Ingersoll-Rand Club Car CARRYALL 1500 Operator's Manual
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Ingersoll-Rand Club Car CARRYALL 1500 Operator's Manual

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CARRYALL 1500 AWD DIESEL
Operators Manual
APPLICABLE TO CARRYALL 1500 AWD D722 DIESEL
VEHICLES WITH SERIAL PREFIX OF RF

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Summary of Contents for Ingersoll-Rand Club Car CARRYALL 1500

  • Page 1 CARRYALL 1500 AWD DIESEL Operators Manual APPLICABLE TO CARRYALL 1500 AWD D722 DIESEL VEHICLES WITH SERIAL PREFIX OF RF...
  • Page 2 Copyright © 2020 Club Car, LLC This manual effective July 1, 2020...

  • Page 3: Introduction

    INTRODUCTION VEHICLE OWNERSHIP Congratulations! The Club Car brand is widely recognized as the industry leader in vehicle efficiency and long-lasting value. Read, understand, and obey the technical content in this manual to protect your investment and provide years of reliable vehicle operation. Read, understand, and obey all instructions and safety precautions in this manual to prevent the risk of personal injury or property damage.
  • Page 4 APPROVED DEALERS AND DISTRIBUTORS Club Car’s customer support system offers fast and courteous service. Speak with your dealer or distributor for: • Accessories • Technical Advice • Publications • Warranty Work • Replacement Parts To find your nearest dealer or distributor: •...
  • Page 5 NOTICES VEHICLE MODEL AND SERIAL NUMBER The vehicle serial number is located on a bar code decal installed near the accelerator. 1. A two-letter code that identifies the vehicle model. 2. A four-digit code that identifies the model year and production week the vehicle was assembled.
  • Page 6 MODIFICATIONS TO THE GOVERNOR WILL VOID THE WARRANTY NOTICE AND DAMAGE THE ENGINE AND OTHER COMPONENTS. DO NOT MODIFY THE GOVERNOR. MODIFICATIONS TO THE VEHICLE MUST NOT COMPROMISE COMPLIANCE WITH STATE OR FEDERAL REGULATIONS. THE DRIVER-SIDE FRAME IS PART OF THE AIR INTAKE SYSTEM. MODIFICATIONS TO THE FRAME CAN DAMAGE THE ENGINE BY CONTAMINATING THE AIR INTAKE SYSTEM.
  • Page 7 • EN ISO 12100:2010 • EN ISO 13857:2008 • EN ISO14982:2009 PUBLICATION COPYRIGHT This manual contains proprietary information that is protected by copyright. All rights are reserved. Express written consent of Club Car, LLC is necessary to photocopy, replicate, or translate this manual. The information contained in this publication is subject to change without notice.
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  • Page 9: Table Of Contents

    CONTENTS INTRODUCTION ............................I NOTICES ..............................III SECTION 1 – SAFETY INFORMATION ....................11 General Safety Information ........................ 12 Note To The Owner ......................... 12 Practice Safety..........................12 Safety Signal Words ........................12 Safety Committee .......................... 13 Vehicle Safety Information........................13 Vehicle Safety And Compliance Decals..................15 Vehicle Safety Features ........................
  • Page 10 SECTION 4 – VEHICLE FEATURES......................41 Vehicle Features Description ....................... 42 Bucket Seats ............................42 Driver Seat Adjustment ......................... 42 Passenger Seat Adjustment......................42 Electric Bed Lift ............................ 43 Description ............................. 43 Capacity ............................43 Operation............................43 IntelliTrak System..........................44 Modular Cab ............................44 Mud Tire Option ...........................
  • Page 11 Vehicle Exterior ..........................69 Vehicle Interior ..........................70 Maintenance Schedule ........................70 Overview............................70 Service Schedule ..........................70 Maintenance Tasks..........................72 Air Filter ............................72 Brake Fluid Level Inspection ......................73 Engine Coolant ..........................74 Engine Oil............................76 Front Differential Fluid Level Inspection..................80 Fuel Filter Drain ..........................
  • Page 12 How To Make A Claim ........................107 California Evaporative Emission Control Warranty Statement ............108 Your Warranty Rights And Obligations..................108 Manufacturer’s Warranty Coverage..................... 108 Owner’s Warranty Responsibilities ....................108 Defects Warranty Coverage ......................108 Evaporative Emissions Warranty Parts List ................. 109 CARRYALL 1500 AWD DIESEL Page x Operators Manual...

  • Page 13: Notices

    Safety Information Notices SAFETY INFORMATION CARRYALL 1500 AWD DIESEL Page 11 Operators Manual TPCC01RF00EN018 (Edition C)

  • Page 14: General Safety Information

    Safety Information General Safety Information GENERAL SAFETY INFORMATION This vehicle is designed and intended to transport people and cargo in off road applications including commercial, industrial and agriculture. Operation on hard, improved surfaces should be limited. Always adhere to local laws and regulations pertaining to the use of the vehicle. Only operate this vehicle as described in this manual.

