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Carryall 295
Club Car Carryall 295 Service Manual
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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
2
Table of Contents
Table of Contents
5
Section 1 - Safety
15
Safety Details
15
Personal Safety
15
Machine Safety
15
Information
16
General Warnings
16
Disabling the Vehicle
17
Disconnecting the Battery - Gasoline/Diesel Vehicles
17
Connecting the Battery - Gasoline/Diesel Vehicles
18
Recycling Lead-Acid Batteries
18
International Safety Symbols on Batteries
19
Section 2 - Vehicle Specifications
21
295/295 SE and 1550/1550 SE Specifications
21
295 Homologated Specifications
24
Intellitach Specifications
26
Section 3 - General Information
29
Model Identification - Domestic
30
Identification Numbers
31
Model Identification - Homologated
33
Identification Numbers
33
Storage
35
Preparing the Vehicle for Extended Storage
36
Returning the Stored Vehicle to Service
36
Lifting the Vehicle
37
Lifting Only the Front
37
Lifting Only the Rear
37
Lifting the Entire Vehicle
38
Using a Booster Battery (Jump Starting)
39
Section 4 - Body and Trim
41
Cleaning the Vehicle
41
Seat Cleaning
41
Front Body Repair
42
Light Scratches
42
Abrasions and Haze
42
Large Scratches and Abrasions
42
Front Body Components
43
Instrument Panel Removal
43
Instrument Panel Installation
43
Front Fascia Removal
44
Front Fascia Installation
44
Hood Removal
44
Hood Installation
44
Center Cowl Panel Removal
44
Center Cowl Panel Installation
45
Side Cowl Panel (Fender) Removal
45
Side Cowl Panel (Fender) Installation
45
Front Fender Flare Removal
46
Front Fender Flare Installation
46
Roll-Over Protective Structure (ROPS)
46
ROPS Removal
46
ROPS Installation
48
Seat
49
Seat Removal
49
Seat Adjustment
49
Seat Installation
49
Seat Support Removal
49
Seat Support Installation
50
Seat Belts
50
Bench Seat Belt Removal - 2008 Models
50
Bench Seat Belt Installation - 2008 Models
51
Bench Seat Belt Removal - 2009 and Newer Models
51
Bench Seat Belt Installation - 2009 and Newer Models
52
Seat Belt Removal - Homologated Models
52
Seat Belt Installation - Homologated Models
53
Cargo Bed - Electric Lift
53
Testing the Bed Lift Motor
53
Bed Lift Motor Removal
53
Bed Lift Motor Installation
54
Cargo Bed Removal
54
Cargo Bed Installation
54
Cargo Bed - Manual Lift
55
Cargo Bed Removal
55
Cargo Bed Installation
55
Rear Fender
57
Rear Fender Removal
57
Rear Fender Installation
57
Section 5 - Accelerator and Brake Pedal Assemblies
59
Accelerator Pedal - through Early 2010 Model Year
59
Accelerator Pedal Removal - through Early 2010 Model Year
59
Accelerator Pedal Installation - through Early 2010 Model Year
60
Accelerator Pedal and RPM Adjustment - through Early 2010 Model Year
60
Accelerator Pedal - from Late 2010 Model Year
61
Accelerator Pedal Removal - from Late 2010 Model Year
61
Accelerator Pedal Installation - from Late 2010 Model Year
61
Brake Pedal
63
Brake Pedal Removal
63
Brake Pedal Installation
63
Brake Pedal Adjustment
63
Park Brake Pedal
64
Park Brake Pedal Assembly Removal - Bell Crank System
64
Park Brake Pedal Assembly Installation - Bell Crank System
64
Park Brake Pedal Assembly Removal - Cable Only System
64
Park Brake Pedal Assembly Installation - Cable Only System
65
Section 6 - Hydraulic and Park Brake Systems
67
Brake System Inspection
67
Brake Pedal Inspection
67
Master Cylinder Inspection
68
Brake Line Inspection
69
Park Brake Inspection
69
Brake Disc and Pad Inspection
69
Brake System Troubleshooting
70
Brake Pads and Caliper - 2008-2011 Models
72
Front Brake Pad and Caliper Removal
72
