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Carryall 1500 2016
Club Car Carryall 1500 2016 Manuals
Manuals and User Guides for Club Car Carryall 1500 2016. We have
1
Club Car Carryall 1500 2016 manual available for free PDF download: Maintenance And Service Manual
Club Car Carryall 1500 2016 Maintenance And Service Manual (436 pages)
Brand:
Club Car
| Category:
Golf Cars
| Size: 37.48 MB
Table of Contents
Table of Contents
5
SECTION 1 - Safety
15
Safety Details
15
Personal Safety
15
Machine Safety
15
Information
15
General Warnings
16
Disabling the Vehicle
17
Side-Post Battery: Disconnecting the Battery - Gasoline/Diesel Vehicles
17
Side-Post Battery: Connecting the Battery - Gasoline/Diesel Vehicles
18
Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles
18
Top-Post Battery: Connecting the Battery- Gasoline/Diesel Vehicles
18
Recycling Lead-Acid Batteries
19
International Safety Symbols on Batteries
20
SECTION 2 - Vehicle Specifications
21
1500/1700 and 1550/1550 SE Specifications
21
Intellitach Specifications
24
SECTION 3 - General Information
27
Model Identification
29
Identification Numbers
29
Storage
31
Preparing the Vehicle for Extended Storage
32
Returning the Stored Vehicle to Service
33
Lifting the Vehicle
33
Lifting Only the Front
33
Lifting Only the Rear
34
Lifting the Entire Vehicle
35
Using a Booster Battery (Jump Starting)
35
SECTION 4 - Body and Trim
37
General Information
37
Cleaning the Vehicle
37
Seat Cleaning
37
Front Body Repair
38
Light Scratches
38
Abrasions and Haze
38
Large Scratches and Abrasions
38
Front Body Components
39
Instrument Panel Removal
39
Instrument Panel Installation
39
Front Fascia Removal
40
Front Fascia Installation
40
Hood Removal
40
Hood Installation
40
Center Cowl Panel Removal
40
Center Cowl Panel Installation
40
Side Cowl Panel (Fender) Removal
41
Side Cowl Panel (Fender) Installation
41
Front Fender Flare Removal
41
Front Fender Flare Installation
42
Roll-Over Protective Structure (ROPS)
42
ROPS Removal
43
ROPS Installation
44
Seat
45
Seat Removal
45
Seat Adjustment
45
Seat Installation
45
Seat Support Removal
46
Seat Support Installation
46
Seat Belts
46
Bench Seat Belt Removal
46
Bench Seat Belt Installation
47
Cargo Bed - Electric Lift
47
Testing the Bed Lift Motor
47
Bed Lift Motor Removal
47
Bed Lift Motor Installation
48
Cargo Bed Removal
48
Cargo Bed Installation
48
Cargo Bed - Manual Lift
49
Cargo Bed Removal
49
Cargo Bed Installation
49
Rear Fender
50
Rear Fender Removal
50
Rear Fender Installation
50
SECTION 5 - Accelerator and Brake Pedal Assemblies
53
Accelerator Pedal
53
Accelerator Pedal Removal
53
Accelerator Pedal Installation
54
Brake Pedal
55
Brake Pedal Removal
55
Brake Pedal Installation
55
Brake Pedal Adjustment
55
Park Brake Pedal
56
Park Brake Pedal Assembly Removal
56
Park Brake Pedal Assembly Installation
56
SECTION 6 - Hydraulic Brake and Park Brake Systems
59
General Information
59
Brake System Inspection
59
Brake Pedal Inspection
59
Master Cylinder Inspection
60
Brake Hose Inspection
60
Park Brake Inspection
60
Brake Disc and Pad Inspection
62
Brake System Troubleshooting
63
Brake Pads and Caliper
65
Front Brake Pad Removal
65
Front Brake Pad Installation
66
Front Caliper Removal
67
Front Caliper Installation
