Club Car 2007 Carryall 295 Vehicle Parts Manuals

Manuals and User Guides for Club Car 2007 Carryall 295 Vehicle Parts. We have 1 Club Car 2007 Carryall 295 Vehicle Parts manual available for free PDF download: Maintenance And Service Manual

Club Car 2007 Carryall 295 Maintenance And Service Manual (564 pages)

Brand: Club Car | Category: Utility Vehicle | Size: 52.29 MB

Maintenance and Service
1
Table of Contents
5
Section 1 - Safety

19
- General Warning
  19
Section 2A - Vehicle Specifications: Honda Gas & Kubota Diesel Powered

23
- 295/295 SE and 1550/1550 SE Specifications
  23
- Intellitach Specifications
  25
Section 2B - Vehicle Specifications: Kawasaki Gas & Kubota Diesel Powered

27
Section 3 - General Information

33
Section 4 - Body and Trim

39
- Cleaning the Vehicle
  39
  - Seat Cleaning
    39
- Front Body Repair
  40
  - Light Scratches
    40
  - Abrasions and Haze
    40
  - Large Scratches and Abrasions
    40
- Front Body Components
  41
  - Instrument Panel Removal
    41
  - Instrument Panel Installation
    41
  - Front Fascia Removal
    42
  - Front Fascia Installation
    42
  - Hood Removal
    42
  - Hood Installation
    42
  - Center Cowl Panel Removal
    42
  - Center Cowl Panel Installation
    43
  - Side Cowl Panel (Fender) Removal
    43
  - Side Cowl Panel (Fender) Installation
    43
  - Front Fender Flare Removal
    44
  - Front Fender Flare Installation
    44
- Roll-Over Protective Structure (ROPS)
  44
  - ROPS Removal
    45
  - ROPS Installation
    46
- Seat
  47
  - Seat Removal
    47
  - Seat Adjustment
    47
  - Seat Installation
    47
  - Seat Support Removal
    48
  - Seat Support Installation
    48
- Safety Belts
  48
  - Safety Belt Removal
    48
  - Safety Belt Installation
    49
- Cargo Bed - Electric Lift
  49
  - Testing the Bed Lift Motor
    49
  - Bed Lift Motor Removal
    49
  - Bed Lift Motor Installation
    50
  - Cargo Bed Removal
    50
  - Cargo Bed Installation
    50
- Cargo Bed - Manual Lift
  51
  - Cargo Bed Removal
    51
  - Cargo Bed Installation
    51
- Rear Fender
  53
  - Rear Fender Removal
    53
  - Rear Fender Installation
    53
- Floor Mat
  53
  - Floor Mat Removal
    53
  - Floor Mat Installation
    53
Section 5 - Accelerator and Brake Pedal Assemblies

55
- Accelerator Pedal
  55
- Brake Pedal
  57
  - Brake Pedal Removal
    57
  - Brake Pedal Installation
    57
  - Brake Pedal Adjustment
    58
- Park Brake Pedal
  58
  - Park Brake Pedal Assembly Removal
    58
  - Park Brake Pedal Assembly Installation
    58
Section 6 - Hydraulic and Park Brake Systems

61
Section 7 - Steering and Front Suspension

91
- Steering Wheel
  91
  - Steering Wheel Removal
    91
  - Steering Wheel Installation
    92
- Steering Column
  92
  - Steering Column Removal
    92
  - Steering Column Installation
    93
- Rack and Pinion
  93
  - Rack and Pinion Removal
    93
  - Rack and Pinion Installation
    94
  - Rack and Pinion Disassembly
    95
  - Rack and Pinion Assembly
    99
- Front Suspension
  101
  - Wheel Alignment
    101
- Front Suspension Components
  103
  - Steering Upright Removal
    103
  - Upper A-Arm Removal
    104
  - Upper A-Arm Installation
    106
  - Lower A-Arm Removal
    106
  - Lower A-Arm Installation
    107
  - Front Coil-Over Shock Absorber Removal
    108
  - Front Coil-Over Shock Absorber Installation
    109
  - Steering Upright Installation
    109
Section 8 - Wheels and Tires

111
- General Information
  111
- Wheels
  112
  - Wheel Removal
    112
  - Wheel Installation
    112
- Tires
  112
  - Tire Removal
    112
  - Tire Installation
    113
Section 9 - Rear Suspension

115
- Rear Coil-Over Shock Absorber
  115
- Swing Arms
  116
  - Swing Arm Removal
    116
  - Swing Arm Installation
    117
Section 10A - Periodic Maintenance: Honda Gasoline & Kubota Diesel Powered Vehicles

