the charger The fins dissipate heat and protect the charger from overheating Cooling fins will become hot during charging Do not touch Use the handle CAUTION The battery charger provided with this vehicle is approved for use only with the battery type originally shipped with the vehicle Using a different battery type different brand different capacity etc can cause under or overcharging and subsequent battery damage unless the charger is first reprogrammed with a new charging algorithm Club Car only recommends OEM replacement batteries Contact your authorized Club Car dealer distributor with any questions about battery and charger compatibility or algorithm updates GENERAL CHARGER INFORMATION The QuiQ high frequency battery charger functions as an integral part of the vehicle electrical system and will not work with other electric vehicles that use different electrical systems The charger is pre programmed with a specific charge algorithm that is appropriate to the specific battery type used in the vehicle When the charger is connected LED lights on the charger perform a start up self test LEDs ligh
25. switch 1 located on the seat support panel under the seat Figure 13 The switch must be in the RUN position in order to operate the vehicle When the switch is in the TOW position power to the vehicle electrical components is turned off and the vehicle will not operate See following NOTE NOTE After placing the Tow Run switch in the TOW position allow 10 seconds to elapse before switching back to the RUN position After placing the Tow Run switch in RUN position allow 10 seconds to elapse before operating the vehicle The Tow Run switch should be placed in the TOW position under the following conditions Before Towing the Vehicle Place the Tow Run switch in the TOW position to disable all motor braking functions thus preventing possible damage that can occur to the vehicle or electrical components if the vehicle is towed while the walk away braking function is operating Before Disconnecting or Connecting Battery Cables Place the Tow Run switch in the TOW position to turn off power to the vehicle electrical system thus preventing arcing and possible battery explosion as the battery cables are disconnected For Long Term Storage Place the Tow Run switch in the TOW position to turn off power to the vehicle electrical System thus preventing vehicle electrical components from discharging the batteries Page 26 CARRYALL 500 550 700 Vehicle Owner s Manual Controls and Indicators 80 Figure 13 Tow Run Switch CIRCUIT B
26. tank ground wire on the tank is properly connected before fueling the vehicle e 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 Ifthe vehicle has an all weather enclosure installed be sure the fuel tank is properly vented as shown in Figure 31 To avoid the possibility of fire clean up any spilled fuel before operating the vehicle CAUTION Use unleaded gasoline only Whenever possible avoid using oxygenated and blended fuels Do not use any fuel with an alcohol content that exceeds 10 by volume such as E15 and E85 Ethanol is an alcohol that readily absorbs moisture causing corrosion of fuel system components It also damages neoprene and other plastic and rubber components Use of these fuels in this vehicle will void the warranty Do not repeatedly attempt to start a vehicle when the fuel pump is dry no gas in tank Doing so can damage the fuel pump Page 62 CARRYALL 500 550 700 Vehicle Owner s Manual Cleaning the Vehicle NOTE Whenever possible avoid using oxygenated fuels and fuels that are blended with alcohol Vehicles to be stored for extended periods should be prepared for storage as instructed See Preparing the Gasoline Vehicle for Extended Storage on page 39 1 Remove the fuel cap located on the passenger side panel and fill the fuel
27. tank with fresh unleaded gasoline only See preceding CAUTION and NOTE 2 Replace fuel cap on tank Ensure cap is tightened securely tighten until it clicks 1 Vent 2 Fuel Vent Line 3 Fuel Tank 2832 Figure 31 Fuel Tank CLEANING THE VEHICLE Carryall vehicles are equipped with an ArmorFlex front body and an all aluminum rear body and cargo bed Use only commercially available automotive cleaners with a sponge or soft cloth for normal cleaning A garden hose at normal residential water pressure is adequate To remove oxidation or discoloration from aluminum use a commercially available aluminum cleaner paste and fine grade No 00 steel wool Club Car does not recommend any type of pressure washer or steam cleaning Such a process will expose electrical components to moisture Moisture entering electrical components can result in water damage and subsequent component failure Use non abrasive wax products Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible stains The seats of the vehicle will last longer with proper cleaning Use a solution of 10 liquid soap and warm water applied with a soft cloth For imbedded dirt a soft bristle brush may be used For heavy soiling difficult stains or scratches blemishes or other body damage see the appropriate Maintenance and Service Manual or contact your local Club Car dealer NOTE Dispose of waste water proper
28. the area of the cover without Replacement battery wires must be 4 gauge AWG with low resistance terminals cover securely in place See vehicle maintenance and service manual before servicing Ci equivalent to factory installed wires 102518301 Ensure that battery connections are clean and properly tightened See owner Cc Frame is isolated from power system Do not use as ground 105124701 48V ACC 113001 FUSE 105163701 GND MAXIMUM TONGUE 8 WEIGHT 150 Ib 667 N BA x Ex BATTERY EXPLOSION COULD RESULT IN o amp v Crush area Can cause severe injury SEVERE PERSONAL INJURY NORMAL TRIPPED N Stay clear when closing bed Do not store items in battery compartment 9 CCI 102459301 Place Run Tow switch in TOW position before Disconnecting or connecting battery cables Towing this vehicle TOW RUN Extended storage Servicing the vehicle CCI 102845101 Decal Trailer Hitch Tongue Weight Notice on Decal 4 Gauge Wire Warning on frame above 1 1011553 5 102967601 trailer receiver hitch electrical component mounting plate Decal Do Not Use as Ground on frame above 2 102459301 Decal Bed Latch Warning 105124701 electrical component mounting plate Decal Component Cover Notice on electrical Decal 48V Accessory Fuse Block on electrical 3 102518
29. 0 CONTINUED GASOLINE EXPLOSION FIRE CAN CAUSE SERIOUS GASOLINE EXPLOSION FIRE CAN CAUSE INJURY OR DEATH SERIOUS INJURY OR DEATH CAN CAUSE SEVERE INJURY No sparks or open flame near fuel or fuel tank Do not disconnect No sparks or open flame near fuel or fuel tank No smoking near fuel or fuel tank pressurized fuel lines No smoking near fuel or fuel tank ji Stop engine and allow to cool before refueling Stop engine and allow to cool before refueling Rotating parts 105082301 105084701 MBA 1 HOT A manifold amp muffler KEEP CLEAR 101960501 NOTICE MAXIMUM TONGUE 8 WEIGHT 150 Ib 667 INCORRECT WIRING COULD RESULT IN SEVERE INJURY OR DEATH Negative frame ground Can cause severe injury ES Excessive speed Do not contact positive battery post or cable to frame Can cause severe injury or death Disconnect negative battery lead first Do not tamper with engine governor adjustment CCI 101915201 Decal F Ground Governor Warnin 2 101915201 Frame Sroung Sov ing 105082301 Decal Gasoline Fuel Warning on fuel tank vehicle frame near battery Decal Rotating Parts Hot Manifold W 101960501 Rotating Parts Hot Manifold Waring on 105084701 Decal Gasoline Fuel Warning at fuel fill starter generator CARRYALL 500 550 700 Vehicle Owner s Manual Page 13 Practice Safety PRACTICE SAFETY N WARNING Rotating Parts 399 Figure 1 Practice Safety Sa
30. 0 5 in 64 5 x 47 5 x 10 5 in Load bed size Box bed inside dimensions 112 2 x 120 6 x 112 2 x 120 6 x 163 8 x 120 6 x 26 6 cm 26 6 cm 26 6 cm 46 2 48 8 46 2 48 8 65 5 48 8 Load bed size Flat bed inside dimensions 117 3 x 123 9 cm 117 3 x 123 9 cm 166 4 x 123 9 cm CARRYALL 500 550 700 Vehicle Owner s Manual Page 65 Vehicle Specifications SPECIFICATIONS CARRYALL 500 CARRYALL 550 CARRYALL 700 TIRE PRESSURE 28 to 32 psig 20 to 22 psig 28 to 32 psig Front and rear 193 to 221 kPa 138 to 152 kPa 193 to 221 kPa NOISE AND VIBRATION Unknown at time Unknown at time Unknown at time Drive by neise Tevel te operator of printing of printing of printing Test method EN 12053 2001 Uncertainty 2 dBa Uncertainty 2 dBa Uncertainty 2 dBa Unknown at time Unknown at time Unknown at time Vibration at driver s seat of printing of printing of printing Test method EN 13059 2002 Uncertainty Uncertainty Uncertainty 0 23 m s2 0 23 m s2 0 23 m s2 QUIQ BATTERY CHARGER SPECIFICATIONS QUIQ BATTERY CHARGER SPECIFICATIONS AC Power Factor nominal 20 99 120 VAC gt 0 98 230 VAC POWER CONSUMPTION Max 12 Amps AC current amps Nominal 9 5 Amps rms 120 VAC 5 Amps rms 230 VAC Interlock current maximum 1 Amp Page 66 CARRYALL 500 550 700 Vehicle Owner s Manual Vehicle Specifications QUIQ BATTERY CHARGER SPECIFICATIONS Weight with standard output
31. 04 108 EC Electromagnetic Compatibility Standards used for verification Standards fur Uberprufung Normes Utilisees pour Verification Normas Usado por Comprobacion Waarden Aangewend voor Verificatie Modelos Utilizado para Verifcacao Standard per la Verifica Standarder Anvendte Nemlig Efterprovning Standarden Anvand for Bekraftanden EN 61000 6 2 EN 61000 6 4 Manufacturer Hersteller Fabricant Fabricante Fabrikant Fabricante Fabbricante Producent Tillverkare Club Car LLC 4125 Washington Road Evans Georgia 30809 USA Authorized representative and person authorized to compile the technical file Autorisierter Handler Representant Dument Accr dit Representante Autorizado Wettige Vertegenwoordiging Representate Autorizado Rappresentante Autorizzato Autoriscret repraesentant Auktoriserad representant Club Car Ingersoll Rand Alma Court Building Lenneke Marelaan 6 B 1932 Sint Stevens Woluwe Belgium 22 A f Geoff Stewart September 17 2013 Director Product Safety Evans Georgia USA Page 78 CARRYALL 500 550 700 Vehicle Owner s Manual NOTES NOTES BC5661 1 Publication Part Number 105062704 Edition Code 1113A00000 This manual is valid for vehicles with build codes between 56658 and the one indicated at the top of this page aa e REGISTERED ff e Club Car LLC Web www clubcar com e P O Box 204658 Phone 1 706 863 3000 Augusta G
32. 221 kPa 138 to 152 kPa 193 to 221 kPa NOISE AND VIBRATION CARRYALL 500 550 700 Vehicle Owner s Manual Page 69 Vehicle Specifications SPECIFICATIONS CARRYALL 500 CARRYALL 550 CARRYALL 700 POWER SOURCE GASOLINE GASOLINE GASOLINE Unknown at time 77 2 dBa 77 2 dBa of printing Drive by noise level to operator Test method EN 12053 2001 Uncertainty 2 dBa Uncertainty 2 dBa l Uncertainty TBD Unknown at time Unknown at time Unknown at time Vibration at driver s seat of printing of printing of printing Test method EN 13059 2002 Uncertainty Uncertainty Uncertainty 0 23 m s2 0 23 m s2 0 23 m s2 Page 70 CARRYALL 500 550 700 Vehicle Owner s Manual Warranties WARRANTIES CLUB CAR LIMITED WARRANTY FOR TRANSPORTATION AND UTILITY VEHICLES WARRANTY CLUB CAR LLC CLUB CAR hereby warrants to the Original Purchaser or Lessee as those terms are defined herein and subject to the provisions limitations and exclusions in this limited warranty that its new vehicle or new component purchased from CLUB CAR or an Authorized Dealer or Distributor shall be free from defects in material and workmanship under normal use and service for the periods stated below subject to the provisions limitations and exclusions in this limited warranty This limited warranty covers material workmanship and repair labor cost as to those items specifically listed below for the periods specified Such repair labor shall b
33. 301 7 105130001 component cover component mounting plate Decal Tow Switch Warning on Tow Run switch Decal Ground on electrical component mounting 4 102845101 105163701 plate under seat plate Page 6 CARRYALL 500 550 700 Vehicle Owner s Manual ELECTRIC CARRYALL 700 Unintended vehicle movement may cause severe injury or death Before using vehicle read owner s manual and vehicle safety warnings Before leaving vehicle Engage park brake to lock wheels Place vehicle in NEUTRAL Turn key to OFF and remove key E MOCAN 105046101 12V 105163601 T HE 12V ACC oo FUSE BLOCK GND Safety Decal Identification UNINTENDED MOVEMENT ROLLOVER OR FALLING OUT CAN CAUSE SERIOUS INJURY OR DEATH Vehicle to be operated by licensed and authorized persons only gt Remain fully seated while moving Use in authorized areas only Do not operate on public roads Hold on and keep entire body inside vehicle while moving One 1 person per bucket seat maximum Never attempt jumps and avoid extreme braking in reverse Two 2 persons per bench seat maximum Do not leave children unattended in vehicle at any time Operate from driver s seat only Children requiring a child safety seat must not ride in vehicle Do not start vehicle until all occupants are fully seated Never operate under t
34. 5 amp circuit or the circuit may become overloaded See QuiQ Battery Charger Specifications on page 66 To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord with an equipment grounding conductor and a grounding type plug The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electric Code and all local codes and ordinances The AC power cord must be a three conductor no 12 AWG American Wire Gauge or no 14 SWG British Standard Wire Gauge heavy duty cord with ground properly wired and in good electrical condition Keep it as short as possible no more than 12 feet 3 7 m Place all cords so they will not be stepped on tripped over or otherwise subject to damage or stress Charging Batteries NOTE Batteries should be put on charge even if they have been used for only a short time i e 10 minutes The charger is automatic and will turn off when batteries are fully charged If the charger does not seem to be operating properly or if the batteries seem weak contact a local Club Car distributor dealer Page 54 CARRYALL 500 550 700 Vehicle Owner s Manual Battery Charger QuiQ Electric Vehicle New batteries will not deliver their full range until the vehicle has been driven and recharged from 50 to 70 times Vehicles should be restricted to 40 to 50 amp hours of discharge between c
35. 700 Vehicle Owner s Manual Battery Gasoline Vehicle DANGER 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 magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately WARNING Do not jump start a dead battery using another battery and jumper cables The battery in a Club Car gasoline vehicle is a 12 volt low maintenance battery that requires infrequent watering Figure 26 1 Level Indicator 2 Cap 3 Plates Electrolyte level at least 1 2 inch 13 mm above plates or to level indicator 2831 22 Figure 26 Gasoline Vehicle Battery Figure 27 Electrolyte Level for Battery Any corrosion around the positive or negative terminals should be washed off with a solution of baking soda and water 1 cup 237 mL per 1 gallon 3 8 L of water Rinse solution off the battery Do not allow this solution to get into the battery Be sure terminals are tight Let the terminals dry and then spray them with Battery Terminal Protector Spray See Connecting the Battery Gaso
36. A 30917 4658 1 800 ClubCar USA Int l 1 706 863 3000 Fax 1 706 863 5808
