Club Car Carryall 1500 IntelliTach, Owner'S Manual

Page 1: ...IntelliTach All Wheel Drive Diesel Vehicle Owner s Manual Carryall 295 and XRT 1550 Refer to back cover for applicable build code range...

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Page 3: ...thout the written consent of Club Car The information contained in this document is subject to change without notice Club Car reserves the right to make design changes to vehicles without obligation t...

Page 4: ...the vehicle Club Car products are backed by a customer support system designed to offer you fast courteous service In the event your Club Car vehicle needs repairs or service please contact your local...

Page 5: ...list 30 Driving Instructions 31 Bed Latch and Prop Rod 34 Attachments and Buckets 35 Loading and Unloading Cargo 47 Vehicle Load Capacities 48 Towing with the Vehicle 49 Transporting on a Trailer 50 S...

Page 6: ...ooster Battery Jump Starting 72 Cleaning the Vehicle 73 Accessories 73 Subsequent Owner Registration 75 Vehicle Specifications 76 Warranties 78 Page 4 IntelliTach All Wheel Drive Diesel Vehicle Owner...

Page 7: ...egulations and safety requirements CAUTION The fuel system and engine on your vehicle are designed and built to government emissions standards Tampering by dealers customers operators and users is str...

Page 8: ...901 Decal Hot Surface Warning on coolant pipes and underside of seats on bed seal 6 102459501 Decal Rotating Hot Parts Warning on frame near battery 3 102459001 Decal Hot Manifold Warning on engine ne...

Page 9: ...d seat near cargo bed 7 102930801 Decal Vehicle Loading Warning on cargo bed 3 102459301 Decal Bed Latch Warning on vehicle body below bed latch 8 102950601 Decal Hydraulic Pressure Warning near hydra...

Page 10: ...Car web site and view the vehicle safety video To locate the video go to www clubcar com and search for safety video Take time to understand the language of safety It is a language that can save your...

Page 11: ...indicates an immediate hazard that will result in severe personal injury or death The color associated with Danger is RED WARNING A WARNING indicates an immediate hazard that could result in severe pe...

Page 12: ...om the wheel or rim prior to welding the wheel or rim Failure to comply will result in death or serious injury WARNING Follow the procedures exactly as stated in this manual and heed all DANGER WARNIN...

Page 13: ...ber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle Use insulated tools when working near batteries or electr...

Page 14: ...nmental damage and personal injury Lead acid batteries are identified by the symbol shown below and should be properly recycled Figure 4 They cannot be disposed as municipal waste and must be collecte...

Page 15: ...battery or batteries 1 2 3 4 5 6 1 Shield eyes 3 No smoking no open flames no sparks 5 Battery acid hazard 2 Read and follow operating instructions 4 Keep away from children 6 Explosive gas hazard Ref...

Page 16: ...the diesel Carryall 295 IntelliTach and XRT 1550 IntelliTach key start vehicles 1 4 3 2 The terms front 1 left hand 2 right hand 3 and rear 4 are used in this manual to indicate the sides as they are...

Page 17: ...le built within a given model year See following NOTE NOTE Have the vehicle serial number available when ordering parts or making inquiries A 17 digit Product Information Number PIN is included on thi...

Page 18: ...ial Number Figure 11 Hydraulic Pump Serial Number Figure 12 PH0901 123456 BC54679 SERIALNUMBER ASSEMBLED IN USA 4 1 2 3 1400 Figure 8 Serial Number Decal with the Vehicle Build Code 2474 Figure 9 ROPS...

Page 19: ...ld result in property damage personal injury or death due to unsafe speeds Do not shift the Forward Reverse handle while the vehicle is in motion Engine must be at idle before shifting the Forward Rev...

Page 20: ...olumn Adjustment Lock 14 Fuel Gauge Hour Meter 3 Key Switch 9 Park Brake Release Handle 15 Joystick 4 Accelerator Pedal 10 Headlight Switch 16 Attachment Arm Float Switch 5 Brake Pedal 11 High Tempera...

Page 21: ...is running CAUTION Do not shift the Forward Reverse handle while the accelerator pedal is pressed Shift the handle only when the vehicle is at a complete stop and the engine is at idle Failure to hee...

