Club Car CARRYALL 100 CE Mark Owner's Manual
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Club Car CARRYALL 100 CE Mark Owner's Manual

Club Car CARRYALL 100 CE Mark Owner's Manual

Carryall 100 ce
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Carryall 100 CE Mark
Owner's Manual
Electric and Gasoline
[Refer to back cover for applicable build code range]

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Summary of Contents for Club Car CARRYALL 100 CE Mark

  • Page 1 Carryall 100 CE Mark Owner’s Manual Electric and Gasoline [Refer to back cover for applicable build code range]...
  • Page 3 Your authorized representative checked the vehicle before it was delivered to you and will provide you a copy of the completed vehicle warranty registration form. Club Car is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.
  • Page 4 Services, P.O. Box 204658, Augusta, Georgia 30917-4658 USA. We hope you will consider this owner’s manual a permanent part of your Club Car vehicle. If you sell the vehicle, please include the manual so that the next owner will have the important operating, safety, and maintenance information it contains.

  • Page 5: Table Of Contents

    Engine Oil – Gasoline Vehicle..........................52 Fueling Instructions – Gasoline Vehicle ........................ 54 Cleaning the Vehicle ............................55 Accessories................................ 56 Subsequent Owner Registration .......................... 56 Vehicle Specifications ............................56 Warranties................................61 EC Declaration of Conformity ..........................64 Carryall 100 CE Mark Owner’s Manual Page 3...

  • Page 6: Safety Decal Identification

    SAFETY DECAL IDENTIFICATION The following pages contain safety decal information. For detailed information on specific features, read the appropriate section in this manual. CARRYALL 100 CE – ELECTRIC VEHICLE 2928 Decal, Tow Switch Warning (on Tow/Run switch Decal, Maintenance Notice (on vehicle body, under...
  • Page 7 Safety Decal Identification CARRYALL 100 CE – ELECTRIC VEHICLE, CONTINUED 2923 Decal, Bed Latch Warning (on vehicle body, below 102825501 Decal, Rollover Warning (on instrument panel) 102832001 bed latch) 102825701 Decal, Operating Instructions (on instrument panel) 105137107 Vehicle Loading Instructions...
  • Page 8 Safety Decal Identification CARRYALL 100 CE – GASOLINE VEHICLE 2924 Decal, Bed Latch Warning (on vehicle body, below 102825401 Decal, Rollover Warning 102832001 bed latch) Decal, Maintenance Notice (on vehicle body, under 102825601 Decal, Operating Instructions 102833301 bed) Decal, Bed Latch Warning (on vehicle body, below...
  • Page 9 Safety Decal Identification CARRYALL 100 CE – GASOLINE VEHICLE, CONTINUED 2895 Decal, Frame Ground/Governor Warning (on 101915201 105082301 Decal, Gasoline Fuel Warning (on fuel tank) vehicle frame near battery) Decal, Rotating Parts/Hot Manifold Warning (on 101960501 starter/generator) Decal, Diode Safety Warning (on vehicle frame,...

  • Page 10: Practice Safety

    PROPOSITION 65 – STATE OF CALIFORNIA WARNING • This product contains or emits chemicals or substances that have been determined by the state of California to cause cancer and birth defects or other reproductive harm. Page 8 Carryall 100 CE Mark Owner’s Manual...

  • Page 11: Safety Details

    • The vehicle will not provide protection from lightning, flying objects, or other storm-related hazards. If caught in a storm while driving a Club Car vehicle, exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location.
  • Page 12 • Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the vehicle or battery charger. • Use insulated tools when working near batteries or electrical connections. Use extreme caution to avoid shorting of components or wiring. Page 10 Carryall 100 CE Mark Owner’s Manual...
  • Page 13 Connect battery cables in reverse order. 3. Remove positive battery cable. Connect battery cables in reverse order. 1436 Figure 2 Battery Cable Removal – Gasoline Vehicle Figure 3 Battery Cable Removal– 6x8-Volt Battery Configuration Carryall 100 CE Mark Owner’s Manual Page 11...
  • Page 14 Responsibility for environmental protection must be shared, not only by the manufacturers of the batteries, but by people who use the batteries as well. Please contact your nearest Club Car dealer or distributor for information on how to properly recycle your batteries. 1403...

  • Page 15: General Information

    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.

  • Page 16: Front Bumper And Brush Guard

    • 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. Figure 6 Bumper Figure 7 Brush Guard Page 14 Carryall 100 CE Mark Owner’s Manual...

