Club Car CARRYALL 100 CE Owner'S Manual Download

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Summary of Contents for CARRYALL 100 CE

Page 1: ...Carryall 100 CE Mark Owner s Manual Electric and Gasoline Refer to back cover for applicable build code range ...

Page 2: ......

Page 3: ...ocopied 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 vehicles intended to transport people and...

Page 4: ...vice 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 www clubcar com or call 1 800 ClubCar 258 2227 If you would prefer to write to us direct your letter to Club Car A...

Page 5: ...0 Transporting on a Trailer 30 Storage Electric Vehicles with PowerDrive Battery Charger 31 Storage Gasoline Vehicles 33 Maintenance 34 Periodic Service Schedules 35 Periodic Lubrication Schedules 38 Batteries Electric Vehicles 40 Single Point Watering System SPWS 44 Battery Charger Electric Vehicles 46 Battery Gasoline Vehicle 50 Engine Oil Gasoline Vehicle 52 Fueling Instructions Gasoline Vehicl...

Page 6: ... features read the appropriate section in this manual CARRYALL 100 CE ELECTRIC VEHICLE 2928 2 3 1 1 101908601 Decal Tow Switch Warning on Tow Run switch plate under seat 3 102833301 Decal Maintenance Notice on vehicle body under bed 2 101931501 Decal Component Cover Notice on electrical component cover Page 4 Carryall 100 CE Mark Owner s Manual ...

Page 7: ...er Warning on instrument panel 4 102832001 Decal Bed Latch Warning on vehicle body below bed latch 2 102825701 Decal Operating Instructions on instrument panel 5 105137107 Vehicle Loading Instructions 3 102831901 Decal Bed Latch Warning on vehicle body below bed latch Carryall 100 CE Mark Owner s Manual Page 5 ...

Page 8: ...2832001 Decal Bed Latch Warning on vehicle body below bed latch 2 102825601 Decal Operating Instructions 5 102833301 Decal Maintenance Notice on vehicle body under bed 3 102831901 Decal Bed Latch Warning on vehicle body below bed latch 6 105137107 Vehicle Loading Instructions Page 6 Carryall 100 CE Mark Owner s Manual ...

Page 9: ...rame near battery 5 105082301 Decal Gasoline Fuel Warning on fuel tank 2 101960501 Decal Rotating Parts Hot Manifold Warning on starter generator 3 102345901 Decal Diode Safety Warning on vehicle frame near diode 4 103205501 Decal Maintenance Operate Warning on Maintenance Operate switch plate under seat Carryall 100 CE Mark Owner s Manual Page 7 ...

Page 10: ...ormation 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 WARNING This product contains or emits chemicals or substances that have been determin...

Page 11: ...r 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 throug...

Page 12: ...ng 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...

Page 13: ...cable first 2 Tighten battery terminals to 80 in lb 9 N m 3 Coat terminals with Battery Terminal Protector Spray CC PN 1014305 to minimize corrosion 4 Connect the spark plug wire to the spark plug 1 2 Viewed from passenger side of vehicle 1 Remove negative battery cable 2 Remove positive battery cable Connect battery cables in reverse order 1 2 3 5 6 4 TOW RUN WARNING 1 2 3 Viewed from driver side...

Page 14: ... 4 Coat terminals with Battery Terminal Protector Spray CC PN 1014305 to minimize corrosion 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...

Page 15: ...l Warnings for more information 1642 Figure 5 International Safety Symbols on Batteries GENERAL INFORMATION This manual features the Carryall 100 CE vehicle The electric vehicle is equipped with the IQ System The gasoline vehicle is equipped with a Subaru engine and accompanying powertrain and has a key start configuration Throughout this manual important features unique to each model are highligh...

Page 16: ...must be installed at all times during vehicle operation to achieve proper balance Figure 6 and Figure 7 See following WARNING WARNING Do not operate the vehicle without an installed front bumper or brush guard that is specifically designed and approved for use on this vehicle Instability in the vehicle can cause serious injury or death 37 Figure 6 Bumper 38 Figure 7 Brush Guard Page 14 Carryall 10...