Page 22: ...NG The park brake has multiple locking positions and should be firmly locked to prevent the vehicle from rolling SER IAL NUMBER 000000 000000 P O BOX 2046 58 AUGUSTA GA 309 17 Club Car R 9 6 231 Figur...

Page 23: ...and the warning light stays on have a trained technician check the vehicle See following CAUTION CAUTION Failure to add oil immediately when the low oil warning light stays on may result in permanent...

Page 24: ...es before stopping the engine Contact a Club Car dealer distributor or a trained technician See following WARNING WARNING Allow the engine to cool before servicing the engine coolant system Engine coo...

Page 25: ...of electrically powered devices i e bed lift work lights lower fan speed on heater etc Either drive the vehicle or allow it to idle occasionally to let the battery recharge Attachment Arm Operation P...

Page 26: ...the auxiliary hydraulic rocker switch 1 to the right 2 Figure 17 2 To rotate the attachment to the left push the auxiliary hydraulic rocker switch 1 to the left 3 NOTE After installing the attachment...

Page 27: ...e female coupler until the couplers disconnect Install the dust covers if equipped on the couplers after they have been disconnected WARNING Hydraulic fluid tubes fittings and quick couplers can get h...

Page 28: ...sible on the hips not on the waist then adjust it to a snug fit by pulling the shoulder portion upward through the latch plate The retractor will lock the belt during a sudden stop It also may lock if...

Page 29: ...le to ride in any part of the vehicle that is not equipped with a seat and a seat belt Do not allow a passenger to hold a child in his or her lap while the vehicle is moving This vehicle is not design...

Page 30: ...t 3 Install the headrest hardware 1 4 Hand tighten the hardware until the headrest is securely attached to the cargo cage See following CAUTION CAUTION Using tools to tighten the headrest hardware cou...

Page 31: ...t is adjustable and can be moved forward or backward to accommodate the driver To adjust seat push lever located under the driver seat to the left towards outside of the vehicle Position seat and retu...

Page 32: ...Engine Oil on page 60 and Hydraulic System on page 66 Check air filter and replace if necessary Inspect air intake for blockage Fuel Check fuel level See Fueling Instructions on page 68 Check fuel tan...

Page 33: ...all controls and operating procedures No one under the age of 16 years should be allowed to drive the vehicle No more than one person per bucket seat at one time or two persons per bench seat Do not a...

Page 34: ...of the following procedures Read and understand all instructions prior to driving the vehicle STARTING THE VEHICLE 1 Read safety and information decals located on the vehicle 2 Be sure load if any is...

Page 35: ...ollowing WARNING WARNING When servicing the vehicle with part of the vehicle on jack stands do not operate the engine with the Forward Reverse handle in either the FORWARD or REVERSE position The all...

Page 36: ...at the prop rod is no longer supported in one of the track notches Push the prop rod toward the front of the vehicle to free it from the track notch and gently lower the bed DO NOT drop the bed See fo...

Page 37: ...the attachment interface Attachment arm rated capacity is determined by using the standard bucket and material of normal density such as dirt or dry gravel If very dense material is loaded the volume...

Page 38: ...ng a pallet fork and for other available attachments 1 236 Figure 23 Do Not Overload Bucket or Attachments 237 Figure 24 Pallet Fork Loads INSTALLING AND REMOVING AN ATTACHMENT Installing an Attachmen...

Page 39: ...n NEUTRAL engage the park brake unfasten your seat belt and exit the vehicle 240 Figure 27 Tilt Backward 241 Figure 28 Lock Attachment WARNING Before you leave the operator s seat Put Forward Reverse...

Page 40: ...ne put the Forward Reverse Handle in NEUTRAL engage the park brake unfasten your seat belt and exit the vehicle 3 Disconnect the hydraulic hoses if equipped See Quick Couplers If Equipped on page 24 4...

Page 41: ...all conditions of the work area NOTE Always warm up the engine before operating the vehicle with an attachment If movement of the attachment arm appears to be progressively slowing the battery must be...

