Club Car Carryall 500 Owner's manual

Carryall

500/550/700

VehicleOwner'sManual

ElectricandGasoline

[Refertobackcoverforapplicablebuildcoderange]

NOTICE

Thismanualisvalidforvehiclesmanufacturedinthebuildcoderangeprovidedonthebackcoverofthismanual.Ifthe

vehiclebuildcodeisdifferentfromthatshownonthebackcoverofthismanual,pleasecontactyournearestdealerorgoto

www.clubcar.comtoretrievetheproperowner'smanualforthevehicle.SeealsoModelIdenticationinthismanual.

Warrantyinformationappearsattheendofthismanual.Nootherwarranties,expressorimplied,arecontainedherein.

Yourauthorizedrepresentativecheckedthevehiclebeforeitwasdeliveredtoyouandwillprovideyouacopyofthe

completedvehiclewarrantyregistrationform.

ClubCarisnotliableforerrorsinthismanualorforincidentalorconsequentialdamagesthatresultfromtheuseof

thematerialinthismanual.

Thismanualcontainsproprietaryinformationthatisprotectedbycopyright.Allrightsarereserved.Nopartofthismanual

maybephotocopied,reproduced,ortranslatedtoanotherlanguagewithoutthewrittenconsentofClubCar,LLC.

Theinformationcontainedinthisdocumentissubjecttochangewithoutnotice.ClubCarreservestherighttomakedesign

changestovehicleswithoutobligationtomakethesechangesonunitspreviouslysold.

Theseutilityvehiclesarefour-wheel,general-purposevehiclesintendedtotransportpeopleandcargoonimprovedor

groomedsurfaces.

ThesevehiclesdonotconformtoU.S.FederalMotorVehicleSafetyStandards(FMVSS)forautomobilesortoFMVSS500

forlow-speedvehicles,andarenotequippedforoperationonpublicstreets,roads,orhighways.

IfinEnglish,thismanualistheOriginalInstructionsprovidedbythemanufacturer.IfinanylanguageotherthanEnglish,

thismanualisatranslationoftheOriginalInstructions.

P .O.Box204658

Augusta,Georgia30917–4658USA

Telephone706–863–3000

ServicePartsFax706–855–7413

www.clubcar.com

ClubCar,Tranquility,andArmorFlex

areregisteredtrademarksofClubCar,LLC

ThismanualeffectiveJune2015

Carryall500/550/700VehicleOwner'sManualPage1

FOREWORD

ThankyouforchoosingClubCar,thenamemostwidelyrecognizedastheindustryleaderinvehicleefciencyand

long-lastingvalue.Youhavechosenthenestutilityvehicleonthemarket.Pleaseprotectyourinvestmentand

ensurethatyourClubCarvehicle(s)providesyearsofreliable,superiorperformancebyreadingandfollowingthe

maintenanceinstructionsinthismanual.

Yourcomfortandsafetyareimportanttous,soweurgeyoutoreadandfollowthestep-by-stepoperatinginstructions

andsafetyproceduresinthismanual.Theseinstructionsmustbefollowedinordertoavoidtheriskofseverepersonal

injury.Ifyourentorloanyourvehicletoothers,werecommendthatyouaskthemtoreadthismanualbeforethey

operatethevehicle.

ClubCarproductsarebackedbyacustomersupportsystemdesignedtoofferyoufast,courteousservice.Intheevent

yourClubCarvehicleneedsrepairsorservice,pleasecontactyourlocalauthorizedClubCardealerordistributor,who

willbeabletoprovidetechnicaladvice,performwarrantywork,andsellpartsandservicemanuals.

TondyourlocalauthorizedClubCardealer,visitwww.clubcardealer.com,call1-800-ClubCar(258–2227),orscan

thisQuickResponse(QR)codetobetakentotheClubCardealerlocator.RefertoFigure1.DownloadaQRcode

readersuchasRedLaserorBarcodeScannertoyourcellphoneortablet.