37. ARRYALL 700 CONTINUED AVOID FIRE HAZARD Replacement battery wires must be 4 gauge AWG with low resistance terminals equivalent to factory installed wires Ensure that battery connections are clean and properly tightened See owner s manual EXPOSURE TO WATER MAY DAMAGE ELECTRONIC COMPONENTS Do not operate vehicle without this cover properly installed Do not direct water stream in the area of the cover without cover securely in place See vehicle maintenance and service manual before servicing CCI 102518301 CCI 102967601 Frame is isolated from power system Do not use as ground 105124701 48V ACC venom FUSE BLOCK GN D 105163701 DIETO WE TEM NOTICE MAXIMUM TONGUE B WEIGHT 150 Ib 667 N BATTERY EXPLOSION COULD RESULT IN c SEVERE PERSONAL INJURY Do not store items in battery compartment Place Run Tow switch in TOW position before Disconnecting or connecting battery cables Towing this vehicle RUN Extended storage Servicing the vehicle CCI 102845101 Decal Trailer Hitch Tongue Weight Notice on Decal Do Not Use as Ground on frame above 1 1011553 5 105124701 trailer receiver hitch electrical component mounting plate Decal Component Cover Notice on electrical Decal 48V Accessory Fuse Block on electrical 2 102518301 105130001
38. CARRYALL CARRYALL 500 550 700 ELECTRIC AND GASOLINE VEHICLE DWNER S MANUAL REFER TO BACK COVER FOR APPLICABLE BUILD CODE RANGE dm Ingersoll Rand NOTICE This manual is valid for vehicles manufactured in the build code range provided on the back cover of this manual If the vehicle build code is different from that shown on the back cover of this manual please contact your nearest dealer or go to www clubcar com to retrieve the proper owner s manual for the vehicle See also Model Identification in this manual Warranty information appears at the end of this manual No other warranties express or implied are contained herein Your authorized representative checked the 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 LLC 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 utility vehicles are four wheel general purpose v
39. NER 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 the need arises Please send your name address and serial number s of the vehicle s to Club Car LLC P O Box 204658 Augusta Georgia 30917 4658 Attention Vehicle Registration VEHICLE SPECIFICATIONS VEHICLE SPECIFICATIONS ELECTRIC VEHICLES SPECIFICATIONS CARRYALL 500 CARRYALL 550 CARRYALL 700 POWER SOURCE ELECTRIC ELECTRIC ELECTRIC Drive motor Direct drive 48 volts DC shunt wound 3 7 hp Transaxle Double reduction helical gear with 12 3 1 direct drive axle Batteries High capacity deep cycle 6 volt Charger Automatic 48 volt UL and CSA listed See QuiQ Battery Charger Specifications on page 66 STEERING SUSPENSION BRAKES Suspension Independent leaf spring with dual hydraulic shocks aS eee Se Page 64 CARRYALL 500 550 700 Vehicle Owner s Manual Vehicle Specifications SPECIFICATIONS CARRYALL 500 CARRYALL 550 CARRYALL 700 POWER SOURCE ELECTRIC ELECTRIC ELECTRIC Brakes Mechanical brake cable system to manually adjusted drum brakes on all four wheels Park brake is automatically released Multi latch ratchet and pawl BODY CHASSIS Frame chassis Twin welded aluminum Side and rear body Aluminum 2402 o om o o 4 Front body finish Automotive grade paint with clear coat finish Tires 20 x 10 10 tubeless
40. REAKER Electric Vehicles Only IQ Plus vehicles are equipped with a circuit breaker 2 located next to the Tow Run switch Figure 13 If the circuit breaker has been tripped a series of rapid beeps will sound and vehicle speed will slow to approximately one half of its top programmed speed In the event of a tripped circuit breaker bring the vehicle to a complete stop remove seat and push the breaker to reset If the circuit breaker trips again when vehicle operation is resumed contact your local Club Car distributor dealer NEUTRAL LOCKOUT SWITCH Gasoline Vehicles Only 81 Figure 14 Neutral Lockout Switch CARRYALL 500 550 700 Vehicle Owner s Manual Page 27 Controls and Indicators For the convenience of the trained technician there is a neutral lockout switch located on the seat support panel under the seat Figure 14 The neutral lockout switch has two positions MAINTENANCE and OPERATE which are clearly marked When the switch is in the MAINTENANCE position it will allow the technician to run the engine in the NEUTRAL position to perform certain maintenance and or repair functions With the switch in this position the vehicle will not operate if the Forward Reverse handle is placed in either the FORWARD or REVERSE position WARNING With the switch in the MAINTENANCE position and the engine running the vehicle can move suddenly if the Forward Reverse handle is shifted or accidentally bumped To prevent this
41. RVICE See Pre Operation and Daily Safety Checklist Pre Operation and Daily Safety Checklist on page 29 Daily service by owner Performance Inspection See Performance 22 page 30 Charge batteries after each daily use only batteries after each daily use only Batteries For vehicles NOT equipped Check electrolyte level Add water if necessary Weekly service by owner with the Single Point Watering System See page 50 Batteries For vehicles equipped with the Water the batteries Observe that water flow occurs Single Point Watering System Water and no water overflows from any cell See Battery monthly or according to the established Care Vehicles Equipped with the Single Point watering interval Watering System SPWS on page 48 Wash battery tops and clean terminals with baking i Monthly service by owner or trained soda water solution technician Check air pressure and adjust if necessary See Vehicle Specifications Electric Vehicles on page 64 Wash battery compartment and underside of General vehicle vehicle For vehicles newly equipped with the SPWS manually check battery electrolyte levels of all cells to verify correct valve operation See page 49 Check brake shoes replace if necessary or adjust as required Check brake cables for DL DEEP replace if Brake system DL DEEP Semi by trained technici See oe RA NS Check brak
42. SIBILITIES As the engine owner you are responsible for the performance of the required maintenance listed in your owner s manual CLUB CAR recommends that you retain all receipts covering maintenance on your engine but CLUB CAR cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the engine owner you should however be aware that CLUB CAR may deny warranty coverage if your engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your engine to the nearest service dealer authorized by CLUB CAR when a problem exists If you have any questions regarding your warranty rights and responsibilities you should contact the CLUB CAR customer service department at 706 863 3000 for the information THINGS YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYSTEM WARRANTY MAINTENANCE AND REPAIRS You are responsible for the proper maintenance of the engine You should keep all receipts and maintenance records covering the performance of regular maintenance in the event questions arise These receipts and maintenance records should be transferred to each subsequent owner of the engine CLUB CAR reserves the right to deny warranty coverage if the engine has not been properly maintained Warranty claims will not be denied however solely because of the lack of required maintenance or failure to keep maintenance r
43. T COTTO 105046101 12V 105163601 12V 1o FUSE BLOCK D T GND 3 105163701 Safety Decal Identification UNINTENDED MOVEMENT ROLLOVER OR FALLING OUT CAN CAUSE SERIOUS INJURY OR DEATH Vehicle to be operated by licensed and authorized persons only Remain fully seated while moving Use in authorized areas only Do not operate on public roads Hold on and keep entire body inside vehicle while moving One 1 person per bucket seat maximum Never attempt jumps and avoid extreme braking in reverse Two 2 persons per bench seat maximum Do not leave children unattended in vehicle at any time Operate from driver s seat only Do not start vehicle until all occupants are fully seated Never operate under the influence of alcohol or drugs Drive slowly in turns and straight up and down slopes Children requiring a child safety seat must not ride in vehicle Riding cargo bed can cause severe injury ordeath Do not ride in cargo s 5 E 3 8 g 5 YOUNG DRIVERS OR PASSENGERS INCREASE CHANCE OF SERIOUS INJURY OR DEATH All occupants must be able to hold on and place both feet flat on the floorboard with their backs against seat backs Children requiring a child safety seat must not ride in vehicle A valid driver s license is required to operate this vehicle
44. T WATERING SYSTEM SPWS 0 0 0 0 To keep batteries in good working condition follow this maintenance program on a regular basis 1 Keep the batteries clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water use 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse solution off of the batteries Do not allow this solution to enter the battery Be sure terminals are tight Let the terminals dry and then coat with Battery Terminal Protector Spray See following NOTE NOTE Dispose of waste water properly 2 The battery hold downs should be tight enough so that the batteries do not move while the vehicle is in motion but not so tight as to crack or buckle the battery case Tighten hold down retaining nuts to 55 in Ib 6 2 N m The terminal connections should be clean and tight and any worn insulation or frayed wires should be replaced Tighten battery terminals to proper torque See Connecting the Batteries Electric Vehicles on page 17 See following WARNING Page 48 CARRYALL 500 550 700 Vehicle Owner s Manual Batteries Electric Vehicles WARNING f battery wire terminals are damaged or corroded replace or clean them as necessary Failure to do so can cause them to overheat during operation and can result in fire property damage or personal injury 3 After use charge the batteries The batteries should never be left discharged any longer than abso
45. To ensure safe operation of the vehicle follow exactly and in order all of the following procedures Read and understand all instructions prior to driving the vehicle STARTING THE VEHICLE 1 Read safety and information decals located on the vehicle 2 Study and understand controls 3 Make sure load is secure 4 Make sure everyone is seated and holding onto hand holds or handrails Driver should have both hands on the steering wheel 5 Make sure wheels are turned in desired direction and that nothing is obstructing vehicle s path 6 Electric and pedal start vehicles Start the vehicle 6 1 Turn the key to the ON position 6 2 Select direction by placing the Forward Reverse handle or switch in the desired position F Forward or R Reverse A buzzer will sound as a warning when the Forward Reverse handle or switch is in the REVERSE position 6 3 Slowly press the 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 NOTE 7 Key start vehicles Start the vehicle 7 1 Make sure the Forward Reverse handle is in the NEUTRAL position 7 2 Press and hold brake pedal 7 3 Turn the key all the way to the START position and release after the engine has started The engine will idle with the Forward Reverse handle in the NEUTRAL position 7 4 Keeping brake engaged place
46. VAL SERVICE Engine air intake system necessary Safety decals Check safety decals Replace if damaged or illegible Two year service by trained technician only Check and adjust valve lash as needed WARNING If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs can result in fire property damage severe personal injury or death CARRYALL 500 550 700 Vehicle Owner s Manual Page 43 Periodic Lubrication Schedules PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE ELECTRIC VEHICLES LUBRICATION REGULAR INTERVAL PONTS RECOMMENDED LUBRICANT Dry Moly Lube CC PN 1012151 Dry Moly Lube CC PN 1012151 Semiannually by owner or trained technician or every 50 f Dry Moly Lube CC PN 1012151 hours of operation whichever comes first Dry Moly Lube CC PN 1012151 Chassis Lube EP NLGI Grade 2 Annually by trained technician 22 fl oz 0 67 L SAE 30 WT API Class SE only or every 100 hours of SF SG Oil or higher operation whichever comes Inspect front wheel bearings Repack o AT first as necessary assis Lube EP NLGI Grade 2
47. able Removal Gasoline Vehicle RECYCLING LEAD ACID BATTERIES WARNING Lead acid batteries contain lead Pb other metals acids and other compounds If improperly handled they can contaminate both water and soil causing environmental damage and personal injury Lead acid batteries are identified by the symbol shown below and should be properly recycled Figure 4 They cannot be disposed as municipal waste and must be collected separately Responsibility for environmental protection must be shared not only by the manufacturers of the batteries but by people who use the batteries as well Please contact your nearest Club Car dealer or distributor for information on how to properly recycle your batteries Page 18 CARRYALL 500 550 700 Vehicle Owner s Manual General Information 1403 Figure 4 Dispose of Lead acid Batteries Properly INTERNATIONAL SAFETY SYMBOLS ON BATTERIES Anyone using repairing or servicing the vehicle must understand and heed the safety symbols on the vehicle battery or batteries 1 Shield eyes 3 No smoking no open flames no sparks 5 Battery acid hazard 2 Read and follow operating instructions 4 Keep away from children 6 Explosive gas hazard Refer to General Warnings for more information 1642 Figure 5 International Safety Symbols on Batteries GENERAL INFORMATION This manual features Carryall 500 550 and 700 electric and gasoline vehicles Electric Carryall 500 550 and 700 veh
48. ace diee bene dina tiene dieron dde ba ia dd duae dde aea dd 41 Periodic Lubrication Schedules iecit dietas eens Litas dene die he in Dd eua LP 44 Batt ries Electric VaMe E ea er e tees ten texit et eo teet Eon Ead et rado ie 46 Battery Charger QUIQ Electric 50 Single Point Watering System 5 5 4 4 nnne tnde nnne sa en nane OTA dann nn these nnns 56 Battery Gasoline Vehicle staite tiine eei a e Senate tbe end Ag dite ding eta eee dd eee dn dde eden ida dd 58 Engine Oil Gasoline 2 0 441041 141 441 kanns ind nnns 60 Fueling Instructions Gasoline een nn nennen hne nnne nnns 62 Gleaning Me vehicle p 63 ACCOSSOLTOS 63 Subsequent Owner Registration 2 2 21 4 441 4 4 nnne d dne nnne dd dne sede dd nna nn da dne sina dne nn 64 Mehicle SpecifICatioris nete dti eae teu eat reu ee 64 Warranties eee titt Mti rat t qr le rea let io hee e cd ett etate 71 EC Declaration of Conformity 2
49. ces only Overloading can affect vehicle handling or cause component failure resulting in loss of control of vehicle and possible severe personal injury Reduce vehicle load and speed when driving up or down slopes or on uneven terrain Reduce speed and avoid sudden stops when backing up Failure to do so can cause the vehicle to overturn or flip over backwards Avoid stopping on a hill when loaded If you must stop on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning can cause vehicle to overturn possibly resulting in severe personal injury Do not load the tailgate The tailgate should be in the upright position and latched securely while the vehicle is in motion WARNING CONTINUED ON NEXT PAGE CARRYALL 500 550 700 Vehicle Owner s Manual Page 33 Vehicle Load Capacities WARNING To help avoid shifting the vehicle load and possibly overturning the vehicle avoid sudden starts sudden stops and abrupt turns The cargo s center of gravity can affect the handling steering and braking of the vehicle Avoid top heavy loads When the vehicle is loaded reduce speed and drive slowly in turns To help prevent cargo from shifting and possibly injuring a passenger or affecting the vehicle s handling make sure cargo is well secured Unload cargo bed before raising vehicle with a lift hoist or jack Cargo load includes the weight of optional equipment C
