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Carryall 295 2013
Club Car Carryall 295 2013 Manuals
Manuals and User Guides for Club Car Carryall 295 2013. We have
1
Club Car Carryall 295 2013 manual available for free PDF download: Maintenance And Service Manual
Club Car Carryall 295 2013 Maintenance And Service Manual (432 pages)
Brand:
Club Car
| Category:
Golf Cars
| Size: 34.35 MB
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
20
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
31
Identification Numbers
31
Model Identification - Homologated
33
Identification Numbers
33
Storage
34
Preparing the Vehicle for Extended Storage
35
Returning the Stored Vehicle to Service
35
Lifting the Vehicle
36
Lifting Only the Front
36
Lifting Only the Rear
36
Lifting the Entire Vehicle
37
Using a Booster Battery (Jump Starting)
38
Section 4 - Body and Trim
41
General Information
41
Cleaning the Vehicle
41
Seat Cleaning
41
Front Body Repair
42
Light Scratches
42
Abrasions and Haze
42
Large Scratches and Abrasions
43
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
47
ROPS Installation
48
Seat
49
Seat Removal
49
Seat Adjustment
49
Seat Installation
50
Seat Support Removal
50
Seat Support Installation
50
Seat Belts
50
Bench Seat Belt Removal
50
Bench Seat Belt Installation
51
Seat Belt Removal - Homologated Models
51
Seat Belt Installation - Homologated Models
52
Cargo Bed - Electric Lift
52
Testing the Bed Lift Motor
52
Bed Lift Motor Removal
52
Bed Lift Motor Installation
53
Cargo Bed Removal
53
Cargo Bed Installation
53
Cargo Bed - Manual Lift
54
Cargo Bed Removal
54
Cargo Bed Installation
54
Rear Fender
54
Rear Fender Removal
54
Rear Fender Installation
55
Section 5 - Accelerator and Brake Pedal Assemblies
57
Accelerator Pedal
57
Accelerator Pedal Removal
57
Accelerator Pedal Installation
58
Brake Pedal
59
Brake Pedal Removal
59
Brake Pedal Installation
59
Brake Pedal Adjustment
59
Park Brake Pedal
60
Park Brake Pedal Assembly Removal - Cable Only System
60
Park Brake Pedal Assembly Installation - Cable Only System
60
Section 6 - Hydraulic and Park Brake Systems
63
Brake System Inspection
63
Brake Pedal Inspection
63
Master Cylinder Inspection
64
Brake Line Inspection
65
Park Brake Inspection
65
Brake Disc and Pad Inspection
65
Brake System Troubleshooting
66
Brake Pads and Caliper
68
Brake Pad and Caliper Removal
68
Brake Pad and Caliper Installation
69
Brake Discs
71
Disc Removal
72
Disc Installation
72
Hydraulic Line Replacement
72
Front Brake Line Removal
73
Front Brake Line Installation
73
Rear Brake Line Removal
74
Rear Brake Line Installation
75
Master Cylinder and Reservoir
76
Filling the Hydraulic System
76
Master Cylinder Removal
76
Master Cylinder Installation
76
Bleeding the Hydraulic Brake System
77
Bleeding Brakes on a DOT 5 Fluid Filled System
77
Purging the Hydraulic System
79
Park Brake System
80
Park Brake Adjustment - at Rear Calipers
80
Front Park Brake Cable Adjustment - Cable Only System
80
Park Brake Wheel Cables
81
Front Park Brake Cable Removal - Cable Only System
82
Front Park Brake Cable Installation - Cable Only System
83
Park Brake Equalizer Removal - Cable Only System
83
Park Brake Equalizer Installation - Cable Only System
84
Section 7 - Steering and Front Suspension
85
Steering Wheel
85
Steering Wheel Removal
85
Steering Wheel Installation
86
Steering Column
86
Steering Column Removal
86
Steering Column Installation
87
Rack and Pinion
87
Rack and Pinion Inspection
88
Rack and Pinion Removal
88
Rack and Pinion Installation
88
Rack and Pinion Disassembly
89
Rack and Pinion Assembly
93
Front Suspension
94
Wheel Alignment
94
Front Suspension Components
98
Steering Upright Removal
98
Steering Upright Installation
100
Upper A-Arm Removal
100
Upper A-Arm Installation
102
Lower A-Arm Removal
102
Lower A-Arm Installation