Ifyouwouldprefertowritetous,directyourletterto:ClubCarLLC,Attention:MarketingServices,P .O.Box204658,

Augusta,Georgia30917-4658USA.

Wehopeyouwillconsiderthisowner’smanualapermanentpartofyourClubCarvehicle.Ifyousellthevehicle,

pleaseincludethemanualsothatthenextownerwillhavetheimportantoperating,safety,andmaintenance

informationitcontains.

DealerLocatorQRCode

3118

Figure1DealerLocatorQRCode

_

MAINTENANCEITEMS

BatteryTerminalProtectorSpray

CCPN1014305

DryMolyLube

CCPN1012151

ChassisLube

EPNLGIGrade2(commerciallyavailable)

EngineAirFilter(404cc)

CCPN102558201

DeionizerFilterReplacementCartridge(SPWS)

CCPN104005901

SparkPlugO.H.C.(404cc)

CCPN105017801

DeionizerFilterReplacementCartridge(non-SPWS)

CCPNAM10975

Page2Carryall500/550/700VehicleOwner'sManual

TABLEOFCONTENTS

TechnicalPublicationCustomerSatisfactionSurvey................................................................................................4

SafetyDecalIdentication.....................................................................................................................................5

PracticeSafety...................................................................................................................................................15

Proposition65–StateofCalifornia......................................................................................................................15

SafetyDetails.....................................................................................................................................................16

GeneralWarnings...............................................................................................................................................16

GeneralInformation............................................................................................................................................21

ModelIdentication.............................................................................................................................................22

ControlsandIndicators.......................................................................................................................................22

Pre-OperationandDailySafetyChecklist.............................................................................................................31

DrivingInstructions.............................................................................................................................................33

LoadingandUnloading.......................................................................................................................................36

VehicleLoadCapacities......................................................................................................................................36

TowingwiththeVehicle.......................................................................................................................................38

TransportingonaTrailer.....................................................................................................................................39

Storage–ElectricVehicles..................................................................................................................................39

Storage–GasolineVehicles................................................................................................................................41

Maintenance......................................................................................................................................................43

PeriodicServiceSchedules.................................................................................................................................44

PeriodicLubricationSchedules...........................................................................................................................47

Batteries–ElectricVehicles................................................................................................................................49

BatteryCharger,QuiQ™–ElectricVehicle...........................................................................................................53

SinglePointWateringSystem(SPWS).................................................................................................................59

Battery–GasolineVehicle..................................................................................................................................61

EngineOil–GasolineVehicle..............................................................................................................................63

FuelingInstructions–GasolineVehicle................................................................................................................66

CleaningtheVehicle...........................................................................................................................................67

Accessories........................................................................................................................................................68

SubsequentOwnerRegistration..........................................................................................................................68

VehicleSpecications.........................................................................................................................................69

Warranties..........................................................................................................................................................74

ECDeclarationofConformity..............................................................................................................................82

Carryall500/550/700VehicleOwner'sManualPage3

TechnicalPublicationCustomerSatisfactionSurvey

TECHNICALPUBLICATIONCUSTOMERSATISFACTIONSURVEY

Letyourvoicebeheard!

PleaseparticipateintheTechnicalPublicationcustomersatisfactiononlinesurvey.

Thissurveytakeslessthanveminutestocompleteandyourresponseswillhelpexaminecurrentperformance

andidentifyareasforfutureimprovement.

Ourtoppriorityistoprovidetimely,accurate,anduserfriendlymanuals.

Theonlinesurveycanbefoundathttp://bit.ly/1w9uFMhorusingtheQRCodebelow.

Figure2TechnicalPublicationCustomerSatisfactionOnlineSurvey

Page4Carryall500/550/700VehicleOwner'sManual

SafetyDecalIdentication

SAFETYDECALIDENTIFICATION

Thefollowingpagescontainsafetydecalinformation.Fordetailedinformationonspecicfeatures,readthe

appropriatesectioninthismanual.

