Related Manuals for Club Car CARRYALL 1500 CE
Summary of Contents for Club Car CARRYALL 1500 CE
- Page 1 CARRYALL 1500/1700 CE Diesel All-Wheel Drive Owner’s Manual [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 For the name and address of the authorized Club Car dealer or distributor nearest you, logon to our web site at www.clubcar.com or call 706-863-3000. If you would prefer to write to us, direct your letter to: Club Car LLC, Attention: Marketing Services, P.O.
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Page 5: Table Of Contents
TABLE OF CONTENTS Note to the Owner ..............................5 Safety Decal and Feature Identification ........................5 Practice Safety ..............................10 Safety Details ..............................11 General Warnings............................... 12 General Information ............................16 Model Identification............................. 17 Controls and Indicators ............................19 Roll-Over Protective Structure and Seat Belts....................... 23 Seat Latch and Adjustment .......................... - Page 6 Vehicle Specifications ............................56 Warranties................................59 EC Declaration of Conformity (Sample Document)....................61 Page 4 CARRYALL 1500/1700 CE Diesel All-Wheel Drive Owner’s Manual...
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Page 7: Note To The Owner
Note to the Owner NOTE TO THE OWNER This utility vehicle, with standard equipment and authorized attachments, is intended for commercial or residential property, farm, ranch or recreational applications. Use only approved accessories and attachments designed for your vehicle. This Operator’s Manual does not include instructions for attachments. Read the manual(s) provided with the authorized attachment to learn safe maintenance and operation of the vehicle. - Page 8 Safety Decal and Feature Identification CARRYALL 1500 DIESEL CE MARK VEHICLES 3008 Decal, Hot Pressurized Fluid Warning (on coolant Decal, Diesel Fuel Warning (on frame, near fuel 102427501 102459201 reserve tank cap, under hood) tank) Decal, Hot Surface Warning (on coolant pipes and Decal, Bed Latch Warning (on vehicle body, below 102458901 102459301...
- Page 9 Safety Decal and Feature Identification CARRYALL 1500 DIESEL CE MARK VEHICLES 2708 Decal, Trailer Hitch Tongue Weight Notice (on 1011553 102884401 Decal, Rollover Warning (on instrument panel) trailer/receiver hitch) Decal, Crush Area Warning (behind seat, near 101609401 102961201 Decal, ROPS Warning (on ROPS) cargo bed) 102459401 Decal, Young Driver Warning (on ROPS)
- Page 10 Safety Decal and Feature Identification CA 1700 DIESEL - CE MARK VEHICLES 3009 Decal, Hot Pressurized Fluid Warning (on coolant Decal, Diesel Fuel Warning (on frame, near fuel 102427501 102459201 reserve tank cap, under hood) tank) Decal, Hot Surface Warning (on coolant pipes and Decal, Rotating/Hot Parts Warning (on frame near 102458901 102459501...
- Page 11 Safety Decal and Feature Identification CA 1700 DIESEL - CE MARK VEHICLES 2706 Decal, Trailer Hitch Tongue Weight Notice (on Decal, Operating Instructions (on instrument 1011553 102884301 trailer/receiver hitch) panel) Decal, Crush Area Warning (behind seat, near 101609401 102884401 Decal, Rollover Warning (on instrument panel) cargo bed) Decal, Bed Latch Warning (on vehicle body, Decal, Falling Off Warning (behind and below...
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Page 12: Practice Safety
CAUTION statements and procedures it contains, along with the safety decals that are affixed to your vehicle. Prior to operating the vehicle, all operators should go to the Club Car web site and view the vehicle safety video. To locate the video, go to www.clubcar.com, and search for “safety video.”... -
Page 13: Safety Details
Safety Details SAFETY DETAILS WARNING • This owner’s manual should be read completely before attempting to drive or service the vehicle. Failure to follow the instructions in this manual could result in property damage, severe personal injury, or death. PERSONAL SAFETY It is important to note that some vital statements throughout this manual and on the decals affixed to the vehicle are preceded by the words DANGER, WARNING, or CAUTION. -
Page 14: General Warnings
• 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 15 General Warnings WARNING all crush areas. Do not drop cargo bed; lower gently and keep entire body clear. Failure to heed this warning could result in severe personal injury or death. • Only trained technicians should service or repair the vehicle. Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair.