50. chock the front and rear wheels and firmly set the park brake before servicing or leaving the vehicle NOTE Be sure to return the switch to the OPERATE position after servicing the vehicle or it will not run with the Forward Reverse handle in either the FORWARD or REVERSE position BED LATCH Carryall 500 and 550 vehicles are equipped with a bed latch on the driver side of the vehicle Figure 15 To lift the bed lift up on the latch handle then lift the bed To close the bed lower it gently until the bed latch engages DO NOT drop the bed A WARNING Keep hands and fingers clear of crush area between the bed and the seat back support 2827 2828 Figure 15 Bed Latch Figure 16 Prop Rod PROP ROD See General Warnings on page 15 Carryall 500 and 550 vehicles are equipped with an automatically engaging prop rod and prop rod track on the driver side of the rear body Figure 16 When pulling the bed latch handle and lifting the bed the prop rod will come to rest in one of the notches in the prop rod track Page 28 CARRYALL 500 550 700 Vehicle Owner s Manual Pre Operation and Daily Safety Checklist DANGER Use caution when working under bed Be sure prop rod is secure Otherwise the bed will fall resulting in severe personal injury or death WARNING Do not disengage prop rod until all persons are clear of cargo bed area Do not dr
51. component cover component mounting plate Decal Tow Switch Warning on Tow Run switch Decal Ground on electrical component mounting 3 102845101 7 105163701 plate under seat plate Decal 4 Gauge Wire Warning on frame above 4 102967601 electrical component mounting plate Page 8 CARRYALL 500 550 700 Vehicle Owner s Manual Safety Decal Identification GASOLINE CARRYALL 500 Unintended vehicle movement may cause severe injury or UNINTENDED MOVEMENT ROLLOVER OR FALLING OUT CAN CAUSE SERIOUS INJURY OR DEATH death Before using vehicle read owner s manual and vehicle Vehicle to be operated by licensed and authorized persons only Remain fully seated while moving safety warnings Use in authorized areas only Do not operate on public roads Hold on and keep entire body inside vehicle while moving Before leaving vehicle 1 person per bucket seat maximum Never attempt jumps and avoid extreme braking in reverse Engage park brake to lock wheels Two 2 persons per bench seat maximum Do notleave children unattended in vehicle at any time Place vehicle NEUTRAL Operate from driver s seat only Children requiring a child safety seat must not ride in vehicle Turn key to OFF and remove key D eian ve a Never operate under the influence of alcohol or drugs 105046107 P I ea M S 104028801 GEZEHED 3 Riding in cargo bed ca
52. cord 11 Ib 5 kg MOUNTING CONFIGURATION CARRYALL 500 550 700 Vehicle Owner s Manual Page 67 Vehicle Specifications VEHICLE SPECIFICATIONS GASOLINE VEHICLES NOTE Engine horsepower and torque specifications are provided by the engine manufacturer Actual horsepower and torque in use may differ and are dependent on environmental conditions as well as maintenance condition of the engine SPECIFICATIONS CARRYALL 500 CARRYALL 550 CARRYALL 700 POWER SOURCE GASOLINE GASOLINE GASOLINE Engine 4 cycle OHC 404 cc 14 0 Horsepower 10 4 kW rated engine 3600 RPM per SAE J 1940 single cylinder air cooled with splash lubrication system Fuel system Electronic fuel injection EFI high pressure rotary fuel pump with 10 micron fuel filter Governor Automatic ground speed sensing internally geared in transaxle Transaxle Precision helical gears forward reverse with neutral position 11 47 1 forward 15 63 1 reverse with optional limited slip differential Electrical system 12 volt 500 cca at 0 F 17 8 C 650 cca at 32 F 0 C 105 minute reserve capacity Gasoline Vehicle Electrical Charging System 23 amps at max RPM Torque converter Automatic variable speed dry type STEERING SUSPENSION BRAKES Steering Self adjusting rack and pinion Suspension Independent leaf spring with dual hydraulic shocks Brakes Mechanical brake cable system to manually adjusted drum brakes on all four wheel
53. due Make sure that the compression washer remains on the drain plug 7 Usea 14 mm socket or wrench and replace the oil drain plug turning it clockwise and tighten to 18 ft lb 24 4 N m 8 Remove the dipstick and add engine oil into the dipstick port Use a funnel or pour spout to direct the oil into the dipstick port The engine requires 40 5 fl oz 1 2 L of oil per change 10W 30 or 5W 30 grade SE or higher is recommended Refer to oil viscosity guidelines for selection of oil grade Figure 30 Replace the dipstick CARRYALL 500 550 700 Vehicle Owner s Manual Page 61 Fueling Instructions Gasoline Vehicle 20 C 10 C 0 C 213 Figure 30 Oil Viscosity Chart 9 Connect battery and spark plug wire See Connecting the Battery Gasoline Vehicles on page 17 10 With the Forward Reverse handle in the NEUTRAL position and the Maintenance Service switch in the SERVICE position start and run the engine for a few minutes Observe the drain plug from under the vehicle and watch for oil leaks If leaks appear begin with step 1 and repeat the appropriate steps as needed to correct the problem 11 Remove the dip stick and check the engine oil as a final step Replace the dip stick FUELING INSTRUCTIONS GASOLINE VEHICLE See General Warnings on page 15 DANGER Turn the key switch to the OFF position before fueling Do not pour fuel into the fuel tank when the engine is hot or while it is running Besure the fuel
54. e cable eee adjustment adjust if only or every 50 hours of operation eee whichever comes first Electrical wiring and connections Check for tightness and damage Check and adjust as required See Steering and Front wheel alignment and camber Front Suspension section in the maintenance and service manual Initial one time inspection by owner or Batteries For vehicles newly equipped trained technician after six weeks of use with the SPWS CARRYALL 500 550 700 Vehicle Owner s Manual Page 41 Periodic Service Schedules PERIODIC SERVICE SCHEDULE ELECTRIC VEHICLES REGULAR INTERVAL SERVICE Motor Controller Output Regulator Check for loose hardware cracks or other damage MCOR Batteries For vehicles equipped with the Manually check battery electrolyte levels of all cells SPWS to verify correct valve operation See page 49 Annual service by trained technician only If batteries are not performing as expected see the or every 100 hours of operation whichever Batteries Batteries section in the maintenance and service comes first manual Check safety decals Replace if damaged or Safety decals MV y P 9 illegible PERIODIC SERVICE SCHEDULE GASOLINE VEHICLES REGULAR INTERVAL SERVICE 7 See Pre Operation and Daily Safety Checklist on Pre Operation and Daily Safety Checklist Daily service by owner page 29 Performance Inspection See Performance Inspection on page 30 Check engine oil level change i
55. e performed only by CLUB CAR its Authorized Dealers or Distributors or a service agency approved by CLUB CAR For repairs made by qualified technicians other than CLUB CAR s factory technicians or an Authorized Dealer or Distributor CLUB CAR will provide only the replacement parts or components 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 HOURS TERMS TO THE ORIGINAL OWNER ONLY NON TRANSFERABLE AMP HOURS COVERED COVERED LIMITED THREE YEAR Engine assembly transaxle assembly gasoline vehicle starter generator gasoline 3 YEARS 3000 vehicle motor transaxle assembly electric vehicle and main frame assembly LIMITED TWO YEAR Solenoid MCOR limit switches voltage regulators FNR switches brake components wiring harness electrical switches canopy systems seats pedal group assembly body cab assembly and 2 YEARS 2000 doors and driving range protective enclosure portable refreshment center and all original equipment options and accessories supplied by CLUB CAR and all remaining components of the vehicle not specified otherwise 6 VOLT BATTERY STANDARD DUTY 6 VOLT BATTERY HEAVY DUTY 8 VOLT BATTERY STANDARD HEAVY DUTY ONBOARD COMPUTER IF SO EQUIPPED BATTERY CHARGER EXCLUSIONS Excluded from any CLUB CAR warranty is damage to a vehicle or component resulting from a cause
56. e regulator or fuel injection system 1 2 Air fuel ratio feedback and control system if applicable 1 3 Cold start enrichment system if applicable 2 Air Induction System 2 1 Intake manifold if applicable 2 2 Air filter 3 Ignition System CARRYALL 500 550 700 Vehicle Owner s Manual Page 73 Warranties 3 1 Spark plugs 3 2 Magneto or electronic ignition system 3 3 Spark advance retard system if applicable 4 Catalyst or Thermal Reactor System 4 1 Exhaust Manifold if applicable 5 Miscellaneous Items Used in Above Systems 5 1 Electronic controls if applicable 5 2 Hoses belts connectors and assemblies EVAPORATIVE EMISSIONS Fuel Line Fuel Line Fittings Clamps Fuel Tank Fuel Cap Vapor Hoses Carbon Canister Carbon Canister Mounting Brackets Air Cleaner Purge Port Connector REPLACEMENT PARTS DISTRIBUTION CENTER Replacement parts are provided to the market upon request by the customers Replacement parts distribution center is located at the Service Parts Department Club Car 4125 Washington Road Evans Georgia 30809 U S A 706 863 3000 If you have a question regarding your replacement part you should contact CLUB CAR at 706 863 3000 OBTAINING WARRANTY SERVICE To obtain warranty service take your engine to the nearest authorized CLUB CAR service dealer Bring your sales receipts indicating date of purchase for this engine The service dealer authorized by CLUB CAR will perf
57. e removed from use until it is properly repaired This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions Contact your local Club Car distributor dealer to perform all repairs and semiannual and annual periodic service WARNING If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs can result in fire property damage severe personal injury or death Only trained technicians should service or repair the vehicle or battery charger Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation Do not work on vehicle powertrain or under the cargo bed when it is loaded Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle Turn the key switch to OFF remove the key place the Forward Reverse handle or switch in the NEUTRAL position and chock tires prior to servicing Do notclose 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 can result in severe personal injury Electric vehicles Hot Do not attempt to service hot motor Attempting to do so can cause severe b
58. e suitable for use in any application other than in its products As in the use of any vehicle batteries computer controller or electrical device a prudent owner will read and study the owner s manual the operator instructions and the warning labels and will exercise due care in working on or around vehicles batteries or electrical devices Transportation expenses for warranty services are also excluded from this warranty VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICLE OR COMPONENT IS ABUSED OR USED IN AN UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY INCLUDING BUT NOT LIMITED TO MODIFICATION OF THE SPEED GOVERNOR BRAKING SYSTEM STEERING TRANSAXLE OR OTHER OPERATING SYSTEMS OF THE CAR TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKEWISE VOID IF THE VEHICLE SHOWS INDICATIONS THAT REASONABLE OR NECESSARY MAINTENANCE AS OUTLINED IN THE OWNER S MANUAL AND MAINTENANCE AND SERVICE MANUAL WAS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS SOLE REMEDY CLUB CAR s liability under this limited warranty or in any action whether based upon warranty contract negligence strict product liability or otherwise shall be the repair or replacement at CLUB CAR s option of the vehicle or component thereof that CLUB CAR deems to be defective Replacement shall mean furnishing during the applicable limited warranty period a new vehicle or fact
59. e 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 distributor dealer DANGER ADANGER indicates an immediate hazard that will result in severe personal injury or death WARNING AWARNING indicates an immediate hazard that can result in severe personal injury or death CAUTION A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that can result in minor personal injury CAUTION A CAUTION without the safety alert symbol indicates a potentially hazardous situation that can result in property damage GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated repaired or serviced See Safety Decal Identification on page 4 Other specific safety statements appear throughout this manual and on the vehicle DANGER Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries Gasoline Flammable Explosive Do not smoke Keep sparks and flames away from the vehicle and service area Service only in a well ventilated area Do not operate engine in an enclosed area without proper ventilation The engine produces carb
60. ecords MAINTENANCE REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL HOWEVER WARRANTY REPAIRS MUST BE PERFORMED BY A SERVICE DEALER AUTHORIZED BY CLUB CAR THE USE OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND DURABILITY TO AUTHORIZED PARTS MAY IMPAIR THE EFFECTIVENESS OF THE EMISSION CONTROL SYSTEM AND MAY HAVE A BEARING ON THE OUTCOME OF A WARRANTY CLAIM If other than the parts authorized by CLUB CAR are used for maintenance replacements or for the repair of components affecting emission control you should assure yourself that such parts are warranted by their manufacturer to be equivalent to the parts authorized by CLUB CAR in their performance and durability HOW TO MAKE A CLAIM All repairs qualifying under this limited warranty must be performed by a service dealer authorized by CLUB CAR In the event that any emission related part is found to be defective during the warranty period you shall notify CLUB CAR customer service department at 706 863 3000 and you will be advised of the appropriate warranty service dealer or service providers where the warranty repair can be performed CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and Club Car LLC CLUB CAR are pleased to explain the emission control system warranty on your 2014 or newer vehicle engine the emission
61. ed from such warranty coverage if CLUB CAR demonstrates that the engine or equipment has been abused neglected or improperly maintained and that such abuse neglect or improper maintenance was the direct cause of the need for repair or replacement of the part That notwithstanding any adjustment of a component that has a factory installed and properly operating adjustment limiting device is still eligible for warranty coverage The following emission warranty parts list are covered SYSTEMS COVERED PARTS DESCRIPTION Fuel Metering Carburetor assembly fuel injection pump fuel injection nozzle fuel regulator Exhaust Catalytic Converter Exhaust Manifold Air Induction Air filter housing air filter crankcase breather tube Ignition Flywheel magneto ignition pulse generator ignition coil assembly ignition control module spark plug cap spark plug Positive Crankcase Ventilation PCV System PCV valve oil filler cap Evaporative System Fuel Tank Fuel Cap Fuel Lines Fuel Line Fittings Clamps Pressure Relief Valves Purge Valves Vapor Hoses Carbon Canister Canister Mounting Brackets Carbon Canister Purge Port Connector Misc Parts Belts hosing tubing fittings seals gaskets clamps and switches associated with the above systems Emission related parts will vary between vehicles therefore certain vehicles may not include all of the listed parts or may include equivalent parts 3 VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY
62. ed water is the most common type of water used in batteries Distilled water is created by boiling water collecting the steam from the boiling and allowing the steam to condense back into water The distilling process results in a water source which is free of minerals that can lead to the degradation of battery performance and life Deionized Water Deionized water is created by inducing electrically charged resins that attract and bind to sodium calcium iron copper chloride and bromide ions The result of this electrical filtering is a purified water which contains little to no mineral ions To make sure the deionized water remains at a high quality replace the filter in the deionizer per the manufacturer s recommendations Deionizer Systems The Service Parts Department at Club Car offers two deionizer systems one for vehicles equipped with the Single Point Watering System SPWS CC PN 104006001 and the other for vehicles without SPWS CC PN AM10974 Alternate Methods e Reverse Osmosis Reverse osmosis involves forcing water through a membrane that allows water to pass while trapping solids The choice of membrane used determines the amount of solids or impurities which get trapped and hence the purity quality of the filtered water In addition the usage frequency of the membrane can also contribute to the filtered water quality Due to the variance in water quality consistency Club Car recommends the use of the deionizer or dist