  • Page 15: Safety Committee

    Safety Information Vehicle Safety Information SAFETY SIGNAL WORD SIGNIFICANCE A DANGER identifies a hazardous situation which will result in DANGER death or serious injury. A WARNING identifies a hazardous situation which could result WARNING in death or serious injury. A CAUTION identifies a hazardous situation which could result CAUTION in minor or moderate injury.
  • Page 16 Safety Information Vehicle Safety Information THE VEHICLE DOES NOT GIVE PROTECTION FROM LIGHTNING, FLYING OBJECTS, OR OTHER STORM RELATED HAZARDS. DO NOT OPERATE THE VEHICLE IN STORMS. STOP THE VEHICLE. GET OUT OF THE VEHICLE IMMEDIATELY AND FIND A SHELTER IN ACCORDANCE WITH APPLICABLE SAFETY GUIDELINES FOR YOUR LOCATION IF IN A STORM.

  • Page 17: Vehicle Safety And Compliance Decals

    Safety Information Vehicle Safety Information ACCESSORIES ATTACHED TO THE BED SIDES CAN ADD WIDTH TO THE VEHICLE, HIT NEARBY PERSONS OR OBJECTS, AND CAUSE PROPERTY DAMAGE AND SERIOUS PERSONAL INJURY. USE CAUTION WHEN OPERATING THE VEHICLE WITH ACCESSORIES ATTACHED TO THE BED SIDES. IF THE CAB HAS DAMAGE, DO NOT OPERATE THE VEHICLE.
  • Page 18 Safety Information Vehicle Safety Information OPERATING INSTRUCTIONS Before using vehicle, read owner’s manual and vehicle safety warnings. Study and understand controls. TO OPERATE • Make sure wheels are turned in desired direction and path is clear. • Place vehicle in NEUTRAL (N) and push the brake pedal. •...
  • Page 19 Safety Information Vehicle Safety Information The engine will stop when the park brake is engaged and the WARNING Forward / Neutral / YOUNG DRIVERS INCREASE CHANCE OF DEATH Reverse control (FNR) • Young drivers may not be able to control vehicle. UNDER is set to F or R.
  • Page 20 Safety Information Vehicle Safety Information WARNING WARNING CRUSH AREA STAY CLEAR ROTATING PARTS Can cause serious injury or Rotating parts can cause serious injury. Keep body, death. hands, hair, and clothes away from rotating parts. 102460201 Remove bed before servicing lift system.

  • Page 21: Vehicle Safety Features

    Safety Information Vehicle Safety Features WARNING WARNING NOTICE ROLLOVERS CAN CAUSE • Read and understand the Operators Manual and safety decals. FALLING OFF SERIOUS INJURY OR DEATH • 1050 lb (476 kg) maximum cargo load. Includes cargo, bed load, CAN CAUSE SERIOUS optional equipment, and trailer tounge weight.

  • Page 22: Cargo Cage Headrest Adjustment

    Safety Information Vehicle Safety Features CARGO CAGE HEADREST ADJUSTMENT Remove the thumb screws (1). Adjust the headrest (2). DAMAGE CAN OCCUR IF THE HEADREST HARDWARE IS TOO NOTICE TIGHT. DO NOT TIGHTEN THE HEADREST HARDWARE TOO MUCH. Install and tighten the thumb screws with your hand. FALLING OBJECT PROTECTION SYSTEM The Falling Object Protection System (FOPS) protects the vehicle occupants from falling debris.
  • Page 23 Safety Information Vehicle Safety Features • Side impacts • Rear impacts • Roll-over PROPER USE OF SEAT BELTS FAILURE TO USE THE SEAT BELT CORRECTLY CAN CAUSE DANGER SERIOUS PERSONAL INJURY OR DEATH. MAKE SURE THAT THE TAB AND BUCKLE ARE LOCKED. MAKE SURE THAT THE BELT IS NOT TWISTED.
  • Page 24 Safety Information Vehicle Safety Features SEAT BELT INSPECTION A SEAT BELT THAT DOES NOT OPERATE CORRECTLY CAN CAUSE DANGER SERIOUS PERSONAL INJURY. DO NOT DISASSEMBLE OR CHANGE THE SEAT BELT SYSTEM. DO NOT DAMAGE THE SEAT BELT OR HARDWARE. SPEAK WITH YOUR LOCAL DEALER OR DISTRIBUTOR FOR REPAIR.

  • Page 25: Battery Safety Information

    Safety Information Battery Safety Information • Injured Persons - Consult your doctor for specific recommendations. • Seat Belt Extenders - Club Car does not recommend the use of seat belt extenders. LATCH A SEAT BELT AN IMPROPERLY POSITIONED SEAT BELT CAN CAUSE SERIOUS WARNING INJURY OR DEATH IN AN ACCIDENT.

