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Club Car CARRYALL 300 GASOLINE, Operator'S Manual

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CARRYALL 300 ELECTRIC
Operators Manual
TPCC01MF00EN019 (Edition A)

Page 69

INTERVAL

DESCRIPTION

Monthly

Examine the tire pressure.

Clean the vehicle.

SPWS: Add water to the batteries.

Clean the batteries.

Clean the battery compartment.

Make sure the battery cables are tight.

Make sure the battery hold-downs are tight.

Quarterly

Do an inspection of the deionizer.

Do an inspection of the SPWS.

50 hours / 6 months

Use WD-40

®

to lubricate the battery charger receptacle.

Have a trained technician:

• examine and lubricate the brake system

• examine the electrical system

• examine the front wheel alignment

• lubricate the front suspension

• examine the Motor Controller Output Regulator (MCOR)

• lubricate the accelerator pedal

100 hours / 12 months

Have a trained technician examine the:

• batteries

• front wheel bearings

• pedal components

• safety decals

• transaxle fluid

Vehicle Maintenance

Maintenance Schedule

8

Summary of Contents for CARRYALL 300 GASOLINE

Page 1: ...CARRYALL 300 ELECTRIC Operators Manual APPLICABLE TO CARRYALL 300 ERIC ELECTRIC VEHICLES WITH SERIAL PREFIX OF MF ...

Page 2: ...Copyright 2018 Club Car LLC This manual effective July 15 2018 ...

Page 3: ...of the vehicle will make sure Club Car is able to communicate necessary information directly to owners Send your name address and serial number of the vehicle to Club Car LLC Attention Vehicle Registration P O Box 204658 Augusta Georgia 30917 4658 United States Of America CALIFORNIA PROPOSITION 65 WARNING OPERATING SERVICING AND MAINTAINING A PASSENGER VEHICLE OR OFF ROAD VEHICLE CAN EXPOSE YOU TO...

Page 4: ...FORMATION Send written correspondence to Club Car LLC Attention Marketing Services P O Box 204658 Augusta Georgia 30917 4658 United States Of America CUSTOMER SATISFACTION SURVEY Let your voice be heard Your feedback will help improve our publications You can access the survey through any internet connected device with a web browser The survey is available in many different languages Scan the Quic...

Page 5: ...ABILITY OR HANDLING OF THE VEHICLE OR INCREASES THE MAXIMUM VEHICLE SPEED CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH NOTICE MODIFICATIONS TO THE VEHICLE MUST NOT COMPROMISE COMPLIANCE WITH STATE OR FEDERAL REGULATIONS Do not install non Club Car approved accessories or change the vehicle function to increased speed or power Modifications or installation of non Club Car approved accessories could c...

Page 6: ...purpose vehicle is intended to transport people and cargo on improved or groomed surfaces EUROPEAN UNION VIBRATION AND NOISE PREN 15997 European Union specification prEN 15997 was used to measure the vibration and noise levels of the vehicle The vibration and noise values are recorded in the vehicle specification section of this manual PUBLICATION COPYRIGHT This manual contains proprietary informa...

Page 7: ...cid Battery Recycling 18 SECTION 2 INDICATORS GAUGES AND DISPLAYS 19 Indicator Gauge And Display Locations 20 Battery Condition Indicator 20 Charge Indicator Light 20 SECTION 3 VEHICLE CONTROLS 23 Vehicle Controls Locator 24 Accelerator Pedal 24 Brake Pedal 25 Electric Bed Lift Switch 25 Forward Neutral Reverse Control 25 Hazard Light Switch 25 Headlight Switch 26 Horn 26 Key Switch 26 Park Brake ...

Page 8: ...ator Lights 41 Battery Charging Interlock 43 External Battery Charger Mounting 43 How To Make Strain Relief And Drip Loop 44 Inspection And Maintenance 44 Electrical Cords 44 Electrical Plugs And Receptacles 45 Clean The Electrical Plugs And Receptacles 45 Battery Charger USB Receptacle 45 Clean The USB Receptacle 45 SECTION 6 VEHICLE SPECIFICATIONS 47 Dimensions 48 Performance 48 Tires 48 Electri...

Page 9: ...E 75 Battery Cleaning 76 Battery Charging 76 Charging With External Charger 76 Charging With Onboard Charger 78 Battery Electrical Connection 79 Disconnect 79 Connect 79 Battery Hold Down 80 Add Water To A Battery Without Single Point Watering System 80 Deionizer 82 Add Water To Batteries With Single Point Watering System 82 Watering Intervals 82 Water Quality 82 Overview 82 Preferred Sources 83 A...

Page 10: ...CARRYALL 300 ELECTRIC Operators Manual TPCC01MF00EN019 Edition A Warranty Timeframe 94 Exclusions 95 Voiding Of Warranty 96 Sole Remedy 96 Disclaimer 96 No Consequential Damages 96 How To Make A Warranty Claim 97 ...