67
Rear Brake Pad and Caliper Removal
68
Rear Brake Pad and Caliper Installation
69
Brake Discs
71
Disc Removal
71
Disc Installation
71
Brake Hose Replacement
72
Front Brake Hose Removal
72
Front Brake Hose Installation
72
MID Brake Hose Removal
73
MID Brake Hose Installation
74
Rear Brake Hose Removal
74
Rear Brake Hose Installation
74
Master Cylinder and Reservoir
75
Filling the Hydraulic System
75
Master Cylinder Removal
75
Master Cylinder Installation
75
Bleeding the Hydraulic Brake System
76
Bleeding Brakes on a DOT 5 Fluid Filled System
76
Purging the Hydraulic System
78
Park Brake System
79
Park Brake Caliper and Pad Replacement
80
Park Brake Disc Replacement
80
Park Brake Cable Replacement
80
Park Brake Adjustment
81
Park Brake Switch
82
SECTION 7 - Steering and Front Suspension
83
Steering Wheel
83
Steering Wheel Removal
83
Steering Wheel Installation
84
Steering Column
84
Steering Column Removal
84
Steering Column Installation
86
Rack and Pinion
89
Rack and Pinion Inspection
89
Rack and Pinion Removal
89
Rack and Pinion Installation
90
Rack and Pinion Disassembly
90
Rack and Pinion Assembly
95
Front Suspension
96
Wheel Alignment
96
Front Suspension Components
100
Steering Upright Removal
100
Steering Upright Installation
102
Upper A-Arm Removal
102
Upper A-Arm Installation
104
Lower A-Arm Removal
104
Lower A-Arm Installation
105
Front Coil-Over Shock Absorber Removal
106
Front Coil-Over Shock Absorber Installation
107
SECTION 8 - Wheels, Tires and Hubs
109
General Information
109
Wheels
110
Wheel Removal
110
Wheel Installation
110
Tires
110
Tire Removal
110
Tire Installation
111
Front Hubs
111
Front Hub Removal
111
Front Hub Installation
113
Rear Hubs
114
Rear Hub Removal
114
Rear Hub Installation
115
SECTION 9 - Rear Suspension
117
Rear Coil-Over Shock Absorber
117
Rear Shock Absorber Removal
117
Rear Shock Installation
118
Trailing Arms and Lateral Links
119
Lateral Link Removal
119
Lateral Link Installation
119
Trailing Arm Removal
119
Trailing Arm Installation
119
SECTION 10 - Periodic Maintenance
121
Periodic Service Schedule
123
Periodic Service Schedule - Intellitach
124
Periodic Lubrication Schedule
126
Periodic Lubrication Schedule - Intellitach
128
Lubricating the Attachment Arm and Interface - Intellitach
129
Brake Fluid Reservoir
130
Brake Fluid
130
Engine Oil
130
Oil Pressure - Gasoline Engine
130
Engine Oil Level Check
131
Engine Oil and Filter Change
131
Oil Viscosity
134
Spark Plugs
135
Spark Plug Cleaning and Inspection
135
Spark Plug Gap Inspection
135
Gearcase Lubrication
136
Lubrication Level Check for Front Differential, Transmission and Rear Differential
136
Lubrication Change for Front Differential, Transmission and Rear Differential
136
Hydraulic System - Intellitach Vehicle
138
Engine Coolant - Diesel Vehicles
139
Engine Coolant Level Check
139
Fueling Instructions
139
Biodiesel Fuel (Diesel Vehicles Only)
140
Draining Water from Fuel Filter
141
Battery
142
SECTION 11 - Troubleshooting and Electrical System: Gasoline Vehicles
143
Troubleshooting Guide
143
Wiring Diagram
148
Test Procedures
151
SECTION 12 - Troubleshooting and Electrical System: Diesel Vehicles
183
Troubleshooting Guide
183
Wiring Diagram
189
Test Procedures
192
SECTION 13 - Electrical Components: Gasoline Vehicles