119
- Periodic Service Schedule
  119
- Periodic Lubrication Schedule
  122
- Lubricating the Attachment Arm and Interface
  124
- Brake Fluid Reservoir
  125
  - Brake Fluid
    125
- Engine Oil
  125
  - Oil Pressure - Gasoline Engine
    125
  - Engine Oil Level Check
    126
  - Engine Oil and Filter Change
    126
  - Oil Viscosity
    130
- Gearcase Lubrication
  131
  - Lubrication Level Check for Front Differential, Transmission, and Rear Differential
    131
  - Lubrication Change for Front Differential, Transmission, and Rear Differential
    131
- Hydraulic System - Intellitach Vehicle
  133
- Engine Coolant - Diesel Vehicles
  134
  - Engine Coolant Level Check
    134
- Fueling Instructions
  134
  - Draining Water from Fuel Filter
    135
- Battery
  136
Section 10B - Periodic Maintenance: Kawasaki Gasoline & Kubota die

137
- Periodic Service Schedule
  137
- Periodic Lubrication Schedule
  140
- Lubricating the Attachment Arm and Interface
  142
- Brake Fluid Reservoir
  143
  - Brake Fluid
    143
- Engine Oil
  143
  - Oil Pressure - Gasoline Engine
    143
  - Engine Oil Level Check
    144
  - Engine Oil and Filter Change
    144
  - Oil Viscosity
    147
- Spark Plugs
  148
  - Spark Plug Cleaning and Inspection
    148
  - Spark Plug Gap Inspection
    148
- Gearcase Lubrication
  149
  - Lubrication Level Check for Front Differential, Transmission, and Rear Differential
    149
  - Lubrication Change for Front Differential, Transmission, and Rear Differential
    149
- Hydraulic System - Intellitach Vehicle
  151
- Engine Coolant - Diesel Vehicles
  152
  - Engine Coolant Level Check
    152
- Fueling Instructions
  152
  - Draining Water from Fuel Filter
    153
- Battery
  154
Section 11A - Troubleshooting and Electrical System: Kawasaki Powered Gasoline Vehicles

155
- Troubleshooting Guide
  155
- Wiring Diagram
  160
- Test Procedures
  162
- Test Procedures
  166
  - Index of Test Procedures
    204
Cles

291
Section 12B - Electrical Components: Honda Powered Gasoline Vehi-

291
- Starter and Starter Solenoid
  291
- Neutral Switch
  292
- Carburetor Heater
  293
- Voltage Regulator
  294
- Warning Lights
  295
- Fuel Gauge/Hour Meter
  296
- Key Switch
  297
- Volt Accessory Receptacle
  298
- Bed Lift Switch
  299
- Light Switch
  300
- Reverse Warning Buzzer (if Equipped)
  301
- Oil Pressure Sensor
  305
  - Wire Harness Diodes
    306
  - Battery
    307
  - Starter and Starter Solenoid
    311
  - Neutral Switch
    312
- Voltage Regulator
  313
  - Warning Lights
    314
  - Fuel Gauge/Hour Meter
    315
  - Key Switch
    316
- Volt Accessory Receptacle
  317
- Bed Lift Switch
  318
- Light Switch
  319
- Reverse Warning Buzzer
  320
- Reverse Warning Buzzer Limit Switch
  321
- Fuel Level Sending Unit
  322
- Charge Coil
  323
- Wire Harness Diodes
  324
- Battery
  325
- Preventive Maintenance
  326
Section 12C - Electrical Components: Diesel Vehicles

329
- Starter and Starter Solenoid
  329
- Neutral Switch
  330
- Amp Fusible Link
  331
- Warning Lights
  333
- Fuel Gauge/Hour Meter
  334
- Key Switch
  335
- Bed Lift Switch
  336
- Bed Lift Circuit Breaker
  337
- Fuse
  338
- Reverse Warning Buzzer Limit Switch (if Equipped)
  339
- Front Differential Limit Switch
  341
  - Electric Fuel Pump
    342
- Oil Pressure Sensor
  344
- Thermostat Switch
  345
- Wire Harness Diodes
  348
  - Battery
    349
  - Gasoline Engine
    353
  - Engine Installation
    355
  - Oil Filter Hoses
    357
  - Exhaust System
    358
  - Intermediate Pipe Removal
    359
  - Muffler Installation
    360
  - Fuel System
    361
  - Fuel Filter
    362
- Fuel Level Sending Unit
  363
  - Fuel Tank
    366
  - Fuel Shut-Off Valve
    369
  - Engine Control Linkages
    370
    
    Choke Cable
    372
    
    Engine Governor Arm
    373
    
    Engine RPM Adjustment
    374
  - Air Intake System
    375
    
    Air Canister Removal
    376
    
    Air Filter Intake Hose Removal
    377
    
    Air Filter Outlet Hose Removal
    378
- Clutches
  379
  - Drive Belt
    380
  - Drive Clutch
    381
  - Driven Clutch
    386
  - Clutch Cover
    389
Clutches

391
Section 13B - Honda Gasoline Engine, Muffler, Fuel System, and

391
- Gasoline Engine
  391
  - Engine Installation
    393
  - Exhaust System
    395
    