103
Front Coil-Over Shock Absorber Removal
104
Front Coil-Over Shock Absorber Installation
105
Section 8 - Wheels, Tires and Hubs
107
General Information
107
Wheels
108
Wheel Removal
108
Wheel Installation
108
Tires
108
Tire Removal
108
Tire Installation
109
Front Hubs
109
Front Hub Removal
109
Front Hub Installation
111
Rear Hubs
112
Rear Hub Removal
112
Rear Hub Installation
113
Section 9 - Rear Suspension
115
Rear Coil-Over Shock Absorber
115
Rear Shock Absorber Removal
115
Rear Shock Installation
116
Trailing Arms and Lateral Links
117
Lateral Link Removal
117
Lateral Link Installation
117
Trailing Arm Removal
119
Trailing Arm Installation
119
Section 10 - Periodic Maintenance
121
Periodic Service Schedule
121
Periodic Service Schedule - Intellitach
124
Periodic Lubrication Schedule
126
Periodic Lubrication Schedule - Intellitach
128
Lubricating the Attachment Arm and Interface - Intellitach
129
Brake Fluid Reservoir
130
Brake Fluid
130
Engine Oil
130
Oil Pressure - Gasoline Engine
131
Engine Oil Level Check
131
Engine Oil and Filter Change
131
Oil Viscosity
134
Spark Plugs
135
Spark Plug Cleaning and Inspection
135
Spark Plug Gap Inspection
135
Gearcase Lubrication
135
Lubrication Level Check for Front Differential, Transmission and Rear Differential
135
Lubrication Change for Front Differential, Transmission and Rear Differential
136
Hydraulic System - Intellitach Vehicle
138
Engine Coolant - Diesel Vehicles
138
Engine Coolant Level Check
139
Fueling Instructions
139
Biodiesel Fuel (Diesel Vehicles Only)
140
Draining Water from Fuel Filter
141
Battery
142
Section 11 - Troubleshooting and Electrical System: Gasoline Vehicles
143
Troubleshooting Guide
143
Wiring Diagram
148
Test Procedures
150
Section 12 - Troubleshooting and Electrical System: Diesel Vehicles
181
Troubleshooting Guide
181
Wiring Diagram
186
Test Procedures
190
Section 13 - Electrical Components: Gasoline Vehicles
225
Starter and Starter Solenoid
225
Relays
225
Testing the Relay
225
Relay Removal
226
Relay Installation
226
Neutral Switch
226
Testing the Neutral Switch
226
Neutral Switch Removal
226
Neutral Switch Installation
226
Carburetor Solenoid
227
Testing the Carburetor Solenoid
227
Carburetor Solenoid Removal
227
Carburetor Solenoid Installation
227
Carburetor Heater
228
Carburetor Heater Removal
228
Carburetor Heater Installation
228
Voltage Regulator
229
Testing the Voltage Regulator
229
Voltage Regulator Removal
229
Voltage Regulator Installation
229
Warning Lights
230
Testing the Warning Lights
230
Warning Light Removal
230
Warning Light Installation
230
Fuel Gauge/Hour Meter
231
Testing the Fuel Gauge/Hour Meter
231
Fuel Gauge/Hour Meter Removal
231
Fuel Gauge/Hour Meter Installation
232
Key Switch
232
Testing the Key Switch
232
Key Switch Removal
232
Key Switch Installation
232
12-Volt Accessory Receptacle
233
Testing the 12-Volt Accessory Receptacle
233
12-Volt Accessory Receptacle Removal
233
12-Volt Accessory Receptacle Installation
233
Bed Lift Switch
233
Testing the Bed Lift Switch
233
Bed Lift Switch Removal
234
Bed Lift Switch Installation
234
Bed Lift Circuit Breaker
234
Testing the Bed Lift Circuit Breaker
234
Bed Lift Circuit Breaker Removal
234
Bed Lift Circuit Breaker Installation
234
Light Switch
234
Testing the Light Switch
235
Light Switch Removal
235
Light Switch Installation
235
Fuse
235
Testing the Fuse
235
Fuse Removal
235
Fuse Installation
235
Reverse Warning Buzzer (if Equipped)
236
Testing the Reverse Warning Buzzer
236
Reverse Warning Buzzer Removal
236
Reverse Warning Buzzer Installation
236
Reverse Warning Buzzer Limit Switch (if Equipped)
237
Testing the Reverse Warning Buzzer Limit Switch
237
Reverse Warning Buzzer Limit Switch Removal
237
Reverse Warning Buzzer Limit Switch Installation
237
Front Differential Limit Switch
238
