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CARRYALL 502 ELECTRIC

Operators Manual

TPCC01DQ00EN019 (Edition C)

• Disable the vehicle.

To remove the wheel assembly:

Remove the wheel cover.

Loosen the lug nuts.

Lift the vehicle to allow for removal of the wheel assembly.

Remove the lug nuts.

Remove the wheel assembly.

WHEEL ASSEMBLY INSTALLATION

Before wheel assembly installation:

• Disable the vehicle.

To install the wheel assembly:

Lift the vehicle to allow for installation of the wheel assembly.

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.

Tighten the lug nuts until they are hand-tight.

Lower the vehicle.

Tighten the lug nuts to the recommended torque specification.

Note:

Go to the approved wheel and tire assemblies matrix on

http://www.clubcar.com

for

information regarding tire type, inflation pressure, and lugnut torque.

Install the wheel cover.

Vehicle Maintenance

Maintenance Tasks

Содержание CARRYALL 502 ELECTRIC

Страница 1: ...CARRYALL 502 ELECTRIC Operators Manual APPLICABLE TO VEHICLES WITH SERIAL PREFIX OF DQ...

Страница 3: ...ude this manual with the vehicle when sold to a new owner Registration of the vehicle will make sure Club Car is able to communicate necessary information directly to owners Send your name address and...

Страница 4: ...ler com Scan the dealer locator Quick Response QR code COMPANY CONTACT INFORMATION Send written correspondence to Club Car LLC Attention Marketing Services P O Box 204658 Augusta Georgia 30917 4658 Un...

Страница 5: ...ERSONAL INJURY OR DEATH NOTICE MODIFICATIONS TO THE VEHICLE MUST NOT COMPROMISE COMPLIANCE WITH STATE OR FEDERAL REGULATIONS Modifications made to vehicles or installation of accessories that are not...

Страница 6: ...ARD ICES 002 This vehicle complies with CAN ICES 2 NMB 2 as it was on the date the vehicle was shipped from the Club Car manufacturing facility EUROPEAN UNION VIBRATION AND NOISE PREN 15997 European U...

Страница 7: ...Battery Safety Information 17 Battery International Safety Symbols 17 Lead Acid Battery Recycling 18 SECTION 2 INDICATORS GAUGES AND DISPLAYS 19 Indicator Gauge And Display Locations 20 Battery Condit...

Страница 8: ...rithm Program Number 38 Electrical Cords 38 Electrical Plugs And Receptacles 39 Troubleshooting 39 Diagnostic Code 39 SECTION 6 VEHICLE SPECIFICATIONS 41 Dimensions 42 Performance 42 Tires 42 Electric...

Страница 9: ...tery Hold Down 70 Add Water To A Battery Without Single Point Watering System 70 Deionizer 72 Add Water To Batteries With Single Point Watering System 72 Watering Intervals 72 Water Quality 72 Overvie...

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Страница 11: ...1 SAFETY INFORMATION CARRYALL 502 ELECTRIC Operators Manual TPCC01DQ00EN019 Edition C Page 9 Safety Information Notices 1...

Страница 12: ...ep body hands hair and clothes away from rotating parts Hot surfaces can cause serious burns Allow to cool before servicing Signal words DANGER WARNING CAUTION and NOTICE and safety messages are in th...

Страница 13: ...mmittee is safe vehicle operation Safety committee objectives include Approve vehicle operation areas Identify all hazards Identify who is approved to operate the vehicle Keep the vehicles in a safe a...

Страница 14: ...WITH A SEAT DO NOT LET A PASSENGER HOLD A CHILD IN HIS OR HER LAP WHILE THE VEHICLE MOVES ONLY TRAINED TECHNICIANS SHOULD SERVICE OR REPAIR THE VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHO...

Страница 15: ...2 persons per bench seat maximum Operate from driver s seat only Do not start vehicle until all occupants are fully seated Drive slowly in turns and straight up and down slopes Remain fully seated whi...

