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Club Car Carryall 295 Service Manual

Club Car Carryall 295
456 pages
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2008-2012 All-Wheel Drive
Maintenance and Service
Manual
Carryall 295/295 SE, XRT 1550/1550 SE and IntelliT ach
Gasoline and Diesel V ehicles
Manual Number 1033731 17
Edition Code 1007F081 1E

Table of Contents

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Club Car Carryall 295 Specifications

General IconGeneral
Towing Capacity1, 000 lbs
Power SourceGasoline
TransaxleDifferential
Parking BrakeMechanical
FrameSteel
BodyPolyethylene

Summary

Club Car Maintenance and Service Manual

Section 1 - Safety

General Warnings

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

Disabling the Vehicle

Provides a step-by-step procedure to disable the vehicle before servicing or repair.

Disconnecting the Battery

Details the procedure for disconnecting the battery, emphasizing safety precautions.

Section 2 - Vehicle Specifications

295/295 SE and 1550/1550 SE Specifications

Lists detailed specifications for various vehicle models including power source, chassis, and dimensions.

295 Homologated Specifications

Lists specifications for diesel vehicles, covering engine, fuel, ignition, and chassis details.

Intellitach Specifications

Lists specifications for the Intellitach model, covering power source, steering, and dimensions.

Section 3 - General Information

Storage

Provides instructions for safely storing the vehicle, including safety precautions for fuel and batteries.

Lifting the Vehicle

Provides essential safety warnings and procedures for lifting the vehicle, including jack stand usage.

Using a Booster Battery (Jump Starting)

Explains the safe and correct procedure for jump-starting the vehicle using a booster battery.

Section 4 - Body and Trim

Roll-Over Protective Structure (ROPS)

Provides safety warnings regarding the ROPS and outlines its removal procedure.

Seat Belts

Provides general warnings and cautions regarding the proper care and function of safety belt systems.

Section 5 - Accelerator and Brake Pedal Assemblies

Accelerator Pedal and RPM Adjustment – Through Early 2010 Model Year

Explains how to adjust the accelerator pedal and engine RPM for early 2010 models.

Section 6 - Hydraulic and Park Brake Systems

Brake Disc and Pad Inspection

Details inspection of brake discs for warping and brake pads for wear and contamination.

Brake System Troubleshooting

Provides a guide for diagnosing and correcting common brake system issues based on symptoms.

Brake Pads and Caliper – 2008-2011 Models

Covers procedures for removing and installing front and rear brake pads and calipers.

Brake Discs – Starting 2012 Model Year

Covers removal and installation of brake discs for models starting in 2012.

Hydraulic Line Replacement

Provides procedures for replacing hydraulic brake lines, including warnings about bleeding the system.

Master Cylinder and Reservoir

Covers inspection, filling, removal, and installation of the master cylinder and reservoir.

Bleeding the Hydraulic Brake System

Explains the specific procedure for bleeding hydraulic brakes using DOT 5 fluid, including vacuum and manual methods.

Park Brake System

Covers park brake adjustment procedures and front park brake cable adjustments.

Section 7 - Steering and Front Suspension

Wheel Alignment

Explains wheel alignment, including toe-in and camber adjustments, and inspection for wear.

Section 10 - Periodic Maintenance

Periodic Lubrication Schedule

Details lubrication intervals and recommended lubricants for various vehicle components.

Fueling Instructions

Provides critical safety warnings and procedures for fueling the vehicle, covering gasoline and diesel.

Section 11 - Troubleshooting and Electrical System: Gasoline Vehicles

Wiring Diagram

Presents wiring diagrams for gasoline utility vehicles, showing front and rear electrical systems.

Test Procedures

Lists and describes various test procedures for electrical components and systems.

Test Procedure 6 – Starter Control Circuit

Explains how to test the starter control circuit, including checking voltage at the starter solenoid.

Test Procedure 7 – Start Relay

Outlines the procedure for testing the start relay, including checking voltage and continuity.

Test Procedure 15 – Neutral Switch (Transmission)

Details testing the neutral switch on the transmission for continuity in different gear positions.

Test Procedure 17 – Front Differential Limit Switch

Covers testing the front differential limit switch, checking for continuity with accelerator pedal movement.

Test Procedure 35 – Bed Lift Motor

Covers testing the bed lift motor by checking voltage readings with the switch in UP and DOWN positions.

Section 12 - Troubleshooting and Electrical System: Diesel Vehicles

Troubleshooting Guide

Provides a guide for identifying operating difficulties in diesel vehicles, including symptoms, causes, and checks.

Engine does not start (starter motor functions).

Lists possible causes and references for troubleshooting when the starter motor functions but the engine does not start.

Engine does not run smoothly.

Identifies potential causes for an engine not running smoothly and directs to relevant troubleshooting sections.

Loss of engine power.

Lists possible causes for loss of engine power and directs to relevant troubleshooting sections.

Engine overheats.

Details common causes for engine overheating and recommended actions.

Test Procedure 1 – Battery

Details procedures for testing the battery, including hydrometer and voltage tests, with safety warnings.

Test Procedure 2 – Fuse

Details the procedure for testing fuses using a multimeter, including safety warnings about fuse replacement.

Test Procedure 4 – Key Switch (Starter Circuit)

Covers testing the key switch for the starter circuit, checking continuity in different positions.

Test Procedure 7 – Starter Control Circuit

Details testing the starter control circuit, including checking voltage at the starter solenoid.

Test Procedure 9 – Fan Relay

Covers testing the fan relay for power, function, and continuity.

Test Procedure 10 – Thermostat Switch

Details testing the thermostat switch for continuity under different temperature conditions.

Test Procedure 12 – Wire Harness Diodes

Details testing in-line diodes in the wire harness for proper function using a multimeter.

Section 15 - Gasoline Engine, Muffler, Fuel System, and Clutches

Section 16 - Diesel Engine, Muffler, Fuel System, and Clutches

Engine Removal

Details the process for removing the diesel engine, including disconnecting components.

Fuel System

Covers fuel system components like lines, filter, pump, and tank, with maintenance info.

Clutches

Covers clutch troubleshooting, drive belt service, drive clutch, driven clutch, and clutch cover procedures.

Section 19 - Hydraulic Attachment System

Relieving Hydraulic System Pressure

Explains the procedure to relieve hydraulic pressure before disconnecting components, with safety warnings.

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