Testing the Front Differential Limit Switch
238
Front Differential Limit Switch Removal
238
Front Differential Limit Switch Installation
239
Fuel Level Sending Unit
239
Testing the Fuel Level Sending Unit
239
Fuel Level Sending Unit Removal
240
Fuel Level Sending Unit Installation
240
Ignition Coil and Charge Coil
240
Testing the Ignition Coil
240
Ignition Coil And/Or Charge Coil Removal
240
Oil Pressure Sensor
240
Headlights
240
Testing the Headlight Bulb and Socket
241
Headlight Bulb Removal
241
Headlight Bulb Installation
241
Wire Harness Diodes
241
Testing the Wire Harness Diodes
242
Wire Harness Diode Removal
242
Wire Harness Diode Installation
242
Battery
242
General Information
243
Testing the Battery
243
Preventive Maintenance
243
Self-Discharge
243
Water Level
244
Vibration Damage
244
Mineral Content
244
Battery Removal
244
Charging the Battery
245
Battery Installation
245
Battery Storage
245
Charging a Dead Battery
246
Section 14 - Electrical Components: Diesel Vehicles
247
Starter and Starter Solenoid
247
Relays
247
Testing the Relay
247
Relay Removal
248
Relay Installation
248
Neutral Switch
248
Testing the Neutral Switch
248
Neutral Switch Removal
248
Neutral Switch Installation
248
Fuel Solenoid
249
Testing the Fuel Solenoid
249
Fuel Solenoid Removal
249
Fuel Solenoid Installation
249
60-Amp Fusible Link
250
Testing the 60-Amp Fusible Link
250
60-Amp Fusible Link Removal
250
60-Amp Fusible Link Installation
250
Warning Lights
251
Testing the Warning Lights
251
Warning Light Removal
251
Warning Light Installation
251
Fuel Gauge/Hour Meter
252
Testing the Fuel Gauge/Hour Meter
252
Fuel Gauge/Hour Meter Removal
253
Fuel Gauge/Hour Meter Installation
253
Key Switch
253
Testing the Key Switch
253
Key Switch Removal
253
Key Switch Installation
253
12-Volt Accessory Receptacle
254
Testing the 12-Volt Accessory Receptacle
254
12-Volt Accessory Receptacle Removal
254
12-Volt Accessory Receptacle Installation
254
Bed Lift Switch
255
Testing the Bed Lift Switch
255
Bed Lift Switch Removal
255
Bed Lift Switch Installation
255
Bed Lift Circuit Breaker
255
Testing the Bed Lift Circuit Breaker
255
Bed Lift Circuit Breaker Removal
255
Bed Lift Circuit Breaker Installation
255
Light Switch
256
Testing the Light Switch
256
Light Switch Removal
256
Light Switch Installation
256
Fuse
256
Testing the Fuse
256
Fuse Removal
256
Fuse Installation
257
Reverse Warning Buzzer (if Equipped)
257
Testing the Reverse Warning Buzzer
257
Reverse Warning Buzzer Removal
257
Reverse Warning Buzzer Installation
258
Reverse Warning Buzzer Limit Switch (if Equipped)
258
Testing the Reverse Warning Buzzer Limit Switch
258
Reverse Warning Buzzer Limit Switch Removal
258
Reverse Warning Buzzer Limit Switch Installation
258
Front Differential Limit Switch
259
Testing the Front Differential Limit Switch
259
Front Differential Limit Switch Removal
259
Front Differential Limit Switch Installation
260
Fuel Level Sending Unit
260
Testing the Fuel Level Sending Unit
260
Fuel Level Sending Unit Removal
261
Fuel Level Sending Unit Installation
261
Alternator
261
Testing the Alternator
261
Alternator and V-Belt Removal
261
Alternator and V-Belt Installation
262
Oil Pressure Sensor
263
Headlights
263
Testing the Headlight Bulb and Socket
263
Headlight Bulb Removal
263
Headlight Bulb Installation
263
Thermostat Switch
264
Testing the Thermostat Switch
264
Thermostat Switch Removal
264
Thermostat Switch Installation
265
Fan
265
Testing the Fan Motor
265
Fan Removal
265
Fan Installation
266
Wire Harness Diodes
266
Testing the Wire Harness Diodes
266
Wire Harness Diode Removal
266
Wire Harness Diode Installation
267
Battery
267
General Information
267
Testing the Battery
268
Preventive Maintenance
268
Self-Discharge
268
Water Level
268
Vibration Damage
268
Mineral Content
268
Battery Removal
269
Charging the Battery