Page 11: ...1 SAFETY INFORMATION CARRYALL 300 ELECTRIC Operators Manual TPCC01MF00EN019 Edition A Page 9 Safety Information Notices 1 ...

Page 12: ...istributor Know and understand all laws and regulations for vehicle operation in your area Speak with your dealer or distributor if you have questions about material contained in this manual or the vehicle SAFETY SIGNAL WORDS Signal words DANGER WARNING CAUTION and NOTICE and safety messages are in this manual and on safety decals Read understand and obey all instructions safety precautions and sa...

Page 13: ...UCTIONS IN THIS MANUAL CAN CAUSE PROPERTY DAMAGE SERIOUS PERSONAL INJURY OR DEATH BEFORE YOU OPERATE THE VEHICLE OR DO THE SERVICING OF THE VEHICLE READ AND FULLY UNDERSTAND THE OWNER S MANUAL CLUB CAR VEHICLES ARE NOT RATED FOR OPERATION IN EXPLOSIVE AREAS THE VEHICLE OR BATTERY CHARGER CAN CAUSE FLAMMABLE MATERIAL AND FUME IGNITION DO NOT OPERATE THE VEHICLE OR BATTERY CHARGER NEAR FLAMMABLE MAT...

Page 14: ...CAL REPAIR THE APPROPRIATE INSTRUCTIONS MUST BE USED WHEN PERFORMING MAINTENANCE SERVICE OR ACCESSORY INSTALLATION CAUTION ACCESSORIES ATTACHED TO THE BED SIDES CAN ADD WIDTH TO THE VEHICLE HIT NEARBY PERSONS OR OBJECTS AND CAUSE PERSONAL INJURY AND PROPERTY DAMAGE USE CAUTION WHEN OPERATING THE VEHICLE WITH ACCESSORIES ATTACHED TO THE BED SIDES VEHICLE SAFETY AND COMPLIANCE DECALS WARNING MAKE SU...

Page 15: ... 105046101 Turn key to OFF and remove key Engage park brake to lock wheels Set the FNR control to NEUTRAL N Before leaving Unintended vehicle movement can cause serious injury or death Read and understand the Operators Manual and safety decals before vehicle operation WARNING the vehicle 3 12V Decal 4 Operating Instructions Decal Safety Information Vehicle Safety Information 1 ...

Page 16: ... Decal 105130001 48V ACC FUSE BLOCK MAXIMUM TONGUE WEIGHT 150 lb 68 kg NOTICE 101155301 9 48V Accessory Fuse Block Decal 10 Trailer Hitch Tongue Weight Notice Decal L A T C H O P E N WARNING CRUSH HAZARD CAN CAUSE SERIOUS INJURY Keep hands clear when closing cargo bed 102459301 WARNING TOW RUN 101908601 Towing this vehicle Extended storage Servicing the vehicle Disconnecting or connecting battery ...

Page 17: ... s seat only Do not start vehicle until all occupants are fully seated Drive slowly in turns and straight up and down slopes 104026801 WARNING 14 Occupant Warning Decal VEHICLE SAFETY FEATURES BATTERY CHARGING INTERLOCK External Battery Charger The battery charging interlock is a safety feature that prevents possible damage to the battery charger and vehicle The battery charging interlock will aut...

Page 18: ...ORE THAN A 20 INCLINE Walk away braking is a safety function that limits the roll away speed of a vehicle when the park brake is disengaged The multi purpose buzzer will make an audible tone when the walk away braking safety device engages for more than two seconds FALLING OBJECT PROTECTION SYSTEM The Falling Object Protection System FOPS protects the vehicle occupants from falling debris The FOPS...

Page 19: ...OSION CAN BECOME TOO HOT AND CAUSE A FIRE PROPERTY DAMAGE OR PERSONAL INJURY REPLACE BATTERY WIRES WITH DAMAGE OR CORROSION CLEAN CORROSION FROM THE BATTERY TERMINALS BATTERY INTERNATIONAL SAFETY SYMBOLS Understand and obey the international safety symbols on the vehicle battery before you use repair or service the vehicle SYMBOL SIGNIFICANCE Shield eyes Read and obey operation and maintenance ins...

Page 20: ...WITH YOUR DEALER OR DISTRIBUTOR FOR INFORMATION ON HOW TO DISCARD A BATTERY CORRECTLY Lead acid batteries and other components which have the Waste Electrical and Electronic Equipment WEEE symbol printed on them must be collected and recycled separately from other waste Do not discard lead acid batteries as municipal waste Speak with your dealer or distributor on how to correctly recycle lead acid...

Page 21: ...2 INDICATORS GAUGES AND DISPLAYS CARRYALL 300 ELECTRIC Operators Manual TPCC01MF00EN019 Edition A Page 19 Indicators Gauges And Displays Battery Safety Information 2 ...