Front Brake Pad and Caliper Installation
73
Rear Brake Pad and Caliper Removal
74
Rear Brake Pad and Caliper Installation
75
Brake Disc and Hub - 2008-2011 Models
76
Front Wheel Disc and Hub Removal
76
Front Wheel Disc and Hub Installation
80
Rear Wheel Disc Removal
81
Rear Wheel Disc Installation
82
Brake Pads and Caliper - Starting 2012 Model Year
83
Brake Pad and Caliper Removal
83
Brake Pad and Caliper Installation
84
Brake Discs - Starting 2012 Model Year
85
Disc Removal
85
Disc Installation
86
Hydraulic Line Replacement
86
Front Brake Line Removal
86
Front Brake Line Installation
87
Rear Brake Line Removal
88
Rear Brake Line Installation
88
Master Cylinder and Reservoir
89
Filling the Hydraulic System
89
Master Cylinder Removal
89
Master Cylinder Installation
90
Bleeding the Hydraulic Brake System
90
Bleeding Brakes on a DOT 5 Fluid Filled System
91
Purging the Hydraulic System
92
Park Brake System
93
Park Brake Adjustment - at Rear Calipers
93
Front Park Brake Cable Adjustment - Bell Crank System
93
Front Park Brake Cable Adjustment - Cable Only System
94
Park Brake Wheel Cables
94
Front Park Brake Cable Removal - Bell Crank System
96
Front Park Brake Cable Installation - Bell Crank System
97
Front Park Brake Cable Removal - Cable Only System
97
Front Park Brake Cable Installation - Cable Only System
98
Park Brake Equalizer Removal - Bell Crank System
98
Park Brake Equalizer Installation - Bell Crank System
98
Park Brake Equalizer Removal - Cable Only System
99
Park Brake Equalizer Installation - Cable Only System
99
Section 7 - Steering and Front Suspension
101
Steering Wheel
101
Steering Wheel Removal
101
Steering Wheel Installation
102
Steering Column
102
Steering Column Removal
102
Steering Column Installation
103
Rack and Pinion
103
Rack and Pinion Inspection
104
Rack and Pinion Removal
104
Rack and Pinion Installation
104
Rack and Pinion Disassembly
105
Rack and Pinion Assembly
109
Front Suspension
110
Wheel Alignment
110
Front Suspension Components
112
Steering Upright Removal
112
Upper A-Arm Removal
114
Upper A-Arm Installation
115
Lower A-Arm Removal
115
Lower A-Arm Installation
116
Front Coil-Over Shock Absorber Removal
117
Front Coil-Over Shock Absorber Installation
118
Steering Upright Installation
118
Section 8 - Wheels and Tires
119
General Information
119
Wheels
120
Wheel Removal
120
Wheel Installation
120
Tires
120
Tire Removal
120
Tire Installation
121
Section 9 - Rear Suspension
123
Rear Coil-Over Shock Absorber - 2008-2011 Models
123
Rear Shock Absorber Removal
123
Rear Shock Absorber Installation
124
Swing Arms - 2008-2011 Models
125
Swing Arm Removal
125
Swing Arm Installation
125
Rear Coil-Over Shock Absorber - Starting 2012 Model Year
126
Rear Shock Absorber Removal
126
Rear Shock Installation
127
Trailing Arms and Lateral Links - Starting 2012 Model Year
128
Lateral Link Removal
128
Lateral Link Installation
128
Trailing Arm Removal
130
Trailing Arm Installation
130
Section 10 - Periodic Maintenance
131
Periodic Service Schedule
131
Periodic Lubrication Schedule
134
Periodic Lubrication Schedule - Intellitach
136
Lubricating the Attachment Arm and Interface
137
Brake Fluid Reservoir
138
Brake Fluid
138
Engine Oil
138
Oil Pressure - Gasoline Engine
139
Engine Oil Level Check
139
Engine Oil and Filter Change
139
Oil Viscosity
142
Spark Plugs
143
Spark Plug Cleaning and Inspection
143
Spark Plug Gap Inspection
143
Gearcase Lubrication
143
Lubrication Level Check for Front Differential, Transmission, and Rear Differential
143
Lubrication Change for Front Differential, Transmission, and Rear Differential
144
Hydraulic System - Intellitach Vehicle