ELECTRICCARRYALL500

_

2852

1

54

2

7

3

8

6

9

1101553901Decal,BedLoadingWarning(oncargobedorseat

back)6105130101Decal,12VAccessoryFuseBlock(underfront

body)

2101609401Decal,CrushAreaWarning(behindseat,near

cargobed)7105137106Decal,VehicleLoad

3101825101Decal,On/OffKeySwitch(abovekeyswitch)8105163601Decal,12V(+)(underfrontbody)

4104026801Decal,OccupantWarning9105163701Decal,Ground(underfrontbody)

5105046101Decal,OperatingInstructions

Carryall500/550/700VehicleOwner'sManualPage5

SafetyDecalIdentication

ELECTRICCARRYALL550

_

2873

1

65

2

8

3

9

7

10

4

1101553901Decal,BedLoadingWarning(oncargobedorseat

back)6105046101Decal,OperatingInstructions

2101609401Decal,CrushAreaWarning7105130101Decal,12VAccessoryFuseBlock(underfront

body)

3101825101Decal,On/OffKeySwitch(abovekeyswitch)8105137103Decal,VehicleLoad

4102075801Decal,Y oungDriverWarning9105163601Decal,12V(+)(underfrontbody)

5104026801Decal,OccupantWarning10105163701Decal,Ground(underfrontbody)

Page6Carryall500/550/700VehicleOwner'sManual

SafetyDecalIdentication

ELECTRICCARRYALL500AND550,CONTINUED

_

2853

CC I 102 967 60 1

WARNING

!

• Re placeme nt ba ttery wires mus t be 4-gauge (AWG) with low-resistance terminals

e quivalent to factory-ins ta lled wires .

• Ens ure tha t ba ttery connections a re clean a nd prope rly tightene d. See owne r’s manua l.

AVOID FIRE HAZARD

42

1

3

5

6

7

8

11011553Decal,TrailerHitchT ongueWeightNotice(on

trailer/receiverhitch)5102967601Decal,4GaugeWireWarning(onframeabove

electricalcomponentmountingplate)

2102459301Decal,BedLatchWarning6105124701Decal,DoNotUseasGround(onframeabove

electricalcomponentmountingplate)

3102518301Decal,ComponentCoverNotice(onelectrical

componentcover)7105130001Decal,48VAccessoryFuseBlock(onelectrical

componentmountingplate)

4102845101Decal,T owSwitchWarning(onT ow/Runswitch

plate,underseat)8105163701Decal,Ground(onelectricalcomponentmounting

plate)

Carryall500/550/700VehicleOwner'sManualPage7

SafetyDecalIdentication

ELECTRICCARRYALL700

_

2854

1

54

2

7

3

8

6

9

1101553901Decal,BedLoadingWarning(oncargobedorseat

back)6105130101Decal,12VAccessoryFuseBlock(underfront

body)

2101609401Decal,CrushAreaWarning(behindseat,near

cargobed)7105151501Decal,VehicleLoad

3101825101Decal,On/OffKeySwitch(abovekeyswitch)8105163601Decal,12V(+)(underfrontbody)

4104026801Decal,OccupantWarning9105163701Decal,Ground(underfrontbody)

5105046101Decal,OperatingInstructions

Page8Carryall500/550/700VehicleOwner'sManual

SafetyDecalIdentication

ELECTRICCARRYALL700,CONTINUED

_

2855

CC I 102 967 60 1

WARNING

!

• Re placeme nt ba ttery wires mus t be 4-gauge (AWG) with low-resista nce terminals

e quivalent to factory-ins ta lled wires .

• Ens ure tha t ba ttery connections a re clean and prope rly tightened. S e e owne r’s manua l.