229
Starter and Starter Solenoid
229
Relays
229
Testing the Relay
229
Relay Removal
230
Relay Installation
230
Neutral Switch
230
Testing the Neutral Switch
230
Neutral Switch Removal
230
Neutral Switch Installation
230
Carburetor Solenoid
230
Testing the Carburetor Solenoid
231
Carburetor Solenoid Removal
231
Carburetor Solenoid Installation
231
Carburetor Heater
231
Carburetor Heater Removal
232
Carburetor Heater Installation
232
Voltage Regulator
233
Testing the Voltage Regulator
233
Voltage Regulator Removal
233
Voltage Regulator Installation
233
Warning Lights
234
Testing the Warning Lights
234
Warning Light Removal
234
Warning Light Installation
234
Fuel Gauge/Hour Meter
235
Testing the Fuel Gauge/Hour Meter
235
Fuel Gauge/Hour Meter Removal
235
Fuel Gauge/Hour Meter Installation
236
Key Switch
236
Testing the Key Switch
236
Key Switch Removal
236
Key Switch Installation
236
12-Volt Accessory Receptacle
237
Testing the 12-Volt Accessory Receptacle
237
12-Volt Accessory Receptacle Removal
237
12-Volt Accessory Receptacle Installation
237
Bed Lift Switch
238
Testing the Bed Lift Switch
238
Bed Lift Switch Removal
238
Bed Lift Switch Installation
238
Bed Lift Circuit Breaker
238
Testing the Bed Lift Circuit Breaker
238
Bed Lift Circuit Breaker Removal
238
Bed Lift Circuit Breaker Installation
238
Light Switch
239
Testing the Light Switch
239
Light Switch Removal
239
Light Switch Installation
239
Fuse
239
Testing the Fuse
239
Fuse Removal
239
Fuse Installation
240
Reverse Warning Buzzer (if Equipped)
240
Testing the Reverse Warning Buzzer
240
Reverse Warning Buzzer Removal
240
Reverse Warning Buzzer Installation
241
Reverse Warning Buzzer Limit Switch (if Equipped)
241
Testing the Reverse Warning Buzzer Limit Switch
241
Reverse Warning Buzzer Limit Switch Removal
241
Reverse Warning Buzzer Limit Switch Installation
242
Front Differential Limit Switch
242
Testing the Front Differential Limit Switch
242
Front Differential Limit Switch Removal
242
Front Differential Limit Switch Installation
243
Fuel Level Sending Unit
243
Testing the Fuel Level Sending Unit
244
Fuel Level Sending Unit Removal
244
Fuel Level Sending Unit Installation
244
Ignition Coil and Charge Coil
244
Testing the Ignition Coil
244
Ignition Coil And/Or Charge Coil Removal
244
Oil Pressure Sensor
244
Headlights
244
Testing the Headlight Bulb and Socket
245
Headlight Bulb Removal
245
Headlight Bulb Installation
245
Wire Harness Diodes
245
Testing the Wire Harness Diodes
246
Wire Harness Diode Removal
246
Wire Harness Diode Installation
246
Battery
246
General Information
247
Testing the Battery
247
Preventive Maintenance
247
Self-Discharge
247
Water Level
247
Vibration Damage
248
Mineral Content
248
Battery Removal
248
Charging the Battery
248
Battery Installation
249
Battery Storage
249
Charging a Dead Battery
250
SECTION 14 - Electrical Components: Diesel Vehicles
251
Starter and Starter Solenoid
251
Relays
251
Testing the Relay
251
Relay Removal
251
Relay Installation
252
Neutral Switch
252
Testing the Neutral Switch
252
Neutral Switch Removal
252
Neutral Switch Installation
252
Fuel Solenoid
253
Testing the Fuel Solenoid
253
Fuel Solenoid Removal
253
Fuel Solenoid Installation
253
60-Amp Fusible Link
254