  • Page 26: Battery International Safety Symbols

    Safety Information Battery Safety Information LOOSE BATTERY WIRES CAN CAUSE A FIRE, PROPERTY DAMAGE, OR SERIOUS PERSONAL INJURY. MAKE SURE THAT ALL BATTERY WIRES AND TERMINALS ARE CLEAN AND TIGHTENED CORRECTLY. BATTERY WIRES WITH DAMAGE OR CORROSION CAN BECOME TOO HOT AND CAUSE A FIRE, PROPERTY DAMAGE, OR SERIOUS PERSONAL INJURY.
  • Page 27 Safety Information Battery Safety Information Lead-acid batteries and other components which have the Waste Electrical and Electronic Equipment (WEEE) symbol printed on them must be collected and recycled separately from other waste. Do not discard lead-acid batteries as municipal waste. Speak with your dealer or distributor on how to correctly recycle lead-acid batteries.
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  • Page 29: Section 2 - Indicators, Gauges, And Displays

    Indicators, Gauges, And Displays Battery Safety Information INDICATORS, GAUGES, AND DISPLAYS CARRYALL 1500 AWD DIESEL Operators Manual Page 27 TPCC01RF00EN018 (Edition C)

  • Page 30: Indicator, Gauge, And Display Locations

    Indicators, Gauges, And Displays Indicator, Gauge, And Display Locations INDICATOR, GAUGE, AND DISPLAY LOCATIONS 1. High-Temperature Warning Light 2. Park Brake Indicator Light 3. Low Oil Warning Light 4. Fuel Gauge/Hour Meter FUEL GAUGE/HOUR METER The fuel gauge/hour meter gives a visual indication of: •...

  • Page 31: Low Oil Warning Light

    Indicators, Gauges, And Displays Low Oil Warning Light STATUS CONDITION Normal Operation Engine coolant is above its normal safe operational temperature. 1. Stop the vehicle. 2. Idle the vehicle for approximately five minutes. 3. Stop the engine. Note: Have a trained technician check the vehicle if the high-temperature warning light stays on after sufficient time has elapsed for the engine coolant to cool down.

  • Page 32: Park Brake Indicator Light

    Indicators, Gauges, And Displays Park Brake Indicator Light PARK BRAKE INDICATOR LIGHT The park brake indicator gives a visual confirmation when the park brake is engaged. CARRYALL 1500 AWD DIESEL Page 30 Operators Manual TPCC01RF00EN018 (Edition C)

  • Page 33: Section 3 - Vehicle Controls

    Vehicle Controls Park Brake Indicator Light VEHICLE CONTROLS CARRYALL 1500 AWD DIESEL Operators Manual Page 31 TPCC01RF00EN018 (Edition C)

  • Page 34: Vehicle Controls Locator

    Vehicle Controls Vehicle Controls Locator VEHICLE CONTROLS LOCATOR 1. Accelerator Pedal 2. Brake Pedal 3. Park Brake 4. Park Brake Release 5. Steering Column Adjustment Lever 6. Key Switch 7. Forward / Neutral / Reverse Control (FNR) 8. Headlight Switch 9.

  • Page 35: Accelerator Pedal

    Vehicle Controls Accelerator Pedal ACCELERATOR PEDAL The accelerator pedal is used to increase and maintain the speed of the vehicle. BRAKE PEDAL The brake pedal is used to decrease speed or stop the vehicle. ELECTRIC BED LIFT SWITCH POSITION FUNCTION The electric bed lift switch controls the movement of the cargo bed.

  • Page 36: Forward / Neutral / Reverse Control

    Vehicle Controls Forward / Neutral / Reverse Control FORWARD / NEUTRAL / REVERSE CONTROL FAILURE TO STOP THE VEHICLE BEFORE SHIFTING THE WARNING FORWARD / NEUTRAL / REVERSE CONTROL (FNR) CAN CAUSE PROPERTY DAMAGE AND SERIOUS PERSONAL INJURY. STOP THE VEHICLE BEFORE SHIFTING THE FORWARD / NEUTRAL / REVERSE CONTROL (FNR).

  • Page 37: Horn

    Vehicle Controls Horn HORN The horn button is used to control the horn. The horn button is spring loaded to stay in the off position. Push and hold the horn button to operate the horn. INTELLITRAK SWITCH KEY SWITCH THE KEY SWITCH CAN BE USED TO DISABLE THE ENGINE IN AN WARNING EMERGENCY.

  • Page 38: Park Brake

    Vehicle Controls Park Brake POSITION CONDITION Normal position when the vehicle is in use. Electrical power from the battery is available to power the engine, engine starter, and electrical systems. A temporary position used to start the engine. START PARK BRAKE FAILURE TO ENGAGE THE PARK BRAKE CAN CAUSE PROPERTY WARNING DAMAGE AND SERIOUS PERSONAL INJURY.

  • Page 39: Turn Signal Lever

    Vehicle Controls Turn Signal Lever The steering column adjustment lever adjusts the steering column. Set the lever in the down position to unlock and adjust the steering column position. Set the lever in the up position to lock the steering column. TURN SIGNAL LEVER The turn signal lever controls the operation of the POSITION...

  • Page 40: Lower Dash Fan Switch

    Vehicle Controls Modular Cab Controls The dome light switch controls the operation of POSITION FUNCTION the interior cabin lights. Note: The dome light operates independently of the key switch position. LOWER DASH FAN SWITCH POSITION FUNCTION The lower dash fan switch controls the operation of the lower dash fan.