Страница 16: ...ING OFF CAN CAUSE SERIOUS INJURY OR DEATH Do not ride in the cargo bed 101553901 WARNING CRUSH AREA STAY CLEAR Do not lift bed with cargo inside Lift bed only for maintenance and service Remove cargo...

Страница 17: ...al 105137106 VEHICLE LOADING WARNING NOTICE ROLLOVERS CAN CAUSE SERIOUS INJURY OR DEATH Place cargo forward in the cargo bed and distribute evenly side to side Secure load On uneven or steep terrain r...

Страница 18: ...BRAKING TO TELL THE DRIVER THAT REGENERATIVE BRAKING PERFORMANCE WILL DECREASE USE THE BRAKE PEDAL TO CONTROL THE VEHICLE SPEED Regenerative braking helps maintain the downhill speed of the vehicle in...

Страница 19: ...S OF MILK OR WATER FOLLOWED WITH MILK OF MAGNESIA OR VEGETABLE OIL CALL A PHYSICIAN IMMEDIATELY EYES FLUSH WITH WATER FOR 15 MINUTES CALL A PHYSICIAN IMMEDIATELY WARNING FROZEN BATTERY ACID CAN CAUSE...

Страница 20: ...AND SOIL CAUSE ENVIRONMENTAL DAMAGE CAUSE PROPERTY DAMAGE AND CAUSE SERIOUS PERSONAL INJURY SPEAK WITH YOUR DEALER OR DISTRIBUTOR FOR INFORMATION ON HOW TO DISCARD A BATTERY CORRECTLY Lead acid batter...

Страница 21: ...2 INDICATORS GAUGES AND DISPLAYS CARRYALL 502 ELECTRIC Operators Manual TPCC01DQ00EN019 Edition C Page 19 Indicators Gauges And Displays Battery Safety Information 2...

Страница 22: ...tate 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 indic...

Страница 23: ...ATUS 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 ch...

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Страница 25: ...3 VEHICLE CONTROLS CARRYALL 502 ELECTRIC Operators Manual TPCC01DQ00EN019 Edition C Page 23 Vehicle Controls Charge Indicator Light 3...

Страница 26: ...ch 6 Turn Signal Lever Optional Equipment 7 Hazard Lights Switch Optional Equipment 8 Horn Optional Equipment 9 Forward Neutral Reverse Control FNR 10 Run Tow Switch And Circuit Breaker 11 Electric Be...

Страница 27: ...of audible beeps and the vehicle will operate at one half normal operational speed POSITION FUNCTION NORMAL Closed Circuit Normal Operation TRIPPED Open Circuit 1 Stop the vehicle 2 Remove the bench...

Страница 28: ...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 operation of the hazard lights Move the turn sign...

Страница 29: ...position when the vehicle is in use Electrical power from the batteries is available to power the motor and electrical systems PARK BRAKE WARNING FAILURE TO ENGAGE THE PARK BRAKE CAN CAUSE PROPERTY D...

Страница 30: ...W for maintenance extended storage or when towed Wait 10 seconds before vehicle operation when the switch is set from TOW to RUN Do not quickly operate the switch from RUN to TOW and back to RUN Wait...

Страница 31: ...4 VEHICLE FEATURES CARRYALL 502 ELECTRIC Operators Manual TPCC01DQ00EN019 Edition C Page 29 Vehicle Features Turn Signal Lever 4...

Страница 32: ...IFTED LOWERED OR DURING MAINTENANCE KEEP HANDS CLEAR OF ALL CRUSH AREAS DO NOT LET THE CARGO BED FALL BEFORE THE CARGO BED IS LIFTED REMOVE ALL CARGO AND ACCESSORIES FROM THE CARGO BED CORRECTLY ENGAG...

