Club Car CARRYALL 502 ELECTRIC, Operator'S Manual

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

Page 2: ...Copyright 2020 Club Car LLC This manual effective September 10 2020...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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

Page 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...

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

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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

Page 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...

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

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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

Page 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...

Page 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...

Page 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...

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

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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

Page 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...

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

Page 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...

Page 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...

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

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...