AVOID FIRE HAZARD

3

1

2

4

5

6

7

11011553Decal,TrailerHitchT ongueWeightNotice(on

trailer/receiverhitch)5105124701Decal,DoNotUseasGround(onframeabove

electricalcomponentmountingplate)

2102518301Decal,ComponentCoverNotice(onelectrical

componentcover)6105130001Decal,48VAccessoryFuseBlock(onelectrical

componentmountingplate)

3102845101Decal,T owSwitchWarning(onT ow/Runswitch

plate,underseat)7105163701Decal,Ground(onelectricalcomponentmounting

plate)

4102967601Decal,4GaugeWireWarning(onframeabove

electricalcomponentmountingplate)

Carryall500/550/700VehicleOwner'sManualPage9

SafetyDecalIdentication

GASOLINECARRYALL500

_

2856

1

65

2

7

8

3

4

1101553901Decal,BedLoadingWarning(oncargobedorseat

back)5104026801Decal,OccupantWarning

2101609401Decal,CrushAreaWarning(behindseat,near

cargobed)6105046101Decal,OperatingInstructions

3101825101Decal,On/OffKeySwitch(abovekeyswitch)

(pedal-startvehicles)7105137102Decal,VehicleLoad(two-wheelbrakevehicles)

4101825102Decal,On/Off/StartKeySwitch(abovekeyswitch)

(key-startvehicles)8105137106Decal,VehicleLoad(four-wheelbrakevehicles)

Page10Carryall500/550/700VehicleOwner'sManual

SafetyDecalIdentication

GASOLINECARRYALL550

_

2874

1

76

2

8

3

4

5

1101553901Decal,BedLoadingWarning(oncargobedorseat

back)5102075801Decal,YoungDriverWarning

2101609401Decal,CrushAreaWarning(behindseat,near

cargobed)6104026801Decal,OccupantWarning

3101825101Decal,On/OffKeySwitch(abovekeyswitch)

(pedal-startvehicles)7105046101Decal,OperatingInstructions

4101825102Decal,On/Off/StartKeySwitch(abovekeyswitch)

(key-startvehicles)8105137103Decal,VehicleLoad

Carryall500/550/700VehicleOwner'sManualPage11

SafetyDecalIdentication

GASOLINECARRYALL500AND550,CONTINUED

_

2857

8

7

3

1

5

4

2

6

11011553Decal,TrailerHitchT ongueWeightNotice(on

trailer/receiverhitch)5102459301Decal,BedLatchWarning

2101915201Decal,FrameGround/GovernorWarning(on

vehicleframenearbattery)6103205501Decal,Maintenance/OperateWarning(on

Maintenance/Operateswitchplate,underseat)

3101960501Decal,RotatingParts/HotManifoldWarning(on

starter/generator)7105082301Decal,GasolineFuelWarning(onfueltank)

4102345901Decal,DiodeWarning(nearbattery)8105084701Decal,GasolineFuelWarning(atfuelll)

Page12Carryall500/550/700VehicleOwner'sManual

SafetyDecalIdentication

GASOLINECARRYALL700

_

2858

1

65

2

7

3

4

1101553901Decal,BedLoadingWarning(oncargobedorseat

back)5104026801Decal,OccupantWarning

2101609401Decal,CrushAreaWarning(behindseat,near

cargobed)6105046101Decal,OperatingInstructions

3101825101Decal,On/OffKeySwitch(abovekeyswitch)7105151501Decal,VehicleLoad

4101825102Decal,On/Off/StartKeySwitch(abovekeyswitch)

(key-startgasolinevehiclesonly)

Carryall500/550/700VehicleOwner'sManualPage13

SafetyDecalIdentication

GASOLINECARRYALL700,CONTINUED

_

2859

7

6

3

1

2

5

4

11011553Decal,TrailerHitchT ongueWeightNotice(on

trailer/receiverhitch)5103205501Decal,Maintenance/OperateWarning(on

Maintenance/Operateswitchplate,underseat)

2101915201Decal,FrameGround/GovernorWarning(on

vehicleframenearbattery)6105082301Decal,GasolineFuelWarning(onfueltank)

3101960501Decal,RotatingParts/HotManifoldWarning(on

starter/generator)7105084701Decal,GasolineFuelWarning(atfuelll)

4102345901Decal,DiodeWarning(nearbattery)

Page14Carryall500/550/700VehicleOwner'sManual

PracticeSafety

PRACTICESAFETY

399

Figure3PracticeSafety

Safetysignslikeyouseeabovemayatrstseemshocking,buttheirimpactismildcomparedwiththereality

ofseverepersonalinjury.