Страница 33: ...e supplies electricity to power and charge portable devices The USB receptacle is not for the movement of data The USB receptacle will only operate when a shielded USB cord is connected When the USB r...

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Страница 35: ...5 BATTERY CHARGER CARRYALL 502 ELECTRIC Operators Manual TPCC01DQ00EN019 Edition C Page 33 Battery Charger VersAttach System 5...

Страница 36: ...ING 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 SERIOUS PE...

Страница 37: ...umber 105161901 DIMENSION AND WEIGHT Dimension 11 in 28 cm length 9 7 in 24 6 cm width 4 3 in 11 cm height Weight 11 lb 4 9 kg OPERATIONAL TEMPERATURE Temperature Range 32 F to 86 F 0 C to 30 C AC INP...

Страница 38: ...G The battery charger has an International Protection Marking IP certification of IP66 The battery charger enclosure has an International Protection Marking IP certification of IP46 The battery charge...

Страница 39: ...will not operate when the AC cord is connected EXTENDED STORAGE CHARGE The battery charger can stay connected to AC electrical power during off season or extended storage STATUS INDICATOR LIGHTS The...

Страница 40: ...tery cable from battery number 8 negative post 4 Plug the AC electrical cord into an approved power source Let the battery charger to do the start up self test 5 When the start up self test is done th...

Страница 41: ...ed to show a diagnostic code if a fault occurs To find the shown fault 1 Count the number of red flashes on the charger indicator lamp The charger will pause between fault code displays 2 Use the Faul...

Страница 42: ...r in a lower ambient temperature environment 4 Battery could not be trickle charged up to minimum voltage Inspect for worn or defective batteries Replace batteries as necessary 5 Charger shutdown beca...

Страница 43: ...6 VEHICLE SPECIFICATIONS CARRYALL 502 ELECTRIC Operators Manual TPCC01DQ00EN019 Edition C Page 41 Vehicle Specifications Troubleshooting 6...

Страница 44: ...5 in 100 3 cm rear wheel Wheel Base 78 1 in 198 3 cm PERFORMANCE Forward Speed On Level Ground 15 to 17 mph 24 to 27 km h Turning Radius SAE J695 119 in 302 2 cm Intersecting Aisle Clearance 86 3 in 2...

Страница 45: ...L 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...

Страница 46: ...ptional equipment Maximum Trailer Tongue Weight The trailer tongue weight is the maximum permitted weight applied by the trailer tongue onto the trailer hitch Maximum Gross Trailer Weight The gross tr...

Страница 47: ...7 VEHICLE OPERATION CARRYALL 502 ELECTRIC Operators Manual TPCC01DQ00EN019 Edition C Page 45 Vehicle Operation Vehicle Weights And Load Capacities 7...

Страница 48: ...THE VEHICLE AND MAKE NECESSARY REPAIRS CAN DECREASE VEHICLE PERFORMANCE CAUSE A FIRE PROPERTY DAMAGE SERIOUS PERSONAL INJURY OR DEATH IF PROBLEMS ARE FOUND DURING SCHEDULED INSPECTION OR SERVICE OPER...

Страница 49: ...SURE 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 DRIVER CAN OPERATE THE VEHICL...

Страница 50: ...ly attached 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 de...

Страница 51: ...dal 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 rev...

Страница 52: ...The Driving Instructions Indicators Gauges Displays Controls MOTOR START Before motor start Read and obey all safety decals and information located on the vehicle Understand how to operate the vehicl...

Страница 53: ...ely Understand the function of all vehicle controls indicators displays and gauges Make sure that all passengers are seated with seat belts fastened if equipped and use the hand holds or handrails The...

Страница 54: ...gage the park brake 3 Slowly push the accelerator pedal SLOW OR STOP THE VEHICLE 1 Release the accelerator pedal 2 Push the brake pedal PARK THE VEHICLE 1 Stop the vehicle 2 Engage the park brake to p...

Страница 55: ...top 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 d...

Страница 56: ...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 v...

