Club Car Xrt 1500 Service Manual
. IntelliTach All-Wheel Drive Diesel Vehicle Owner’s Manual Carryall 295 and XRT 1550 Refer to back cover for applicable build code range. 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.
The maintenance and service manual before attempting. Can obtain the name and phone number of your closest authorized Club Car dealer. XRT Vehicles. View and Download Club Car CARRYALL 1500 owner's manual. Utility Vehicle Club Car FE290 Maintenance Service. Vehicle Club Car 2009 XRT 950 4x2 Owner's Manual.
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. TABLE OF CONTENTS Note to the Owner.5 Safety Decal and Feature Identification.5 Practice Safety.8 Proposition 65 Warning – State of California.8 Safety Details. 9 General Warnings. 10 General Information.14 Model Identification. 15 Controls and Indicators.
Using A Booster Battery (Jump Starting).72 Cleaning the Vehicle.73 Accessories. 73 Subsequent Owner Registration.
75 Vehicle Specifications.76 Warranties.78 Page 4 IntelliTach All-Wheel Drive Diesel Vehicle Owner’s Manual. 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. Safety Decal and Feature Identification CARRYALL 295 & XRT 1550 INTELLITACH DIESEL VEHICLES 2417 Decal, Hot Pressurized Fluid Warning (on coolant Decal, Diesel Fuel Warning (on frame, near fuel 102459201 reserve tank cap, under hood) tank) Decal, Hot Surface Warning (on coolant pipes and Decal, Rotating/Hot Parts Warning (on frame near 102459501.
Safety Decal and Feature Identification CARRYALL 295 & XRT 1550 INTELLITACH DIESEL VEHICLES 2709 Decal, Trailer Hitch Tongue Weight Notice (on Decal, Lock Lever Warning (on hydraulic 1026101 trailer/receiver hitch) attachment arm) Decal, Crush Area Warning (behind seat, near 101630801 Decal, Vehicle Loading Warning (on cargo bed). 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.”.
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. General Warnings GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated, repaired, or serviced. See Safety Decal and Feature Identification on page 5. Other specific safety statements appear throughout this manual and on the vehicle. General Warnings WARNING. For vehicles with cargo beds, remove all cargo (including accessories) before raising the bed or servicing the vehicle. If the vehicle is equipped with a prop rod, ensure that it is securely engaged while bed is raised.
Do not close bed until all persons are clear of cargo bed area. Keep hands clear of all crush areas.
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. General Warnings 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. No smoking, no open flames, no sparks. Battery acid hazard.
General Information GENERAL INFORMATION This manual includes operating procedures, maintenance, and regular servicing information on the diesel Carryall 295 IntelliTach and XRT 1550 IntelliTach key-start vehicles. 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.
Model Identification 1. Fuel Fill Cap 4. Bed Lift Latch – vehicles with manual (standard) bed lift only 6. Engine Compartment, Battery, Fuel Tank (under seat) 7. Bucket Seats 8. Brake Fluid Reservoir (under hood) 9. Radiator and Coolant Reservoir (under hood) 10.
Joystick Control 11. Model Identification Vehicle Model and Type Vehicle Serial Number (Figure 8) Year of Build (Figure 8) Vehicle PIN Number ROPS Serial Number (Figure 9) Engine Serial Number (Figure 10) Differential Serial Number (Figure 11) Hydraulic Pump Serial Number (Figure 12) SERIAL NUMBER PH0901-123456 BC54679. Controls and Indicators 1882 Figure 12 Hydraulic Pump Serial Number Location CONTROLS AND INDICATORS See General Warnings on page 10. WARNING. Before allowing anyone to drive the vehicle, make sure the driver is familiar with all controls and operating procedures.
Controls and Indicators 1. Forward/Reverse Handle A. Move up for FORWARD travel 7. Electric Bed Lift Switch (If Equipped) 13.
Low Oil Warning light B. NEUTRAL Position C. Move down for REVERSE travel 2. 12 Volt Accessory Outlet 8. Forward/Reverse handle.
