Club Car Carryall 1500 2016 User Manual (English)

Questions and Answers:

M
Michelle JohnsonAug 15, 2025
How to fix a low brake pedal on Club Car Golf Cars?
- J
  johnstevensAug 15, 2025
  If the brake pedal on your Club Car Golf Cars feels low and goes to the floor, it could be due to excessive clearance between the disc and brake pads. A leak in the hydraulic system, possibly in the master cylinder, brake hoses, or connections, could also be the cause; replace any damaged parts and bleed the brake system. Another cause may be air in the hydraulic system. A weak or bulging brake hose can also lead to this issue, so replace the worn hose. Lastly, an improperly adjusted master cylinder push rod might be the problem.
M
michael75Aug 18, 2025
Why are all the brakes dragging on my Club Car Carryall 1500 2016?
- H
  Heather JohnsonAug 18, 2025
  If all the brakes on your Club Car Golf Cars are dragging, it could be due to a binding brake pedal, so you should replace bushings and adjust. Also replace any bent or damaged components. Another cause may be soft or swollen rubber parts, requiring replacement of the master cylinder and/or calipers. A binding park brake cable (adjust or replace cable) or improper park brake adjustment could also be the culprit.
A
Amy PageAug 21, 2025
Why is the brake pedal on my Club Car Golf Cars spongy?
- H
  Howard EsparzaAug 21, 2025
  If the brake pedal of your Club Car Golf Cars feels soft, springy, or spongy, it could be due to several reasons. One potential cause is cracked or thin discs, which would require replacing the brake discs. Another reason could be poor quality brake fluid or water in the fluid, in this case you should purge the hydraulic fluid and fill with approved DOT 5 (silicone) brake fluid. Weak or bulging brake hoses that expand under pressure may also cause this issue, so check the master cylinder and brake hoses for leaks or bulges and replace any damaged parts. Finally, air in the hydraulic system can also lead to a spongy pedal feel.
T
tsmithAug 25, 2025
What to do if my Club Car Golf Cars pulls to one side when braking?
- D
  David MartinezAug 25, 2025
  If your Club Car Golf Cars pulls to one side when braking, several factors could be responsible. It might be due to incorrect or distorted brake pads, in which case you should replace the brake pads. Grease or brake fluid on the brake pads can also cause this issue; replace the hub, axle seal, or caliper and replace the brake pads. Other potential causes include a scored or warped brake disc (replace the brake disc), water on the brakes (apply the brakes several times to dry the brake pads and disc), a sticking caliper piston (replace the caliper), or faulty suspension parts or alignment.
D
Donna Williams MDAug 27, 2025
Why does my Club Car Carryall 1500 2016 Golf Cars have a hard brake pedal?
- M
  Mr. Mark StewartAug 27, 2025
  If you're experiencing a hard pedal on your Club Car Golf Cars, requiring excessive pressure to stop the vehicle, several issues could be the cause. There might be grease or brake fluid on the brake discs or pads, in which case you should replace the hub or axle seal and replace the brake pads. Glazed, damaged, or distorted brake pads can also lead to this problem, so replace the brake pads. Other potential causes include clogged brake hoses (replace brake hoses as required) or a frozen master cylinder piston or bent rod, which would necessitate replacing the master cylinder.
A
allencarlosAug 30, 2025
Why do my Club Car Carryall 1500 2016 brakes make noise?
- M
  Matthew MayerAug 30, 2025
  If you hear clicking or scraping sounds upon brake application in your Club Car Golf Cars, it could be due to several reasons. The brake pads might be bent, damaged, or incorrect, in which case you should replace them. Worn brake pads or foreign material embedded in the brake pads can also cause these noises, so replace the brake pads. Additionally, cracked or scored brake discs could be the source of the sound, requiring replacement of the brake discs.
L
Leslie JonesSep 2, 2025
What causes a pulsating brake pedal on Club Car Golf Cars?
- M
  Maria MezaSep 2, 2025
  If you feel a pulsating brake pedal in your Club Car Golf Cars, it could be caused by warped or worn brake discs, in which case you should replace them. Another possibility is a bent wheel, which would also need replacement. Worn or damaged wheel bearings can also cause this issue, so replace the bearings.
J
Jennifer KrauseSep 5, 2025
What causes decreasing brake pedal travel on Club Car Carryall 1500 2016 Golf Cars?
- J
  James ChaseSep 5, 2025
  If you notice decreasing brake pedal travel in your Club Car Golf Cars, it could be due to a sticking caliper piston. In this case, you should replace the caliper.
S
Susan HendersonSep 8, 2025
Why is only one brake dragging on my Club Car Carryall 1500 2016 Golf Cars?
- M
  Michaela GoodSep 8, 2025
  If one brake on your Club Car Golf Cars is dragging, it could be due to sticking caliper pistons, in which case you should replace the caliper. Bent or distorted brake pads can also cause this issue, so replace the brake pads. Worn front or rear wheel bearings might be the problem, so replace the front wheel bearings. A damaged brake hose could also be the cause, so replace brake hoses as required.
M
mark74Sep 12, 2025
What causes over-aggressive braking in Club Car Golf Cars?
- H
  hurleytamaraSep 12, 2025
  If your Club Car Golf Cars has over-aggressive braking, it may be due to incorrect or distorted brake pads, in which case you should replace the brake pads.