145
Engine Coolant - Diesel Vehicles
146
Engine Coolant Level Check
146
Fueling Instructions
146
Biodiesel Fuel (Diesel Vehicles Only)
147
Draining Water from Fuel Filter
148
Battery
149
Section 11 - Troubleshooting and Electrical System: Gasoline Vehicles
151
Troubleshooting Guide
151
Wiring Diagram
158
Test Procedures
160
Section 12 - Troubleshooting and Electrical System: Diesel Vehicles
191
Troubleshooting Guide
191
Wiring Diagram
198
Test Procedures
202
Section 13 - Electrical Components: Gasoline Vehicles
237
Starter and Starter Solenoid
237
Relays
237
Testing the Relay
237
Relay Removal
238
Relay Installation
238
Neutral Switch
238
Testing the Neutral Switch
238
Neutral Switch Removal
238
Neutral Switch Installation
238
Carburetor Solenoid
239
Testing the Carburetor Solenoid
239
Carburetor Solenoid Removal
239
Carburetor Solenoid Installation
239
Carburetor Heater
240
Carburetor Heater Removal
240
Carburetor Heater Installation
240
Voltage Regulator
241
Testing the Voltage Regulator
241
Voltage Regulator Removal
241
Voltage Regulator Installation
241
Warning Lights
242
Testing the Warning Lights
242
Warning Light Removal
242
Warning Light Installation
242
Fuel Gauge/Hour Meter
243
Testing the Fuel Gauge/Hour Meter
243
Fuel Gauge/Hour Meter Removal
243
Fuel Gauge/Hour Meter Installation
244
Key Switch
244
Testing the Key Switch
244
Key Switch Removal
244
Key Switch Installation
244
12-Volt Accessory Receptacle
245
Testing the 12-Volt Accessory Receptacle
245
12-Volt Accessory Receptacle Removal
245
12-Volt Accessory Receptacle Installation
245
Bed Lift Switch
246
Testing the Bed Lift Switch
246
Bed Lift Switch Removal
246
Bed Lift Switch Installation
246
Bed Lift Circuit Breaker
246
Testing the Bed Lift Circuit Breaker
246
Bed Lift Circuit Breaker Removal
246
Bed Lift Circuit Breaker Installation
247
Light Switch
247
Testing the Light Switch
247
Light Switch Removal
247
Light Switch Installation
247
Fuse
247
Testing the Fuse
247
Fuse Removal
248
Fuse Installation
248
Reverse Warning Buzzer (if Equipped)
248
Testing the Reverse Warning Buzzer
248
Reverse Warning Buzzer Removal
248
Reverse Warning Buzzer Installation
249
Reverse Warning Buzzer Limit Switch (if Equipped)
249
Testing the Reverse Warning Buzzer Limit Switch
249
Reverse Warning Buzzer Limit Switch Removal
249
Reverse Warning Buzzer Limit Switch Installation
250
Front Differential Limit Switch
250
Testing the Front Differential Limit Switch
251
Front Differential Limit Switch Removal
251
Front Differential Limit Switch Installation
251
Fuel Level Sending Unit
252
Testing the Fuel Level Sending Unit
252
Fuel Level Sending Unit Removal
252
Fuel Level Sending Unit Installation
252
Ignition Coil and Charge Coil
252
Testing the Ignition Coil
252
Ignition Coil And/Or Charge Coil Removal
252
Oil Pressure Sensor
253
Headlights
253
Testing the Headlight Bulb and Socket
253
Headlight Bulb Removal
253
Headlight Bulb Installation
253
Wire Harness Diodes
254
Testing the Wire Harness Diodes
254
Wire Harness Diode Removal
254
Wire Harness Diode Installation
254
Battery
255
General Information
255
Testing the Battery
255
Preventive Maintenance
255
Self-Discharge
256
Water Level
256
Vibration Damage
256
Mineral Content
256
Battery Removal
257
Charging the Battery
257
Battery Installation
257
Battery Storage
258
Charging a Dead Battery
258
Section 14 - Electrical Components: Diesel Vehicles
259
Starter and Starter Solenoid
259
Relays
259
Testing the Relay
259
Relay Removal
260
Relay Installation
260
Neutral Switch
260
Testing the Neutral Switch
260
Neutral Switch Removal
260
Neutral Switch Installation