  • Page 17: Model Identification

    This owner’s manual is valid for the build code range indicated on the back cover of this owner’s manual. SERIAL NUMBER CC5819-123456 BC54679 ASSEMBLED IN USA 2843 Figure 8 Serial Number Decal Carryall 100 CE Mark Owner’s Manual Page 15...

  • Page 18: Controls And Indicators

    ON position to the START position and hold until the engine is running smoothly. Release the key and it will return to the ON position and the engine should idle. Page 16 Carryall 100 CE Mark Owner’s Manual...
  • Page 19 F (FORWARD), N (NEUTRAL), and R (REVERSE). Rotate the 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).
  • Page 20 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.
  • Page 21 See the battery charger owner’s manual. This indicates an abnormal charge cycle. The charger and batteries should be checked by your Club Car distributor/dealer. • The warning light will repeatedly illuminate for 10 seconds, with 4 second intervals during a charge cycle (DC plug is still connected) if AC power to the charger is interrupted.
  • Page 22 The brake pedal is the large pedal on the left with the word STOP molded into it (Figure 13). To slow or stop the vehicle, press the brake pedal with your right foot (Figure 14). Page 20 Carryall 100 CE Mark Owner’s Manual...
  • Page 23 • Before Towing the Vehicle: Place the Tow/Run switch in the TOW position to disable all motor braking functions, thus preventing possible damage that could occur to the vehicle or electrical components if the vehicle is towed while the walk-away braking function is operating. Carryall 100 CE Mark Owner’s Manual Page 21...
  • Page 24 With the switch in this position, the vehicle will not operate if the Forward/Reverse handle is placed in either the FORWARD or REVERSE position. See following WARNING and NOTE. Page 22 Carryall 100 CE Mark Owner’s Manual...

  • Page 25: Pre-Operation And Daily Safety Checklist

    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 become familiar with its controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery.
  • Page 26 Club Car vehicles operate at reduced speed in reverse. When the pedal is released, it should return to the original position and the motor should rotate freely or go into motor braking mode. See Pedal Up Motor Braking below.

  • Page 27: Driving Instructions

    (17.7 km/h). Motor braking will disengage when vehicle slows to 11 mph (17.7 km/h). This feature is adjustable for IQ System vehicles. Contact your local Club Car dealer/distributor to inquire about this adjustable feature. • Pedal Down Motor Braking: Accelerate down an incline with the accelerator pedal pressed. When the vehicle reaches maximum programmed speed, motor braking should engage and limit the vehicle to its maximum programmed speed.
  • Page 28 7.2. Press and hold brake pedal. 7.3. Turn the key all the way to the START position and release after the engine has started. The engine will idle with the Forward/Reverse handle in the NEUTRAL position. Page 26 Carryall 100 CE Mark Owner’s Manual...
  • Page 29 1 to 3 mph (1.6 to 4.8 km/h) unless the accelerator is pressed. This prevents the possibility of a parked vehicle (with the park brake disengaged) rolling away too fast to be overtaken on foot. Carryall 100 CE Mark Owner’s Manual Page 27...

  • Page 30: Loading And Unloading

    The vehicle rated capacity is the maximum amount of weight on the vehicle. This capacity includes the weight of occupants, cargo, bed load, and optional equipment. Vehicle Combination Rated Capacity The vehicle combination rated capacity includes the vehicle rated capacity and gross trailer weight. Maximum Gross Vehicle Weight Page 28 Carryall 100 CE Mark Owner’s Manual...
  • Page 31 1663 lb (754.3 kg) A + B + D + Vehicle Weight, not to exceed stated Maximum Gross 1780 lb (807.4 kg) 1663 lb (754.3 kg) Vehicle Combination Weight 2894 Figure 19 Vehicle Load Capacity Carryall 100 CE Mark Owner’s Manual Page 29...

  • Page 32: Towing With The Vehicle

    • Reduce normal driving speed when transporting a Club Car vehicle on a trailer. • Do not tow a Club Car vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer.

  • Page 33: Storage - Electric Vehicles With Powerdrive Battery Charger

    Adjust tires to recommended tire pressure. See Vehicle Specifications – Electric Vehicles on page 56. Perform semiannual periodic lubrication. See Periodic Lubrication Schedules on page 38. 10. Thoroughly clean front body, rear body, seats, battery compartment, and underside of vehicle. Carryall 100 CE Mark Owner’s Manual Page 31...
  • Page 34 Adjust tires to recommended tire pressure. See Vehicle Specifications – Electric Vehicles on page 56. Perform the Pre-Operation and Daily Safety Checklist on page 23 and the Performance Inspection on page 24. Page 32 Carryall 100 CE Mark Owner’s Manual...