Page 17: ...the hyphen represent the unique sequential number assigned to each vehicle built within a given 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 veh...

Page 18: ...ing the vehicle 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 KEY SWITCH 1 2 794 Figure 9 Key Switch The key switch is mounted on the dash to the right of the steering column Figure 9 Each vehicle is equipped with either a two po...

Page 19: ...e handle towards the driver FORWARD to operate the vehicle in the forward direction or towards the passenger REVERSE to operate the vehicle in reverse Club Car vehicles operate at reduced speed in REVERSE The engine can be started only when the handle is in the straight up position NEUTRAL The engine must be at idle before shifting the Forward Reverse handle See preceding WARNING and CAUTION Elect...

Page 20: ...illuminates when the vehicle is operating there will be enough power remaining to drive the vehicle for approximately 30 minutes However the vehicle should be charged at the first opportunity If the warning light illuminates and the vehicle is unable to operate for 30 minutes have your Club Car distributor dealer check the vehicle for a possible battery or electrical system problem When the batter...

Page 21: ...oil immediately when the low oil warning light stays on may result in permanent engine damage ACCELERATOR PEDAL The accelerator pedal is the pedal on the right with the word GO molded into it Figure 13 Electric 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 automatically re...

Page 22: ... speed slows below the programmed top speed See following WARNING Pedal Up Motor Braking When vehicle speed is above 11 mph 17 7 km h releasing the accelerator pedal will activate motor braking which slows the vehicle speed Once vehicle speed slows to below approximately 11 mph 17 7 km h with the accelerator pedal still released motor braking will be deactivated and the vehicle will coast freely T...

Page 23: ...ow 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 switch located under the seat just above the Forward Reverse switch Figure 16 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...

Page 24: ...L LOCKOUT Gasoline Vehicles Only 81 Figure 17 Neutral Lockout Switch For the convenience of the trained technician there is a neutral lockout switch located on the seat support panel under the seat Figure 17 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 t...

Page 25: ...ed To close the bed gently lower the bed to a closed position DO NOT drop the bed See following WARNING WARNING Keep hands and fingers clear of crush area between the bed and the seat back support 1 42 Figure 18 Bed Latch 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 beco...

Page 26: ...ecklist 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 16 Brakes Be sure the brakes function properly When brake pedal is...

Page 27: ...stop Governor Check maximum speed of the vehicle on a level surface Refer to Vehicle Specifications beginning on page 59 for the rated speed of the vehicle 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 ...

Page 28: ... 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 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 V...

Page 29: ... THE VEHICLE WARNING Driving through water may affect the brakes After driving through water check effectiveness of the brakes by gently pressing the brake pedal If the vehicle 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...

Page 30: ... 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 Center and secure cargo as far forward as possible in the cargo bed Do not overload the vehicle See the...

Page 31: ...soline A Occupant Capacity 500 lb 226 kg 500 lb 226 kg B Cargo Capacity includes cargo bed load and optional equipment 300 lb 136 kg 300 lb 136 kg C Maximum Trailer Tongue Weight 150 lbf 667 N 150 lbf 667 N D Maximum Gross Trailer Weight 300 lb 136 kg 300 lb 136 kg A B Vehicle Rated Capacity 800 lb 363 kg 800 lb 363 kg A B D not to exceed stated Vehicle Combination Rated Capacity 800 lb 363 kg 800...

Page 32: ...RANSPORTING 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 ...

Page 33: ...trolyte level should be from 1 2 inch 13 mm above plates to 1 4 inch 6 mm below the level indicator Figure 22 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 t...

Page 34: ...he storage charge cycles may have depleted the available electrolyte it will stop the charger from further operation Disconnecting then reconnecting the DC cord stationary charger or AC cord onboard charger indicates the electrolyte levels have been maintained and allows the OBC to resume operation 12 3 If AC power is off for 7 days or longer the OBC will not function or charge the vehicle again u...

Page 35: ...DED 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 following manufacturer s directions add...