  • Page 41: Windshield Washer Switch

    Vehicle Controls Modular Cab Controls WINDSHIELD WASHER SWITCH The windshield washer switch controls the operation of the washer fluid supply to the windshield. The switch is spring loaded to stay in the off position. Push and hold the switch in the on position to apply washer fluid to the windshield. CARRYALL 1500 AWD DIESEL Operators Manual Page 39...
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  • Page 43: Section 4 - Vehicle Features

    Vehicle Features Modular Cab Controls VEHICLE FEATURES CARRYALL 1500 AWD DIESEL Page 41 Operators Manual TPCC01RF00EN018 (Edition C)

  • Page 44: Vehicle Features Description

    Vehicle Features Vehicle Features Hazard Statements The vehicle features listed are standard and optional. BUCKET SEATS DRIVER SEAT ADJUSTMENT DO NOT ADJUST THE DRIVER-SIDE SEAT WHILE THE VEHICLE IS WARNING IN MOTION. Pull the driver seat adjustment lever (1) to the left. Adjust the driver seat forward or rearward.

  • Page 45: Electric Bed Lift

    Vehicle Features Electric Bed Lift Align the mounting plate (4) holes with the holes in the passenger seat. Install the washers and bolts. Tighten the bolts to 80 lb·in (9.0 N·m). Install the passenger seat. Make sure that the passenger seat is engaged. ELECTRIC BED LIFT USE CAUTION WHEN WORKING UNDER THE BED.

  • Page 46: Intellitrak System

    Vehicle Features IntelliTrak System INTELLITRAK SYSTEM IntelliTrak is an on-demand all-wheel drive traction control system. IntelliTrak system supplies power from wheels that have lost traction to wheels that have traction. Speak with your local approved dealer or distributor for a detailed system description and demonstration. MODULAR CAB The modular cab is available in different configurations for a wide range of operator requirements.

  • Page 47: Operation

    Vehicle Features Tilt Cargo Bed OPERATION LIFT THE TILT CARGO BED Disable the vehicle. Pull the bed latch handle. Lift the bed. Make sure that the prop rod (1) is in a notch (2). LOWER THE TILT CARGO BED Lift the tilt cargo bed. CARRYALL 1500 AWD DIESEL Page 45 Operators Manual...

  • Page 48: 12-Volt Power Receptacle

    Vehicle Features 12-Volt Power Receptacle Remove the prop rod (1) from the notch (2). Lower the tilt cargo bed. Make sure that the cargo bed latch engages. 12-VOLT POWER RECEPTACLE The 12-volt 6.5-amp power receptacle supplies electricity to power and charge accessories when the key switch is ON.

  • Page 49: Section 5 - Vehicle Specifications

    Vehicle Specifications Winch VEHICLE SPECIFICATIONS CARRYALL 1500 AWD DIESEL Page 47 Operators Manual TPCC01RF00EN018 (Edition C)

  • Page 50: Dimensions

    Vehicle Specifications Dimensions DIMENSIONS 122 in (309.9 cm) - box bed configuration without a Length brushguard 58.5 in (148.5 cm) - without mirror Width 63.6 in (161.5 cm) - with mirror 82.3 in (209 cm) - with ROPS Height 34 in (86.4 cm) Bed Height 48.0 x 49.8 x 10.9 in (122 x 127 x 28 cm) Box Bed Size...

  • Page 51: Diesel Engine

    Vehicle Specifications Diesel Engine DIESEL ENGINE Horsepower Rating 14 hp (10.4 kW) at 3600 RPM (per SAE J1995) Diesel fuel grade no. 2 with a cetane rating of 45 or Fuel Type higher Fuel Capacity 6.5 gal (24.6 l) Engine Oil Capacity 3 qt (2.8 l) BATTERY Battery Type...

  • Page 52: Vehicle Weights And Load Capacities

    Vehicle Specifications Vehicle Weights And Load Capacities VEHICLE WEIGHTS AND LOAD CAPACITIES IF THE RATED CAPACITIES OF THE VEHICLE ARE EXCEEDED, WARNING PROPERTY DAMAGE, SERIOUS PERSONAL 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 FAILURE, RESULTING IN LOSS OF CONTROL OF VEHICLE AND SERIOUS PERSONAL...
  • Page 53 Vehicle Specifications Vehicle Weights And Load Capacities TERM DEFINITION The cargo capacity is the maximum weight of a load that the vehicle can have Maximum Cargo in the cargo area. The cargo capacity includes the weight of optional Capacity equipment. Maximum Trailer The trailer tongue weight is the maximum permitted weight applied by the Tongue Weight...
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  • Page 55: Section 6 - Vehicle Operation

    Vehicle Operation Vehicle Weights And Load Capacities VEHICLE OPERATION CARRYALL 1500 AWD DIESEL Operators Manual Page 53 TPCC01RF00EN018 (Edition C)
  • Page 56 Vehicle Operation Vehicle Operations Hazard Statements OPERATING THE VEHICLE WHILE OCCUPANTS ARE NOT FULLY DANGER SEATED CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH. START THE VEHICLE ONLY WHEN ALL OCCUPANTS ARE FULLY SEATED WITH SEAT BELTS FASTENED. DO NOT LET PASSENGERS RIDE IN THE CARGO BED. FALLING OBJECTS CAN CAUSE PROPERTY DAMAGE, SERIOUS WARNING PERSONAL INJURY, OR DEATH.