63. ee following CAUTION CARRYALL 500 550 700 Vehicle Owner s Manual Page 49 Battery Charger QuiQ Electric Vehicle CAUTION Do not overfill the batteries 3 The battery hold downs should be tight enough so that the batteries do not move while the vehicle is in motion but not so tight as to crack or buckle the battery case Tighten hold down retaining nuts to 55 in Ib 6 2 N m The terminal connections should be clean and tight and any worn insulation or frayed wires should be replaced Tighten battery terminals to proper torque See Connecting the Batteries Electric Vehicles on page 17 See following WARNING WARNING f battery wire terminals are damaged or corroded replace or clean them as necessary Failure to do so can cause them to overheat during operation and can result in fire property damage or personal injury 4 After use charge the batteries The batteries should never be left discharged any longer than absolutely necessary do not leave discharged overnight 1 Level Indicator 2 Cap 3 Plates Maintain electrolyte level from at least 1 2 inch 13 mm above plates to 1 4 inch 6 mm below level indicator Figure 20 Electric Battery Electrolyte Level BATTERY CHARGER QuiQ ELECTRIC VEHICLE DANGER Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging
64. ehicle avoid sudden starts sudden stops and abrupt turns To help 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 in only specified areas by trained drivers Do not drive while under the influence of alcohol drugs or medications Use brakes to reduce speed when coasting downhill Never attempt jumps This vehicle is not intended to be used where risk of falling objects exists If your vehicle will be used in such an environment contact your local dealer Do not drive the vehicle under tree limbs bridges tunnels or other objects that are less than 80 inches 203 cm from the ground Use caution when operating the vehicle with accessories attached to the bed sides Accessories can add to the width of the vehicle increasing the likelihood of striking nearby persons or objects which can cause damage or personal injury No one should drive the vehicle without first being instructed in the proper operation and use of the vehicle s controls An experienced operator should accompany each first time driver on a test drive before allowing them to operate the vehicle alone CARRYALL 500 550 700 Vehicle Owner s Manual Page 31 Driving Instructions
65. ehicles intended to transport people and cargo on improved or groomed surfaces These vehicles do not conform to U S Federal Motor Vehicle Safety Standards FMVSS for automobiles or to FMVSS 500 for low speed vehicles and are not equipped for operation on public streets roads or highways If in English this manual is the Original Instructions provided by the manufacturer If in any language other than English this manual is a translation of the Original Instructions Club Car i P O Box 204658 Augusta Georgia 30917 4658 USA Telephone 706 863 3000 Service Parts Fax 706 855 7413 www clubcar com Copyright 2013 Club Car LLC Club Car Tranquility and ArmorFlex are registered trademarks of Club Car LLC This manual effective January 2014 CARRYALL 500 550 700 Vehicle Owner s Manual Page 1 FOREWORD Thank you for choosing Club Car the name most widely recognized as the industry leader in vehicle efficiency and long lasting value You have chosen the finest utility vehicle on the market Please protect your investment and ensure that your Club Car vehicle s provides years of reliable superior performance by reading and following the maintenance instructions in this manual Your comfort and safety are important to us 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 avoid the risk of severe personal injury If y
66. el in an approved fuel container only Store in a well ventilated area away from sparks open flames heaters or heat sources Keep fuel out of the reach of children Do not siphon fuel from the vehicle Page 38 CARRYALL 500 550 700 Vehicle Owner s Manual Storage Gasoline Vehicles WARNING Only trained technicians should service or repair the vehicle or battery charger Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation Turn the key switch to the OFF position 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 battery Frozen batteries can explode CAUTION Batteries in a low state of charge will freeze at low temperatures PREPARING THE GASOLINE VEHICLE FOR EXTENDED STORAGE 1 Unload the vehicle so that tires are supporting only the weight of the vehicle 2 Store vehicle in a cool dry place This will minimize battery self discharge If the battery appears to be weak have it charged by a trained technician Use an automotive type 12 volt battery charger rated at 10 amps or less 3 Seal the fuel tank 3 1 Fill fuel tank and
67. enter and secure cargo as far forward as possible in the cargo bed Do not overload the vehicle See the following chart for vehicle capacities VEHICLE LOAD CAPACITIES Occupant Capacity The occupant capacity is the maximum allowable weight for occupants operator and passengers to operate the vehicle safely Cargo Capacity The cargo capacity is the maximum amount of load that the vehicle can haul in the cargo areas and cargo bed and includes the weight of optional equipment Trailer Tongue Weight Trailer tongue weight is the maximum allowable amount of weight exerted by the trailer tongue onto the trailer hitch Gross Trailer Weight Gross trailer weight is the combination of the trailer weight and the trailer load weight Vehicle Rated Capacity The vehicle rated capacity is the maximum amount of weight on the vehicle This capacity includes the weight of occupants cargo bed load and optional equipment Vehicle Combination Rated Capacity The vehicle combination rated capacity includes the vehicle rated capacity and gross trailer weight Maximum Gross Vehicle Weight The maximum gross vehicle weight includes the vehicle weight and the vehicle rated capacity The stated maximum gross vehicle weight must not be exceeded to maintain safe vehicle operation Maximum Gross Vehicle Combination Weight The maximum gross vehicle combination weight includes the maximum gross vehicle weight and the gross trailer weight The stated maximum
68. es on IQ Plus models CAUTION Turn off all accessories before charging batteries NOTE Recycle or dispose of discarded batteries in accordance with local state and federal regulations Club Car electric vehicles use deep cycle batteries Automotive batteries should never be used in electric vehicles New batteries will not deliver their full capabilities until they have been discharged and recharged 50 to 70 times To obtain maximum service life from new batteries restrict the use of vehicles with new batteries to one hour of operation between charges for the first two months vehicle is in service Batteries should be fully charged before first use of new vehicle before first use of a vehicle after storage and before releasing vehicle for use each day WATER QUALITY Water purity is the most important factor in the performance and life span of the vehicle batteries Club Car has therefore placed an increased importance on battery maintenance Outlined below are four battery watering procedures grouped into two categories Preferred and Alternate methods Club Car recommends the use of a deionizer or distilled water Alternate methods of reverse osmosis or tap water are allowable but should be avoided since water quality can change from day to day depending on additives water main leaks etc Page 46 CARRYALL 500 550 700 Vehicle Owner s Manual Batteries Electric Vehicles Preferred Methods e Distilled Water Distill
69. evel of performance When this occurs use the brake pedal to control vehicle speed 77 Figure 10 Accelerator and Brake Pedals BRAKE PEDAL The brake pedal is the large pedal on the left with the word STOP molded into it Figure 10 To slow or stop the vehicle press the brake pedal with your right foot Figure 11 PARK BRAKE PEDAL The park brake pedal is the small raised portion in the upper left corner of the brake pedal It has the word PARK molded into it and the words PARK BRAKE marked on top of it Figure 10 To set the park brake press the brake pedal firmly and tilt the park brake portion of the pedal forward with your foot Figure 12 See following WARNING CARRYALL 500 550 700 Vehicle Owner s Manual Page 25 Controls and Indicators 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 78 79 Figure 11 Brake Pedal Figure 12 Park Brake TOW RUN SWITCH Electric Vehicles Only WARNING Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning can result in a battery explosion or severe personal injury When the Tow Run switch is in the TOW position all motor braking functions including walk away braking are disabled Electric vehicles are equipped with a Tow Run
70. f necessary See Periodic Lubrication Schedules on page 44 Dispose of used oil properly Check engine cooling air intake visually inspect unshrouded area around engine exhaust for grass Monthly service by owner or trained and debris and clean if necessary technician Check air pressure and adjust if necessary See Vehicle Specifications Gasoline Vehicles on page 68 f Wash engine compartment and underside of vehicle General vehicle Do not wash engine when hot Clean terminals and wash dirt from casing check Battery y electrolyte level Figure 26 Check and adjust if necessary Front wheel alignment and camber See Steering and Front Suspension section in the maintenance and service manual Semiannual service by trained technician Electrical wiring and connections Check for tightness and damage only or every 50 hours of operation whichever comes first Check brake shoes replace if necessary or adjust as required Brakersystem Check brake cables for damage replace as required Check brake cable equalizer adjustment adjust if necessary Annual service by trained technician Check for leaks around gaskets fill plugs etc only or every 100 hours of operation Engine Inspect clean and gap spark plug replace if whichever comes first necessary Page 42 CARRYALL 500 550 700 Vehicle Owner s Manual Periodic Service Schedules PERIODIC SERVICE SCHEDULE GASOLINE VEHICLES REGULAR INTER
71. fety 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 us 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 decals that are affixed to your vehicle Take time to understand the language of safety It is a language that can save your life PROPOSITION 65 STATE OF CALIFORNIA A WARNING This product contains or emits chemicals or substances that have been determined by the state of California to cause cancer and birth defects or other reproductive harm Page 14 CARRYALL 500 550 700 Vehicle Owner s Manual Safety Details 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 can 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 the vehicle 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 safety decals on th
72. g wire See Disconnecting the Battery Gasoline Vehicles on page 17 Frame ground Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wiring Do not allow a positive wire to touch the vehicle frame engine or any other metal component All vehicles Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle or battery charger Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Page 16 CARRYALL 500 550 700 Vehicle Owner s Manual General Warnings DISABLING THE VEHICLE Po JM Engage park brake to lock wheels Turn the key switch OFF and remove the key Place the Forward Reverse control in the NEUTRAL position In addition chock the wheels if servicing or repairing the vehicle DISCONNECTING THE BATTERIES ELECTRIC VEHICLES Disable the vehicle See Disabling the Vehicle on page 17 Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning can result in a battery explosion or severe personal injury Disconnect the batteries negative cable first as shown Figure 2 After disconnecting t
73. ger Do not operate this charger if the AC supply cord is damaged or if the charger has received a sharp blow been dropped or otherwise damaged in any way Refer all repair work to the manufacturer or qualified personnel WARNING Only trained technicians should repair or service the charger Contact your nearest Club Car distributor dealer This charger is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the charger by a person responsible for their safety Children should be supervised to ensure that they do not play with the charger Do not attempt to charge frozen batteries or batteries with bulged cases Discard the battery in accordance with all environmental laws or return to an authorized Club Car dealer Frozen batteries can explode Each charger should have its own dedicated 15 or 20 ampere separately protected circuit breaker or fuse single phase branch circuit in accordance with all applicable electrical codes for the location 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 three prong plug into a two prong outlet Improper connection of the equipment grounding conductor can result in a fire or an elec
74. ght switch 3 is located on the right side of the instrument panel Figure 7 or Figure 8 Press the side of the switch with the headlight symbol to turn the headlights on and press the other side to turn the headlights off NOTE Gasoline vehicles Using the headlights for extended periods of time without the engine running or with the engine idling will discharge the battery CHARGE INDICATOR LIGHT Electric Vehicles Only The electric vehicle features a charge indicator light 4 located at the top of the instrument panel Figure 7 The light serves two functions 1 Battery low state of charge warning and 2 Charging confirmation Battery Low State of Charge Warning The light comes on and remains solid when the battery state of charge falls below 20 The light begins flashing when the battery state of charge falls below 10 CAUTION When the light indicates a low state of charge the vehicle should be placed on charge as soon as possible Charging Confirmation The light will flash three times and the reverse buzzer simultaneously will sound three times to indicate a battery charging session has begun Page 22 CARRYALL 500 550 700 Vehicle Owner s Manual Controls and Indicators LOW OIL WARNING LIGHT Gasoline Vehicles Only The gasoline vehicle is equipped with a low oil warning light 4 located at the top of the instrument panel Figure 8 If the warning light comes on oil should be checked and added to the e
75. go bed Remove the vehicle windshield and secure the seat bottom before transporting on a trailer When trailering the vehicle make sure the removable front body is correctly installed to prevent separation from the vehicle during transport If the vehicle or vehicles must be transported over long distances or on public highways they should be transported on an approved trailer that has an approved load rating in excess of the weight of the vehicles being transported Page 36 CARRYALL 500 550 700 Vehicle Owner s Manual Storage Electric Vehicles STORAGE ELECTRIC VEHICLES See General Warnings on page 15 WARNING Turn the key switch to the OFF position remove the key and leave the Forward Reverse handle or Switch in the NEUTRAL position during storage This is to prevent unintentionally starting the vehicle or a fire hazard Place Tow Run switch in the TOW position Only trained technicians should service or repair the vehicle or battery charger Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation Do not attempt to charge frozen batteries or batteries with bulged cases Discard the battery Frozen batteries can explode CAUTION Batteries in a low state of charge will freeze at low temperatures To avoid exposing electrical compone