- Page 16 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. Page 14...
- Page 17 General Warnings 1403 Figure 4 Dispose of Lead-acid Batteries Properly INTERNATIONAL SAFETY SYMBOLS ON BATTERIES Anyone using, repairing, or servicing the vehicle must understand and heed the safety symbols on the vehicle battery or batteries. 1. Shield eyes. 3. No smoking, no open flames, no sparks. 5.
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Page 18: General Information
General Information GENERAL INFORMATION This manual includes operating procedures, maintenance, and regular servicing information for diesel CE-Mark Carryall 1500 and Carryall 1700 vehicles. All operating procedures, maintenance, and regular servicing are identical unless otherwise noted. 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 seen from the operator’s seat. 1629 Figure 6 Vehicle Orientation... -
Page 19: Model Identification
Model Identification 1. Hood 2. ROPS 3. Fuel Fill Cap 4. Cargo Bed 5. Bed Lift Latch – vehicles with manual (standard) bed lift only 6. Engine Compartment, Battery, Fuel Tank (under seat; for four–passenger model, engine compartment is under rear seat) 7. Seat 8. Brake Fluid Reservoir (under hood) 9. Radiator and Coolant Reservoir (under hood) –... - Page 20 Model Identification Vehicle Model and Type Vehicle Serial Number (Figure 8) Year of Build (Figure 8) ROPS Serial Number (Figure 9) Engine Serial Number (Figure 10) Differential Serial Number (Figure 11) SERIAL NUMBER CC5819-123456 BC54679 ASSEMBLED IN USA 2843 1632 Figure 8 Serial Number Decal with the Vehicle Build Code Figure 9 ROPS Serial Number Location 2703...
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Page 21: Controls And Indicators
Controls and Indicators CONTROLS AND INDICATORS See General Warnings on page 12. WARNING • Before allowing anyone to drive the vehicle, make sure the driver is familiar with all controls and operating procedures. • Do not tamper with the high idle speed setting on the diesel vehicle. Doing so will void the warranty, as well as damage the engine and other components, and could result in property damage, personal injury, or death due to unsafe speeds. - Page 22 NEUTRAL (middle) position. The engine must be at idle before shifting the Forward/Reverse handle. See preceding WARNING and CAUTION. Club Car vehicles operate at a reduced speed in reverse. The reverse buzzer will sound as a warning when the Forward/Reverse handle is in the REVERSE position.
- Page 23 Controls and Indicators engaged, the park brake indicator light will illuminate (16). To disengage the park brake, pull the park brake release handle (4) (Figure 13). See following WARNING. WARNING • The park brake has multiple locking positions and should be firmly locked to prevent the vehicle from rolling.
- Page 24 If the warning light comes on, stop the vehicle and allow it to idle for approximately five minutes before stopping the engine. Contact a Club Car dealer/distributor or a trained technician. See following WARNING.