  • Page 35: Storage - Gasoline Vehicles

    To protect the engine, remove spark plug and pour 0.5 fl-oz (14.2 mL) of SAE 10 weight oil into the engine through the spark plug hole. Rotate engine crankshaft by hand several times and then install the spark plug and tighten it to 20 ft·lb (27 N·m). Carryall 100 CE Mark Owner’s Manual Page 33...

  • Page 36: Maintenance

    Any vehicle not functioning correctly should be removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service. WARNING •...

  • Page 37: Periodic Service Schedules

    Periodic Service Schedule. Both the Periodic Service Schedules and the Periodic Lubrication Schedules must be followed to keep vehicle in optimum operating condition. Carryall 100 CE Mark Owner’s Manual Page 35...
  • Page 38 If batteries are not performing as expected, (or every 100 hours of operation, whichever Batteries see the Batteries section in the maintenance comes first) and service manual. Check safety decals. Replace if damaged or Safety decals illegible. Page 36 Carryall 100 CE Mark Owner’s Manual...
  • Page 39 Check for loose hardware and tighten if General vehicle necessary. Check safety decals. Replace if damaged or Safety decals illegible. Two-year service by trained technician only. Engine Check and adjust valve lash as needed. Carryall 100 CE Mark Owner’s Manual Page 37...

  • Page 40: Periodic Lubrication Schedules

    (or every 100 hours of operation, whichever comes Inspect front wheel bearings (Repack Chassis Lube – EP NLGI Grade 2 first) as necessary) 2777 Figure 20 Lubrication Points – Electric Vehicles Page 38 Carryall 100 CE Mark Owner’s Manual...
  • Page 41 200 Change engine oil 5W-30 grade SE or higher. hours of operation or annually, See also Figure 34, Page 54. whichever comes first 2778 Figure 21 Lubrication Points – Gasoline Vehicles Carryall 100 CE Mark Owner’s Manual Page 39...

  • Page 42: Batteries - Electric Vehicles

    WATER QUALITY Water purity is the most important factor in the performance and life span of the vehicle batteries. Club Car has, therefore, placed an increased importance on battery maintenance.
  • Page 43 Water testing, however, is expensive, and water quality can change from day to day depending on additives, water main leaks, etc. Due to the cost and labor of performing water quality tests, Club Car recommends the use of distilled water or a deionizer.
  • Page 44 Tighten battery terminals to proper torque. See Connecting the Batteries – Electric Vehicles on page 12. See following WARNING. Page 42 Carryall 100 CE Mark Owner’s Manual...
  • Page 45 In this case, add just enough water to cover the plates, charge, and then check the level again. Never charge batteries if plates are exposed above electrolyte level. For best battery life, add only distilled water. See following CAUTION and NOTE. Carryall 100 CE Mark Owner’s Manual Page 43...

  • Page 46: Single Point Watering System (Spws)

    • Use water that meets the quality standards shown on page 40. Maximize battery life by removing ions and heavy metals from water with the use of a deionizer. See Water Quality on page 40. Page 44 Carryall 100 CE Mark Owner’s Manual...
  • Page 47 Locate the battery fill coupling (9) on the driver side of the battery compartment, remove the dust cover (10) from the male connector (Figure 25), and connect the hose-end assembly (3) (Figure 26). The water flow will begin immediately. Carryall 100 CE Mark Owner’s Manual Page 45...

  • Page 48: Battery Charger - Electric Vehicles

    • Do not charge the vehicle batteries with the vehicle covered or enclosed. Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged. An accumulation of hydrogen gas can result in an explosion. Page 46 Carryall 100 CE Mark Owner’s Manual...
  • Page 49 Battery Charger – Electric Vehicles WARNING • Only trained technicians should repair or service the charger. Contact your nearest Club Car distributor/dealer. • Each charger should have its own dedicated 15 or 20 ampere separately protected (circuit breaker or fuse) single phase branch circuit, in accordance with all applicable electrical codes for the location.
  • Page 50 When inserting the DC plug, align the raised guide on the plug with the guide slot in the receptacle and push straight in slowly. Club Car battery chargers interact with the vehicle’s onboard computer. The computer records the amount of energy consumed during vehicle use. While the charger is plugged in, the vehicle’s control circuit is locked out, preventing operation of the vehicle as well as the possibility of consequent damage to the charger and the vehicle.
  • Page 51 Figure 27 Correct Insertion of Charger DC Plug Figure 28 Incorrect Insertion of Charger DC Plug Club Car electric vehicles are supplied with a battery charger. Other Club Car models or vehicles made by other manufacturers are not compatible. As long as the charger is allowed to shut off by itself, the batteries will be fully charged. Overcharging and undercharging will normally be prevented.

