Club Car Carryall 295 Owner's Manual
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Club Car Carryall 295 Owner's Manual

Club Car Carryall 295 Owner's Manual

2007 intellitach all-wheel drive vechicles diesel
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2007
IntelliTach
All-Wheel Drive Vehicles
Diesel
Owner's Manual
Carryall 295
XRT 1550

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Summary of Contents for Club Car Carryall 295

  • Page 1 2007 IntelliTach All-Wheel Drive Vehicles Diesel Owner’s Manual Carryall 295 XRT 1550...
  • Page 3 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 We hope you will consider this owner’s manual a permanent part of your Club Car vehicle. If you sell the vehi- cle, please include the manual so that the next owner will have the important operating, safety, and mainte- nance information it contains.

  • Page 5: Table Of Contents

    Battery ............................... 58 Using a Booster Battery (Jump Starting) ....................60 Cleaning the Vehicle ..........................61 Accessories ............................... 61 Subsequent Owner Registration ........................ 62 Vehicle Specifications ..........................63 2007 Carryall 295 IntelliTach and XRT 1550 IntelliTach Diesel Vehicle Owner’s Manual Page 3...
  • Page 6 (ON VEHICLE FRAME NEAR BATTERY) HOT SURFACE WARNING DECAL (ON COOLANT PIPES AND UNDERSIDE OF BOTH SEATS) ROTATING PARTS AND HOT MANIFOLD DECAL (ON DRIVER-SIDE VEHICLE FRAME) Page 4 2007 Carryall 295 IntelliTach and XRT 1550 IntelliTach Diesel Vehicle Owner’s Manual...

  • Page 7: Vehicle Feature Identification

    • Do not attempt to repair hydraulic pump or lines while engine or pump is in operation. 102950601 • Relieve pressure before disconnecting hydraulic lines or fittings. HIGH PRESSURE VEHICLE LOADING DECAL DECAL 2007 Carryall 295 IntelliTach and XRT 1550 IntelliTach Diesel Vehicle Owner’s Manual Page 5...
  • Page 8 Page 6 2007 Carryall 295 IntelliTach and XRT 1550 IntelliTach Diesel Vehicle Owner’s Manual...

  • Page 9: Safety Details

    • A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could result in property damage. TO FUSE BLOCK Remove negative (–) cable first. TO GROUND Figure 1 Battery Cable Removal 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 7...

  • Page 10: General Warnings

    • A Club Car 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 11 • 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-wheel drive system will engage any wheel(s), front or rear, with traction. 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 9...

  • Page 12: General Information

    Forward/Reverse handle in the NEUTRAL position, turn the key switch to the OFF position, and remove the key when leaving the vehicle. Page 10 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...
  • Page 13 The joystick ON/OFF switch (18) is located on the rear face of the joystick box. When the switch is placed in the “OFF” position, the joystick and the hydraulic interface controls will not operate. 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 11...

  • Page 14: Key Switch

    NEUTRAL (middle) position. The engine must be at idle before shifting the Forward/Reverse handle. See WARNING and CAUTION on page 12. 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 15: Park Brake

    STEERING ADJUSTMENT LOCK The steering wheel on the Carryall 295 IntelliTach and XRT 1550 IntelliTach is adjustable. To adjust the steer- ing wheel, press down on the steering adjustment lock lever (8), then move the steering wheel to the desired position (Figure 4).

  • Page 16: Low Oil Warning Light

    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/dis- tributor or a trained technician. See following WARNING.
  • Page 17 When engaged in heavy attachment use, avoid the continued use of electrically powered devices (i.e. bedlift, worklights, lower fan speed on heater, etc.). Either drive the vehicle or allow it to idle occasionally to let the battery recharge. 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 15...
  • Page 18 FLOAT ACTIVATE TOGETHER FOR FLOAT AUX HYD Figure 8 Front Auxiliary Hydraulics Operation Page 16 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...