Page 22: ...state of charge SOC The battery condition indicator has a 10 bar LED display CHARGE INDICATOR LIGHT NOTICE WHEN THE CHARGE INDICATOR LIGHT IS ON CHARGE BATTERIES AS QUICKLY AS POSSIBLE The charge indicator lamp gives a visual indication when The battery state of charge SOC is less than 20 Charge the batteries as quickly as possible The batteries start to charge Note The multi purpose buzzer will o...

Page 23: ...TATUS CONDITION OFF Battery SOC is more than 20 ON CONSTANT Battery SOC is less than 20 but more than 10 ON FLASH ON AND OFF Battery SOC is less than 10 ON FLASH ON AND OFF THREE TIMES The batteries charging has started Indicators Gauges And Displays Charge Indicator Light 2 ...

Page 24: ... Page intentionally left blank ...

Page 25: ...3 VEHICLE CONTROLS CARRYALL 300 ELECTRIC Operators Manual TPCC01MF00EN019 Edition A Page 23 Vehicle Controls Charge Indicator Light 3 ...

Page 26: ...ntrol FNR 6 Headlight Switch 7 Run Tow Switch 8 Electric Bed Lift Switch Optional Equipment 9 Turn Signal Lever Optional Equipment 10 Horn Optional Equipment 11 Windshield Wiper Switch Optional Equipment 12 Hazard Lights Switch Optional Equipment ACCELERATOR PEDAL The accelerator pedal is used to increase and maintain the speed of the vehicle 3 Vehicle Controls Vehicle Controls Locator ...

Page 27: ...TING THE FORWARD NEUTRAL REVERSE CONTROL FNR CAN CAUSE PERSONAL INJURY AND VEHICLE DAMAGE STOP THE VEHICLE BEFORE SHIFTING THE FORWARD NEUTRAL REVERSE CONTROL FNR The Forward Neutral Reverse control FNR sets the direction of vehicle movement Stop the vehicle to change the FNR position POSITION FUNCTION F Forward N Center Neutral R Reverse HAZARD LIGHT SWITCH The hazard light switch controls the op...

Page 28: ...sed to control the horn The horn button is spring loaded to stay in the off position Push and hold the horn button to operate the horn Note The horn will not operate when the key switch is OFF KEY SWITCH The key switch controls the motor and electrical system A key is used to select the key switch position The key can only be inserted or removed when the key switch set to OFF 3 Vehicle Controls He...

Page 29: ...UTOMATICALLY WHEN THE ACCELERATOR OR BRAKE PEDAL IS PUSHED PREVENT ACCIDENTAL ACCELERATOR OR BRAKE PEDAL ACTUATION The park brake is a variable position control that is used to make sure that a vehicle does not move while parked Push the park brake firmly to engage the park brake To disengage the park brake push the accelerator or brake pedal RUN TOW SWITCH WARNING UNINTENDED VEHICLE MOVEMENT CAN ...

Page 30: ...en turned on POSITION FUNCTION Down Left Center Off Up Right WINDSHIELD WIPER SWITCH The windshield wiper switch controls the operation of the wiper blades Note The windshield wiper operates independently of the key switch position POSITION FUNCTION Top On Bottom Off MODULAR CAB CONTROLS DEFROST AND HEATER SWITCH The defrost and heater switch controls the operation of the defrost and heater system...

Page 31: ...trols the operation of the lower dash fan Note The lower dash fan operates independently of the key switch position POSITION FUNCTION H High OFF Off L Low STROBE LIGHT SWITCH The strobe light switch controls the operation of the strobe light POSITION FUNCTION Top On Bottom Off UPPER CAB FAN SWITCH The upper cab fan switch controls the operation of the upper cab fan Note The upper cab fan operates ...

Page 32: ...SHER SWITCH The windshield washer switch controls the operation of the washer fluid supply to the windshield The switch is spring loaded to stay in the off position Push and hold the switch in the on position to apply washer fluid to the windshield 3 Vehicle Controls Modular Cab Controls ...

Page 33: ...4 VEHICLE FEATURES CARRYALL 300 ELECTRIC Operators Manual TPCC01MF00EN019 Edition A Page 31 Vehicle Features Modular Cab Controls 4 ...

Page 34: ...GO BED WARNING THE AREA BETWEEN THE CARGO BED AND SEAT BACK SUPPORT CAN CRUSH KEEP HANDS AND FINGERS AWAY FROM THIS AREA The electric bed lift lowers and lifts the tilt cargo bed The electric bed lift is controlled through the electric bed lift switch ELECTRIC BED LIFT CAPACITY The electric bed lift has a maximum capacity of 500 lb 226 kg OPERATION LIFT THE ELECTRIC BED LIFT 1 Turn the key to ON 2...