260
Fuel Solenoid
261
Testing the Fuel Solenoid
261
Fuel Solenoid Removal
261
Fuel Solenoid Installation
261
60-Amp Fusible Link
262
Testing the 60-Amp Fusible Link
262
60-Amp Fusible Link Removal
262
60-Amp Fusible Link Installation
262
Warning Lights
263
Testing the Warning Lights
263
Warning Light Removal
263
Warning Light Installation
263
Fuel Gauge/Hour Meter
264
Testing the Fuel Gauge/Hour Meter
264
Fuel Gauge/Hour Meter Removal
265
Fuel Gauge/Hour Meter Installation
265
Key Switch
265
Testing the Key Switch
265
Key Switch Removal
265
Key Switch Installation
265
12-Volt Accessory Receptacle
266
Testing the 12-Volt Accessory Receptacle
266
12-Volt Accessory Receptacle Removal
266
12-Volt Accessory Receptacle Installation
266
Bed Lift Switch
267
Testing the Bed Lift Switch
267
Bed Lift Switch Removal
267
Bed Lift Switch Installation
267
Bed Lift Circuit Breaker
267
Testing the Bed Lift Circuit Breaker
267
Bed Lift Circuit Breaker Removal
267
Bed Lift Circuit Breaker Installation
267
Light Switch
268
Testing the Light Switch
268
Light Switch Removal
268
Light Switch Installation
268
Fuse
268
Testing the Fuse
268
Fuse Removal
268
Fuse Installation
269
Reverse Warning Buzzer (if Equipped)
269
Testing the Reverse Warning Buzzer
269
Reverse Warning Buzzer Removal
269
Reverse Warning Buzzer Installation
270
Reverse Warning Buzzer Limit Switch (if Equipped)
270
Testing the Reverse Warning Buzzer Limit Switch
270
Reverse Warning Buzzer Limit Switch Removal
270
Reverse Warning Buzzer Limit Switch Installation
270
Front Differential Limit Switch Diesel
271
Testing the Front Differential Limit Switch
271
Front Differential Limit Switch Removal
271
Front Differential Limit Switch Installation
272
Fuel Level Sending Unit
272
Testing the Fuel Level Sending Unit
272
Fuel Level Sending Unit Removal
273
Fuel Level Sending Unit Installation
273
Alternator
273
Testing the Alternator
273
Alternator and V-Belt Removal
273
Alternator and V-Belt Installation
274
Oil Pressure Sensor
275
Headlights
275
Testing the Headlight Bulb and Socket
275
Headlight Bulb Removal
275
Headlight Bulb Installation
275
Thermostat Switch
276
Testing the Thermostat Switch
276
Thermostat Switch Removal
276
Thermostat Switch Installation
277
Fan
277
Testing the Fan Motor
277
Fan Removal
277
Fan Installation
278
Wire Harness Diodes
278
Testing the Wire Harness Diodes
278
Wire Harness Diode Removal
278
Wire Harness Diode Installation
279
Battery
279
General Information
279
Testing the Battery
280
Preventive Maintenance
280
Self-Discharge
280
Water Level
280
Vibration Damage
280
Mineral Content
280
Battery Removal
281
Charging the Battery
281
Battery Installation
282
Battery Storage
282
Charging a Dead Battery
282
Section 15 - Gasoline Engine, Muffler, Fuel System, and Clutches
285
Gasoline Engine
285
Engine Removal
285
Engine Installation
287
Oil Filter Hoses
289
Exhaust System
290
Muffler Removal
290
Intermediate Pipe Removal
290
Intermediate Pipe Installation
291
Muffler Installation
291
Fuel System
292
Fuel Lines
292
Fuel Filter
294
Fuel Pump
294
Carburetor
294
Fuel Level Sending Unit
295
Fuel Tank
298
Carbon Canister
301
Fuel Shut-Off Valve
302
Engine Control Linkages
303
Accelerator Cable
303
Choke Cable
305
Engine Governor Arm
306
Engine RPM Adjustment
307
Air Intake System
310
Air Filter Replacement
310
Air Canister Removal
311
Air Canister Installation
311
Air Filter Intake Hose Removal
311
Air Filter Intake Hose Installation
312
Air Filter Outlet Hose Removal
313
Air Filter Outlet Hose Installation
313
Clutches
314
Clutch Troubleshooting
315
Drive Belt
315
Drive Clutch
316
Driven Clutch