Страница 57: ...n at night is not recommended When driving at night is unavoidable the vehicle must have Headlights Taillights Reflectors Precautions if driving at night is unavoidable Always have headlights on Alway...

Страница 58: ...t 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...

Страница 59: ...8 VEHICLE MAINTENANCE CARRYALL 502 ELECTRIC Operators Manual TPCC01DQ00EN019 Edition C Page 57 Vehicle Maintenance Driving Conditions 8...

Страница 60: ...SSORY INSTALLATION FAILURE TO CORRECTLY MAINTAIN THE VEHICLE AND MAKE NECESSARY REPAIRS CAN DECREASE VEHICLE PERFORMANCE CAUSE A FIRE PROPERTY DAMAGE SERIOUS PERSONAL INJURY OR DEATH IF PROBLEMS ARE F...

Страница 61: ...he key to OFF 4 Remove 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 w...

Страница 62: ...enance 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...

Страница 63: ...f 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 electr...

Страница 64: ...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 li...

Страница 65: ...he 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 Li...

Страница 66: ...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 th...

Страница 67: ...re 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 t...

Страница 68: ...icle 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 th...

Страница 69: ...316V 9 BATTERY MAINTENANCE CARRYALL 502 ELECTRIC Operators Manual TPCC01DQ00EN019 Edition C Page 67 Battery Maintenance Maintenance Tasks 9...

Страница 70: ...battery top and terminals Remove all corrosion 3 Use tap water to clean the solution from the batteries Correctly discard the waste water 4 If the battery cable has corrosion have a trained technicia...

Страница 71: ...e power source Note The vehicle will start to charge in 10 seconds or less 4 Before vehicle operation 4 A Disconnect the AC cord from the power source 4 B Retract the AC cord BATTERY ELECTRICAL CONNEC...

Страница 72: ...RY WIRES CAN CAUSE A FIRE PROPERTY DAMAGE OR SERIOUS PERSONAL INJURY MAKE SURE THAT ALL BATTERY WIRES AND TERMINALS ARE CLEAN AND TIGHTENED CORRECTLY 4 Tighten the hardware to 110 lb in 12 4 N m 5 App...

Страница 73: ...the batteries 4 If the battery 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...

Страница 74: ...nstallation operation and maintenance manual hand pump manual and deionizer operator and maintenance manual WATERING INTERVALS The watering intervals are affected by Age of the batteries Application C...

Страница 75: ...ines 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 de...

Страница 76: ...owering 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...

Страница 77: ...10 TRANSPORT AND TOW CARRYALL 502 ELECTRIC Operators Manual TPCC01DQ00EN019 Edition C Page 75 Transport And Tow Water Quality 10...

Страница 78: ...IC 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...

Страница 79: ...a safe area 5 Set the Run Tow switch to TOW 6 Remove all cargo from the vehicle 7 Remove the windshield from the vehicle 8 Secure all doors access panels seat bottoms and windshield 9 Examine the veh...

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Страница 81: ...11 EXTENDED STORAGE CARRYALL 502 ELECTRIC Operators Manual TPCC01DQ00EN019 Edition C Page 79 Extended Storage Vehicle Transport Recovery 11...

Страница 82: ...attery 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...

Страница 83: ...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 ch...

Страница 84: ...Page intentionally left blank...

Страница 85: ...12 WARRANTIES CARRYALL 502 ELECTRIC Operators Manual TPCC01DQ00EN019 Edition C Page 83 Warranties Return To Service From Extended Storage 12...

Страница 86: ...s factory technicians or an Authorized Dealer or Distributor Club Car will provide only the replacement parts or components If the warranty registration form is not completed and returned to Club Car...

Страница 87: ...Club 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 s...

Страница 88: ...r 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 i...

Страница 89: ...y 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 F...

Страница 90: ...Publication Part Number TPCC01DQ00EN019 Edition Code C 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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