Page 35: ...BEFORE THE CARGO BED IS LIFTED REMOVE ALL CARGO AND ACCESSORIES FROM THE CARGO BED CORRECTLY ENGAGE THE PROP ROD CAREFULLY LOWER THE CARGO BED WARNING THE AREA BETWEEN THE CARGO BED AND SEAT BACK SUPPORT CAN CRUSH KEEP HANDS AND FINGERS AWAY FROM THIS AREA A tilt cargo bed makes the removal of cargo easier and gives additional access for vehicle maintenance The cargo bed release handle is used to ...

Page 36: ...ages 12 VOLT POWER RECEPTACLE The 12 volt 6 5 amp power receptacle supplies electricity to power and charge accessories when the key switch is ON The 12 volt power receptacle and the electrical circuit is protected by a 10 amp fuse Note The continuous operation of the 12 volt power receptacle can cause in a full discharge of vehicle batteries Note Do not use the 12 volt power receptacle for long p...

Page 37: ... A Page 35 VERSATTACH SYSTEM VersAttach is a track based attachment system that organizes and secures cargo bed accessories Speak with your local approved dealer or distributor for a full list of accessories and configurations Vehicle Features VersAttach System 4 ...

Page 38: ... Page intentionally left blank ...

Page 39: ...5 BATTERY CHARGER CARRYALL 300 ELECTRIC Operators Manual TPCC01MF00EN019 Edition A Page 37 Battery Charger VersAttach System 5 ...

Page 40: ...L CONNECTION CAN CAUSE A FIRE PROPERTY DAMAGE PERSONAL INJURY OR DEATH DO NOT USE A BATTERY CHARGER THAT HAS DAMAGE FELL OR WAS HIT PUT THE CORDS IN AN AREA TO PREVENT THEM FROM BEING STEPPED ON TRIPPED OVER OR SUBJECTED TO DAMAGE OR STRESS SPEAK WITH YOUR LOCAL DEALER OR DISTRIBUTOR FOR REPAIRS LIQUID ON THE BATTERY CHARGER CAN CAUSE PROPERTY DAMAGE ELECTRICAL SHOCK PERSONAL INJURY OR DEATH DO NO...

Page 41: ...NT Status indicator lights to identify AC power stages of charge and faults Visual signal when charging starts CONNECTED Two way data communication through a USB receptacle Update the charger with the latest charge algorithm Collect status and condition data for charger monitoring ERIC IC650 SPECIFICATIONS MANUFACTURER INFORMATION Manufacturer Delta Q Technologies Model Name ERIC Model Number IC65...

Page 42: ...of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in an industrial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a reside...

Page 43: ...ectrical Code local codes and local ordinances WARNING AN EXTENSION CORD IS NOT RECOMMENDED INCORRECT CONNECTION OF THE CHARGER AC CORD TO AN EXTENSION CORD CAN CAUSE A FIRE OR AN ELECTRICAL SHOCK Use of an extension cord with the charger is not recommended Precautions when the use of an extension cord is necessary The extension cord must accept a three prong plug The extension cord must be as sho...

Page 44: ...Flash On And Off The USB receptacle is on Do not remove the USB flash drive Green Constant Safe to remove the USB flash drive Green Constant Charging is complete Batteries are fully charged Green Flash On And Off Charging Batteries are at high state of charge SOC Green Constant Off Charging Batteries are not at a high SOC Green Flash On And Off Blue Constant There is AC power to charger The table ...

Page 45: ...ehicle The vehicle will not operate when the DC cord is connected Note The AC cord does not have to be connected for the battery charging interlock to operate Onboard Battery Charger The battery charging interlock is a safety feature that prevents possible damage to the battery charger and vehicle The battery charging interlock will automatically engage when the AC cord is connected to a power sou...

Page 46: ...ug 2 Supply sufficient AC cord to make a drip loop and strain relief 3 Secure the AC cord to the battery charger with a plastic cable tie 2 INSPECTION AND MAINTENANCE ELECTRICAL CORDS NOTICE AN ELECTRICAL SHORT IN THE DC CORD CAN CAUSE THE 30 AMP FUSE TO BLOW IF THERE IS DAMAGE TO THE DC CORD SPEAK WITH YOUR LOCAL DEALER OR DISTRIBUTOR Examine electrical cords for wear and damage before use Immedi...

Page 47: ... electrical plugs and receptacles Refer to the manufacturer instructions 5 Clean the electrical plugs and receptacles 6 Lubricate the electrical plugs and receptacles with WD 40 BATTERY CHARGER USB RECEPTACLE The movement of charger data and download of the charge algorithm is done through the USB receptacle Use of the USB receptacle is for approved persons and technicians If the batteries are rep...

Page 48: ...RRYALL 300 ELECTRIC Operators Manual TPCC01MF00EN019 Edition A 6 If contamination continues apply dielectric grease to the USB receptacle 7 Install the USB dust cover 5 Battery Charger Inspection And Maintenance ...

