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2007 Carryall 295
Club Car 2007 Carryall 295 Manuals
Manuals and User Guides for Club Car 2007 Carryall 295. We have
1
Club Car 2007 Carryall 295 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
Table of Contents
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
295/295 SE and 1550/1550 SE Specifications
27
295 Homologated Specifications
29
Intellitach Specifications
31
Section 3 - General Information
33
General Information
33
Model Identification
33
Storage
34
Preparing the Vehicle for Extended Storage
35
Returning the Stored Vehicle to Service
36
Using a Booster Battery (Jump Starting)
37
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
Accelerator Pedal Removal
55
Accelerator Pedal Installation
56
Accelerator Pedal and RPM Adjustment
56
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
Brake System Inspection
61
Brake System Troubleshooting
63
Brake Pads and Caliper
65
Front Brake Pad and Caliper Removal
65
Front Brake Pad and Caliper Installation
67
Rear Brake Pad and Caliper Removal
68
Rear Brake Pad and Caliper Installation
69
Brake Disc and Hub
70
Front Wheel Disc and Hub Removal
70
Front Wheel Disc and Hub Installation
74
Rear Wheel Disc Removal
75
Rear Wheel Disc Installation
76
Hydraulic Line Replacement
77
Front Brake Line Removal
77
Front Brake Line Installation
77
Rear Brake Line Removal
78
Rear Brake Line Installation
79
Master Cylinder and Reservoir
80
Filling the Hydraulic System
80
Reservoir Removal
80
Reservoir Installation
80
Master Cylinder Removal
81
Master Cylinder Installation
81
Bleeding the Hydraulic Brake System
82
Bleeding Brakes on a DOT 5 Fluid Filled System
82
Purging the Hydraulic System
84
Park Brake System
85
Park Brake Adjustment
85
Park Brake Cable Adjustment
85
Park Brake Wheel Cables
86
Front Park Brake Cable Removal
87
Front Park Brake Cable Installation
88
Park Brake Equalizer Removal
88
Park Brake Equalizer Installation
88
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
Reverse Warning Buzzer Limit Switch (if Equipped)
302
Front Differential Limit Switch
303
Fuel Level Sending Unit
304
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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