Club Car Carryall 1500 2016 Specifications

General

Model Year	2016
Model	Carryall 1500
Type	Utility Vehicle
Category	Golf Cars
Seating Capacity	2-4
Cargo Box Material	Steel
Fuel Type	Gasoline
Rear Suspension	Leaf Spring
Brakes	4-wheel hydraulic drum
Payload Capacity	1, 500 lb
Towing Capacity	1, 500 lbs
Ground Clearance	5.5 in
Vehicle Load Capacity	1, 500 lbs
Powertrain	Gasoline
Fuel Capacity	6.5 gal
Top Speed	15 mph
Front Suspension	Independent
Dry Weight	1, 200 lbs
Engine Type	Single Cylinder

Summary

FOREWORD

Technical Publication Customer Satisfaction Online Survey

Invitation to participate in a survey to help improve technical publications and identify areas for future improvement.

SECTION 1 — SAFETY

Safety Details

Provides definitions for DANGER, WARNING, and CAUTION safety alert symbols and their associated colors.

General Warnings

Lists general safety statements to be heeded during operation, repair, or service of the vehicle.

Battery Safety Procedures

Safe procedures for disconnecting and connecting side-post and top-post vehicle batteries.

Recycling Lead-Acid Batteries

Guidelines for the proper recycling of lead-acid batteries to prevent environmental contamination.

SECTION 2 — VEHICLE SPECIFICATIONS

1500/1700 and 1550/1550 SE Specifications

Detailed specifications for Carryall and XRT models, including power source, dimensions, and capacities.

Intellitach Specifications

Specific technical specifications for Intellitach equipped vehicles.

SECTION 3 — GENERAL INFORMATION

Model Identification

Information on identifying vehicle model and serial numbers via decals and build codes.

Storage Procedures

Guidelines for preparing and storing the vehicle for extended periods, including battery maintenance.

Lifting and Supporting the Vehicle

Safe procedures for lifting and supporting the vehicle for service, including jack stand placement.

Jump Starting a Dead Battery

Step-by-step instructions for jump-starting a vehicle with a booster battery using proper safety precautions.

SECTION 4 — BODY AND TRIM

Cleaning and Repair Procedures

Guidelines for cleaning vehicle body panels and seats, and repairing light scratches.

Front Body Components

Detailed procedures for removing and installing instrument panel, fascia, and hood.

Roll-Over Protective Structure (ROPS)

Information on ROPS removal and installation procedures and critical safety warnings.

Seat and Cargo Bed Systems

Procedures for seat adjustment, removal, installation, and cargo bed removal/installation.