76. harges until the batteries have been properly seasoned 50 to 70 charge cycles For maximum battery life Club Car recommends that electric vehicles always be recharged after 40 to 50 amp hours of discharge or each night in order to avoid deep discharging the batteries When temperatures fall below 65 F 18 3 C batteries charged in unheated areas should be placed on charge as soon as possible after use Batteries are warmest immediately after use while cold batteries require more time to fully charge 1 Insert the onboard charger AC plug into a dedicated and properly wired AC receptacle to begin a charge cycle See QuiQ Battery Charger Specifications on page 66 NOTE Only connect ONE charger to a single 15 amp circuit or the circuit may become overloaded 2 Place the charger AC cord so it will not be stepped on tripped over or otherwise subject to damage or stress 3 Do not place items in the compartment where the battery charger is installed After the charger is plugged in the vehicle s control circuit is locked out preventing operation of the vehicle as well as the possibility of subsequent damage to the charger and vehicle The charger monitors battery voltage charge current and charge time to determine when the batteries are properly charged The charger will shut off by itself and the green light will stop flashing and remain on The vehicle s control circuit lockout remains activated until the charger AC plug is disco
77. he batteries wait 90 seconds for the controller capacitors to discharge CONNECTING THE BATTERIES ELECTRIC VEHICLES Ensure the Tow Run switch is the TOW position Connect the battery cables positive cable first Tighten battery terminals to 110 in Ib 12 4 Coat terminals with Battery Terminal Protector Spray to minimize corrosion DISCONNECTING THE BATTERY GASOLINE VEHICLES 1 2 3 Disable the vehicle See Disabling the Vehicle on page 17 Disconnect the battery cables negative cable first as shown Figure 3 Disconnect the spark plug wire from the spark plug CONNECTING THE BATTERY GASOLINE VEHICLES moo mo Connect the battery cables positive cable first Tighten battery terminals to 80 in Ib 9 N m Coat terminals with Battery Terminal Protector Spray CC PN 1014305 to minimize corrosion Connect the spark plug wire to the spark plug CARRYALL 500 550 700 Vehicle Owner s Manual Page 17 General Warnings Viewed from driver side of vehicle Viewed from passenger side of vehicle 1 Place TOW RUN Switch in TOW before disconnecting or connecting 1 Remove negative battery cable battery cables 2 Remove positive battery cable 2 Remove negative battery cable Connect battery cables in reverse order 3 Remove positive battery cable Connect battery cables in reverse order 27 1 80 Figure 2 Battery Cable Removal Electric Vehicle Figure 3 Battery C
78. he forward direction or press the REVERSE side of the switch to operate the vehicle in reverse When the rocker switch is positioned in NEUTRAL with neither side down the vehicle will not operate if the accelerator pedal is pressed Club Car vehicles operate at reduced speed in reverse The reverse buzzer will sound as a warning when the Forward Reverse switch is in the REVERSE position Gasoline Vehicles The Forward Reverse handle 2 is located at the bottom center of the instrument panel Figure 8 The handle has three distinct positions F FORWARD N NEUTRAL and R REVERSE Push the handle up to operate the vehicle in the forward direction or pull the handle down to operate the vehicle in reverse Pedal start vehicles The engine will not run when the handle is in the NEUTRAL position Key start vehicles The engine will idle while in the NEUTRAL position The engine must be at idle before shifting the Forward Reverse handle See preceding WARNING and CAUTION Club Car vehicles operate at reduced speed in reverse The reverse buzzer will sound as a warning when the Forward Reverse handle is in the REVERSE position CARRYALL 500 550 700 Vehicle Owner s Manual Page 21 Controls and Indicators 2820 2821 Figure7 Instrument Panel Electric Vehicles Figure8 Instrument Panel Gasoline Vehicles HEADLIGHT CONTROL Vehicles with Headlights The headli
79. he influence of alcohol or drugs Drive slowly in turns and straight up and down slopes BLA 10402650 Riding in cargo bed can cause severe injury ordeath Do not ride in cargo bed CI 10155390 53801 CRUSH AREA STAY CLEAR CCI 101609401 Vehicle rated capacity 1500 Ib 680 kg on level surface only VEHICLE rs ong d Includes occupants and cargo load LOADING Maximum cargo load 1000 Ib 454 kg Includes cargo bed load and optional equipment Mee ead Vehicle combination rated capacity 1500 Ib 680 kg 101825101 Decal On Off Key Switch above key switch 104026801 Decal Occupant Warning Includes vehicle fated capacity andigrose traller weight Avoid top heavy loads mu IIH 10 0 000 Decal Bed Loading Warning on cargo bed or seat 1 101553901 back ROLLOVER CAN CAUSE SERIOUS INJURY OR DEATH Place cargo forward in the cargo bed and distribute evenly side to side Secure load On uneven or steep terrain reduce speed and load Avoid stopping on or backing down steep hills 105151501 Decal 12V Accessory Fuse Block under front 105130101 body y 105163601 Decal 12V under front body 105163701 Decal Ground under front body Decal Crush Area Warning behind seat near 2 101609401 7 105151501 Decal Vehicle Load cargo bed 105046101 Decal Operating Instructions CARRYALL 500 550 700 Vehicle Owner s Manual Page 7 Safety Decal Identification ELECTRIC C
80. hicle does not slow down at the normal rate continue to press the brake pedal until the brakes dry out and normal performance returns After stopping the vehicle firmly set the park brake until it is fully engaged and prevents the vehicle from rolling CAUTION When stopped on a hill use the brake pedal to hold your position Do not use the accelerator pedal to hold position To stop vehicle release the accelerator pedal and press the brake pedal until vehicle comes to a complete stop PARKING AND LEAVING THE VEHICLE 1 After coming to a complete stop engage the park brake until it locks the wheels and prevents the vehicle from rolling 2 Turn the key switch to the OFF position and place the Forward Reverse handle or switch in the NEUTRAL position Remove the key when the vehicle is not in use Electric vehicles only When the Tow Run switch is in the RUN position with the Forward Reverse switch or key switch in any position the walk away braking function will prevent the vehicle from rolling at more than 1 to 3 mph 1 6 to 4 8 km h unless the accelerator is pressed This prevents the possibility of a parked vehicle with the park brake disengaged rolling away too fast to be overtaken on foot LOADING AND UNLOADING WARNING Engage park brake to lock wheels 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 surfa
81. icles are equipped with IQ Plus electrical systems and onboard Delta Q QuiQ battery chargers Gasoline Carryall 500 550 and 700 vehicles are equipped with Subaru engines and accompanying powertrains and are available with a pedal start standard or key start optional configuration Throughout this manual important features unique to each model are highlighted We urge the owner operator to read and understand this manual and to pay special attention to the features specific to their vehicle s CARRYALL 500 550 700 Vehicle Owner s Manual Page 19 Model Identification CARRYALL 550 WHEELS Carryall 550 front and rear wheels are NOT interchangeable The front wheels have no offset whereas the rear wheels do have an offset A rectangular sticker on the inside of each wheel designates its correct position on the vehicle as either FRONT front or REAR rear WARNING Installing the wrong wheel can reduce vehicle stability and cause serious injury or death MODEL IDENTIFICATION The serial number of each vehicle is printed on a bar code decal mounted below the center dash panel Example CC5819 123456 Figure 6 The two letters 1 at the beginning of the serial number indicate the vehicle model The following four digits 2 indicate the model year and production week during which the vehicle was built The six digits 3 following the hyphen represent the unique sequential number assigned to each vehicle built within a given
82. illed water Tap Water While the use of tap water without filtering is an alternate method of battery watering its use should be limited due to the levels of dissolved minerals and chemicals that can degrade battery performance and life If unfiltered tap water is used regular water analyses must be conducted to check for impurities The following chart lists the maximum allowable minerals solids and contaminates in parts per million and their impact on battery performance Water testing however is expensive and water quality can change from day to day depending on additives water main leaks etc Due to the cost and labor of performing water quality tests Club Car recommends the use of distilled water or a deionizer CARRYALL 500 550 700 Vehicle Owner s Manual Page 47 Batteries Electric Vehicles ALLOWABLE CONTENT PARTS IMPURITY PER MILLION EFFECTS OF IMPURITY Organic and volatile matter Corrosion of positive plates Self discharge reduces life lower Antimony 5 0 on charge voltage Loss of capacity in plates greater Chloride 5 n loss in positive plates Increased self discharge lower Copper 5 on charge voltage Increased self discharge lower Iron 3 on charge voltage None allowed Intense lowering of on charge voltage 25 Plate corrosion loss of capacity Nitrites 5 reduced life Violent self discharge lower Platinum None allowed on charge voltage BATTERY CARE VEHICLES EQUIPPED WITH THE SINGLE POIN
83. io is rare but should be monitored in the initial inspection and during routine watering sessions Replace malfunctioning valves to ensure maximum battery life See following CAUTION CAUTION After checking the electrolyte fully tighten the battery caps to prevent electrolyte leakage 2 After the initial six week inspection manually check the electrolyte level at least once per year particularly after long term storage or any other period of vehicle inactivity See preceding CAUTION BATTERY CARE VEHICLES WITHOUT THE SINGLE POINT WATERING SYSTEM SPWS To keep batteries in good working condition follow this maintenance program on a regular basis 1 Keep the batteries clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water use 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse solution off of the batteries Do not allow this solution to enter the battery Be sure terminals are tight Let the terminals dry and then coat with Battery Terminal Protector Spray See following NOTE NOTE Dispose of waste water properly 2 Checkthe electrolyte level weekly Figure 20 Add water only after charging unless the electrolyte level is below the top of the plates In this case add just enough water to cover the plates charge and then check the level again Never charge batteries if plates are exposed above electrolyte level For best battery life add only distilled water S
84. iori icy EH a eb e b te RR I kei a aca gn eese e eta e ehe ed i ta e a o edt 4 Practice Safety eee eite kt p t ae eee ee 14 Proposition 65 State 14 Safety Details m n 15 EI TIMIDI S 15 General IMO ANON 2 2 19 rere M e mupiifeLrTor eem 20 Controls and Indicators sss o da oe ee e et e t vada Oba a 20 Pre Operation and Daily Safety 29 Driving Instructioris diei ee E Hee Peor uoo eds 31 Loading and Unloading vss ih fe pen RI e BI Edd 33 Vehicle Load Gapacitl6s 9 cenis oho e e rhe Ue do lote 34 owing with the Vehicle tos coi teste oat er Peer er oix repo tex ueste 36 Transporting on a Trailer eene cere eee te eee eves donne ede ddan deeds Sone conn e ead Ed up e eau Hd e e dave e ede eee d 36 Storage Electric Vehlcles deoe or o bete HER 37 Storage Gasoline Vehicles etr epar dx ta aee AR Ra Ee RENTRER ARRA ERUATEN MER 38 eda a e a E c iui dE imet eese d a Mr 40 Periodic Service eese deesse d
85. l Single Point Watering System SPWS 68 69 Figure 22 Connecting Hose with Filter to Water Source Figure 23 Checking the Water Flow Rate 4 Completely open the water faucet until the water flows out of the hose end assembly 3 and note the movement of the red flow indicator balls 6 See following NOTE NOTE This step also eliminates any trapped air from the water hose The water flow rate must be at least 2 gallons per minute 7 6 L per minute and the water pressure must be no more than 100 psig 689 5 kPa when static no flow for the SPWS to function properly 5 Check the water quality light on the deionizer to make sure the light is green in color indicating acceptable water quality If the light indicates unacceptable water quality the cartridge must be replaced 6 After ensuring adequate water flow rate and water quality press the grey button 7 on the end of the female coupler 8 to disconnect the purger from the pressure regulator Refilling the Batteries 1 Locate the battery fill coupling 9 on the driver side of the battery compartment remove the dust cover 10 from the male connector Figure 24 and connect the hose end assembly 3 Figure 25 The water flow will begin immediately CARRYALL 500 550 700 Vehicle Owner s Manual Page 57 Battery Gasoline Vehicle AI CA 2829 2830 Figure 24 Dust Cap Figure 25 Connecting Hose end Asse
86. l persons can properly operate the vehicle prior to allowing them to drive the vehicle e Be sure all passengers are capable of securing themselves in a vehicle before allowing them to ride in one For night use the vehicle must be equipped with headlights taillights and reflectors Stop the vehicle before shifting the Forward Reverse handle or switch Failure to do so can result in injury to inattentive passengers and or damage to the vehicle Do not leave children unattended in vehicle at any time To help avoid being struck do not stand in front of or behind the vehicle Operate the vehicle from the driver seat only To help prevent falls from the vehicle remain seated in a moving vehicle and hold on to hand holds or handrails at all times Driver should keep both hands on the steering wheel when the vehicle is in motion To 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 rolling backwards and stopping suddenly Failure to heed this warning can result in overturning the vehicle To help avoid possible injury to inattentive passengers and or damage to the v
87. l system to operation 1 1 Remove plug from the fuel tank vent Figure 31 Page 63 1 2 Connect vent tube to fuel tank vent 2 Connect battery and spark plug wire See Connecting the Battery Gasoline Vehicles on page 17 CARRYALL 500 550 700 Vehicle Owner s Manual Page 39 Maintenance 3 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position Crank the engine until the engine starts Turn the engine off and return the neutral lockout switch to the OPERATE position See following NOTE NOTE Due to the oil added to the engine in preparation for storage engine may smoke excessively for a short time when it is run for the first time after storage 4 Adjust tires to recommended tire pressure See Vehicle Specifications Gasoline Vehicles on page 68 5 Perform the Pre Operation and Daily Safety Checklist on page 29 and the Performance Inspection on page 30 MAINTENANCE See General Warnings on page 15 To ensure trouble free vehicle performance it is very important to follow an established preventive maintenance program Regular and consistent vehicle maintenance can prevent vehicle downtime and expensive repairs that can result from neglect Use the Pre Operation and Daily Safety Checklist on page 29 and the following Periodic Service Schedules and Periodic Lubrication Schedules to keep the vehicle in proper working condition Any vehicle not functioning correctly should b