  • Page 19: Roll-Over Protective Structure (Rops) And Safety Belts

    (1) to the right (2) and to the left (3) (Figure 8) several times. This will relieve hydraulic pressure that is in the auxiliary circuit. ROLL-OVER PROTECTIVE STRUCTURE (ROPS) AND SAFETY BELTS The Carryall 295 IntelliTach and XRT 1550 IntelliTach is equipped with a Roll-Over Protective Structure (ROPS). Safety belts are provided for each occupant. See following WARNING. ý...
  • Page 20 Failure to do so could reduce the amount of protection and increase the chance of injury. • Do not place the shoulder belt under arm. • WARNING CONTINUED ON NEXT PAGE... Page 18 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...
  • Page 21 • Do not insert coins, clip, etc. in the buckle as this may prevent the tab from locking into the buckle properly. If the safety belt does not function normally, contact your Club Car dealer/distributor or trained tech- nician immediately. Do not occupy the seat until the safety belt is repaired.

  • Page 22: Seat Latch And Adjustment

    4. Install washers and bolts and tighten to 96 in-lb (10.8 N·m). 5. Install seat in the vehicle. See preceding WARNING “Make sure seat hinges and latch...”. Page 20 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...

  • Page 23: Pre-Operation And Daily Safety Checklist

    Pre-Operation and Daily Safety Checklist 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 24: Performance Inspection

    Use the following checklist as a guide to inspect the vehicle and check daily for proper operation. Any prob- lems should be corrected by a Club Car dealer/distributor or a trained technician. • Forward/Reverse shifter: Check for proper operation. See Controls and Indicators on page 10.

  • Page 25: Starting The Vehicle

    WARNING • The vehicle is not specially equipped for handicapped persons: - Be sure all passengers are capable of securing themselves in a moving Club Car vehicle before allowing them to ride in one. - Be sure all persons can properly operate the vehicle prior to allowing them to drive the vehicle.
  • Page 26 ALL-WHEEL DRIVE (AWD) OPERATION The Carryall 295 IntelliTach and XRT 1550 IntelliTach vehicle features an all-wheel drive (AWD) system. The AWD system automatically directs power to the wheel, or wheels, that have the most traction, providing opti- mum traction at all times.

  • Page 27: Bed Latch And Prop Rod

    The bed latch (Figure 12) has an automatically engaging prop rod and prop rod track (Figure 13) as standard features. To lift the bed, pull the bed latch handle toward the rear of the vehicle and lift the bed. The prop rod 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 25...
  • Page 28 Failure to heed this warning could result in severe personal injury or death. 4. Carryall 295 IntelliTach and XRT 1550 IntelliTach vehicles are equipped with an automatically engaging prop rod (Figure 13), unless equipped with the electric bed lift accessory.

  • Page 29: Attachments And Buckets

    See your dealer for more information about pallet fork inspection, maintenance and replacement. See your dealer for attachment arm rated capacity when using a pallet fork and for other available attachments. 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 27...
  • Page 30 8. Stop the engine, put the Forward/Reverse Handle in NEUTRAL, engage the park brake, unfasten your seat belt, and exit the vehicle. Figure 18 Tilt Backward Figure 19 Lock Attachment Page 28 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...
  • Page 31 3. Disconnect the hydraulic hoses, if equipped. See Quick Couplers (If Equipped) on page 17. 4. Pull the attachment interface lever (1) fully to the left and into the unlocked position (Figure 21). 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 29...
  • Page 32 • Keep the heavy end of the vehicle uphill. • Do not overload the vehicle. • Failure to obey warnings can cause the vehicle to tip or roll over and cause injury or death. Page 30 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...
  • Page 33 1. Lower the attachment arm all the way (A) and tilt the bucket forward (D) (Figure 27) until the cutting edge is on the ground. 2. Drive slowly forward to push the bucket slightly into the material. 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 31...
  • Page 34 • When using a bucket, never drive forward when the control for the attachment arm is in float position. 3. Drive backward to level loose material. 4. Pull the joystick backward (B) to unlock the attachment arm from the float position. Page 32 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...
  • Page 35 3. Remove the retaining ring (1) and pin (2) from the attachment interface cylinder rod end, and keep the retaining ring and pin for later use in this procedure (Figure 32). 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 33...
  • Page 36 15. To store, install the pins (1) into the attachment arm holes (both sides) and secure with the retaining pins (Figure 37). Figure 35 Secure Attachment and Interface Cylinders Figure 36 Remove Attachment Arm Retaining Pins Page 34 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...
  • Page 37 6. Remove the two retaining rings (4 and 7) and pins (3 and 6) that secure the two cylinders (1 and 5) to the locking plate (2) (Figure 40). Figure 39 Align the Attachment Arm Holes Figure 40 Remove Retainer Pins from Both Cylinders 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 35...
  • Page 38 13. Raise the attachment interface and align it with the cylinder. Install the pin (2) and the retaining ring (1) (Figure 43). Figure 43 Raise Interface, Install Pin and Retainer Ring Page 36 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...