  • Page 52: Battery - Gasoline Vehicle

    See following WARNING. WARNING • If the receptacle fuse link is blown, determine the source of the electrical problem and correct it before replacing the fuse. Contact your nearest Club Car distributor/dealer. BATTERY – GASOLINE VEHICLE See General Warnings on page 9.
  • Page 53 WARNING • Do not jump-start a dead battery using another battery and jumper cables. The battery in a Club Car gasoline vehicle is a 12-volt, low-maintenance battery that requires infrequent watering (Figure 30). 1. Level Indicator 2. Cap 3. Plates Electrolyte level at least 1/2 inch (13 mm) above plates or to level indicator.

  • Page 54: Engine Oil - Gasoline Vehicle

    Turn the key switch to the OFF position, then remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the front wheels. Access the engine compartment. Disconnect battery and spark plug wire. See Disconnecting the Battery – Gasoline Vehicles on page 11. Page 52 Carryall 100 CE Mark Owner’s Manual...
  • Page 55 The engine requires 40.5 fl-oz (1.2 L) of oil per change. 10W-30 or 5W-30 grade SE or higher is recommended. Refer to oil viscosity guidelines for selection of oil grade (Figure 34). Replace the dipstick. Carryall 100 CE Mark Owner’s Manual Page 53...

  • Page 56: Fueling Instructions - Gasoline Vehicle

    Use of these fuels in this vehicle will void the warranty. • Do not repeatedly attempt to start a vehicle when the fuel pump is dry (no gas in tank). Doing so can damage the fuel pump. Page 54 Carryall 100 CE Mark Owner’s Manual...

  • Page 57: Cleaning The Vehicle

    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 subsequent component failure.

  • Page 58: Accessories

    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 CLUB CAR, LLC, P.O.
  • Page 59 (124 to 138 kPa) NOISE AND VIBRATION Drive-by noise level to operator 65.2 dBA Test method: Uncertainty: 2 dBA EN 12053:2001 Vibration at driver’s seat 0.58 m/s Test method: Uncertainty: 0.20 SAE J1013 Carryall 100 CE Mark Owner’s Manual Page 57...
  • Page 60 -22 °F to 122 °F -22 °F to 122 °F Normal Operating Temperature (-30 °C to 50 °C) (-30 °C to 50 °C) (-30 °C to 50 °C) (-30 °C to 50 °C) Page 58 Carryall 100 CE Mark Owner’s Manual...
  • Page 61 Overall length 100.2 in (254.5 cm) Overall width 45 in (114.3 cm) Overall height (at steering wheel) 46.9 in (119.1 cm) Wheelbase 66.5 in (168.9 cm) Ground clearance 5.5 in (14 cm) Carryall 100 CE Mark Owner’s Manual Page 59...
  • Page 62 Drive-by noise level to operator Unknown at time Test method: of printing EN 12053:2001 Uncertainty: 2 dBA Unknown at time Vibration at driver’s seat of printing Test method: Uncertainty: 0.20 SAE J1013 Page 60 Carryall 100 CE Mark Owner’s Manual...

  • Page 63: Warranties

    4 YEARS EXCLUSIONS Excluded from any CLUB CAR warranty is damage to a vehicle or component resulting from a cause other than a defect including poor maintenance, neglect, abuse, accident and collision, maintenance adjustments, unreasonable or unintended strain or use, improper installation of accessories, installation of parts or accessories that are not original equipment including Club Car approved or non-approved GPS systems, non-approved alteration and acts of God.
  • Page 64 A vehicle not having an operational charger on a circuit that has the parameters specified in the vehicle owner’s manual. (Number of operational chargers must equal the number of operational vehicles.) Improper charging of a vehicle due to the use of a battery charger model not approved by Club Car for use with the vehicle.
  • Page 65 Warranties In the event that another pre-printed warranty document, certificate or both offered by or through Club Car at the time of sale of this vehicle (each an “Additional Warranty Document”) is deemed to conflict with the limitations or exclusions contained herein, the limitations and exclusions contained herein shall continue to apply to both this limited warranty statement and, to the maximum extent permitted by law, to each Additional Warranty Document.

  • Page 66: Ec Declaration Of Conformity

    B-1932 S int-S te ve ns -Woluwe , Be lgium _______________________________________________ Ge off S te wa rt Ma y 1, 2013 Le a d Engine e r, P roduct S a fe ty Eva ns , Ge orgia , US A Page 64 Carryall 100 CE Mark Owner’s Manual...
  • Page 68 BC56607 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.

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