88. lerator With the key switch in the ON position and the Forward Reverse switch in the FORWARD position as the accelerator pedal is pressed the motor should start and the vehicle should accelerate smoothly to full speed Club Car vehicles operate at reduced speed in reverse When the pedal is released it should return to the original position and the motor should rotate freely or go into motor braking mode See Pedal Up Motor Braking below Walk Away Braking With the vehicle parked on level ground and the park brake disengaged place the Tow Run Switch in the RUN position and attempt to push the vehicle Motor braking should engage and limit rolling to no more than 1 to 3 mph 1 6 to 4 8 km h with the Forward Reverse switch in any position When walk away motor braking is engaged the reverse buzzer should emit a distinct pattern of beeps Pedal Up Motor Braking Accelerate the vehicle to full speed and then release the accelerator pedal Motor braking should quickly and smoothly slow the vehicle Motor braking will disengage when vehicle slows to the programmed speed for IQ Plus vehicles This feature is programmable for IQ Plus vehicles Contact your local Club Car dealer distributor to inquire about this adjustable feature Pedal Down Motor Braking Accelerate down an incline with the accelerator pedal pressed When the vehicle reaches maximum programmed speed motor braking should engage and limit the vehicle to its maximum programmed speed On ver
89. line Vehicles on page 17 See following WARNING WARNING f battery wire terminals are damaged or corroded replace or clean them as necessary Failure to do so can cause them to overheat during operation and can result in a fire property damage or personal injury Be sure battery clamp is properly tightened Tighten to 144 in Ib 16 N m A loose clamp may allow the battery to become damaged from vibration or jarring If battery appears weak have it charged by a trained technician The battery should never be left discharged any longer than absolutely necessary do not leave discharged overnight CARRYALL 500 550 700 Vehicle Owner s Manual Page 59 Engine Oil Gasoline Vehicle ENGINE OIL GASOLINE VEHICLE Even though the low oil warning light on the dash should illuminate if oil level becomes low engine oil level should be checked monthly Vehicle should be on a level surface when checking oil Do not overfill with oil ENGINE OIL LEVEL CHECK 1 Remove the oil level dipstick from the oil filler tube and wipe oil off dipstick Figure 28 See following CAUTION CAUTION Do not remove dipstick while engine is running Check oil by fully inserting the dipstick into the oil filler tube and immediately removing it 3 Ifthe oil level is at or below the low level mark on the dipstick gauge add oil until the level is between low and full levels safe level 4 Insert the dipstick into the oil filler tube See
90. lutely necessary do not leave discharged overnight 4 Water the batteries monthly or according to the watering interval See Establishing the Watering Interval for New Vehicles on page 49 See Watering Batteries with the SPWS on page 56 CAUTION The watering interval must adequately maintain the electrolyte level above the top of the plates Figure 20 Page 50 Water the batteries only AFTER charging NOTE Bottled distilled water with the hand pump CC PN 104006101 is recommended for private consumer SPWS applications Establishing the Watering Interval for New Vehicles If you do not already have a battery watering interval for your vehicles manually check the battery water level weekly to establish the correct watering interval Thereafter water batteries according to the established interval During periods of heavy use add additional watering as required Single Point Watering System SPWS Maintenance 1 For vehicles newly equipped with the Single Point Watering System the initial electrolyte level check on all battery cells verifies that all the valves in the SPWS are functioning correctly See Periodic Service Schedules on page 41 If a valve fails to open the cell will eventually dry out The initial one time inspection of all cells will identify any occurrence of a valve that fails to open If a valve fails to close it will become evident due to the cell overflowing during routine watering Either failure scenar
91. ly 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 clubcar com and clicking the Dealer Locator link CARRYALL 500 550 700 Vehicle Owner s Manual Page 63 Subsequent Owner Registration 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 WARNING Custom cab assemblies weatherproof enclosures door kits and tinted windshields will not protect occupants from flying objects Ifthe vehicle has a portable refreshment center option installed in the bed it must be removed before unlatching and lifting the bed f the vehicle is equipped with an electric powered lift bed remove the bed before servicing the bed lift system Cargo load includes the weight of optional equipment See Vehicle Load Capacities on page 34 CAUTION Combined use of electric powered accessories for an extended period of time could discharge the battery even with the engine running Be aware of charging system capacity rating and keep combined accessory use at or below that rating See Vehicle Specifications on page 64 Failure to heed this caution could result in the vehicle shutting off possibly leaving operator and passengers stranded SUBSEQUENT OW
92. mbly to Battery Fill Connector 2 The red flow indicator balls should swirl indicating that the batteries are being filled See following CAUTION CAUTION If at any time water overflows from the batteries immediately stop the refill process disconnect the pressure regulator from the battery fill coupling and call for service 3 When the red flow indicator balls stop moving immediately press the grey button to disconnect the hose end assembly from the battery fill coupling 9 and squeeze the dust cover 10 to lightly secure it to the male connector of the battery fill coupling Figure 24 4 Place the battery fill coupling into the space between the batteries and the car body Leaving the fill coupling on top of the battery bank or tucked between the batteries can result in coupling damage 5 Turn the water faucet off when finished filling the vehicle s BATTERY GASOLINE VEHICLE See General Warnings on page 15 DANGER Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries Tools wires and 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 DANGER CONTINUED ON NEXT PAGE Page 58 CARRYALL 500 550
93. n cause severe injury ordeath Do not ride in cargo bed CCI 101553901 101609401 Vehicle rated capacity 1200 Ib 544 kg on level surface only VEHICLE Se daca Includes occupants and cargo load ROLLOVER CAN CAUSE SERIOUS INJURY OR DEATH LOADING Maximum cargo load 800 Ib 363 kg Place cargo forward in the cargo bed and distribute Read v Includes cargo bad load and optional equipment ven on bd ecd Rance speed and load ead owner s manual Vehicle combination rated capacity 1200 Ib 544 kg Brae and warnings on dash Includes vehicle rated capacity and gross trailer weight Avold stopping ra Sal backing down staap hills y onm ADLIUC 105137102 VEHICLE Vehicle rated capacity 1200 Ib 544 kg on level surface only neludes occupants cargo load ROLLOVER CAN CAUSE SERIOUS INJURY OR DEATH LOAD Maximum cargo load 800 Ib 363 kg Place cargo forward in the cargo bed and distribute Includes cargo bed load and optional equipment evenly side to side Secure load Read owner s manual Vehicle combination rated capacity 1500 Ib 680 kg at backing dow i Bi Includes vehicle rated capacity and gross taller weight void top heavy loads gi U1 Decal Bed Loading Warning on cargo bed or seat 101553901 back 5 104026801 Decal Occupant Warning Decal Crush Area Warning behind seat near 105137106 101609401 105046101 Decal
94. n key switch are referred to as key start Electric and pedal start vehicles The key switch has two positions OFF and ON Key start vehicles The key switch has three positions OFF ON and START To start the vehicle turn the key past the ON position to the START position and hold until the engine is running smoothly Release the key and it will return to the ON position and the engine should idle WARNING Moving parts Keep clear of the engine compartment while the engine is running CAUTION Key start vehicles Do not rev the engine for long periods of time while the Forward Reverse handle is in the NEUTRAL position Failure to heed this caution can result in damage to the unitized transaxle Key start vehicles Do not shift the Forward Reverse handle while the accelerator pedal is pressed Shift the handle only when the vehicle is at a complete stop Failure to heed this caution can result in damage to the unitized transaxle NOTE When the key is turned to the OFF position the main vehicle systems are disabled The key switch may be used as an emergency shut off The key can be removed only when the key switch is in the OFF position FORWARD REVERSE CONTROL Electric Vehicles The Forward Reverse rocker switch 2 is located at the bottom center of the instrument panel Figure 7 The F FORWARD and R REVERSE positions are clearly marked Press the FORWARD side of the switch to operate the vehicle in t
95. n them 94 Figure 21 80 LED Flashes in Algorithm Display Mode CARRYALL 500 550 700 Vehicle Owner s Manual Page 53 Battery Charger QuiQ Electric Vehicle CHARGER OPERATING INSTRUCTIONS See General Warnings on page 15 Charger Display LED Color Indication following the power on self test Ammeter f Displays approximate scale of current output during Bulk phase Amber Flashing High internal charger temperature Output reduced Also displays algorithm 1 6 for 11 seconds if no battery is connected Flashing With no battery connected indicates algorithm selected by number of flashes 100 Charge Solid charging complete Charger Maintenance Mode Flashing Absorption phase complete In Finish phase Amber Flashing Low AC Voltage Check voltage and power cord length see above for guidelines Fault Red Flashing Charger error Reset charger power and refer to Troubleshooting Instructions below Charger can be hot during charging Use hand protection if handling the charger while charging Ox Green ill o 11 80 Charge EN Solid Bulk charge phase complete 8096 charged In Absorption Amber phase e AC Power Connection CAUTION NOTE Make sure that the AC cord provided with your charger has the proper AC plug for your location If it does not contact your Club Car representative to obtain the proper cord or plug Only use ONE charger on a single 1
96. nd factory specifications can result in serious personal injury or death FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE This emission warranty is applicable in all States except the State of California Club Car LLC CLUB CAR warrant s to the initial retail purchaser and each subsequent owner that this Non road engine engine has been designed built and equipped to conform at the time of initial sale to all applicable regulations of the U S Environmental Protection Agency EPA and that the engine is free of defects in materials and workmanship which would cause this engine to fail to conform with EPA regulations during its warranty period For the components listed under PARTS COVERED the service dealer authorized by CLUB CAR will at no cost to you make the necessary diagnosis repair or replacement necessary to ensure that the engine complies with applicable U S EPA regulations EMISSION COMPONENT DEFECT WARRANTY PERIOD The warranty period for this engine begins on the date of sale to the initial purchaser and continues for a period of three years PARTS COVERED Listed below are the parts covered by the Emission Components Defect Warranty Some of the parts listed below may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part EXHAUST EMISSIONS 1 Fuel Metering System 1 1 Carburetor and internal parts and or pressur
97. ngine as necessary before continuing to use the vehicle See following CAUTION The vehicle should never be driven when the low oil warning light remains on If the warning light goes on and off the vehicle may be driven but oil should be added at the first opportunity The light will flash repeatedly to indicate a possible problem with the electronic fuel injection EFI system If the oil level is correct and the warning light stays on have a trained technician check the vehicle CAUTION Failure to add oil immediately when the low oil warning light stays on can result in permanent engine damage FUEL GAUGE HOUR METER OPTIONAL Gasoline Vehicles Only If so equipped the fuel gauge hourmeter 5 is located on the instrument panel Figure 8 The fuel gauge allows the operator to monitor 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 Schedules on page 41 ELECTRIC BED LIFT NOTE An electric bed lift is standard on the Carryall 700 It is optional on the other models For vehicles equipped with an electric bed lift the electric bed lift switch 6 is located on the upper left side of the instrument panel Figure 7 or Figure 8 To lift the bed press the side of the switch with the up arrow and press the other side of the switch to lower the bed The bed lift will make a loud clicking sound
98. ngine owner you should however be aware that CLUB CAR may deny you warranty coverage if vehicle engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting vehicle engine to a CLUB CAR distribution center as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact WARRANTY SERVICES CLUB CAR LLC P O Box 204658 Augusta Georgia 30917 4658 U S A 1 706 863 3000 CLUB CAR EXPLANATION OF EMISSION CONTROL WARRANT Y 1 WARRANTY CLUB CAR warrants to the ultimate purchaser and each subsequent purchaser that the SORE and related emissions equipment is designed built and equipped so as to conform with all applicable California environmental emission regulations and free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in CLUB CAR s application for certification with CARB The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser or first placed into service The warranty period is two years from the date of purchase 2 COVERAGE Subject to certain conditions and exclusions as stated below the warranty on emission related parts is as follows 1 Any warranted part tha
99. nnected from the AC receptacle CHARGER MAINTENANCE See General Warnings on page 15 To ensure trouble free performance it is very important to follow an established preventive maintenance program Regular and consistent maintenance can prevent vehicle downtime and expensive repairs that can result from neglect Any charger not functioning correctly should be removed from use until it is properly repaired This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions Contact your local Club Car distributor dealer to perform all repairs and semiannual and annual periodic service WARNING If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs can result in fire property damage severe personal injury or death Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the charger Do not expose charger to oil dirt mud or direct heavy water spray when cleaning vehicle Keep all AC connections clean and dry If the detachable input power supply cord set is damaged replace with a cord that meets the following criteria For North UL or CSA listed approved detachable cord 3 conductor 16AWG minimum and rated SJT terminating in a America grounding type IEC 60320 C14 plug rated 250V 13A minimum For all other Safety approved detachable cord