Testing the 60-Amp Fusible Link
254
60-Amp Fusible Link Removal
254
60-Amp Fusible Link Installation
254
Warning Lights
255
Testing the Warning Lights
255
Warning Light Removal
255
Warning Light Installation
255
Fuel Gauge/Hour Meter
256
Testing the Fuel Gauge/Hour Meter
256
Fuel Gauge/Hour Meter Removal
257
Fuel Gauge/Hour Meter Installation
257
Key Switch
257
Testing the Key Switch
257
Key Switch Removal
257
Key Switch Installation
257
12-Volt Accessory Receptacle
258
Testing the 12-Volt Accessory Receptacle
258
12-Volt Accessory Receptacle Removal
258
12-Volt Accessory Receptacle Installation
258
Bed Lift Switch
259
Testing the Bed Lift Switch
259
Bed Lift Switch Removal
259
Bed Lift Switch Installation
259
Bed Lift Circuit Breaker
259
Testing the Bed Lift Circuit Breaker
259
Bed Lift Circuit Breaker Removal
259
Bed Lift Circuit Breaker Installation
259
Light Switch
260
Testing the Light Switch
260
Light Switch Removal
260
Light Switch Installation
260
Fuse
260
Testing the Fuse
260
Fuse Removal
260
Fuse Installation
261
Reverse Warning Buzzer (if Equipped)
261
Testing the Reverse Warning Buzzer
261
Reverse Warning Buzzer Removal
261
Reverse Warning Buzzer Installation
262
Reverse Warning Buzzer Limit Switch (if Equipped)
262
Testing the Reverse Warning Buzzer Limit Switch
262
Reverse Warning Buzzer Limit Switch Removal
262
Reverse Warning Buzzer Limit Switch Installation
263
Front Differential Limit Switch
263
Testing the Front Differential Limit Switch
263
Front Differential Limit Switch Removal
263
Front Differential Limit Switch Installation
264
Fuel Level Sending Unit
264
Testing the Fuel Level Sending Unit
265
Fuel Level Sending Unit Removal
265
Fuel Level Sending Unit Installation
265
Alternator
265
Testing the Alternator
265
Alternator and V-Belt Removal
265
Alternator and V-Belt Installation
266
Oil Pressure Sensor
267
Headlights
267
Testing the Headlight Bulb and Socket
267
Headlight Bulb Removal
267
Headlight Bulb Installation
267
Thermostat Switch
268
Testing the Thermostat Switch
268
Thermostat Switch Removal
268
Thermostat Switch Installation
269
Fan
269
Testing the Fan Motor
269
Fan Removal
269
Fan Installation
270
Wire Harness Diodes
270
Testing the Wire Harness Diodes
270
Wire Harness Diode Removal
270
Wire Harness Diode Installation
271
Battery
271
General Information
271
Testing the Battery
272
Preventive Maintenance
272
Self-Discharge
272
Water Level
272
Vibration Damage
272
Mineral Content
272
Battery Removal
273
Charging the Battery
273
Battery Installation
274
Battery Storage
274
Charging a Dead Battery
274
SECTION 15 - Gasoline Engine, Muffler, Fuel System, and Clutches
277
Gasoline Engine
277
Engine Removal
277
Engine Installation
279
Oil Filter Hoses
281
Exhaust System
282
Muffler Removal
282
Intermediate Pipe Removal
283
Intermediate Pipe Installation
283
Muffler Installation
283
Fuel System
284
Fuel Lines
285
Fuel Filter
286
Fuel Pump
286
Carburetor
286
Fuel Level Sending Unit
288
Fuel Tank
292
Carbon Canister
295
Fuel Shut-Off Valve
296
Engine Control Linkages
297
General Information
297
Ground Speed
297
Accelerator Cable
297
Choke Cable
298
Engine Governor Arm
300
Engine RPM Adjustment
301
Air Intake System
303
Air Filter Replacement
303
Air Canister Removal
304