  • Page 39: Loading And Unloading The Cargo Bed

    The vehicle rated capacity is the maximum amount of weight the vehicle can carry, haul, and tow. This capac- ity includes weight of occupants, bed load, gross trailer weight, attachment arm, and the attachment arm load. 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 37...
  • Page 40 1200 lb. (544 kg) A + B + C + E + Vehicle Weight: Maximum gross 3200 lb. (1451 kg) vehicle weight limit Figure 44 Vehicle Load Capacity Page 38 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...

  • Page 41: Towing With The Vehicle

    • 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 42: Storage

    4.2. Disconnect the fuel vent line from the fuel tank vent nipple (Figure 62, Page 56). 4.3. Plug the fuel tank vent nipple so that it is air tight. Club Car recommends using a slip-on vinyl cap. 5. Change engine oil. See Engine Oil and Filter Change on page 48.

  • Page 43: Maintenance

    Any vehicle not functioning correctly should not be used 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 dealer/distributor for repairs and semiannual and annual periodic service. ý...

  • Page 44: Periodic Service Schedule

    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 Ser- vice and Lubrication Schedule. Page 42 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...
  • Page 45 Operation and Daily Safety Checklist on page 21. See also Section 6 – Brake System in the appropriate maintenance and service manual. Periodic Service Schedule continued on next page..2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 43...
  • Page 46 • If any problems are found during scheduled inspection or service, do not operate the vehicle until repairs are made. Failure to make necessary repairs could result in fire, property damage, severe personal injury, or death. Page 44 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...

  • Page 47: Periodic Lubrication Schedule

    20 oz. (600 mL) Mobil 424, Exxon tion or annually, whichever Change transmission lubricant Hydraul 560, or Esso Hydraul 56 comes first lubricant Figure 45 Lubrication Points – Diesel Vehicles 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 45...
  • Page 48 3. Attachment Arm Cylinder (both ends). 4. Attachment Arm Pivot - interface side (both sides). Figure 46 Lubricate Grease Zerks located on Cylinder and Attachment Arm Ends Page 46 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...

  • Page 49: Brake Fluid Reservoir

    Remove the oil level dipstick from the oil filler tube and wipe oil from the dipstick. See Figure 51 or Figure 50. See following CAUTION. ý CAUT ION • Do not remove dipstick while engine is running. 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 47...
  • Page 50 • Wear safety glasses or approved eye protection when servicing the vehicle. Wear rubber gloves when handling oil drain plug, oil filter, and oil drain pan. Page 48 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...
  • Page 51 NOTE: Use only Club Car oil filters designed for your engine. 6. Tighten the oil filter by hand 2/3 turn after gasket contact. Do not use a band wrench or channel lock pliers. 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 49...
  • Page 52 Choose the viscosity according to the temperature as shown in the appropriate oil viscosity chart (Figure 55). See following NOTE. NOTE: Use engine oil with API classification CF for diesel engines. Page 50 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...

  • Page 53: Gearcase Lubrication

    (Figure 56). Tighten the drain plug to 9 ft-lb (12 N·m). Use a funnel when filling the front differential through the lubricant level indicator hole (1). See Periodic Lubrication Schedule on page 45. Tighten the level indi- cator plug to 10 ft-lb (14 N·m). 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 51...
  • Page 54 (1). See Periodic Lubrication Schedule on page 45. Apply Loctite 567 to the threads of the level indicator plug and tighten to 21 ft-lb (28 N·m). Figure 58 Rear Differential Lubrication Level Page 52 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...