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Page 25: Roll-Over Protective Structure And Seat Belts
Roll-Over Protective Structure and Seat Belts ROLL-OVER PROTECTIVE STRUCTURE AND SEAT BELTS Carryall 1500 CE and 1700 CE vehicles are equipped with a Roll-Over Protective Structure (ROPS) and seat belts for each occupant. See following WARNING. WARNING • The ROPS must be properly installed before operating the vehicle. Club Car strongly urges that the vehicle’s occupants be properly restrained at all times with the seat belts provided. -
Page 26: Seat Latch And Adjustment
Do not allow a passenger to hold a child in his or her lap while the vehicle is moving. • The Club Car vehicle is not designed to meet child seat compatibility requirements. Children requiring a child safety seat must not ride on the vehicle. Comply with state and local laws pertaining to child safety. -
Page 27: Pre-Operation And Daily Safety Checklist
Install the seat. See preceding WARNING “Make sure seat hinges and 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 the controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery. -
Page 28: Driving Instructions
Use the following list, in addition to the Pre-Operation and Daily Safety Checklist, as a guide to inspect the vehicle daily for proper operation. Any problems should be corrected by a Club Car dealer/distributor or a trained technician. - Page 29 Driving Instructions WARNING • Stop the vehicle before shifting the Forward/Reverse handle. Engine must be at idle before shifting the Forward/Reverse handle. Failure to do so may result in injury to inattentive passengers and (or) damage to the vehicle. • To help avoid being struck, do not stand in front of or behind the vehicle. •...
- Page 30 ALL-WHEEL DRIVE (AWD) OPERATION Carryall 1500 CE and 1700 CE vehicles feature an all-wheel drive (AWD) system. The AWD system automatically directs power to the wheel, or wheels, that have the most traction, providing optimum traction at all times. For example, if all wheels except the rear passenger-side wheel lose traction, then power will be directed to the rear passenger-side wheel.
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Page 31: Bed Latch And Prop Rod
Do not drop cargo bed; lower gently and keep entire body clear. Failure to heed this warning could result in severe personal injury or death. NOTE: Carryall 1500 CE and 1700 CE vehicles are equipped with an automatically engaging prop rod (Figure 16), unless equipped with the electric bed lift accessory. -
Page 32: Loading And Unloading Cargo
Loading and Unloading Cargo Figure 15 Bed Latch Figure 16 Prop Rod LOADING AND UNLOADING CARGO WARNING • Firmly engage park brake before loading vehicle. • Do not allow riders in the cargo bed. • Reduce vehicle load and speed when driving up or down slopes or on uneven terrain. •... -
Page 33: Vehicle Load Capacities
Vehicle Load Capacities VEHICLE LOAD CAPACITIES Occupant Capacity The occupant capacity is the maximum allowable weight for occupants (operator and passengers) to operate the vehicle safely. Cargo Capacity The cargo capacity is the maximum amount of load that the vehicle can haul in the cargo bed and includes the weight of vehicle accessories and trailer tongue weight. -
Page 34: Towing With The Vehicle
• Stay clear from the area between the tow vehicle and the towed vehicle or trailer. Towing another Club Car vehicle or a trailer can have adverse effects on vehicle handling. Be especially cautious when towing other equipment with a Club Car vehicle. See Vehicle Load Capacities on page 31 for vehicle capacity information. -
Page 35: Storage
• For use on public roads, the trailer must meet all federal, state, and local requirements such as taillights, brake lights, etc. • Never tow a Club Car vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer. - Page 36 4.2. Disconnect the fuel vent line from the fuel tank vent nipple (Figure 32). 4.3. Plug the fuel tank vent nipple so that it is air tight. Club Car recommends using a slip-on vinyl cap. Change engine oil. See Engine Oil and Filter Change on page 42.
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Page 37: Maintenance
Any vehicle not functioning correctly should not be used until it is properly repaired. This will prevent further damage to the vehicle and help prevent injury to occupants resulting from unsafe conditions. Contact your local Club Car dealer/distributor for repairs and semiannual and annual periodic service. WARNING •... -
Page 38: Periodic Service Schedule
Periodic Service Schedule PERIODIC SERVICE SCHEDULE See General Warnings on page 12. WARNING • Service, repairs, and adjustments must be made per instructions in the appropriate maintenance and service manual. NOTE: If the vehicle is constantly subjected to heavy use or severe operating conditions, the preventive maintenance procedures should be performed more often than recommended in the Periodic Service and Lubrication Schedule. - Page 39 Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Clean terminals and wash dirt from Battery casing; check electrolyte level. Add distilled water if necessary. See page52. Check and adjust if necessary. See Steering and Front Suspension Section Front wheel alignment and toe-in in the appropriate maintenance and service manual.