  • Page 57: Daily Pre-Operational Safety And Performance Checks

    Vehicle Operation Daily Pre-Operational Safety And Performance Checks A SHARP TURN AT HIGH SPEEDS CAN CAUSE A ROLL-OVER OR FALLING OFF WHICH CAN RESULT IN PROPERTY DAMAGE, AND SERIOUS PERSONAL INJURY. OPERATE THE VEHICLE SLOWLY IN TURNS. UNINTENDED VEHICLE OPERATION CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH.

  • Page 58: Daily Pre-Operational Safety Checklist

    Vehicle Operation Daily Pre-Operational Safety And Performance Checks DAILY PRE-OPERATIONAL SAFETY CHECKLIST INSPECTION INSPECTION CRITERIA AREA • Make sure that all parts are correctly installed. • Make sure that all nuts, bolts, and screws are tight. General • Replace missing, worn, or damaged items. •...

  • Page 59: Vehicle Performance Inspection

    Vehicle Operation Daily Pre-Operational Safety And Performance Checks INSPECTION INSPECTION CRITERIA AREA • Examine the fuel system for leakage. • Examine the fuel level. Add fuel as necessary. Engine Fuel • Replace missing, worn, or damaged items. • Drain water from the fuel filter. Engine Air Filter •...

  • Page 60: Vehicle Movement

    Vehicle Operation Vehicle Movement Set the Forward / Neutral / Reverse control (FNR) to R. Make sure that the multi-purpose buzzer operates. Release the brake pedal. Slowly push the accelerator pedal. Make sure the vehicle moves in reverse. Slowly push the brake pedal. Stop the vehicle. Set the FNR to F.

  • Page 61: Turn Off Engine

    Vehicle Operation Vehicle Movement TRYING TO START THE VEHICLE AGAIN AND AGAIN WITH AN NOTICE EMPTY FUEL TANK WILL CAUSE FUEL PUMP DAMAGE. DO NOT TRY TO START A VEHICLE WHEN THE FUEL TANK IS EMPTY. MAKE SURE THAT THERE IS FUEL IN THE FUEL TANK BEFORE VEHICLE OPERATION.

  • Page 62: Reverse Movement

    Vehicle Operation Vehicle Movement Before forward movement: • Read and obey all safety decals and information located on the vehicle. • Understand how to operate the vehicle correctly and safely. • Understand the function of all vehicle controls, indicators, displays, and gauges. •...

  • Page 63: Slow Or Stop The Vehicle

    Vehicle Operation Driving Conditions SLOW OR STOP THE VEHICLE Release the accelerator pedal. Push the brake pedal. PARK THE VEHICLE Stop the vehicle. Engage the park brake to prevent vehicle movement. Set the Forward / Neutral / Reverse control (FNR) to N. Turn the key to OFF.

  • Page 64: Side Hill Slope

    Vehicle Operation Driving Conditions SIDE HILL SLOPE TO PREVENT ROLL-OVER, PROPERTY DAMAGE, AND SERIOUS WARNING PERSONAL INJURY, OPERATE THE VEHICLE SLOWLY ON A SLOPE. VEHICLE ROLLBACK WHEN STARTING ON AN INCLINE CAN CAUSE PROPERTY DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH. USE THE BRAKE PEDAL TO HOLD THE VEHICLE UNTIL THE DRIVETRAIN IS FULLY ENGAGED.

  • Page 65: Over Obstacles

    Vehicle Operation Driving Conditions • Prevent driving at an offset angle. An offset angle will cause the vehicle to lean sharply to one side. • Continue at a stable rate of speed. Do not accelerate quickly. • Decrease the vehicle speed. •...

  • Page 66: Through Water

    Vehicle Operation Driving Conditions • Look forward and learn to read the terrain. Be constantly alert for hazards. • Drive slowly and use caution when operating on unfamiliar terrain. Not all obstacles are immediately visible. THROUGH WATER DRIVING THROUGH WATER CAN DECREASE BRAKE WARNING PERFORMANCE.
  • Page 67 Vehicle Operation Driving Conditions • Secure all loads before operating. Unsecured loads can cause unstable operating conditions, which could cause loss of vehicle control. • Operate only with stable and safely arranged loads. When handling off-centered loads that cannot be centered, correctly fasten the load and operate with extra caution. Always attach the tow load to the hitch point designated for the vehicle.
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  • Page 69: Section 7 - Vehicle Maintenance

    Vehicle Maintenance Driving Conditions VEHICLE MAINTENANCE CARRYALL 1500 AWD DIESEL Operators Manual Page 67 TPCC01RF00EN018 (Edition C)
  • Page 70 Vehicle Maintenance Vehicle Maintenance Hazard Statements FUEL IS FLAMMABLE AND EXPLOSIVE. DO NOT SMOKE. KEEP DANGER SPARKS AND OPEN FLAMES AWAY FROM THE VEHICLE AND SERVICING AREA. DO THE SERVICING OF THE VEHICLE IN A VENTILATED AREA. INCORRECT OPERATION OF THE CARGO BED CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH.

  • Page 71: Disable The Vehicle

    Vehicle Maintenance Disable The Vehicle LIFT ONLY ONE END OF THE VEHICLE AT A TIME. USE A SUITABLE LIFTING DEVICE WITH 1000 LB (454 KG) MINIMUM LIFTING CAPACITY. DO NOT USE THE LIFTING DEVICE TO HOLD THE VEHICLE IN THE LIFTED POSITION. USE APPROVED JACK STANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR.