Page 49: ...6 VEHICLE SPECIFICATIONS CARRYALL 300 ELECTRIC Operators Manual TPCC01MF00EN019 Edition A Page 47 Vehicle Specifications Inspection And Maintenance 6 ...

Page 50: ... 6 cm Flat Bed Size 36 5 x 48 8 in 92 7 x 123 9 cm Ground Clearance 5 2 in 13 2 cm Wheel Tread 36 6 in 92 9 cm front wheel 39 5 in 100 3 cm rear wheel PERFORMANCE Forward Speed On Level Ground 15 to 17 mph 24 to 27 km h Turning Radius SAE J695 108 7 in 276 2 cm Intersecting Aisle Clearance 87 in 221 0 cm Curb To Curb 230 5 in 585 4 cm Wall To Wall Unknown At Time Of Print TIRES Go to the approved ...

Page 51: ... SERIOUS PERSONAL INJURY OR DEATH CAN OCCUR DO NOT EXCEED THE RATED CAPACITY OF THE VEHICLE RATED CAPACITY IS FOR LEVEL SURFACES ONLY TOO MUCH WEIGHT IN THE VEHICLE CAN AFFECT THE VEHICLES HANDLING OR CAUSE COMPONENT FAILURE RESULTING IN LOSS OF CONTROL OF VEHICLE AND SERIOUS PERSONAL INJURY DO NOT EXCEED THE VEHICLE LOAD CAPACITIES DO NOT TOW WHEN THE CARGO CAPACITY IS EXCEEDED Description Weight...

Page 52: ...maximum towing weight is the maximum weight the vehicle can tow with a Club Car approved tow kit Trailer Tongue Weight The trailer tongue weight is the maximum permitted weight applied by the trailer tongue onto the trailer hitch Gross Trailer Weight The gross trailer weight is the trailer weight plus the weight of the load on the trailer Vehicle Rated Capacity The vehicle rated capacity is the ma...

Page 53: ...7 VEHICLE OPERATION CARRYALL 300 ELECTRIC Operators Manual TPCC01MF00EN019 Edition A Page 51 Vehicle Operation Vehicle Weights And Load Capacities 7 ...

Page 54: ...N THE VEHICLE OR TRAILER BEING TOWED DO NOT LET PASSENGERS RIDE IN THE CARGO BED WARNING KEEP AWAY FROM DROP OFFS STEEP SLOPES AND UNSTABLE SURFACES THE VEHICLE IS NOT DESIGNED TO BE USED ON PUBLIC ROADS DO NOT LICENSE THE VEHICLE FOR PUBLIC ROADS DO NOT OPERATOR THE VEHICLE ON PUBLIC ROADS SUDDEN STARTS STOPS AND TURNS CAN CAUSE PERSONAL INJURY AND VEHICLE DAMAGE PREVENT SUDDEN STARTS STOPS AND T...

Page 55: ...SORY OR MENTAL CAPABILITIES OR LACK OF EXPERIENCE AND KNOWLEDGE UNLESS THEY HAVE BEEN GIVEN SUPERVISION OR INSTRUCTION CONCERNING USE OF THE APPLIANCE BY A PERSON RESPONSIBLE FOR THEIR SAFETY CHILDREN SHOULD BE SUPERVISED TO ENSURE THAT THEY DO NOT PLAY WITH THE VEHICLE CAUTION OPERATE THE VEHICLE ONLY FROM THE DRIVERS SEAT OPERATE THE VEHICLE ONLY IN SPECIFIED AREAS ONLY AN AUTHORIZED LICENSED DR...

Page 56: ...ched Tighten as necessary Examine the battery posts for corrosion If corrosion is found remove the corrosion Make sure that the batteries are fully charged Examine the battery acid level Add deionized or distilled water as necessary Replace missing worn or damaged items Battery Charger Examine the electrical cords for cracks loose connections and frayed wires Examine receptacle contacts and plug t...

Page 57: ...edal 3 Set the Forward Neutral Reverse control FNR to R Make sure that the multi purpose buzzer operates 4 Release the brake pedal 5 Slowly push the accelerator pedal Make sure the vehicle moves in reverse 6 Slowly push the brake pedal Stop the vehicle 7 Set the FNR to F Make sure that the multi purpose buzzer does not operate 8 Release the brake pedal 9 Slowly push the accelerator pedal Make sure...

Page 58: ...isplays Controls MOTOR START Before motor start Read and obey all safety decals and information located on the vehicle Understand how to operate the vehicle correctly and safely Understand the function of all vehicle controls indicators displays and gauges Make sure that all passengers are seated and use the hand holds or handrails The operator must have both hands on the steering wheel Front whee...

Page 59: ... gauges Make sure that all passengers are seated and use the hand holds or handrails The operator must have both hands on the steering wheel Make sure that the front wheels are turned in the direction of travel Make sure that there are no obstructions are in the vehicles path The key switch is set to ON The vehicle is at a full stop To move the vehicle forward 1 Set the Forward Neutral Reverse con...