Page 36: ... prevent vehicle downtime and expensive repairs that can result from neglect Use the Pre Operation and Daily Safety Checklist on page 23 and the following Periodic Service Schedules and Periodic Lubrication Schedules to keep the vehicle in proper working condition Any vehicle not functioning correctly should be removed from use until it is properly repaired This will prevent further damage to the ...

Page 37: ...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 PERIODIC SERVICE SCHEDULES See General Warnings on page 9 WARNING Service repairs and adjustments must be made per instructions in the maintenance and service manual If any problems are found during scheduled inspection or service do not op...

Page 38: ... underside of vehicle Initial one time inspection by owner or trained technician after six weeks of use Batteries For vehicles newly equipped with the SPWS For vehicles newly equipped with the SPWS manually check battery electrolyte levels of all cells to verify correct valve operation See page 43 Check brake shoes replace if necessary or adjust as required Check brake cables for damage replace if...

Page 39: ... alignment and camber Check and adjust if necessary See Steering and Front Suspension section in the maintenance and service manual Electrical wiring and connections Check for tightness and damage Check brake shoes replace if necessary or adjust as required Check brake cables for damage replace as required Semiannual service by trained technician only or every 50 hours of operation whichever comes...

Page 40: ...Brake slides Dry Moly Lube CC PN 1012151 Semiannually by owner or trained technician or every 50 hours of operation whichever comes first Front suspension Chassis Lube EP NLGI Grade 2 Transaxle Check fill to plug level 7 22 fl oz 0 67 L SAE 30 WT API Class SE SF SG Oil or higher Annually by trained technician only or every 100 hours of operation whichever comes first Inspect front wheel bearings R...

Page 41: ...f operation whichever comes first Brake slides Dry Moly Lube CC PN 1012151 Transaxle Check fill to plug level 67 6 fl oz 2 L SAE 80W 90 API Class GL 5 Annually by trained technician only or every 100 hours of operation whichever comes first Inspect front wheel bearings Repack as necessary 7 Chassis Lube EP NLGI Grade 2 First change 100 hours additional change every 200 hours of operation or annual...

Page 42: ... Single Point Watering System SPWS on page 42 or Battery Care Vehicles Without the Single Point Watering System SPWS on page 43 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 vehic...

Page 43: ...everse 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 c...

Page 44: ...ES EQUIPPED WITH 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 ...

Page 45: ... 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 scenario is rare but should be monitored in the initial inspection and during routine watering sessions Replace malfunctioning valves to ensure maximum battery life See fo...

Page 46: ...wire terminals are damaged or corroded replace or clean them as necessary Failure to do so may 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 3 2 1 Level Indicator 2 Cap 3 Plates Maintain electroly...

Page 47: ...ter 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...

Page 48: ...ng Figure 25 4 Place the battery fill coupling into the space between the battery bucket and the car body Leaving the fill coupling on top of the battery bank or tucked between the batteries and the battery bucket can result in coupling damage 5 Turn the water faucet off when finished filling the vehicle s BATTERY CHARGER ELECTRIC VEHICLES DANGER The charging area must be ventilated Hydrogen level...

Page 49: ...d can cause batteries to explode Do not block or cover the charger ventilation slots The slots provide ventilation and protect the charger from overheating Do not allow clothing blankets or other material to cover the charger Do not allow the charger to operate for more than 30 minutes at 19 or more amperes Install surge arrestors on incoming AC power lines Surge arrestors will help protect electr...

Page 50: ... have any exposed wires or are damaged in any way Using the charger with any of the above symptoms can result in a fire property damage personal injury or death NOTE 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 and cold batteries require more time to fully charge Ins...

Page 51: ...ing properly or if the batteries seem weak contact your local Club Car distributor dealer PLUG AND RECEPTACLE The charger cord plug and receptacle are wear items and should be inspected daily Visually inspect them for cracks loose connections and frayed wiring they must be replaced when worn or damaged If charger plug or receptacle show signs of corrosion or the plug is difficult to insert or remo...

Page 52: ...lem and correct it before replacing the fuse Contact your nearest Club Car distributor dealer BATTERY GASOLINE VEHICLE See General Warnings on page 9 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 Too...