  • Page 72: Vehicle Interior

    Vehicle Maintenance Maintenance Schedule Use non-abrasive wax products. Battery acid, fertilizers, tars, asphalt, creosote, paint, or chewing gum should be removed immediately to prevent possible stains. Discard the waste water correctly. CLEANING THE VEHICLE INTERIOR MOISTURE CAN CAUSE ELECTRICAL COMPONENT DAMAGE. DO NOTICE NOT USE A PRESSURE WASHER OR STEAM CLEANER TO CLEAN THE VEHICLE.
  • Page 73 Vehicle Maintenance Maintenance Schedule INTERVAL DESCRIPTION Do the Daily Pre-Operational Safety Check. Do the Daily Vehicle Performance Inspection. Examine the engine oil level. Daily Examine the brake fluid level. Make sure that the brake pedal operates correctly. Drain the water from the fuel filter. Examine the engine coolant level.

  • Page 74: Maintenance Tasks

    Vehicle Maintenance Maintenance Tasks INTERVAL DESCRIPTION Examine the vehicle for loose hardware. Tighten as necessary. Replace the air filter. If the vehicle is operated in dirty environments, replace the air filter more frequently Examine the air filter hose for damage. Make sure the air filter hose clamps are tight.

  • Page 75: Brake Fluid Level Inspection

    Vehicle Maintenance Maintenance Tasks Release the wire latches (1). Remove the air cleaner cover (2). Remove the air filter (3). AIR FILTER INSTALLATION Use a wet lint-free cloth to clean the inside of the air filter container. Install the air filter (3). Install the air cleaner cover (2).

  • Page 76: Engine Coolant

    Vehicle Maintenance Maintenance Tasks If the brake fluid level is below the minimum indicator, have a trained technician do a check of the brake system. ENGINE COOLANT ENGINE COOLANT LEVEL INSPECTION REMOVAL OF THE ENGINE COOLANT CAP WHEN THE ENGINE IS WARNING HOT CAN CAUSE PROPERTY DAMAGE AND SERIOUS PERSONAL INJURY.
  • Page 77 Vehicle Maintenance Maintenance Tasks Make sure that the engine coolant level is between the maximum and minimum indicators. If the engine coolant level is below the minimum indicator, add engine coolant. ADD ENGINE COOLANT REMOVAL OF THE ENGINE COOLANT CAP WHEN THE ENGINE IS WARNING HOT CAN CAUSE PROPERTY DAMAGE AND SERIOUS PERSONAL INJURY.

  • Page 78: Engine Oil

    Vehicle Maintenance Maintenance Tasks Remove the coolant cap (1). Add engine coolant until the engine coolant level is at the maximum indicator. Install the coolant cap. ENGINE OIL ENGINE OIL VISCOSITY Select the engine oil viscosity for your environmental conditions. CARRYALL 1500 AWD DIESEL Page 76 Operators Manual...
  • Page 79 Vehicle Maintenance Maintenance Tasks ENGINE OIL LEVEL INSPECTION Before the engine oil is examined: • Disable the vehicle. To examine the engine oil: Remove the dipstick (1). Make sure that there is oil on the dipstick. Install the dipstick. Start and operate the engine for three minutes. If the low oil warning light stays on, turn off the engine immediately.
  • Page 80 Vehicle Maintenance Maintenance Tasks Turn off the engine. Wait two minutes. Remove and clean the dipstick. Install the dipstick. Remove the dipstick. Make sure that the oil level is between the maximum (1) and minimum (2) indicators. If the oil level is below the minimum indicator, add engine oil. Install the dipstick.
  • Page 81 Vehicle Maintenance Maintenance Tasks Remove the oil fill cap (1). Clean the area around the oil drain plug (2) and oil filter (3). Put a drain pan below the oil drain plug. Remove the oil drain plug. Drain the oil fully. Clean the oil drain plug.

  • Page 82: Front Differential Fluid Level Inspection

    Vehicle Maintenance Maintenance Tasks Speak with your dealer or distributor to get more information on how to recycle the used engine oil and filter correctly. ADD ENGINE OIL DO NOT REMOVE THE DIPSTICK WHILE THE ENGINE IS ON. CAUTION TOO MUCH ENGINE OIL CAN DECREASE ENGINE PERFORMANCE NOTICE AND DAMAGE THE ENGINE.

  • Page 83: Fuel Filter Drain

    Vehicle Maintenance Maintenance Tasks Remove the plug (1). Make sure that the fluid level is at the bottom of the hole. If the fluid level is low, add recommended fluid until the fluid level is at the bottom of the hole. Apply Loctite 567 on the threads of the plug.
  • Page 84 Vehicle Maintenance Maintenance Tasks FUEL IS FLAMMABLE AND EXPLOSIVE. DO NOT FILL THE FUEL TANK WHEN THE ENGINE IS ON OR HOT. WAIT FOR THE ENGINE TEMPERATURE TO DECREASE BEFORE FUEL IS ADDED. FUEL IS FLAMMABLE AND EXPLOSIVE. DO NOT OPERATE THE VEHICLE WHEN FUEL IS SPILLED.