Page 42: ...c located and marked 1 2 Remove objects or other construction material that could damage the vehicle or cause personal injury Operating with a Full Bucket and Empty Cargo Box 1 Raise the bucket only h...

Page 43: ...attachment arm 2 and tilt the bucket backward 3 Figure 37 WARNING Load unload and turn on flat level ground Do not exceed attachment arm rated capacity Failure to obey warnings can cause the vehicle t...

Page 44: ...y the bucket 1 2 3 4 252 Figure 39 Joystick Position Backfilling REMOVING AND INSTALLING THE ATTACHMENT ARM MECHANISM When the attachment arm mechanism is not being used it can be removed from the veh...

Page 45: ...chment arm cylinder rod end Figure 42 5 Turn the start key to the ON position but DO NOT start the engine 6 Retract the attachment arm cylinder fully by moving the joystick 1 back Figure 43 7 Retract...

Page 46: ...taining rings 1 and pins 2 from the attachment arms and mounting plate Figure 45 14 Lower the attachment arms to the ground 15 To store install the pins 1 into the attachment arm holes both sides and...

Page 47: ...and 5 to the locking plate 2 Figure 49 258 Figure 48 Align the Attachment Arm Holes 261 Figure 49 Remove Retainer Pins from Both Cylinders 7 Swing the attachment interface cylinder down 8 Turn the key...

Page 48: ...Arm Install Pin and Retainer Ring 13 Raise the attachment interface and align it with the cylinder Install the pin 2 and the retaining ring 1 Figure 52 254 Figure 52 Raise Interface Install Pin and Re...

Page 49: ...loads The center of gravity of load should never exceed 15 inches 38 cm above the bottom of the cargo bed The cargo s center of gravity may affect handling steering and braking of the vehicle When the...

Page 50: ...t and the gross trailer weight The stated maximum gross vehicle combination weight must not be exceeded to maintain safe vehicle operation Attachment Arm Rated Capacity The attachment arm rated capaci...

Page 51: ...y cause vehicle to overturn possibly resulting in severe personal injury Stay clear from the area between the tow vehicle and the towed vehicle or trailer Towing another Club Car vehicle or a trailer...

Page 52: ...ic road unless it is on an approved trailer The vehicle to be transported should be tied securely to the trailer with the Forward Reverse handle or switch in the NEUTRAL position the key switch in the...

Page 53: ...is dead see Using A Booster Battery Jump Starting on page 72 3 Make sure the key switch is in the OFF position and the Forward Reverse handle is in the NEUTRAL position Chock the wheels 4 Prepare the...

Page 54: ...and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation If any problems are found during scheduled in...

Page 55: ...at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 lb 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack...

Page 56: ...olant add if necessary See Engine Coolant Level Check on page 65 Engine Clean debris from radiator Fuel filters Diesel vehicles Drain water from fuel filter See Draining Water from Fuel Filter on page...

Page 57: ...sel vehicles Check the V belt for proper tension or damage Adjust or replace if necessary Engine Diesel vehicles Change engine coolant See Radiator and Cooling System Section in the maintenance and se...

Page 58: ...trained technician or every 50 hours of operation whichever comes first Attachment Arm and Interface 8 fittings Chassis Lube EP NLGI Grade 2 First change 50 hours additional change every 100 hours of...

Page 59: ...ease the 8 grease fittings every 50 hours of operation 2 times a year whichever occurs first or whenever the attachment arm and interface are removed and reinstalled on the vehicle Lubricate the follo...

Page 60: ...Level 3 Low Level 201 Figure 56 Brake Fluid and Engine Coolant Access 2693 Figure 57 Brake Fluid Reservoir The brake fluid reservoir 1 is located under the hood Figure 56 Raise the hood to check the...

Page 61: ...other damage BRAKE FLUID Brake fluid level should be within 1 4 inch 6 mm from the top of the reservoir Figure 57 Also brake fluid should be clean with no residue in the bottom of the reservoir or ot...

Page 62: ...into the tube and immediately removing it 3 If the oil level is at or below the low level mark on the dipstick gauge add oil to the engine until the level is between low and full levels safe level Se...