See WARNING and CAUTION on page 17. Club Car vehicles operate at a reduced speed in reverse. If equipped with a reverse buzzer, the reverse buzzer will sound as a warning when the Forward/Reverse handle is in the REVERSE position.
Controls and Indicators BRAKE PEDAL The brake pedal (5) is located to the immediate left of the accelerator pedal (Figure 13). To slow or stop the vehicle, press the brake pedal. PARK BRAKE The park brake pedal (6) is located to the left of the brake pedal (Figure 13 and 14). To engage the park brake, first apply pressure to the brake pedal, then firmly press the park brake pedal until it latches into place.
Controls and Indicators 12-VOLT ACCESSORY OUTLET The 12-volt accessory outlet (2) is located to the right of the key switch. It provides a constant 12VDC with the key switch in the ON or OFF position. Extended use of this accessory outlet can cause the battery to become heavily discharged. 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. Controls and Indicators Figure 15 Lift Function Figure 16 Tilt Function Movement of the joystick (1) (Figure 15 and Figure 16) controls the hydraulic cylinders for the lift and tilt functions. See following NOTE. NOTE: The joystick will not activate the attachment arm unless the start key is ON and the joystick ON/OFF rocker switch is in the ON position (Figure 13). Controls and Indicators Front Auxiliary Hydraulics Operation (If Equipped) CAUTION. Never use unapproved devices (i.e. Hydraulic hand tools) with the auxiliary hydraulic system.
Failure to comply may result in premature failure of the power unit and drain the battery. To rotate the attachment to the right, push the auxiliary hydraulic rocker switch (1) to the right (2) (Figure 17). Controls and Indicators Figure 18 Quick Couplers To Connect: Remove dirt or debris from the surface of both the male and female couplers and from the outside diameter of the male coupler. Install the male coupler (1) into the female coupler. Full connection is made when the ball sleeve (2) slides forward onto the female coupler. Roll-Over Protective Structure (ROPS) and Seat Belts ROLL-OVER PROTECTIVE STRUCTURE (ROPS) AND SEAT BELTS The Carryall 295 IntelliTach and XRT 1550 IntelliTach are equipped with a Roll-Over Protective Structure (ROPS).
Club Car Xrt 1500 Service Manual
Seat belts are provided for each occupant. See following WARNING. Roll-Over Protective Structure (ROPS) and Seat Belts WARNING. Do not operate the vehicle if the ROPS is damaged. If the ROPS is damaged, replace the structure. Do not attempt repair. The driver and passenger must be restrained at all times with the seat belts provided to help prevent injury in the event of sudden braking, collision, or roll-over.
Roll-Over Protective Structure (ROPS) and Seat Belts Figure 20 Adjust Headrests To adjust the headrests Remove the headrest hardware (1) (Figure 20). Raise or lower the headrest to the desired height. Install the headrest hardware (1). Hand-tighten the hardware until the headrest is securely attached to the cargo cage. See following CAUTION. Seat Latch and Adjustment SEAT LATCH AND ADJUSTMENT The seats are hinged to allow easy access to the engine compartment.
A latch at the rear of each seat bottom keeps the seat from moving on its hinges while the vehicle is in operation. To disengage the latch, grasp the seat back and pull firmly in a forward/upward direction until the latch releases.
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. Governor: Check maximum vehicle speed. It should operate in forward at 25 mph (40 kph) on a level surface. General: Listen for any unusual noises such as squeaks or rattles.
Mark Wagner
Check the vehicle’s ride and performance. Have a Club Car dealer or a trained technician investigate anything unusual. DRIVING INSTRUCTIONS WARNING. Driving Instructions WARNING. Avoid stopping a loaded vehicle on a hill. If a loaded vehicle must be stopped on a hill, avoid sudden starts or rolling backwards and stopping suddenly. Failure to heed this warning could result in overturning the vehicle.