SECTION 5 — ACCELERATOR AND BRAKE PEDAL ASSEMBLIES

Accelerator Pedal Procedures

Steps for removing, installing, and adjusting the accelerator pedal assembly.

Brake Pedal Procedures

Steps for removing, installing, and adjusting the brake pedal.

Park Brake Pedal Assembly

Procedures for removing and installing the park brake pedal assembly.

SECTION 6 — HYDRAULIC BRAKE AND PARK BRAKE SYSTEMS

Brake System Inspection and Troubleshooting

Guidelines for inspecting brake systems and a guide for diagnosing common symptoms.

Brake Pad and Caliper Procedures

Steps for removing and installing front and rear brake pads and calipers.

Brake Hose Replacement

Procedures for replacing front, mid, and rear hydraulic brake hoses.

Master Cylinder and Reservoir Service

Instructions for removing, installing, and bleeding the master cylinder and reservoir.

SECTION 7 — STEERING AND FRONT SUSPENSION

Steering System Components

Procedures for removing and installing steering wheel, column, and rack and pinion.

Front Suspension Component Service

Procedures for removing and installing steering uprights, A-arms, and shock absorbers.

Wheel Alignment Procedures

Instructions for measuring and adjusting front wheel toe-in, toe-out, and camber.

SECTION 8 — WHEELS, TIRES AND HUBS

Wheel and Tire Procedures

Steps for removing and installing wheels and tires, including tire mounting notes.

Front Hub Procedures

Steps for removing and installing front wheel hubs, including bearing replacement.

Rear Hub Procedures

Steps for removing and installing rear wheel hubs, including brake caliper service.

SECTION 9 — REAR SUSPENSION

Rear Shock Absorber Service

Procedures for removing and installing rear coil-over shock absorbers.

Trailing Arms and Lateral Links

Procedures for removing and installing trailing arms and lateral links.

SECTION 10 — PERIODIC MAINTENANCE

Periodic Service and Lubrication Schedules

Recommended maintenance intervals for engine, tires, brakes, and lubrication.

Engine Oil and Filter Service

Procedures for checking engine oil level, draining oil, and changing oil filter.

Spark Plug Service

Instructions for cleaning, inspecting, and gapping spark plugs.

Gearcase Lubrication Procedures

Steps for checking and changing lubricant in differentials and transmission.

SECTION 11 — TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES

Troubleshooting Guide

Symptom-based guide to identify and resolve operating difficulties with the electrical system.

Wiring Diagrams

Front and rear electrical wiring diagrams for troubleshooting and component identification.

Electrical Test Procedures Index

Index of electrical test procedures with corresponding page numbers for gasoline vehicles.

SECTION 12 — TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES

Troubleshooting Guide

Symptom-based guide to identify and resolve operating difficulties with the electrical system.

Wiring Diagrams

Front and rear electrical wiring diagrams for diesel vehicle systems.

Electrical Test Procedures Index

Index of electrical test procedures with corresponding page numbers for diesel vehicles.

SECTION 13 — ELECTRICAL COMPONENTS: GASOLINE VEHICLES

Starter and Starter Solenoid Service

Reference to engine manual for starter and solenoid testing, removal, and installation.

Relay Service

Procedures for testing, removing, and installing start relay, carburetor heater relay.

Neutral Switch Service

Procedures for testing, removing, and installing the neutral switch.

Carburetor Solenoid and Heater Service

Procedures for testing, removing, and installing carburetor solenoid and heater.

Voltage Regulator Service

Procedures for testing, removing, and installing the voltage regulator.

Warning Lights and Fuses

Procedures for testing, removing, and installing warning lights and fuses.

Fuel Gauge/Hour Meter Service

Procedures for testing, removing, and installing the fuel gauge and hour meter.

Key Switch Service

Procedures for testing, removing, and installing the key switch.

Accessory Receptacle and Bed Lift Systems

Procedures for accessory receptacle, bed lift switch, and circuit breaker service.