Page 60: ... Stop the vehicle 2 Engage the park brake to lock the wheels 3 Set the Forward Neutral Reverse control FNR to N 4 Turn the key to OFF 5 Remove the key Keep the key in a safe area DRIVING CONDITIONS UNPAVED SURFACES Precautions for operation on unpaved or unimproved surfaces Decrease vehicle speed Use extreme caution UPHILL SLOPE WARNING PREVENT STOPPING ON A HILL WHEN TOWING OR WITH A LOADED VEHIC...

Page 61: ... Do not stop a vehicle with a load on a slope If a vehicle with a load must stop on a slope prevent backwards movement or sudden starts or stops Do not go over the top of a hill at high speed Obstacles sharp drop offs other vehicles or persons could be on the other side of the hill SIDE HILL SLOPE WARNING TO PREVENT ROLL OVER PROPERTY DAMAGE AND PERSONAL INJURY OPERATE THE VEHICLE SLOWLY ON A SLOP...

Page 62: ...CLE UNTIL THE DRIVETRAIN IS FULLY ENGAGED Precautions when on a downhill slope Prevent driving on slopes that exceed 20 grade Always examine the terrain carefully before driving on a slope Do not drive on a slope with slippery or loose surfaces Keep the heavy end of the vehicle uphill Keep your feet on the floorboard Drive in a straight line on the slope Prevent driving at an offset angle An offse...

Page 63: ...OPERATE THE VEHICLE AT NIGHT THE VEHICLE MUST HAVE HEADLIGHTS TAILLIGHTS AND REFLECTORS Vehicle operation at night is not recommended When driving at night is unavoidable the vehicle must have Headlights Tail lights Reflectors Precautions if driving at night is unavoidable Always have headlights on Always examine the terrain for obstacles before driving in a new area Look forward and learn to read...

Page 64: ...d on the trailer tongue The combined weight of these items must not exceed the maximum weight capacity Keep the heavy end of the vehicle uphill Always load the cargo box with the load as far forward and as low as possible Always operate the vehicle with extreme caution when hauling or towing loads Secure all loads before operating Unsecured loads can cause unstable operating conditions which could...

Page 65: ...RRYALL 300 ELECTRIC Operators Manual TPCC01MF00EN019 Edition A Page 63 km h when towing loads in rough terrain while cornering or while climbing or going down a hill Vehicle Operation Driving Conditions 7 ...

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Page 67: ...8 VEHICLE MAINTENANCE CARRYALL 300 ELECTRIC Operators Manual TPCC01MF00EN019 Edition A Page 65 Vehicle Maintenance Driving Conditions 8 ...

Page 68: ...ORY INSTALLATION FAILURE TO CORRECTLY MAINTAIN THE VEHICLE CAN CAUSE DECREASED VEHICLE PERFORMANCE SERIOUS PERSONAL INJURY OR DEATH FAILURE TO MAKE NECESSARY REPAIRS CAN CAUSE A FIRE PROPERTY DAMAGE SERIOUS PERSONAL INJURY OR DEATH IF PROBLEMS ARE FOUND DURING SCHEDULED INSPECTION OR SERVICE OPERATE THE VEHICLE ONLY WHEN REPAIRS ARE MADE UNINTENTIONAL VEHICLE STARTUP CAN CAUSE PERSONAL INJURY PROP...

Page 69: ...move the key 5 Set the Forward Neutral Reverse control FNR to N 6 Put the chocks against the wheels VEHICLE CLEANING CLEANING THE WINDSHIELD Use a soft towel and water to clean the windshield Use mild soap as necessary Do not use a household window cleaner CLEANING THE VEHICLE EXTERIOR NOTICE MOISTURE WILL CAUSE ELECTRICAL COMPONENT DAMAGE DO NOT USE A PRESSURE WASHER OR STEAM CLEANER TO CLEAN THE...

Page 70: ...tenance Service Schedule If a vehicle is found to be in bad operational condition remove it from operation Removal from operation will prevent more damage to the vehicle and prevent the possible injury because of dangerous conditions Speak with your dealer or distributor for maintenance and repairs MAINTENANCE SERVICE SCHEDULE Note The Maintenance Service Schedule must be done more frequently on v...

Page 71: ...of the deionizer Do an inspection of the SPWS 50 hours 6 months Use WD 40 to lubricate the battery charger receptacle Have a trained technician examine and lubricate the brake system examine the electrical system examine the front wheel alignment lubricate the front suspension examine the Motor Controller Output Regulator MCOR lubricate the accelerator pedal 100 hours 12 months Have a trained tech...

Page 72: ...R DEATH REMOVE ALL CARGO FROM THE CARGO BED BEFORE THE VEHICLE IS LIFTED Before the vehicle is lifted Disable the vehicle Disconnect the batteries Use a jack and jack stands rated for the vehicle To lift the front of the vehicle 1 Place the jack in the center of the lift point 2 Lift the front of the vehicle 3 Put jack stands under the frame rails 4 Lower the vehicle onto the jack stands 8 Vehicle...