322
Clutch Cover
325
Section 16 - Diesel Engine, Muffler, Fuel System, and Clutches
327
Diesel Engine
327
Engine Removal
327
Engine Installation
329
Exhaust System
331
Muffler Removal
331
Intermediate Pipe Removal
331
Manifold Pipe Removal
332
Manifold Pipe Installation
332
Intermediate Pipe Installation
332
Muffler Installation
332
Fuel System
334
Fuel Lines
334
Bleeding Air from Fuel System
335
Fuel Filter Replacement
335
Fuel Pump
338
Fuel Level Sending Unit
338
Fuel Tank
341
Engine Control Linkages
344
Accelerator Cable
344
Engine RPM Adjustment
345
Air Intake System
348
Air Filter Replacement
348
Air Canister Removal
349
Air Canister Installation
349
Air Filter Intake Hose Removal
350
Air Filter Intake Hose Installation
350
Air Filter Outlet Hose Removal
351
Air Filter Outlet Hose Installation
351
Clutches
352
Clutch Troubleshooting
353
Drive Belt
353
Drive Clutch
354
Driven Clutch
360
Clutch Cover
363
Section 17 - Drivetrain Components
365
Half Shafts
365
Half Shaft Removal
365
Half Shaft Installation
367
Front Differential
368
Front Differential Removal
368
Front Differential Installation
369
Front Driveshaft
370
Front Driveshaft Removal
370
Front Driveshaft Installation
370
Rear Receiver Hitch
371
Rear Receiver Hitch Removal
371
Rear Receiver Hitch Installation
371
Rear Axle - 2008-2011 Models
372
Rear Axle Removal
372
Rear Axle Installation
373
Rear Axle - Starting 2012 Model Year
375
Rear Axle Removal
375
Rear Axle Installation
376
Rear Driveshaft
377
Rear Driveshaft Removal
377
Rear Driveshaft Installation
377
Transmission
377
Transmission Removal
377
Transmission Installation
379
Forward/Reverse Shifter Cable
380
Forward/Reverse Shifter Handle
382
Rear Differential and Axle Shafts
383
Rear Differential and Axle Shaft Removal
383
Rear Differential and Axle Shaft Installation
384
Rear Wheel Bearings
384
Section 18 - Radiator and Coolant System (Diesel)
387
General Information
387
Engine Coolant Level Check
387
Engine Coolant Change
387
Coolant Reservoir
389
Coolant Reservoir Removal
389
Coolant Reservoir Installation
390
Radiator
390
Radiator Removal
390
Radiator Installation
391
Coolant Pipe Weldment
392
Coolant Pipe Weldment Removal
392
Coolant Pipe Weldment Installation
392
Fan
393
Fan Removal
393
Fan Installation
393
Section 19 - Hydraulic Attachment System
395
Model Identification
395
Relieving Hydraulic System Pressure
395
To Relieve Hydraulic Fluid Pressure
395
Attachment Interface
396
Inspection
396
Removing and Installing the Attachment Arm Mechanism
397
Electrical
402
Joystick
404
Joystick ON/OFF Switch
406
Attachment Arm Float Switch
407
Auxiliary Hydraulic Switch
409
Relays
410
Solenoid
412
Circuit Breaker
412
Control Valves
413
Hoses
415
Hose Routing
415
Hose Removal
416
Hose Installation
416
Quick Connect Fittings (Auxiliary Hydraulic Circuit Only)
417
Quick Connect Removal
417
Quick Connect Installation
417
Cylinders
418
Vehicle Mounted Cylinders
418
Auxiliary Cylinder (Optional)
419
Cylinder Disassembly
421
Cylinder Assembly
424
Cylinder Bushings (if Equipped)
430
Angle Frame Bushings
431
Snow Blade Angle Frame
431
Whisk Broom Angle Frame
432
Front Mount
433
Front Mount Removal
433
Front Mount Installation
434
Hydraulic Pump Assembly
434
Fluid Level Inspection
435
Fluid Change
435
Pump Assembly
436
Reservoir
438
Motor
439
Pump
440
Priming the Pump
440
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Club Car Carryall 295 Specifications
General
Towing Capacity
1, 000 lbs
Power Source
Gasoline
Transaxle
Differential
Parking Brake
Mechanical
Frame
Steel
Body
Polyethylene
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