Driving Instructions 13. Release the brake pedal completely, and then slowly press the accelerator pedal. As the accelerator pedal is pressed, the vehicle will begin to move. Vehicle speed will increase as the accelerator is pressed until full speed is reached.
Bed Latch and Prop Rod CAUTION. When stopped on a hill, use the brake pedal to hold your position. Do not use the accelerator pedal to hold position. PARKING AND LEAVING THE VEHICLE After stopping the vehicle, firmly set the park brake until it is fully engaged and prevents the vehicle from rolling. Push the joystick forward to lower the attachment arm fully to the ground.
Attachments and Buckets Figure 21 Bed Latch Figure 22 Prop Rod ATTACHMENTS AND BUCKETS WARNING. Never use attachments or buckets that are not approved. Buckets and attachments for safe loads of specified densities are approved for each model. Unapproved attachments can cause injury or death. NOTE: Warranty is void if non-approved attachments are used.
Attachments and Buckets WARNING. AVOID INJURY OR DEATH. Do not exceed attachment arm rated capacity.
Excessive load can cause tipping or loss of control. 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. Attachments and Buckets Pull the attachment interface lever (1) fully to the left and into the unlocked position (Figure 25). Enter the vehicle and fasten the seat belt. Start the engine and disengage the park brake. Press the joystick ON/OFF rocker switch (18) to ON (Figure 13).
Club Car Xrt 1500 Accessories
Lower the attachment arm and tilt the attachment interface forward. Attachments and Buckets WARNING. Attachment interface pins must extend through the holes in attachment with lever in the locked position. Failure to secure pins can allow attachment to come off and cause serious injury or death. Figure 29 Interface Pins Figure 30 Interface Lever in Unlocked Position Removing an Attachment Tilt the attachment at least half way back and slightly off of the ground.
Attachments and Buckets Figure 31 Remove Interface from Attachment OPERATING WITH ATTACHMENTS New operators must operate the vehicle in an open area without bystanders. Operate the controls until the vehicle can be handled at an efficient and safe rate for all conditions of the work area. NOTE: Always warm up the engine before operating the vehicle with an attachment.
Attachments and Buckets WARNING. Keep the attachment arm as low as possible and watch for obstructions. Do not travel or turn with the attachment arm up.
Turn on level ground. Slow down when turning. Go up and down slopes, not across them. Attachments and Buckets Filling and Emptying the Bucket Figure 36 Joystick Position – Filling Bucket Figure 37 Joystick Position – Raise Arm and Tilt Bucket Backward Lower the attachment arm all the way (1) and tilt the bucket forward (4) (Figure 36) until the cutting edge is on the ground. Attachments and Buckets Raise the attachment arm (2) and tilt the bucket forward (4) (Figure 38). Push the float rocker switch to the right and the joystick forward (1) until the float is engaged (rocker switch light will be illuminated).
The attachment arm will slowly lower. Attachments and Buckets Figure 40 Lower Arm and Tilt Interface Forward Figure 41 Remove Interface Cylinder Retaining Pin Figure 42 Remove Attachment Cylinder Retaining Pin Figure 43 Joystick Remove the retaining ring (1) and the pin (2) from the attachment arm cylinder rod end (Figure 42). Turn the start key to the ON position but DO NOT start the engine.
Attachments and Buckets 10. Install the existing pin (3) and retaining ring to secure the cylinder to the mount. Rotate the attachment interface cylinder (5) upward against the vehicle and snap it into place (8).
Install the existing pin (6) and retaining ring (7) in the locking hole on the mounting plate. Attachments and Buckets Installing the Attachment Arm Align the vehicle with the attachment arms (Figure 47). Stop the engine, put the Forward/Reverse Handle in NEUTRAL, engage the park brake, unfasten your seat belt, and exit the vehicle. Remove the retaining rings (2) and the pins (1) from the attachment arm (both sides) (Figure 46). Raise the attachment arms and align the holes in the attachment arms to the vehicle mounting holes (Figure 48).