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Page 40: Periodic Lubrication Schedule
Periodic Lubrication Schedule WARNING • If any problems are found during scheduled inspection or service, do not operate vehicle until repairs are made. Failure to make necessary repairs could result in fire, property damage, severe personal injury, or death. PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL... - Page 41 Periodic Lubrication Schedule 3012 Figure 19 Lubrication Points – Diesel Vehicles CARRYALL 1500/1700 CE Diesel All-Wheel Drive Owner’s Manual Page 39...
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Page 42: Brake Fluid Reservoir
Brake Fluid Reservoir BRAKE FLUID RESERVOIR 1. Full Level 2. Safe Level 3. Low Level 2693 Figure 20 Brake Fluid and Coolant Access (diesel vehicle Figure 21 Brake Fluid Reservoir shown) The brake fluid reservoir (1) is located under the hood (Figure 20). Raise the hood to check the brake fluid level. During the brake fluid level inspection, also inspect the following: •... -
Page 43: Engine Oil
Engine Oil ENGINE OIL Even though the low oil warning light on the instrument panel should illuminate if the oil level becomes low, the engine oil level should be checked daily. The vehicle should be on a level surface when the oil is checked. Do not overfill the engine with oil. - Page 44 Engine Oil ENGINE OIL AND FILTER CHANGE Engine oil and oil filter should be changed after the first 50 hours of operation (diesel). After that, they should be changed every 100 hours of operation or annually, whichever comes first. Engine Oil Draining Turn the key switch to the OFF position and remove the key.
- Page 45 Coat filter gasket with clean engine oil (Figure 25). Install the new oil filter (diesel: CC PN 102703301). See following NOTE. NOTE: Use only Club Car oil filters designed for your engine. Hand tighten 2/3 to 3/4 turn after the filter gasket contacts the mounting surface.
- Page 46 Engine Oil Figure 26 Add Engine Oil – Diesel Vehicles Engine Oil Filling Add engine oil (Figure 26). With filter change, the engine requires 3 qt (2.8 L) of oil for diesel vehicles. Refer to oil viscosity guidelines for selection of oil grade (Figure 27). See following CAUTION. CAUTION •...
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Page 47: Gearcase Lubrication
Gearcase Lubrication OIL VISCOSITY Choose the viscosity according to the temperature as shown in the appropriate oil viscosity chart (Figure 27). See following NOTE. NOTE: Use engine oil with API classification CF for diesel engines. Using multi-grade oils (5W-20, 10W-30, and 10W-40) will increase oil consumption. If multi-grade oil is used, check the oil level more frequently. - Page 48 Gearcase Lubrication Front differential: Clean and install the drain plug (2) and washer before filling the front differential with new lubricant (Figure 28). Tighten the drain plug to 108 in·lb (12 N·m). Use a funnel when filling the front differential through the lubricant level indicator hole (1).
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Page 49: Engine Coolant - Diesel Vehicles
Engine Coolant – Diesel Vehicles 2480 Figure 30 Rear Differential Lubrication Level ENGINE COOLANT – DIESEL VEHICLES ENGINE COOLANT LEVEL CHECK The coolant reserve tank (2) is located under the hood on the passenger side (Figure 20). Raise the hood to check the coolant level before every operation. -
Page 50: Air Intake System
Remove the air filter cartridge (1). See following NOTE. NOTE: The air filter cartridge is specifically designed for this engine. It only fits into the canister one way. Use only the Club Car part (CC PN 102498601) designed for this engine. Figure 31 Air Filter Cartridge Air Filter Installation Push the new air filter cartridge onto the nozzle inside the canister. -
Page 51: Fueling Instructions
Fueling Instructions FUELING INSTRUCTIONS See General Warnings on page 12. DANGER • Turn the key switch to the OFF position before fueling. • Do not pour fuel into the fuel tank when the engine is hot or while it is running. •... - Page 52 Fueling Instructions BIODIESEL FUEL (DIESEL VEHICLES ONLY) Biodiesel has unique qualities that should be considered before it is used in the Kubota D722 diesel engine. During cold weather, plugged fuel lines, plugged fuel systems, hard starting, and other unknown failures can result from use of this fuel.