Page 73: ...the vehicle is lifted Disable the vehicle Disconnect the batteries Use a jack and jack stands rated for the vehicle To lift the rear of the vehicle 1 Place the jack in the center of the lift point 2 Lift the rear of the vehicle 3 Put jack stands under the frame rails 4 Lower the vehicle onto the jack stands LOWER THE VEHICLE LOWER THE FRONT OF THE VEHICLE Before the front of the vehicle is lowered...

Page 74: ...f the vehicle 1 Place the jack in the center of the lift point 2 Lift the vehicle off of the jack stands 3 Remove the jack stands 4 Lower the vehicle LOWER THE REAR OF THE VEHICLE Before the rear of the vehicle is lowered Use a jack rated for the vehicle 8 Vehicle Maintenance Maintenance Tasks ...

Page 75: ...ure measurement Disable the vehicle To measure the tire pressure 1 Remove the valve stem cap 2 Use a pressure gauge to measure the tire pressure 3 Adjust to meet the recommended tire pressure Note Go to the approved wheel and tire assemblies matrix on http www clubcar com for information regarding tire type inflation pressure and lug nut torque 4 Install the valve stem cap WHEEL ASSEMBLY WHEEL ASS...

Page 76: ...hicle to allow for installation of the wheel assembly 2 Align the wheel assembly onto the hub of the vehicle Note Make sure that the valve stem points to the outer side of the vehicle Note Make sure that the tire tread is in the correct direction of travel 3 Tighten the lug nuts until they are hand tight 4 Lower the vehicle 5 Tighten the lug nuts to the recommended torque specification Note Go to ...

Page 77: ...316V 9 BATTERY MAINTENANCE CARRYALL 300 ELECTRIC Operators Manual TPCC01MF00EN019 Edition A Page 75 Battery Maintenance Maintenance Tasks 9 ...

Page 78: ...able has corrosion have a trained technician replace the battery cable 5 Make sure the battery cables are tight If a battery cable is not tight tighten the hardware to 110 lb in 12 4 N m 6 Let the terminals dry 7 Apply battery terminal protector spray to the terminals BATTERY CHARGING CHARGING WITH EXTERNAL CHARGER DANGER CHARGING BATTERIES EMIT HYDROGEN GAS THAT IS EXPLOSIVE ABOVE 2 AIR CONCENTRA...

Page 79: ...urce NOTICE INCORRECT REMOVAL AND INSTALLATION OF THE DC CORD CAN CAUSE DC CORD DAMAGE AND VEHICLE CHARGER RECEPTACLE DAMAGE DO NOT TWIST BEND OR MOVE THE DC CORD PLUG SIDE TO SIDE DO NOT PULL ON THE DC CORD HOLD THE PLUG HANDLE AND PUSH THE PLUG STRAIGHT INTO THE VEHICLE CHARGER RECEPTACLE 5 Connect the DC cord to the vehicle charger receptacle 1 Note The vehicle will start to charge in 2 to 10 s...

Page 80: ...EA MUST BE CHANGED AT LEAST FIVE TIMES PER HOUR EXHAUST FANS MUST BE LOCATED AT THE HIGHEST POINT OF THE ROOF SPEAK WITH A LOCAL HVAC ENGINEER CHARGING THE BATTERIES WITH ACCESSORIES ON CAN CAUSE A FIRE AND PERSONAL INJURY TURN OFF ALL ACCESSORIES BEFORE CHARGING THE BATTERIES WARNING LOOSE CORD CONNECTIONS CAN CAUSE A FIRE MAKE SURE THAT ALL CORD CONNECTIONS AT THE RECEPTACLE ARE CLEAN AND TIGHT ...

Page 81: ...RUN TOW SWITCH TO TOW BEFORE THE BATTERIES ARE DISCONNECTED OR CONNECTED 1 Set the Run Tow switch to TOW 2 Disconnect the negative cable 1 3 Disconnect the positive cable 2 Note Wait 90 seconds for the controller capacitors to discharge CONNECT THE BATTERIES DANGER BATTERIES DISCONNECTED OR CONNECTED WITH THE RUN TOW SWITCH SET TO RUN CAN CAUSE A BATTERY EXPLOSION AND SERIOUS PERSONAL INJURY SET T...

Page 82: ... BATTERY HOLD DOWN Each hold down must be tight to prevent the battery movement while the vehicle is in operation Do not tighten too much or the battery case can crack or buckle 1 Tighten the hold down nuts to 110 lb in 12 4 N m ADD WATER TO A BATTERY WITHOUT SINGLE POINT WATERING SYSTEM This information is for batteries without a Single Point Watering System SPWS Before water is added Disable the...