Attachments and Buckets Figure 50 Joystick Figure 51 Raise Attachment Arm, Install Pin, and Retainer Ring 13. Raise the attachment interface and align it with the cylinder. Install the pin (2) and the retaining ring (1) (Figure 52). Figure 52 Raise Interface, Install Pin and Retainer Ring Page 46 IntelliTach All-Wheel Drive Diesel Vehicle Owner’s Manual. Loading and Unloading Cargo 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. 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 attachment arm and cargo bed and includes the weight of vehicle accessories and trailer tongue weight. 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 48 for vehicle capacity information.
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. Storage STORAGE See General Warnings on page 10. DANGER.
Do not attempt to drain fuel when the engine is hot or while it is running. Clean up any spilled fuel before operating the vehicle. Store fuel in an approved fuel container only. Store in a well-ventilated area away from sparks, open flames, heaters, or heat sources. 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 semi-annual and annual periodic service. Maintenance WARNING – Do not attempt to repair hydraulic pump or lines while engine or pump is in operation.
– Relieve pressure before disconnecting hydraulic lines or fittings. If wires are removed or replaced make sure wiring and wire harness are properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death. Periodic Service Schedule PERIODIC SERVICE SCHEDULE See General Warnings on page 10.
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, these preventive maintenance procedures should be performed more often than recommended in the Periodic Service and Lubrication Schedules. Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Battery Clean terminals and wash dirt from casing; check electrolyte level.
Add distilled water if necessary. Front wheel alignment and toe-in Check and adjust if necessary. See Steering and Front Suspension Section in the appropriate maintenance and service manual. Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Diesel vehicle: First change 50 hours – additional change Diesel vehicles: 3 qt. (2.8 L) with filter. See for both every 100 hours of Change engine oil and oil filter Oil Viscosity on page 63.
Lubricating the Attachment Arm and Interface Figure 54 Lubrication Points – Diesel Vehicles LUBRICATING THE ATTACHMENT ARM AND INTERFACE DESCRIPTION Always use a good quality, lithium-based, multi-purpose grease. Apply lubricant until extra grease shows.
Grease the 8 grease fittings every 50 hours of operation, 2 times a year (whichever occurs first) or whenever the attachment arm and interface are removed and reinstalled on the vehicle. Brake Fluid Reservoir Figure 55 Lubricate Grease Zerks located on Cylinder and Attachment Arm Ends BRAKE FLUID RESERVOIR 1.
Full Level 2. Safe Level 3. Low Level 2693 Figure 56 Brake Fluid and Engine Coolant Access Figure 57 Brake Fluid Reservoir The brake fluid reservoir (1) is located under the hood (Figure 56). Brake Fluid Reservoir. The presence of brake fluid on the exterior surface of the master cylinder indicates a leak.
The brake fluid reservoir diaphragm (located in the cap) should not have holes or other damage. BRAKE FLUID Brake fluid level should be within 1/4-inch (6 mm) from the top of the reservoir (Figure 57). Also, brake fluid should be clean with no residue in the bottom of the reservoir or other evidence of contamination. 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. Engine Oil Engine Oil Draining Turn the key switch to the OFF position and remove the key.
Place the Forward/Reverse handle in the NEUTRAL position. Chock the front wheels.
Disconnect battery. See Disconnecting the Battery – Diesel Vehicles on page 11. Remove the oil filler cap to allow the oil to drain properly. Engine Oil directed into the oil pan. A drip guard can be made by folding a piece of cardboard, thin metal, or plastic under the oil filter, forming a channel to direct the filter port oil into the drain pan. Dispose of used oil according to the environmental laws and regulations for your area. Gearcase Lubrication OIL VISCOSITY Choose the viscosity according to the temperature as shown in the appropriate oil viscosity chart (Figure 63).