Page 53: ...round 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 Gasoline Vehicles on page 11 See follow...

Page 54: ...pstick gauge add oil until the level is between low and full levels safe level 4 Insert the dipstick into the oil filler tube See following NOTE NOTE Properly recycle or dispose of used oil in accordance with local state and federal regulations 3 2 1 1 Full level 2 Safe level 3 Low level 2662 Figure 32 Engine Oil Level Check ENGINE OIL CHANGE Engine oil should be changed after the first 100 hours ...

Page 55: ...he 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 residue Make sure that the compression washer remains on the drain plug 7 Use a 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 U...

Page 56: ...uel tank ground wire on the tank is properly connected before fueling the vehicle To 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 If the vehicle has an all weather enclosure installed be sure the fuel tank is properly vented as shown Figur...

Page 57: ... automotive cleaners with a sponge or soft cloth for normal cleaning A garden hose at normal residential water pressure is adequate Club Car does not recommend any type of pressure washing or steam cleaning Such a process especially if the vehicle has the rear body removed will expose electrical components to moisture Moisture entering electrical components can result in water damage and subsequen...

Page 58: ... page 59 Failure to heed this caution can result in the vehicle shutting off possibly leaving operator and passengers stranded SUBSEQUENT OWNER 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 of the vehicle to CLU...

Page 59: ... cm Wheelbase 66 5 in 168 9 cm Ground clearance 5 5 in 14 cm Front wheel tread 34 5 in 88 cm Rear wheel tread 38 5 in 98 cm Weight Standard electric vehicle without batteries Curb weight 572 lb 260 kg 980 lb 444 5 kg Vehicle rated capacity Level surface only 800 lb 363 kg Forward speed 17 mph 27 km h Standard seating capacity 2 LIQUID CAPACITIES Transaxle 22 fl oz 0 67 L TIRE PRESSURE Front and re...

Page 60: ...60 Hz 6 1 6 1 6 3 6 3 Max AC current amps at 220 to 230 VAC 50 Hz 6 3 7 2 6 3 7 2 6 9 6 9 Max AC current amps at 220 to 230 VAC 60 Hz 5 6 6 9 5 6 6 9 6 3 6 3 Max AC current amps at 240 VAC 50 Hz 5 9 5 9 5 9 5 9 Max AC current amps at 240 VAC 60 Hz 5 2 5 2 5 1 5 1 DC OUTPUT DC voltage VDC Typical start of charge cycle 48 48 48 48 DC current amps maximum start of charge cycle 17 17 17 17 DC voltage ...

Page 61: ...xle Ignition Digital CDI with electronic RPM limiter 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 dr...

Page 62: ...orward speed 17 mph 27 km h Standard seating capacity 2 LIQUID CAPACITIES Engine crankcase 40 5 fl oz 1 2 L Transaxle 67 6 fl oz 2 L Fuel tank 4 6 gallons 17 4 L TIRE PRESSURE Front and rear 18 to 20 psig 124 to 138 kPa NOISE AND VIBRATION Drive by noise level to operator Test method EN 12053 2001 Unknown at time of printing Uncertainty 2 dBA Vibration at driver s seat Test method SAE J1013 Unknow...

Page 63: ...h axle shafts 2 YEARS 2000 HOURS ALL REMAINING COMPONENTS Solenoid MCOR limit switches voltage regulators F R switches brake components wiring harness electrical switches canopy systems seats pedal group assembly body and all original equipment options and accessories supplied by CLUB CAR and all remaining components of the vehicle not specified otherwise 1 YEAR 1000 HOURS 1 YEAR 1000 HOURS 6 VOLT...

Page 64: ...xpenses 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...

Page 65: ...itation 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 veh...

Page 66: ...ion Stan dard s fur Uberprufung Normes Utilisees pour Verification Norma s 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 Fabrican t Fabricante Fab rikan t Fabricante Fab bricante Producent Tillverkare Cl...

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Page 68: ...Publication Part Number 105062707 Edition Code 1113A00000 This manual is valid for vehicles with build codes between 56658 and the one indicated at the top of this page 105062707 ...

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