Page 83: ...attery acid is below the top of the plates 4 A Add water until the battery acid is level with the top of the plates 4 B Install and lock the cap 4 C Fully charge the batteries 5 Unlock and remove the cap 6 Make sure that the battery acid is 0 5 inches 13 mm above the top of the plates Add water as necessary CAUTION LOOSE BATTERY CAPS CAN CAUSE BATTERY ACID TO LEAK FULLY ATTACH THE BATTERY CAPS TO ...

Page 84: ...LS The watering intervals are affected by Age of the batteries Application Charging methods Local climate Examine the consumption rates manually Examine new batteries monthly until consumption rates are known Examine used batteries weekly until consumption rates are known The watering interval must maintain the electrolyte level above the top of the plates During periods of heavy use water the bat...

Page 85: ...mines the quantity of solids or impurities which get caught and hence the purity quality of the filtered water Because of the variance in water quality consistency Club Car recommends the use of the deionizer or distilled water TAP WATER Because of the levels of dissolved minerals and chemicals that can degrade battery performance and life the use of tap water without filtering should be limited R...

Page 86: ...lowering of on charge voltage Nitrates 10 0 Increased sulfation of negative plate Nitrites 5 0 Plate corrosion loss of capacity and decreased life Platinum None allowed Violent self discharge and lower on charge voltage Selenium 2 0 Positive plate shedding Zinc 4 0 Slight self discharge of negative plates Organic and volatile matter 50 0 Corrosion of positive plates Suspended matter Trace None Tot...

Page 87: ...10 TRANSPORT AND TOW CARRYALL 300 ELECTRIC Operators Manual TPCC01MF00EN019 Edition A Page 85 Transport And Tow Water Quality 10 ...

Page 88: ...ILER WITH A LOAD IN THE VEHICLE CARGO BED BEFORE TRANSPORTING THE VEHICLE ON A TRAILER REMOVE THE WINDSHIELD SECURE THE SEAT BOTTOM WHEN A TRAILER IS USED ON A PUBLIC ROAD THE TRAILER MUST MEET ALL FEDERAL STATE AND LOCAL REQUIREMENTS SUCH AS TAILLIGHTS AND BRAKE LIGHTS PREPARE THE VEHICLE TO BE TOWED 1 Turn the key to OFF 2 Remove the key Keep the key in a safe area 3 Set the Forward Neutral Reve...

Page 89: ...hicle 7 Secure all doors access panels seat bottoms and windshield 8 Examine the vehicle for loose parts Tighten as necessary 9 Secure the vehicle to the trailer VEHICLE TRANSPORT RECOVERY 1 Make sure that the trailer is correctly configured to remove the vehicle from the trailer safely 2 Remove all materials used to secure the vehicle to the trailer 3 Examine the vehicle for loose parts Tighten a...

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Page 91: ...11 EXTENDED STORAGE CARRYALL 300 ELECTRIC Operators Manual TPCC01MF00EN019 Edition A Page 89 Extended Storage Vehicle Transport Recovery 11 ...

Page 92: ...orrectly mix the water with battery acid To prepare your vehicle for extended storage 1 Turn off all electronic accessories 2 Set the Forward Neutral Reverse control FNR to N 3 Turn the key to OFF 4 Remove the key Keep the key in a safe area 5 Put chocks against the wheels Note Do not engage the park brake 6 Remove all cargo and personal items 7 Run Tow switch position Note The charge indicator li...

Page 93: ... will be kept at a sufficient level while in storage 14 A Connect the battery charger to the vehicle Keep battery chargers connected during storage The charger will automatically connect when necessary 14 B Examine the battery acid level and charger function monthly Note The charger is operating correctly when the blue light is on and the triangular light is off RETURN TO SERVICE FROM EXTENDED STO...

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Page 95: ...12 WARRANTIES CARRYALL 300 ELECTRIC Operators Manual TPCC01MF00EN019 Edition A Page 93 Warranties Return To Service From Extended Storage 12 ...

Page 96: ...actory 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 the Purchaser must provide proof of date of purchase with any warranty claim WARRANTY TIMEFRAME ITEM SUB ITEMS COVERAGE VEHICLE MAINFRAME Not applicable 2 years or...

Page 97: ...lub Car for use with the vehicle 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 must be used to ensure water quality Abuse such as overcharging undercharging improper fluid levels loose wiring and fasteners or rusted or corroded hardware Use of energy management systems that...

Page 98: ... to be defective Replacement shall mean furnishing during the applicable limited warranty period a new vehicle or factory 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 lim...

Page 99: ...ay 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 E mail cci_warrantyadministration clubcar com Postal Se...

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Page 102: ...Publication Part Number TPCC01MF00EN019 Edition Code A Club Car LLC P O Box 204658 Augusta GA 30917 4658 USA Web Phone Fax www clubcar com 1 706 258 2225 1 800 ClubCar 1 706 863 5858 ...

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