100. nnections as outlined in the owner s manual Damages caused by improper installation of the component 5 Neglect breakage freezing fire explosion wreckage melted terminal posts the addition of any chemical or the operation of the battery in an uncharged condition below half charge 1 200 specific gravity the installation of the batteries in reverse or recharging in reverse breakage of containers covers or terminal post or batteries used in applications for which they were not designed 6 Abattery damaged by a defective charger or batteries in vehicles that do not receive proper charging 7 A vehicle not having an operational charger on a circuit that has the parameters specified in the vehicle owner s manual Number of operational chargers must equal the number of operational vehicles 8 Improper charging of a vehicle due to the use of a battery charger model not approved by Club Car for use with the vehicle 9 Failed semiconductor parts such diodes and fuses that are vulnerable to electrical overloads including lightning beyond the control of CLUB CAR 10 Damaged charger DC cord set with plug which is a wear item and subject to user abuse 11 Use of gasoline containing more than 1096 ethanol Without limiting the generality of the foregoing in any way and as part of its limited warranty exclusion CLUB CAR does not warrant that its vehicle or components such as batteries computer controller or electrical device ar
101. nted charger information light are disabled when the Tow Run switch is in the TOW position 5 Batteries should be clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water use 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse solution off batteries Do not allow this solution to enter the batteries Let the terminals dry and then coat them with Battery Terminal Protector Spray 6 Tighten all battery cable connections to 110 in lb 12 4 N m 7 Store vehicle in a cool dry place This will minimize battery self discharge CARRYALL 500 550 700 Vehicle Owner s Manual Page 37 Storage Gasoline Vehicles 8 Adjust tires to recommended tire pressure See Vehicle Specifications Electric Vehicles on page 64 9 Perform semiannual periodic lubrication See Periodic Lubrication Schedules on page 44 10 Thoroughly clean front body rear body seats battery compartment and underside of vehicle 11 Do not engage the park brake Chock the wheels to prevent the vehicle from rolling NOTE It is recommended that the vehicles be plugged in and the electrolyte level maintained throughout the storage period If any of the following conditions exist however then disconnect the batteries for storage 1 The charger cannot remain plugged in 2 AC power will not be available during extended storage or 3 Electrolyte levels will not be maintained To disconnect batteries for storage go to
102. nts to moisture and subsequent damage do not use any type or pressure washing or steam cleaning equipment to wash the vehicle PREPARING THE ELECTRIC VEHICLE FOR EXTENDED STORAGE Check Battery Water Levels Two Weeks Prior to Storage Check water levels at least two weeks prior to winter storage to ensure proper mixing of water and electrolyte Note that it takes approximately five charge cycles with a minimum of 10 amp hours removed after each charge to properly mix the water with electrolyte Do NOT water batteries immediately prior to storage because this will not provide sufficient charge time to mix the water with the electrolyte Freezing can occur when batteries are stored in this condition 1 Check the water levels in each battery cell If water is required fill the cells to cover the plates charge the batteries and then use distilled water to fill each cell to the correct level Electrolyte level should be from 1 2 inch 13 mm above plates to 1 4 inch 6 mm below the level indicator Figure 20 Immediately Prior to Storage Perform the Following Steps 1 Unload the vehicle so that tires are supporting only the weight of the vehicle 2 Turn the key switch to the OFF position remove the key and leave the Forward Reverse switch in the NEUTRAL position during storage 3 If so installed turn off all accessories including GPS units fans etc 4 Place the Tow Run switch in the TOW position NOTE All functions of the dash mou
103. on monoxide which is an odorless deadly poison The vehicle will not provide protection from lightning flying objects or other storm related hazards If caught in a storm while driving a Club Car vehicle exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location CARRYALL 500 550 700 Vehicle Owner s Manual Page 15 General Warnings WARNING Follow the procedures exactly as stated in this manual and heed all DANGER WARNING and CAUTION statements in this manual as well as those on the vehicle and battery charger Do not leave children unattended in vehicle at any time Prior to leaving the vehicle unattended or servicing the vehicle set the park brake place the Forward Reverse handle or switch 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 can result in decreased vehicle performance severe personal injury or death Any modification or change to the vehicle that affects the electrical system stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications can result in severe personal injury or death e Check the vehicle for proper location of all vehicle safety and operation decals and make sure they in place and are easy to read For vehicles with cargo beds remove all cargo
104. op tilt bed lower gently and keep entire body clear Failure to follow these instructions can result in severe injury Keep hands clear of crush area between bed and seat back support To lower the bed of a Carryall 500 or 550 vehicle lift the bed so that the prop rod is no longer supported in one of the track notches Push the prop rod toward the front of the vehicle to free it from the track notch and gently lower the bed DO NOT drop the bed PRE OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory however upon receiving your new vehicle s you should become familiar with its controls indicators and operation Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery Use the following checklist as a guide to inspect the vehicle This checklist should be used daily to ensure that the vehicle is in proper working condition and in conjunction with the Performance Inspection on page 30 and the Periodic Service Schedules on page 41 Any problems should be corrected by a Club Car distributor dealer or a trained technician General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tight On gasoline vehicles check all hose clamps for tight fit as well as the starter belt for tightness Safety and information decals Check to ensure that all safety and information decals are
105. orm the necessary repairs or adjustments within a reasonable amount of time and furnish you with a copy of the repair order All parts and accessories replaced under this warranty become the property of CLUB CAR For owners located more than 100 miles from an authorized service center the following will be provided to those applicable owners excluding the states with high altitude areas CLUB CAR will either pay for the shipping costs of replacement parts to and from an authorized service center Or CLUB CAR will provide for a service technician to come to the owner to make the warranty repair Or CLUB CAR will pay for the repair to be made at a local non authorized service center WHAT IS NOT COVERED Conditions resulting from tampering misuse improper adjustment unless they were made by the service dealer authorized by CLUB CAR during a warranty repair alteration accident failure to use the recommended fuel and oil or not performing required maintenance services The replacement parts used for required maintenance services Consequential damages such as loss of time inconvenience loss of use of the engine or equipment etc Diagnosis and inspection charges that do not result in warranty eligible service being performed Any non authorized replacement part or malfunction of authorized parts due to use of non authorized parts Page 74 CARRYALL 500 550 700 Vehicle Owner s Manual Warranties OWNER S WARRANTY RESPON
106. ory reconditioned vehicle or component thereof that is identical or reasonably equivalent to the warranted product or component at no cost to the purchaser Repair shall mean remedying a defect in the vehicle or component thereof at no cost to the purchaser during the applicable limited warranty period CLUB CAR reserves the right to test and recharge any component returned for adjustment If CLUB CAR elects to repair the vehicle or component it may provide factory reconditioned parts or components All parts and components replaced under warranty shall become the property of CLUB CAR DISCLAIMER THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANT Y THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE SOLE REMEDY OF THE REPLACEMENT OR REPAIR OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE DISTRIBUTOR 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 In the event that another pre printed warranty document certificate or both offered by or through Club Car at the time of sale of this vehicle each an Additional Warranty Document i
107. other than a defect including poor maintenance neglect abuse accident and collision maintenance adjustments unreasonable or unintended strain or use improper installation of accessories installation of parts or accessories that are not original equipment including Club Car approved or non approved GPS systems non approved alteration and acts of God Also excluded from any CLUB CAR warranty are all fuses filters decals except safety decals lubricants routine wear items such as the charger plug and receptacle engine mounts bed floor lining mats pads spark plugs light bulbs brake shoes belts brushes bushings drive buttons cosmetic deterioration and items that deteriorate fade or fail due to exposure or ordinary wear and tear The provisions of this limited warranty shall not apply to failure due to the following conditions 1 Abuse such as overcharging undercharging improper fluid levels loose wiring and fasteners or rusted or corroded hardware 2 Use of water in batteries including tap water that contains impurities Distilled water or a properly maintained Club Car approved battery water deionizer and filter system should be used to ensure water quality CARRYALL 500 550 700 Vehicle Owner s Manual Page 71 Warranties 3 Lack of proper maintenance such as preventive maintenance checks proper rotation of vehicles in a fleet application maintaining proper tire pressure and alignment and tightening loose wire co
108. ou 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 your Club Car vehicle needs repairs or service please contact your local authorized Club Car dealer or distributor who will be able to provide technical advice perform warranty work and sell parts and service manuals For the name and address of the authorized Club Car dealer or distributor nearest you logon to our web site at ClubCar com or call 1 800 ClubCar 258 2227 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 USA We hope you will consider this owner s manual a permanent part of your Club Car 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 MAINTENANCE ITEMS Battery Terminal Protector Spray Dry Moly Lube CC PN 1014305 CC PN 1012151 Chassis Lube Engine Air Filter 404 cc EP NLGI Grade 2 commercially available Deionizer Filter Replacement Cartridge SPWS Spark Plug O H C 404 cc CC PN 104005901 CC PN 105017801 Deionizer Filter Replacement Cartridge non SPWS CC PN AM10975 Page 2 CARRYALL 500 550 700 Vehicle Owner s Manual TABLE OF CONTENTS Safety DecalIderitifiCat
109. park brake The vehicle will roll at about 1 to 3 mph 1 6 to 4 8 km h If the walk away braking function remains engaged for two seconds or more a warning buzzer will sound to alert the driver that motor braking has been activated See following WARNING Page 24 CARRYALL 500 550 700 Vehicle Owner s Manual Controls and Indicators WARNING Walk away braking will not limit vehicle speed to 3 mph 4 8 km h on very steep grades Do not operate vehicle on slopes exceeding 20 grades Pedal Down Motor Braking This feature helps to control vehicle downhill speed Motor braking is activated when the vehicle reaches the programmed top speed and holds the vehicle at that speed Motor braking is automatically disengaged when vehicle speed slows below the programmed top speed Pedal Up Motor Braking Speed settings are programmable for IQ Plus vehicles Motor braking is activated when the accelerator pedal is released at or above the programmed speed When the vehicle slows to the programmed lower speed motor braking will disengage If no speed settings are programed motor braking will be activated at any time accelerator pedal is released and it will only disengage when the vehicle comes to a stop Contact your dealer distributor to inquire about this programmable feature WARNING When batteries are fully charged a warning buzzer will sound during motor braking to alert the driver that motor braking is operating at a reduced l
110. ructions pedal start vehicles Decal On Off Start Key Switch above key switch 3 4 101825102 105137103 Decal Vehicle Load key start vehicles 105137103 Page 10 CARRYALL 500 550 700 Vehicle Owner s Manual Safety Decal Identification GASOLINE CARRYALL 500 AND 550 CONTINUED GASOLINE EXPLOSION FIRE CAN CAUSE SERIOUS GASOLINE EXPLOSION FIRE CAN CAUSE INJURY OR DEATH SERIOUS INJURY OR DEATH CAN CAUSE SEVERE INJURY No sparks or open flame near fuel or fuel tank Do not disconnect No sparks or open flame near fuel or fuel tank No smoking near fuel or fuel tank pressurized fuel lines No smoking near fuel or fuel tank 2 i Stop engine and allow to cool before refueling Stop engine and allow to cool before refueling 2 O Rotating parts 105082301 ER UELUT 10508470 zi men manifold amp muffler KEEP CLEAR cci 101960501 NOTICE MAXIMUM TONGUE WEIGHT 150 Ib 667 N Crush area Can cause severe injury INCORRECT WIRING COULD RESULT IN Stay clear when closing bed SEVERE INJURY OR DEATH CCI 102458301 Negative frame ground Can cause severe injury Excessive speed Do not contact positive battery post or cable to frame Can cause severe injury or death Disconnect negative battery lead first i ji 9 Do not tamper with engine governor adjustment 2857 Decal Trailer Hitch Tongue Weight Notice on 1 1011553 102459301 Decal Bed Latch Warning trailer receiver hi
111. s Park brake is automatically released Multi latch ratchet and pawl NEN 20 EN A BODY CHASSIS Frame chassis Twin welded aluminum Side and rear body Aluminum Front body ArmorFlex Front body finish Automotive grade paint with clear coat finish Tires 20 x 10 10 tubeless 6 ply rated load range front and rear ce uj Tires Turf 23 x 10 5 12 tubeless 4 ply rated load range front and rear Tires All Terrain 22 x 11 10 tubeless 6 ply rated load range front and rear DIMENSIONS WEIGHT Overall length Standard boxbed configuration 118 in 299 7 cm 118 in 299 7 cm 139 3 in 358 8 cm Add for Heavy Duty Bumper 1 8 in 4 5 cm 1 8 in 4 5 cm 1 8 in 4 5 cm Page 68 CARRYALL 500 550 700 Vehicle Owner s Manual Vehicle Specifications SPECIFICATIONS CARRYALL 500 CARRYALL 550 CARRYALL 700 POWER SOURCE GASOLINE GASOLINE GASOLINE Overall width 50 3 in 127 7 cm 50 3 in 127 7 cm 50 3 in 127 7 cm with mirrors 62 6 in 159 0 cm 62 6 in 159 0 cm 62 6 in 159 0 cm 15 to 17 mph 15 to 17 mph 15 to 17 mph Maximum forward speed 24 to 27 km h 24 to 27 km h 24 to 27 km h 44 2 x 47 5 x 10 5 in 44 2 x 47 5 x 10 5 in 64 5 x 47 5 x 10 5 in Load bed size Box bed inside dimensions 112 2 x 120 6 x 112 2 x 120 6 x 163 8 x 120 6 x 26 6 cm 26 6 cm 26 6 cm 117 3 x 123 9 cm 117 3 x 123 9 cm 166 4 x 123 9 cm E 28 to 32 psig 20 to 22 psig 28 to 32 psig Front and rear 193 to
112. s deemed to conflict with the limitations or exclusions Page 72 CARRYALL 500 550 700 Vehicle Owner s Manual Warranties contained herein the limitations and exclusions contained herein shall continue to apply to both this limited warranty statement and to the maximum extent permitted by law to each Additional Warranty Document 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 INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitation of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state HOW TO MAKE A WARRANTY CLAIM To make a warranty claim under this limited warranty you must present the vehicle or defective component with evidence of proof of purchase date and number of amp hours if applicable to an authorized CLUB CAR dealer For warranty related communication contact Warranty Services Club Car 4125 Washington Rd Evans GA 30809 USA 706 863 3000 WARNING Any modification or change to the vehicle that affects the electrical system stability or handling of the vehicle or increases maximum vehicle speed beyo