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Page 53: Battery
Battery Drain the water until it changes color (to fuel). See following WARNING. WARNING • Clean up spilled fuel. Keep sparks and flames away from the vehicle and service area. Failure to heed this warning could result in an explosion or fire, resulting in severe personal injury or death. Close the valve by rotating it counterclockwise until the valve is firmly sealed. - Page 54 • Do not jump start or charge a frozen or damaged battery. Unplug charger before connecting or disconnecting cables to the battery. Never lean over battery while boosting, testing, or charging. The battery in a Club Car vehicle is a 12-volt, low-maintenance battery that requires infrequent checks (Figure 34). Electrolyte level should be checked semiannually.
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Page 55: Using A Booster Battery (Jump Starting)
Using A Booster Battery (Jump Starting) WARNING • If battery wire terminals are damaged or corroded, replace or clean them as necessary. Failure to do so may cause them to overheat during operation and could result in a fire, property damage, or personal injury. -
Page 56: Cleaning The Vehicle
Cleaning the Vehicle Figure 36 Jump Starting CLEANING THE VEHICLE Each vehicle is equipped with hand wash-washable front and rear bodies. The vehicle has a powder-coated steel cargo bed (or optional aluminum flat bed). Use commercial automotive cleaning solutions with a sponge or soft cloth for normal cleaning. -
Page 57: 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 58: Vehicle Specifications
Vehicle Specifications VEHICLE SPECIFICATIONS SPECIFICATIONS CARRYALL 1500 CARRYALL 1700 POWER SOURCE Diesel Diesel Engine: 4-cycle OHV, 719 cc, 20.0 Engine Horsepower (15.0 kW) rated @ 3600 RPM (per SAE ● ● J1995), three-cylinder, water-cooled, with pressure lubrication system. Fuel system: Mechanical injection, fuel water separator, fuel filters, and electric fuel pump ●... - Page 59 Vehicle Specifications SPECIFICATIONS CARRYALL 1500 CARRYALL 1700 Wheelbase 81.5 in (207 cm) 114 in (289.5 cm) Ground clearance: 8.2 in (20.8 cm) under differential Front and rear wheel tread 48.8 in (124 cm) *Vehicle Weight: (with ROPS) 1430 lb (649 kg) ●...
- Page 60 Vehicle Specifications SPECIFICATIONS CARRYALL 1500 CARRYALL 1700 NOISE AND VIBRATION SPECIFICATIONS 81.6 dBA Drive-by noise level to operator (Noise Power Level: Unknown at time of print Unknown at time of print Test method: EN 12053:2001 Uncertainty: 2 dBA Vibration at driver’s seat 0.9 m/s Unknown at time of print Test method: EN 13059:2002...
- Page 61 CLUB CAR, and all remaining components of the vehicle not specified otherwise. 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 62 THIS WARRANTY. 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 63 KG, MG Complies with Directive: 2006/42/EC Machinery 2006/66/EC Battery Manufacturer: Club Car, LLC Club Car Ingersoll Rand 4125 Washington Road Alma Court Building, Lenneke Marelaan 6 Evans, Georgia 30809 USA B-1932 Sint-Stevens-Woluwe, Belgium CARRYALL 1500/1700 CE Diesel All-Wheel Drive Owner’s Manual...
- Page 68 BC56663 Publication Part Number 105062721 Edition Code 0114A00000...
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