Air Canister Installation
304
Clutches
305
Clutch Troubleshooting
305
Drive Belt
306
Drive Clutch
306
Driven Clutch
310
Clutch Cover
313
SECTION 16 - Diesel Engine, Muffler, Fuel System, and Clutches
315
Diesel Engine
315
Engine Removal
315
Engine Installation
317
Exhaust System
319
Muffler Removal
319
Intermediate Pipe Removal
319
Manifold Pipe Removal
320
Manifold Pipe Installation
320
Intermediate Pipe Installation
320
Muffler Installation
320
Fuel System
322
Fuel Lines
323
Bleeding Air from Fuel System
323
Fuel Filter Replacement
323
Fuel Pump
325
Fuel Level Sending Unit
325
Fuel Tank
328
Engine Control Linkages
332
General Information
332
Ground Speed
332
Accelerator Cable
332
Engine RPM Adjustment
333
Air Intake System
335
Air Filter Replacement
335
Air Canister Removal
336
Air Canister Installation
337
Clutches
338
Clutch Troubleshooting
338
Drive Belt
339
Drive Clutch
339
Driven Clutch
343
Clutch Cover
346
SECTION 17 - Drivetrain Components
349
Half Shafts
349
Half Shaft Removal
349
Half Shaft Installation
350
Front Differential
351
Front Differential Removal
351
Front Differential Installation
353
Front Driveshaft
354
Front Driveshaft Removal
354
Front Driveshaft Installation
354
Transmission
355
Transmission Removal
355
Transmission Installation
356
Forward/Reverse Shifter Cable
358
Forward/Reverse Shifter Handle
360
Rear Driveshaft
361
Rear Driveshaft Removal
361
Rear Driveshaft Installation
361
Rear Axle
362
Rear Axle Removal
362
Rear Axle Installation
363
Rear Axle Tubes, Axle Shafts and Wheel Bearings
364
Rear Axle Tube and Axle Shaft Removal
364
Rear Axle Tube and Axle Shaft Installation
365
Rear Wheel Bearing Removal
365
Rear Wheel Bearing Installation
366
SECTION 18 - Radiator and Coolant System (Diesel)
367
General Information
367
Engine Coolant Level Check
367
Engine Coolant Change
367
Coolant Reservoir
369
Coolant Reservoir Removal
369
Coolant Reservoir Installation
370
Radiator
370
Radiator Removal
370
Radiator Installation
371
Coolant Pipe Weldment
372
Coolant Pipe Weldment Removal
372
Coolant Pipe Weldment Installation
372
Fan
373
Fan Removal
373
Fan Installation
373
SECTION 19 - Hydraulic Attachment System
375
Model Identification
375
Relieving Hydraulic System Pressure
375
To Relieve Hydraulic Fluid Pressure
375
Attachment Interface
376
Inspection
376
Removing and Installing the Attachment Arm Mechanism
377
Electrical
382
Joystick
384
Joystick ON/OFF Switch
386
Attachment Arm Float Switch
387
Auxiliary Hydraulic Switch
389
Relays
390
Solenoid
392
Circuit Breaker
393
Control Valves
394
Hoses
396
Hose Routing
396
Hose Removal
397
Hose Installation
397
Quick Connect Fittings (Auxiliary Hydraulic Circuit Only)
398
Quick Connect Removal
398
Quick Connect Installation
398
Cylinders
399
Vehicle Mounted Cylinders
399
Auxiliary Cylinder (Optional)
400
Cylinder Disassembly
402
Cylinder Assembly
406
Cylinder Bushings (if Equipped)
411
Angle Frame Bushings
412
Snow Blade Angle Frame
412
Whisk Broom Angle Frame
414
Front Mount
415
Front Mount Removal
415
Front Mount Installation
416
Hydraulic Pump Assembly
416
Fluid Level Inspection
417
Fluid Change
417
Pump Assembly
417
Reservoir
420
Motor
421
Pump
422
Priming the Pump
422
Index
423
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