113. t in conjunction with the Pre Operation and Daily Safety Checklist as a guide to inspect the vehicle and check daily for proper operation Any problems should be corrected by a Club Car distributor dealer or a trained technician All Vehicles Forward Reverse control Check for proper operation See Controls and Indicators on page 20 Brakes Be sure the brakes function properly When brake pedal is fully pressed under moderate pressure 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 to stop have the brake system checked and adjusted as required Brake adjustment must be maintained so that the brake pedal cannot be pressed to the floor under any circumstance Park brake When latched the park brake should lock the wheels and hold the vehicle stationary on an incline of 20 or less It should release when either the accelerator or brake pedal is pressed Reverse buzzer The reverse buzzer should sound as a warning when the Forward Reverse handle or switch is in the REVERSE position Steering The vehicle should be easy to steer and should not have any play in the steering wheel 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 technician investigate anything unusual Electric Vehicles Acce
114. t is not scheduled for replacement as required maintenance in the written instructions supplied is warranted for the warranty period stated above If the part fails during the period of warranty coverage the part will be repaired or replaced by CLUB CAR according to subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the original warranty period 2 Any warranted part that is scheduled only for regular inspection in the written instructions supplied is warranted for the warranty period stated above Any such part repaired or replaced under warranty will be warranted for the remaining original warranty period 3 Any warranted part that is scheduled for replacement as required maintenance in the written instructions supplied is warranted for the period of time before the first scheduled replacement date for that part If the part fails before the first scheduled replacement the part will be repaired or replaced by CLUB CAR according to subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the period prior to the first scheduled replacement point for the part 4 Repair or replacement of any warranted part under the warranty provisions herein must be performed at a warranty station at no charge to the owner 5 Notwithstanding the provisions herein warranty services or repairs will be provided at all of our distribution centers that
115. t up in sequence See Charger Display on page 54 As long as the charger is allowed to shut off by itself the batteries will be fully charged Overcharging and undercharging will normally be prevented Features Charge Interlock When the AC power cord is inserted into a wall receptacle the charger locks out the vehicle drive system This prevents the possibility of driving the vehicle while the charger is plugged in and potentially damaging the vehicle and charger Long Term Storage Charge Club Car chargers are designed to be left connected with AC power to the charger during off season or long term storage See Preparing the Electric Vehicle for Extended Storage on page 37 UL and CSA Listing When operated on a 120 VAC 60 Hz this battery charger has been listed by UL and by the Canadian Underwriters and meets the criteria of the Canadian Standards Association CE Compliance This battery charger is compliant with the EU EMC Directive 2004 108 EC IP Ingress Protection Rating The charger has been tested successfully to EN60529 meeting IP66 The AC supply inlet is rated to IP20 which is suitable for indoor use only Keep all AC connections clean and dry Page 52 CARRYALL 500 550 700 Vehicle Owner s Manual Battery Charger QuiQ Electric Vehicle Charger Power Connection Fuse The vehicle charger power circuit has an in line 30 amp fuse located near the solenoid AC Input Voltage Detection The QuiQ charger automaticall
116. tch 2 101915201 Frame Ground Governor Warning on 103205501 Decal Maintenance Operate Warning on vehicle frame near battery Maintenance Operate switch plate under seat 5 7 Decal Rotating Parts Hot Manifold Warning 3 101960501 105082301 Decal Gasoline Fuel Warning on fuel tank starter generator 102345901 Decal Diode Warning near battery 105084701 Decal Gasoline Fuel Warning at fuel fill CARRYALL 500 550 700 Vehicle Owner s Manual Page 11 Safety Decal Identification GASOLINE CARRYALL 700 Unintended vehicle movement may cause severe injury or UNINTENDED MOVEMENT ROLLOVER OR FALLING OUT CAN CAUSE SERIOUS INJURY OR DEATH death Before using vehicle read owner s manual and vehicle Vehicle to be operated by licensed and authorized persons only Remain fully seated while moving safety warnings Use in authorized areas only Do not operate on public roads Hold on and keep entire body inside vehicle while moving Before leaving vehicle One 1 person per bucket seat maximum Never attempt jumps and avoid extreme braking in reverse Engage park brake to lock wheels Two 2 persons per bench seat maximum Do not leave children unattended in vehicle at any time Place vehicle in NEUTRAL Operate from driver s seat only Children requiring a child safety seat must not ride in vehicle key to OFF and remove key Do not start vehicle until all occupants are fully seated
117. the Forward Reverse handle in desired position F Forward or R Reverse Engine must be at idle before moving the handle A buzzer will sound as a warning when the vehicle is in the REVERSE position 7 5 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 NOTE WARNING Operator must control vehicle speed when going downhill Stop the vehicle before shifting the Forward Reverse handle or switch Failure to do so can result in injury to inattentive passengers and or damage to the vehicle Electric vehicles only Pedal down or pedal up motor braking can be used to help control speed when going downhill however steep terrain or other conditions can require that pedal braking be used in conjunction with motor braking Gasoline vehicles only Press the brake pedal as necessary and partially press the accelerator when descending a hill With the accelerator pedal partially pressed the governor will cause the engine to assist the brakes in controlling downhill speed Page 32 CARRYALL 500 550 700 Vehicle Owner s Manual Loading and Unloading STOPPING THE VEHICLE A WARNING Driving through water can affect the brakes After driving through water check effectiveness of the brakes by gently pressing the brake pedal If the ve
118. to signal the bed is in the rest position WARNING Gasoline vehicles Keep clear of moving parts when bed is in the raised position and the engine is running Keep hands and fingers clear of crush area between the bed and the seat back support 12 VOLT POWER POINT A 12 volt power point is located in the driver s side dash pocket and is rated at 6 5 amps Figure 9 When the key Switch is in the ON position the power point provides power to accessories plugged into it The electrical circuit to the power point also powers all additional electrical accessories on the vehicle and is protected by a 10 amp fuse Exceeding a 10 amp total draw on the circuit will result in a blown fuse NOTE The power point circuit is disabled while the battery charger is plugged in The power point is not for continuous use Extended use can cause the vehicle battery or batteries to become heavily discharged For gasoline vehicles do not use the power point for long periods of time when the engine is not running CARRYALL 500 550 700 Vehicle Owner s Manual Page 23 Controls and Indicators 2848 Figure 9 12 Volt Power Point ACCELERATOR PEDAL The accelerator pedal is the pedal on the right with the word GO molded into it Figure 10 Electric and pedal start vehicles When the key switch is in the ON position and the Forward Reverse handle or switch is in either the FORWARD or REVERSE position pressing the accelerator pedal will
119. trical shock Use only an appropriately sized AC power cord See AC Power Connection on page 54 Do not use near fuels grain dust solvents thinners or other flammables Chargers can ignite flammable materials and vapors Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and remove the battery charger from the vehicle See removal procedure in the appropriate maintenance and service manual Do not use a battery charger if the cord or plug is damaged any way Replace worn or damaged parts immediately Failure to heed this warning can result in a fire property damage severe personal injury or death Do not operate the charger if it has received a sharp blow was dropped or otherwise damaged in any way Have worn cut or damaged power cords or wires replaced immediately WARNING CONTINUED ON NEXT PAGE CARRYALL 500 550 700 Vehicle Owner s Manual Page 51 Battery Charger QuiQ Electric Vehicle WARNING Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightening strikes Ensure battery connections are clean and properly tightened Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry
120. urns To avoid unintentionally starting the vehicle disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 17 Gasoline vehicles only Moving parts Do not attempt to service gasoline vehicle while the engine is running Hot Do not attempt to service hot engine or exhaust system Failure to heed this warning can result in severe burns To avoid unintentionally starting the vehicle disconnect battery and spark plug wire See Disconnecting the Battery Gasoline Vehicles on page 17 Frame ground Do not allow tools or other metal objects to contact frame when disconnecting batteries or other electrical wiring Never allow a positive wire to touch the vehicle frame engine or other metal component Page 40 CARRYALL 500 550 700 Vehicle Owner s Manual Periodic Service Schedules PERIODIC SERVICE SCHEDULES See General Warnings on page 15 WARNING Service repairs and adjustments must be made per instructions in the maintenance and service manual NOTE If the vehicle is constantly hauling heavy loads or hauling a trailer these preventive maintenance procedures should be performed more often than recommended in the Periodic Service Schedule Both the Periodic Service Schedules and the Periodic Lubrication Schedules must be followed to keep vehicle in optimum operating condition PERIODIC SERVICE SCHEDULE ELECTRIC VEHICLES REGULAR INTERVAL SE
121. us when towing with a vehicle See the preceding chart for vehicle capacities Parking the vehicle with a trailer on a hill should be avoided If you must park on a hill apply the brakes and have someone chock the tires of the trailer Brakes should be released to allow the chocks to absorb the load of the trailer After the tires have been chocked engage the park brake TRANSPORTING ON A TRAILER WARNING Do not allow riders in the 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 can cause the vehicle to overturn possibly resulting in severe personal injury For use on public roads the trailer must meet all federal state and local requirements such as taillights brake lights etc Reduce normal driving speed when transporting a Club Car vehicle on a trailer 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 or switch in the NEUTRAL position the key switch in the OFF position and the park brake engaged to lock wheels Because of the added length of the trailer use caution when making turns Do not transport the vehicle on a trailer with a load in the vehicle car
122. warranty In California new small off road engines SORE must be designed built and equipped to meet the State s stringent anti smog standards CLUB CAR shall warrant the emission control system on the vehicle engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your small off road engine Your emission control system may include parts such as the carburetor or fuel injection system the ignition system the catalytic converter and related hoses belts connectors and other emission assemblies or components Where a warrantable condition exists as defined herein CLUB CAR will repair your vehicle engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE CARRYALL 500 550 700 Vehicle Owner s Manual Page 75 Warranties This emission control system is warranted for two years from the vehicles date of purchase If any emission related part on your CLUB CAR SORE is defective the part will be repaired or replaced by CLUB CAR OWNER S WARRANTY RESPONSIBILITIES As the vehicle engine owner you are responsible for the performance of the required maintenance listed in your owner s manual CLUB CAR recommends that you retain all receipts covering maintenance on your vehicle engine but CLUB CAR cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the vehicle e
123. y detects the AC input voltage and will operate at full power if the voltage is within the 120 to 230 VAC range The charger also will function outside of that range down to 85 VAC and up to 265 VAC although charging times will be longer Outside of the 85 to 265 VAC range the charger will not operate Thermal Cutback The QuiQ charger operates at full power in ambient temperatures between 32 F 0 C and 86 F 30 C The charger also will function outside of that range although charging times will be longer How to Identify the Charger Algorithm Number To see the charger algorithm number initiate the Algorithm Display Mode To enter Algorithm Display Mode take the following steps Unplug the AC power supply cord from the wall outlet Place the Tow Run switch in the TOW position Disconnect the heavy gauge black wire from the negative post of battery no 8 Plug the AC power supply cord into the wall outlet See following NOTE EO Nm oc NOTE When the charger AC cord is connected LED lights on the charger perform a start up self test LEDs light up in sequence 5 After the start up self test the 80 LED will display a series of flashes that represent the algorithm number Figure 21 Example Algorithm number 125 is represented as one flash pause two flashes pause five flashes The charger will not repeat this series of flashes To see the number again repeat steps 1 and 4 with a 20 second pause betwee
124. y steep grades the vehicle may slightly exceed its maximum programmed speed requiring use of the brake pedal Gasoline Vehicles Accelerator for pedal start vehicles With the key switch in the ON position and the Forward Reverse handle in the FORWARD position as the accelerator pedal is pressed the engine should start and the vehicle should accelerate smoothly to full speed When the pedal is released it should return to the original position and the engine should stop Accelerator for key start vehicles After starting the engine with the key switch and placing the Forward Reverse handle in the FORWARD position the vehicle should accelerate smoothly to full speed as the accelerator pedal is pressed When the accelerator pedal is released it should return to the original position and the engine should idle Governor Check maximum speed of the vehicle on a level surface Refer to Vehicle Specifications beginning on page 68 for the rated speed of the vehicle Page 30 CARRYALL 500 550 700 Vehicle Owner s Manual Driving Instructions DRIVING INSTRUCTIONS WARNING Only licensed drivers should be allowed to drive the 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 should be in the vehicle at one time Do not allow riders in the cargo bed The vehicle is not specially equipped for handicapped persons Be sure al

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