  • Page 85: Lift The Vehicle

    Vehicle Maintenance Maintenance Tasks LIFT THE VEHICLE LIFT THE FRONT OF THE VEHICLE LIFTING THE VEHICLE WITH CARGO CAN CAUSE PROPERTY WARNING DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH. REMOVE ALL CARGO FROM THE CARGO BED BEFORE THE VEHICLE IS LIFTED. WHEN SERVICING THE VEHICLE WITH PART OF THE VEHICLE ON JACK STANDS, DO NOT OPERATE THE ENGINE WITH THE FORWARD / NEUTRAL / REVERSE CONTROL (FNR) IN EITHER...
  • Page 86 Vehicle Maintenance Maintenance Tasks LIFT THE REAR OF THE VEHICLE LIFTING THE VEHICLE WITH CARGO CAN CAUSE PROPERTY WARNING DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH. REMOVE ALL CARGO FROM THE CARGO BED BEFORE THE VEHICLE IS LIFTED. WHEN SERVICING THE VEHICLE WITH PART OF THE VEHICLE ON JACK STANDS, DO NOT OPERATE THE ENGINE WITH THE FORWARD / NEUTRAL / REVERSE CONTROL (FNR) IN EITHER THE FORWARD OR REVERSE POSITION.

  • Page 87: Lower The Vehicle

    Vehicle Maintenance Maintenance Tasks LOWER THE VEHICLE LOWER THE FRONT OF THE VEHICLE Before the front of the vehicle is lowered: • Use a jack rated for the vehicle. To lower the front of the vehicle: Place the jack in the center of the lift point. Lift the vehicle off of the jack stands.

  • Page 88: Rear Differential Fluid Level Inspection

    Vehicle Maintenance Maintenance Tasks To lower the rear of the vehicle: Place the jack in the center of the lift point. Lift the vehicle off of the jack stands. Remove the jack stands. Lower the vehicle. REAR DIFFERENTIAL FLUID LEVEL INSPECTION [SampleTaskID] Disable the vehicle.

  • Page 89: Tire Pressure Measurement

    Vehicle Maintenance Maintenance Tasks Make sure that the fluid level is at the bottom of the hole. If the fluid level is low, add recommended fluid until the fluid level is at the bottom of the hole. Apply Loctite® 567 on the threads of the plug. Install the plug.
  • Page 90 Vehicle Maintenance Maintenance Tasks Lift the vehicle to allow for removal of the wheel assembly. Remove the lug nuts. Remove the wheel assembly. WHEEL ASSEMBLY INSTALLATION Before wheel assembly installation: • Disable the vehicle. To install the wheel assembly: Lift the vehicle to allow for installation of the wheel assembly. Align the wheel assembly onto the hub of the vehicle.

  • Page 91: Section 8 - Battery Maintenance

    Battery Maintenance Maintenance Tasks 316V BATTERY MAINTENANCE CARRYALL 1500 AWD DIESEL Operators Manual Page 89 TPCC01RF00EN018 (Edition C)

  • Page 92: Battery Cleaning

    Battery Maintenance Battery Maintenance Hazard Statements ELECTRICAL SHORTS CAN CAUSE A FIRE, ELECTRICAL SHOCK, WARNING SERIOUS PERSONAL INJURY, OR DEATH. PREVENT CONTACT BETWEEN POSITIVE VOLTAGE AND THE GROUND CIRCUIT. USE INSULATED TOOLS. WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN CAUTION YOU DO THE SERVICING OF THE VEHICLE.

  • Page 93: Battery Electrical Connection

    Battery Maintenance Battery Electrical Connection BATTERY ELECTRICAL CONNECTION DISCONNECT THE BATTERY Before the battery is disconnected: • Disable the vehicle. To disconnect the battery: Disconnect the negative (–) cable (1). Disconnect the positive (+) cable (2). CONNECT THE BATTERY Connect the positive (+) cable (2). Connect the negative (–) cable (1).
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  • Page 95: Section 9 - Transport And Tow

    Transport And Tow Battery Electrical Connection TRANSPORT AND TOW CARRYALL 1500 AWD DIESEL Operators Manual Page 93 TPCC01RF00EN018 (Edition C)

  • Page 96: Prepare The Vehicle To Be Towed

    Transport And Tow Transport And Tow Hazard Statements DO NOT LET PASSENGERS RIDE IN THE VEHICLE OR TRAILER DANGER BEING TOWED. KEEP AWAY FROM THE AREA BETWEEN THE TOW VEHICLE AND WARNING THE TOWED VEHICLE OR TRAILER. DO NOT TOW A CLUB CAR VEHICLE BEHIND A PASSENGER VEHICLE OR TRUCK ON A PUBLIC ROAD.