Yoursafetyandsatisfactionareoftheutmostimportancetous.Thatiswhybeforeoperatingthevehicle,weurge

youtoreviewtheinformationinthismanual.UnderstandandbecomefamiliarwiththeDANGER,WARNING,and

CAUTIONstatementsandproceduresitcontains,alongwiththesafetydecalsthatareafxedtoyourvehicle.

Taketimetounderstandthelanguageofsafety.Itisalanguagethatcansaveyourlife.

PROPOSITION65–STATEOFCALIFORNIA

WARNING

•Thisproductcontainsoremitschemicalsorsubstancesthathavebeendeterminedbythestateof

Californiatocausecancerandbirthdefectsorotherreproductiveharm.

Carryall500/550/700VehicleOwner'sManualPage15

SafetyDetails

SAFETYDETAILS

WARNING

•Thisowner’smanualshouldbereadcompletelybeforeattemptingtodriveorservicethevehicle.

Failuretofollowtheinstructionsinthismanualcanresultinpropertydamage,severepersonal

injury,ordeath.

Itisimportanttonotethatsomevitalstatementsthroughoutthismanualandonthedecalsafxedtothevehicleare

precededbythewordsDANGER,WARNING,orCAUTION.Foryourprotection,werecommendthatyoutakespecial

noticeofthesesafetyprecautions.Safetyprecautionsareessentialandmustbefollowed.

Ifanyoftheoperationorsafetydecalsonthevehiclebecomedamaged,havebeenremoved,orcannotbeeasily

read,theyshouldbereplacedimmediatelytoavoidpossiblepropertydamage,personalinjury,ordeath.Contactyour

distributor/dealer.

DANGER

•ADANGERindicatesanimmediatehazardthatwillresultinseverepersonalinjuryordeath.

WARNING

•AWARNINGindicatesanimmediatehazardthatcanresultinseverepersonalinjuryordeath.

CAUTION

•ACAUTIONwiththesafetyalertsymbolindicatesahazardorunsafepracticethatcanresultin

minorpersonalinjury.

CAUTION

•ACAUTIONwithoutthesafetyalertsymbolindicatesapotentiallyhazardoussituationthatcanresult

inpropertydamage.

GENERALWARNINGS

Thefollowingsafetystatementsmustbeheededwheneverthevehicleisbeingoperated,repaired,orserviced.See

SafetyDecalIdenticationonpage5.Otherspecicsafetystatementsappearthroughoutthismanualandon

thevehicle.

Page16Carryall500/550/700VehicleOwner'sManual

GeneralWarnings

DANGER

•Battery–Explosivegases!Donotsmoke.Keepsparksandamesawayfromthevehicleandservice

area.Ventilatewhenchargingoroperatingvehicleinanenclosedarea.Wearafullfaceshieldand

rubbergloveswhenworkingonornearbatteries.

•Gasoline–Flammable!Explosive!Donotsmoke.Keepsparksandamesawayfromthevehicleand

servicearea.Serviceonlyinawell-ventilatedarea.

•Donotoperateengineinanenclosedareawithoutproperventilation.Theengineproducescarbon

monoxide,whichisanodorless,deadlypoison.

•Thevehiclewillnotprovideprotectionfromlightning,yingobjects,orotherstorm-relatedhazards.If

caughtinastormwhiledrivingaClubCarvehicle,exitthevehicleandseekshelterinaccordancewith

applicablesafetyguidelinesforyourlocation.