See following NOTE. NOTE: Use engine oil with API classification CF for diesel engines. SAE 30 SAE 20 SAE 10W SAE 10W-30/SAE 10W-40 Figure 63 Oil Viscosity Chart –. Gearcase Lubrication Front differential: Clean and install the drain plug (2) and washer before filling the front differential with new lubricant (Figure 64). Tighten the drain plug to 108 in-lb (12 Nm). Use a funnel when filling the front differential through the lubricant level indicator hole (1). Engine Coolant – Diesel Vehicles Figure 67 Rear Differential Fill and Drain Plugs (2012 and Figure 66 Rear Differential Lubrication Level (2009 to newer vehicles) 2011 vehicles) ENGINE COOLANT – DIESEL VEHICLES ENGINE COOLANT LEVEL CHECK The coolant reserve tank (2) is located under the hood on the passenger side (Figure 56).
Raise the hood to check the coolant level before every operation. Hydraulic System HYDRAULIC SYSTEM WARNING.
Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand.
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 P/N 102498601) designed for this engine.
Figure 70 Air Filter Cartridge Air Filter Installation Push the new air filter cartridge onto the nozzle inside the canister. Fueling Instructions FUELING INSTRUCTIONS See General Warnings on page 10. 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.
Fueling Instructions NOTE: Use of biodiesel may result in premature failure of fuel system components. Kubota has documented problems such as plugged fuel filters and deteriorated fuel lines during testing of biodiesel. Biodiesel can damage painted surfaces. Be sure to remove all spilled fuel immediately to help prevent damage to painted surfaces. Battery NOTE: Dispose of water according to the environmental laws and regulations for your area.
1452 2327 Figure 72 Fuel Filter with Water Separator – Style A Figure 73 Fuel Filter with Water Separator – Style B BATTERY See General Warnings on page 10. Battery The battery in this vehicle is a 12-volt, low-maintenance battery that requires infrequent checks (Figure 74). Electrolyte level should be checked semiannually. Level Indicator 2.
Plates Electrolyte level at least 1/2 inch (13 mm) above plates or to level indicator. Using A Booster Battery (Jump Starting) USING A BOOSTER BATTERY (JUMP STARTING) WARNING. Wear safety glasses or approved eye protection when servicing the vehicle. Wear a full face shield and rubber gloves when working on or near batteries. When jumping from a booster battery make final connection (negative) at engine frame. 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.clubcar.com and clicking the “Dealer Locator” link. Accessories WARNING. If the vehicle is equipped with an electric-powered bed lift, remove the bed before servicing the bed lift system. CAUTION. Do not drill into the driver-side frame because it is part of the air intake system. Failure to heed this caution could damage the engine by allowing excessive contamination to enter the air intake system.
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. Vehicle Specifications VEHICLE SPECIFICATIONS CARRYALL 295 & SPECIFICATIONS XRT 1550 INTELLITACH POWER SOURCE 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 Fuel system: Mechanical injection, fuel water separator, fuel filters, and electric fuel pump ●. Vehicle Specifications CARRYALL 295 & SPECIFICATIONS XRT 1550 INTELLITACH Wheelbase 82 in.
(208.3 cm) Ground clearance: 7.3 in. (18.5cm) under differential 11.1 in. (28 cm) under floorboard Front wheel tread 48.25 in. (122.5 cm) Rear wheel tread 48.63 in. (123.5 cm) Weight (with all-terrain tires) 1710 lb (776 kg) 25 mph. 4 YEARS 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.
Use of gasoline containing more than 10% ethanol. Without limiting the generality of the foregoing in any way, and as part of its limited warranty exclusion, CLUB CAR does not warrant that its vehicle or components such as batteries, computer, controller or electrical device are suitable for use in any application other than in its products. To make a warranty claim under this limited warranty, you must present the vehicle or defective component with evidence of proof of purchase date and number of energy units (if applicable) to an authorized CLUB CAR dealer.
For warranty-related communication, contact Warranty Services, Club Car, 4125 Washington Rd., Evans, GA 30809, USA, 706.863.3000. BC56643 Publication Part Number 103472517 Edition Code 0608G0613F.