Wire Harness Diodes and Battery Maintenance

Procedures for testing/replacing diodes and battery preventive maintenance.

SECTION 14 — ELECTRICAL COMPONENTS: DIESEL VEHICLES

Relays and Neutral Switch Service

Procedures for testing, removing, and installing relays and the neutral switch.

Fuel Solenoid and 60-Amp Fusible Link

Procedures for testing, removing, and installing the fuel solenoid and fusible link.

Warning Lights and Fuel Gauge/Hour Meter

Procedures for testing, removing, and installing warning lights and fuel gauge/hour meter.

Key Switch and Accessory Receptacle

Procedures for testing, removing, and installing the key switch and 12-volt receptacle.

Bed Lift Systems

Procedures for testing, removing, and installing bed lift switch and circuit breaker.

Light Switch and Fuses

Procedures for testing, removing, and installing light switch and fuses.

Reverse Warning Buzzer Systems

Procedures for testing, removing, and installing reverse warning buzzer and limit switch.

Front Differential Limit Switch

Procedures for testing, removing, and installing the front differential limit switch.

Alternator, Oil Pressure Sensor, and Headlights

Procedures for servicing alternator, oil pressure sensor, and headlights.

Thermostat Switch and Fan Motor

Procedures for testing, removing, and installing thermostat switch and fan motor.

Wire Harness Diodes and Battery Maintenance

Procedures for testing/replacing diodes and battery preventive maintenance.

SECTION 15 — GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES

Gasoline Engine Service

Information on engine removal and installation procedures, referencing engine manual.

Exhaust System Maintenance

Procedures for removing and installing mufflers and intermediate pipes.

Fuel System Components

Information on fuel lines, filter, pump, and carburetor service.

Engine Control Linkages

Adjustments for accelerator cable, governor, and RPM settings.

Air Intake System

Procedures for replacing air filter cartridge and servicing air canister.

Clutch System Service

Information on clutch troubleshooting, drive belt, drive clutch, and driven clutch service.

SECTION 16 — DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES

Diesel Engine Service

Information on engine removal and installation, referencing Kubota D722 manual.

Exhaust System Maintenance

Procedures for removing and installing mufflers and intermediate pipes.

Fuel System Components

Information on fuel lines, filter, pump, and fuel level sending unit service.

Engine Control Linkages

Procedures for accelerator cable and RPM adjustments.

Air Intake System

Procedures for replacing air filter cartridge and servicing air canister.

Clutch System Service

Information on clutch troubleshooting, drive belt, drive clutch, and driven clutch service.

SECTION 17 — DRIVETRAIN COMPONENTS

Half Shaft Service

Procedures for removing and installing half shafts.

Front Differential Service

Procedures for removing and installing the front differential assembly.

Front Driveshaft Service

Procedures for removing and installing the front driveshaft.

Transmission Service

Procedures for removing and installing the transmission assembly.

Rear Axle Assembly Service

Procedures for removing and installing the rear axle assembly.

Rear Axle Tubes, Axle Shafts, and Wheel Bearings

Procedures for removing and installing axle tubes, shafts, and wheel bearings.

SECTION 18 — RADIATOR AND COOLANT SYSTEM (DIESEL)

Engine Coolant Procedures

Procedure for checking engine coolant level and changing coolant.

Coolant Reservoir Service

Procedures for removing and installing the coolant reservoir.

Radiator Service

Procedures for removing and installing the radiator.

Coolant Pipe Weldment Service

Procedures for removing and installing coolant pipe weldments.

Fan Service

Procedures for removing and installing the fan motor.

SECTION 19 — HYDRAULIC ATTACHMENT SYSTEM

Relieving Hydraulic System Pressure

Procedure to safely relieve hydraulic pressure before servicing components.

Attachment Interface Inspection

Inspection of hand lever, pins, and linkages for wear, damage, or missing parts.

Attachment Arm Mechanism Service

Procedures for removing and installing the attachment arm mechanism.

Hydraulic System Electrical Components

Wiring diagrams for hydraulic attachment system electrical components.