WARNING

•Followtheproceduresexactlyasstatedinthismanual,andheedallDANGER,WARNING,and

CAUTIONstatementsinthismanualaswellasthoseonthevehicleandbatterycharger.

•Donotleavechildrenunattendedinvehicleatanytime.

•Priortoleavingthevehicleunattendedorservicingthevehicle,settheparkbrake,placethe

Forward/ReversehandleorswitchintheNEUTRALposition,turnthekeyswitchtotheOFFposition,

andremovethekey.Chockthewheelswhenservicingthevehicle.

•Improperuseofthevehicleorfailuretoproperlymaintainitcanresultindecreasedvehicle

performance,severepersonalinjury,ordeath.

•Anymodicationorchangetothevehiclethataffectstheelectricalsystem,stabilityorhandlingof

thevehicle,orincreasesmaximumvehiclespeedbeyondfactoryspecications,canresultinsevere

personalinjuryordeath.

•Checkthevehicleforproperlocationofallvehiclesafetyandoperationdecalsandmakesuretheyare

inplaceandareeasytoread.

•Forvehicleswithcargobeds,removeallcargo(includingaccessories)beforeraisingthebedor

servicingthevehicle.Ifthevehicleisequippedwithaproprod,ensurethatitissecurelyengaged

whilebedisraised.Donotclosebeduntilallpersonsareclearofcargobedarea.Keephandsclearof

allcrushareas.Donotdropcargobed;lowergentlyandkeepentirebodyclear.Failuretoheedthis

warningcanresultinseverepersonalinjuryordeath.

•Onlytrainedtechniciansshouldserviceorrepairthevehicleorbatterycharger.Anyonedoingeven

simplerepairsorserviceshouldhaveknowledgeandexperienceinelectricalandmechanicalrepair.

Theappropriateinstructionsmustbeusedwhenperformingmaintenance,service,oraccessory

installation.

Electricvehiclesonly:

•Ensurebatteryconnectionsarecleanandproperlytightened.SeeBatteryCare–VehiclesEquipped

withtheSingle-PointWateringSystem(SPWS)onpage51orBatteryCare–VehiclesWithoutthe

Single-PointWateringSystem(SPWS)onpage52.

•PlaceTow/RunswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failureto

heedthiswarningcanresultinabatteryexplosionorseverepersonalinjury.

•Toavoidunintentionallystartinganelectricvehicle,disconnectthebatteriesanddischargethe

controller.SeeDisconnectingtheBatteries–ElectricVehiclesonpage19.

WARNINGCONTINUEDONNEXTPAGE

Carryall500/550/700VehicleOwner'sManualPage17

GeneralWarnings

WARNING

Gasolinevehiclesonly:

•Toavoidunintentionallystartingagasolinevehicle,disconnectthebatteryandsparkplugwire.See

Side-PostBattery:DisconnectingtheBattery-GasolineVehiclesonpage19.

SeeTop-PostBattery:DisconnectingtheBattery-GasolineVehiclesonpage20.

•Frameground–Donotallowtoolsorothermetalobjectstocontactframewhendisconnectingbattery

cablesorotherelectricalwiring.Donotallowapositivewiretotouchthevehicleframe,engine,or

anyothermetalcomponent.

Allvehicles:

•Wearsafetyglassesorapprovedeyeprotectionwhenservicingthevehicleorbatterycharger.Weara

fullfaceshieldandrubbergloveswhenworkingonornearbatteries.

•Donotwearlooseclothingorjewelrysuchasrings,watches,chains,etc.,whenservicingthe

vehicleorbatterycharger.

•Useinsulatedtoolswhenworkingnearbatteriesorelectricalconnections.Useextremecautionto

avoidshortingofcomponentsorwiring.

Page18Carryall500/550/700VehicleOwner'sManual

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