  • Page 55: Hydraulic System

    9. If hydraulic oil must be added, thoroughly clean the area around the fill cap. Remove the fill cap and add hydraulic fluid until it is between the Maximum Fluid Level and the Minimum Fluid Level lines. 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 53...

  • Page 56: Engine Coolant - Diesel Vehicles

    1. Release both canister tab lock (Figure 61). 2. Pull the canister cap away from the canister. 3. Remove the air filter cartridge (1). See following NOTE. Page 54 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...

  • Page 57: Fueling Instructions

    Fueling Instructions 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 (CCI P/N 102498601) designed for this engine. Figure 61 Air Filter Cartridge Air Filter Installation 1.
  • Page 58 • Check the engine oil level daily before the engine is started. See Engine Oil Level Check on page 47. • Before vehicle storage, run the engine with conventional diesel fuel for at least 30 minutes to flush the Page 56 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...
  • Page 59 6. To resupply the filter with fuel, turn the key switch to the ON position for 10 seconds. See following NOTE. NOTE: Dispose of water according to the environmental laws and regulations for your area. 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 57...

  • Page 60: Battery

    • 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. Page 58 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...
  • Page 61 Battery The battery in a Club Car vehicle is a 12-volt, low-maintenance battery that requires infrequent checks (Figure 64). Electrolyte level should be checked semiannually. BATTERY LEVEL FRONT INDICATOR PLATES OF VEHICLE ELECTROLYTE LEVEL AT LEAST 1/2-INCH (13 MM) ABOVE...

  • Page 62: Using A Booster Battery (Jump Starting)

    CAUT ION • The alternator can be damaged if the following actions occur: - Engine is operated with battery cables disconnected. - Booster cables are connected wrong. Page 60 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...

  • Page 63: Cleaning The Vehicle

    There is a complete line of accessory equipment available from Club Car and our dealers/distributors. You can obtain the name and phone number of your closest Club Car contact by visiting our web site at www.Club Car.com and clicking the “Dealer Locator” link.

  • Page 64: 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 Inc., P.O.

  • Page 65: Vehicle Specifications

    (40 kph) Governed RPM 3825 Turning radius (per SAE J 695) 23 ft-10 in. Load bed height 32.5 in. (83 cm) continued on next page... DIMENSIONS/WEIGHT 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 63...

  • Page 66: Specifications

    6.5 gallons (24.6 L) Hydraulic fluid: Bobcat Hydraulic Fluid 1.3 gallons (5.0 L) TIRE PRESSURE 20-22 psi All-terrain tread and mud tires (1.38 - 1.52 Bars) Page 64 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual...
  • Page 67 Repair shall mean remedying a defect in the vehicle or component thereof at no cost to the purchaser during the applicable limited warranty period. If CLUB CAR elects to repair the vehicle, it may provide factory-reconditioned parts or components.
  • Page 68 To make a warranty claim under this limited warranty, you must present the vehicle or defective component to an authorized CLUB CAR dealer or send the defective component, freight prepaid, to WARRANTY SERVICES, CLUB CAR, INC., 4125 Washington Road, Evans, Georgia 30809, U.S.A., 706-863-3000.
  • Page 69 3. Clarity of Illustrations 4. Periodic Service and Periodic Lubrication Schedules Comments/Suggestions Please fax a copy of this page to (706) 228-2662. Thank You! Club Car Technical Publication Department 2007 Carryall 295 Intellitach and XRT 1550 Intellitach Diesel Vehicle Owner’s Manual Page 67...
  • Page 72 Publication Part Number 103218304 Edition Code 0606B0307A Club Car, Inc. www.clubcar.com P.O. Box 204658 Phone 1.706.863.3000 Augusta, GA 30917-4658 1.800.ClubCar Intl’l +1 706.863.3000 1.706.863-5808...

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Intellitach xrt 1550

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