Club Car Carryall 500 Owner's manual

Brand: Club Car

Model: Carryall 500

Category: Utility Vehicle

Type: Owner's manual

This manual is also suitable for

Carryall 700

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

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

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

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

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

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

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

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

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

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

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

Page is loading ...

Club Car Carryall 500 Owner's manual

Brand: Club Car

Model: Carryall 500

Category: Utility Vehicle

Type: Owner's manual

This manual is also suitable for

Carryall 700

Download PDF

report

Club Car Carryall 500 Owner's manual

This manual is also suitable for

Club Car Carryall 500 Owner's manual

Related papers

Other documents