    Intermediate Pipe Installation
    396
  - Fuel System
    397
    
    Fuel Lines
    398
    
    Fuel Level Sending Unit
    399
    
    Fuel Tank
    402
  - Fuel Shut-Off Valve
    405
  - Oil Filter Hoses
    406
  - Governor Guard
    409
  - Accelerator Cable Retention Clip Adjustment
    410
  - Ground Speed (Transmission) Governor Arm Adjustment
    411
  - Engine Governor Arm
    413
- Choke and Air Intake System
  414
  - Choke Cable Removal
    415
  - Choke Cable Installation
    416
    
    Air Canister Installation
    417
    
    Air Filter Intake Hose Installation
    418
    
    Air Filter Outlet Hose Installation
    419
  - Clutch Troubleshooting
    420
    
    Drive Clutch
    421
    
    Driven Clutch
    426
    
    Clutch Cover
    429
  - Diesel Engine
    431
    
    Engine Installation
    433
    
    Exhaust System
    435
    
    Manifold Pipe Removal
    436
    
    Muffler Installation
    437
    
    Fuel System
    438
    
    Fuel Lines
    439
    
    Electric Fuel Pump
    441
    
    Fuel Level Sending Unit
    442
    
    Fuel Tank
    446
    
    Engine Control Linkages
    449
    
    Engine RPM Adjustment
    450
    
    Air Intake System
    453
    
    Air Canister Installation
    454
    
    Air Filter Intake Hose Installation
    455
    
    Air Filter Outlet Hose Removal
    456
  - Clutches
    457
    
    Drive Belt
    458
    
    Drive Clutch
    459
    
    Driven Clutch
    463
    
    Driven Clutch Disassembly
    464
    
    Clutch Cover
    465
Section 13C - Diesel Engine, Muffler, Fuel System, and Clutches

431
Section 14 - Drivetrain Components

469
- Half Shafts
  469
  - Half Shaft Installation
    471
- Front Differential
  472
  - Front Differential Installation
    474
  - Front Driveshaft Installation
    475
- Rear Axle
  476
  - Rear Axle Installation
    478
- Rear Driveshaft
  479
  - Rear Driveshaft Installation
    480
  - Transmission Installation
    482
  - Forward/Reverse Shifter Cable
    483
  - Forward/Reverse Shifter Handle
    486
  - Rear Differential and Axle Shaft Installation
    488
  - General Information
    491
  - Coolant Reservoir
    493
    
    Coolant Reservoir Installation
    494
    
    Radiator Installation
    495
  - Coolant Pipe Weldment
    496
    
    Fan Removal
    497
  - Model Identification
    499
  - Attachment Interface
    500
    
    Removing and Installing the Attachment Arm Mechanism
    501
  - Electrical
    506
    
    Joystick
    508
    
    Joystick ON/OFF Switch
    510
    
    Attachment Arm Float Switch
    512
    
    Auxiliary Hydraulic Switch
    513
    
    Relays
    515
    
    Solenoid
    517
    
    Circuit Breaker
    518
    
    Control Valves
    519
  - Hoses
    521
    
    Hose Removal
    522
  - Quick Connect Fittings (Auxiliary Hydraulic Circuit Only)
    523
- Cylinders
  524
  - Auxiliary Cylinder (Optional)
    525
  - Cylinder Disassembly
    527
  - Cylinder Assembly
    530
  - Cylinder Bushings (if Equipped)
    535
- Angle Frame Bushings
  537
  - Whisk Broom Angle Frame
    538
- Front Mount
  539
  - Front Mount Installation
    540
- Hydraulic Pump Assembly
  541
  - Pump Assembly
    542
  - Reservoir
    545
  - Motor
    546
  - Pump
    547

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Club Car 2007 Carryall 295 Maintenance And Service Manual (564 pages)

Table of Contents

Section 1 - Safety

Section 2A - Vehicle Specifications: Honda Gas & Kubota Diesel Powered

Section 2B - Vehicle Specifications: Kawasaki Gas & Kubota Diesel Powered

Section 3 - General Information

Section 4 - Body and Trim

Section 5 - Accelerator and Brake Pedal Assemblies

Section 6 - Hydraulic and Park Brake Systems

Section 7 - Steering and Front Suspension

Section 8 - Wheels and Tires

Section 9 - Rear Suspension

Section 10A - Periodic Maintenance: Honda Gasoline & Kubota Diesel Powered Vehicles

Section 10B - Periodic Maintenance: Kawasaki Gasoline & Kubota die

Section 11A - Troubleshooting and Electrical System: Kawasaki Powered Gasoline Vehicles

Cles

Section 12B - Electrical Components: Honda Powered Gasoline Vehi-

Section 12C - Electrical Components: Diesel Vehicles

Clutches

Section 13B - Honda Gasoline Engine, Muffler, Fuel System, and

Section 13C - Diesel Engine, Muffler, Fuel System, and Clutches

Section 14 - Drivetrain Components

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