  • Page 97: Vehicle Transport Recovery

    Transport And Tow Vehicle Transport Recovery Set the park brake. Set the Forward / Neutral / Reverse control (FNR) to N. Turn the key to OFF. Remove the key. Keep the key in a safe area. Remove all cargo from the vehicle. Remove the windshield from the vehicle.
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  • Page 99: Section 10 - Extended Storage

    Extended Storage Vehicle Transport Recovery EXTENDED STORAGE CARRYALL 1500 AWD DIESEL Operators Manual Page 97 TPCC01RF00EN018 (Edition C)

  • Page 100: Extended Storage Preparation

    Extended Storage Extended Storage Hazard Statements FUEL IS FLAMMABLE AND EXPLOSIVE. DO NOT OPERATE THE DANGER VEHICLE WHEN FUEL IS SPILLED. CORRECTLY CLEAN THE SPILLED FUEL. FUEL IS FLAMMABLE AND EXPLOSIVE. DO NOT DRAIN FUEL WHEN THE ENGINE IS ON. FUEL IS FLAMMABLE AND EXPLOSIVE.

  • Page 101: Return To Service From Extended Storage

    Extended Storage Return To Service From Extended Storage Plug the fuel tank vent nipple with a slip-on vinyl cap (1). Make sure that the connection is air tight. Replace the engine oil. Disconnect the battery. Clean the battery. Keep the vehicle in a cool and dry area to keep battery self-discharge to a minimum. Adjust pressure in each tire to the recommended tire pressure.
  • Page 102 Extended Storage Return To Service From Extended Storage Start and run the engine. Note: The engine exhaust may smoke for a short time after returning to service. Adjust the pressure in each tire to the recommended tire pressure. Note: Go to the approved wheel and tire assemblies matrix on http://www.clubcar.com information regarding tire type, inflation pressure, and lugnut torque.

  • Page 103: Section 11 - Warranties

    Warranties Return To Service From Extended Storage WARRANTIES CARRYALL 1500 AWD DIESEL Operators Manual Page 101 TPCC01RF00EN018 (Edition C)

  • Page 104: Limited Warranty

    Warranties Limited Warranty LIMITED WARRANTY WARRANTY Club Car, LLC (“Club Car”) hereby warrants to the original purchaser or lessee, as those terms are defined herein, and subject to the provisions, limitations and exclusions in this limited warranty, that its new vehicle or new component purchased from Club Car or an Authorized Dealer or Distributor shall be free from defects in material and workmanship under normal use and service for the periods stated below, subject to the provisions, limitations and exclusions in this limited warranty.

  • Page 105: Exclusions

    Warranties Limited Warranty 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 106: Sole Remedy

    Warranties Limited Warranty SOLE REMEDY Club Car’s liability under this limited warranty or in any action whether based upon warranty, contract, negligence, strict product liability or otherwise, shall be the repair or replacement, at Club Car’s option, of the vehicle or component thereof that Club Car deems to be defective. Replacement shall mean furnishing, during the applicable limited warranty period, a new vehicle or factory-reconditioned vehicle or component thereof that is identical or reasonably equivalent to the warranted product or component at no cost to the purchaser.

  • Page 107: Federal Emissions Component Defect Warranty

    Warranties Federal Emissions Component Defect Warranty FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY WARRANTY COVERAGE This emission warranty is applicable in all States in the United States Of America, except the State of California. Club Car, LLC(“Club Car”) warrant(s) to the initial retail purchaser and each subsequent owner, that this Non-road engine (“engine”) has been designed, built, and equipped to conform at the time of initial sale to all applicable regulations of the United States Of America Environmental Protection Agency (EPA), and that the engine is free of defects in materials and workmanship which would cause...

  • Page 108: Distribution Center

    Warranties Federal Emissions Component Defect Warranty – Electronic controls (ECU), if applicable – Hoses, belts, connectors, gaskets, brackets, clamps, accessories, and assemblies used in the above systems. EVAPORATIVE EMISSIONS • Fuel Line • Fuel Line Fittings • Clamps • Fuel Tank •...

  • Page 109: Owner's Responsibilities

    Warranties Federal Emissions Component Defect Warranty • Consequential damages such as loss of time, inconvenience, loss of use of the engine or equipment, etc. • Diagnosis and inspection charges that do not result in warranty-eligible service being performed. • Any non-authorized replacement part, or malfunction of authorized parts due to use of non- authorized parts.

  • Page 110: California Evaporative Emission Control Warranty Statement

    Warranties California Evaporative Emission Control Warranty Statement CALIFORNIA EVAPORATIVE EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (“CARB”) and Club Car, LLC (“Club Car”) are pleased to explain the emission control system warranty on your model year 2019 vehicle engine (the “emission warranty”). In California, new equipment that uses small off-road engines (“SORE”) must be designed, built and equipped to meet the State's stringent anti-smog standards.

  • Page 111: Evaporative Emissions Warranty Parts List

    Warranties California Evaporative Emission Control Warranty Statement warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser or first placed into service. The warranty period is two years from the date of purchase. Subject to certain conditions and exclusions as stated below, the warranty on emission-related parts is as follows: 1.
  • Page 112 Warranties California Evaporative Emission Control Warranty Statement • Fuel tank • Fuel cap • Fuel lines (for liquid fuel and fuel vapors) • Fuel line fittings • Fuel metering carburetor assembly • Fuel regulator/filter • Fuel injection pump • Fuel injection nozzle •...
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  • Page 116 Publication Part Number TPCC01RF00EN018 Edition Code Club Car, LLC www.clubcar.com Phone 1 706 258 2225 P.O. Box 204658 1 800 ClubCar Augusta, GA 30917-4658 1 706 863 5858...

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