Page 63: ...Make sure that the compression washer or sealing o ring remains on the drain plug Inspect the compression washer or the sealing o ring and replace if necessary 7 Use a socket or wrench to replace the...

Page 64: ...cles 1 Add engine oil Figure 62 With filter change the engine requires 3 qt 2 8 L for diesel vehicles Refer to oil viscosity guidelines for selection of oil grade Figure 63 See following CAUTION CAUTI...

Page 65: ...the bottom of level indicator hole 1 NOTE For 2012 and newer vehicles do not use the fill hole in the rear differential as a lubricant level indicator LUBRICATION CHANGE FOR FRONT DIFFERENTIAL TRANSMI...

Page 66: ...g and tighten to 21 ft lb 28 N m Check the level of lubricant at the level indicator plug 1 Apply Loctite 567 to the threads of the level indicator plug and tighten to 21 ft lb 28 N m Rear differentia...

Page 67: ...hood on the passenger side Figure 56 Raise the hood to check the coolant level before every operation 1 Check the coolant level of the reserve tank 2 If the coolant is at or below the LOW mark add pr...

Page 68: ...ition but DO NOT start the engine 3 Press the joystick ON OFF switch 18 to ON Figure 13 4 Move the joystick 1 back and raise the attachment arm fully Figure 68 5 Move the joystick 1 to the right and t...

Page 69: ...or a roughly running engine service the air filter immediately Air Filter Removal 1 Raise the cargo bed and locate the air filter canister 2 Release both canister tab locks Figure 70 3 Pull the canis...

Page 70: ...ing CAUTION CAUTION Diesel vehicles Use only diesel fuel grade no 2 with a cetane rating of 45 or higher 2 Replace the fuel cap Ensure that the cap is tightened securely tighten until it clicks 3 Clea...

Page 71: ...ee Draining Water from Fuel Filter Check the engine oil level daily before the engine is started See Engine Oil Level Check on page 60 Before vehicle storage run the engine with conventional diesel fu...

Page 72: ...ternal Flush with water Call a physician immediately Internal Drink large quantities of milk or water followed with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water...

Page 73: ...the electrolyte level and add distilled water if necessary Do not fill the battery cells above the designated fill line Replace battery cell caps 6 Clean both battery terminals with a solution of baki...

Page 74: ...ess the engine compartment by raising the cargo bed See WARNING For vehicles with cargo beds in General Warnings on page 10 4 Locate the vehicle battery on the driver s side of the vehicle under the c...

Page 75: ...mediately to prevent possible stains The seats of the vehicle will last longer with proper cleaning Use a solution of 10 liquid soap and warm water applied with a soft cloth For imbedded dirt a soft b...

Page 76: ...tion switch The winch kit available includes a remote operation switch which enables the operator to move away from the vehicle and cable See following WARNING and CAUTION WARNING Before beginning a w...

Page 77: ...ll of each tire or the tread performance will be severely compromised Club Car tires are made specifically for the AWD vehicle therefore Club Car recommends that only tires purchased from Club Car be...

Page 78: ...hicles Swing arms with coil over shock absorbers Rear 2012 and newer vehicles Semi independent four link suspension with coil over shock absorbers Steering Self adjusting rack and pinion Ackerman Brak...

Page 79: ...gross vehicle weight fully loaded vehicle including accessories 3160 lb 1433 kg Standard seating capacity 2 LIQUID CAPACITIES Engine crankcase with filter SAE 10W 30 API classification CF 3 qt 2 8 L...

Page 80: ...rotective Enclosure 2 YEARS 2000 LIMITED ONE YEAR Solenoid MCOR limit switches voltage regulators F R switches brake components wiring harness electrical switches canopy systems seats pedal group asse...

Page 81: ...SPEED GOVERNOR BRAKING SYSTEM STEERING TRANSAXLE OR OTHER OPERATING SYSTEMS OF THE CAR TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKEWISE VOID IF THE VEHICLE SHOWS INDICA...

Page 82: ...e limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state HOW TO MAKE A WARRANTY CLAIM To make a...

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Page 84: ...Publication Part Number 103472517 Edition Code 0608G0613F 103472517...