Joystick and Switch Service

Procedures for testing, removing, and installing joystick and ON/OFF switch.

Auxiliary Hydraulic Switch Service

Procedures for testing, removing, and installing the auxiliary hydraulic switch.

Relay Service

Procedures for testing, removing, and installing float and accessory relays.

Solenoid and Circuit Breaker Service

Procedures for testing, removing, and installing solenoid and circuit breaker.

Control Valves Service

Troubleshooting and repair procedures for two-way, three-way, and four-way control valves.

Hoses and Quick Connect Fittings

Procedures for hose routing, removal, installation, and quick connect fittings.

Cylinders Service

Procedures for removing and installing vehicle-mounted and auxiliary cylinders.

Hydraulic Pump Assembly Service

Procedures for removing, installing, and priming the hydraulic pump assembly.

Reservoir Service

Procedures for removing and installing the hydraulic fluid reservoir.

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Club Car Carryall 1500 2016 User Manual

Table of Contents

Questions and Answers:

Club Car Carryall 1500 2016 Specifications

Summary

FOREWORD

Technical Publication Customer Satisfaction Online Survey

SECTION 1 — SAFETY

Safety Details

General Warnings

Battery Safety Procedures

Recycling Lead-Acid Batteries

SECTION 2 — VEHICLE SPECIFICATIONS

1500/1700 and 1550/1550 SE Specifications

Intellitach Specifications

SECTION 3 — GENERAL INFORMATION

Model Identification

Storage Procedures

Lifting and Supporting the Vehicle

Jump Starting a Dead Battery

SECTION 4 — BODY AND TRIM

Cleaning and Repair Procedures

Front Body Components

Roll-Over Protective Structure (ROPS)

Seat and Cargo Bed Systems

SECTION 5 — ACCELERATOR AND BRAKE PEDAL ASSEMBLIES

Accelerator Pedal Procedures

Brake Pedal Procedures

Park Brake Pedal Assembly

SECTION 6 — HYDRAULIC BRAKE AND PARK BRAKE SYSTEMS

Brake System Inspection and Troubleshooting

Brake Pad and Caliper Procedures

Brake Hose Replacement

Master Cylinder and Reservoir Service

SECTION 7 — STEERING AND FRONT SUSPENSION

Steering System Components

Front Suspension Component Service

Wheel Alignment Procedures

SECTION 8 — WHEELS, TIRES AND HUBS

Wheel and Tire Procedures

Front Hub Procedures

Rear Hub Procedures

SECTION 9 — REAR SUSPENSION

Rear Shock Absorber Service

Trailing Arms and Lateral Links

SECTION 10 — PERIODIC MAINTENANCE

Periodic Service and Lubrication Schedules

Engine Oil and Filter Service

Spark Plug Service

Gearcase Lubrication Procedures

SECTION 11 — TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES

Troubleshooting Guide

Wiring Diagrams

Electrical Test Procedures Index

SECTION 12 — TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES

Troubleshooting Guide

Wiring Diagrams

Electrical Test Procedures Index

SECTION 13 — ELECTRICAL COMPONENTS: GASOLINE VEHICLES

Starter and Starter Solenoid Service

Relay Service

Neutral Switch Service

Carburetor Solenoid and Heater Service

Voltage Regulator Service

Warning Lights and Fuses

Fuel Gauge/Hour Meter Service

Key Switch Service

Accessory Receptacle and Bed Lift Systems

Wire Harness Diodes and Battery Maintenance

SECTION 14 — ELECTRICAL COMPONENTS: DIESEL VEHICLES

Relays and Neutral Switch Service

Fuel Solenoid and 60-Amp Fusible Link

Warning Lights and Fuel Gauge/Hour Meter

Key Switch and Accessory Receptacle

Bed Lift Systems

Light Switch and Fuses

Reverse Warning Buzzer Systems

Front Differential Limit Switch

Alternator, Oil Pressure Sensor, and Headlights

Thermostat Switch and Fan Motor