269
Battery Installation
270
Battery Storage
270
Charging a Dead Battery
270
Section 15 - Gasoline Engine, Muffler, Fuel System, and Clutches
273
Gasoline Engine
273
Engine Removal
273
Engine Installation
275
Oil Filter Hoses
277
Exhaust System
278
Muffler Removal
278
Intermediate Pipe Removal
278
Intermediate Pipe Installation
279
Muffler Installation
279
Fuel System
280
Fuel Lines
281
Fuel Filter
281
Fuel Pump
281
Carburetor
281
Fuel Level Sending Unit
284
Fuel Tank
287
Carbon Canister
290
Fuel Shut-Off Valve
291
Engine Control Linkages
292
General Information
292
Ground Speed
292
Accelerator Cable
292
Choke Cable
293
Engine Governor Arm
295
Engine RPM Adjustment
296
Air Intake System
298
Air Filter Replacement
298
Air Canister Removal
299
Air Canister Installation
299
Clutches
300
Clutch Troubleshooting
300
Drive Belt
301
Drive Clutch
301
Driven Clutch
305
Clutch Cover
308
Section 16 - Diesel Engine, Muffler, Fuel System, and Clutches
311
Diesel Engine
311
Engine Removal
311
Engine Installation
313
Exhaust System
315
Muffler Removal
315
Intermediate Pipe Removal
315
Manifold Pipe Removal
316
Manifold Pipe Installation
316
Intermediate Pipe Installation
316
Muffler Installation
316
Fuel System
318
Fuel Lines
318
Bleeding Air from Fuel System
319
Fuel Filter Replacement
319
Fuel Pump
322
Fuel Level Sending Unit
322
Fuel Tank
325
Engine Control Linkages
328
General Information
328
Ground Speed
328
Accelerator Cable
328
Engine RPM Adjustment
329
Air Intake System
332
Air Filter Replacement
332
Air Canister Removal
332
Air Canister Installation
333
Clutches
334
Clutch Troubleshooting
334
Drive Belt
334
Drive Clutch
335
Driven Clutch
339
Clutch Cover
342
Section 17 - Drivetrain Components
345
Half Shafts
345
Half Shaft Removal
345
Half Shaft Installation
347
Front Differential
348
Front Differential Removal
348
Front Differential Installation
349
Front Driveshaft
350
Front Driveshaft Removal
350
Front Driveshaft Installation
350
Rear Axle
351
Rear Axle Removal
351
Rear Axle Installation
352
Rear Driveshaft
353
Rear Driveshaft Removal
353
Rear Driveshaft Installation
354
Transmission
354
Transmission Removal
354
Transmission Installation
355
Forward/Reverse Shifter Cable
356
Forward/Reverse Shifter Handle
358
Rear Axle Tubes, Axle Shafts and Wheel Bearings
359
Rear Axle Tube and Axle Shaft Removal
359
Rear Axle Tube and Axle Shaft Installation
360
Rear Wheel Bearing Removal
360
Rear Wheel Bearing Installation
361
Section 18 - Radiator and Coolant System (Diesel)
363
General Information
363
Engine Coolant Level Check
363
Engine Coolant Change
363
Coolant Reservoir
365
Coolant Reservoir Removal
365
Coolant Reservoir Installation
366
Radiator
366
Radiator Removal
366
Radiator Installation
367
Coolant Pipe Weldment
368
Coolant Pipe Weldment Removal
368
Coolant Pipe Weldment Installation
368
Fan
369
Fan Removal
369
Fan Installation
369
Section 19 - Hydraulic Attachment System
371
Model Identification
371
Relieving Hydraulic System Pressure
371
To Relieve Hydraulic Fluid Pressure
371
Attachment Interface
372
Inspection
372
Removing and Installing the Attachment Arm Mechanism
373
Electrical
378
Joystick
380
Joystick ON/OFF Switch
382
Attachment Arm Float Switch
383
Auxiliary Hydraulic Switch
385
Relays
386
Solenoid
388
Circuit Breaker
388
Control Valves
389
Hoses
391
Hose Routing
391
Hose Removal
392
Hose Installation
392
Quick Connect Fittings (Auxiliary Hydraulic Circuit Only)
393
Quick Connect Removal
393
Quick Connect Installation
393
Cylinders
394
Vehicle Mounted Cylinders
394
Auxiliary Cylinder (Optional)
395
Cylinder Disassembly
397
Cylinder Assembly
400
Cylinder Bushings (if Equipped)
406
Angle Frame Bushings
407
Snow Blade Angle Frame
407
Whisk Broom Angle Frame
408
Front Mount
409
Front Mount Removal
409
Front Mount Installation
410
Hydraulic Pump Assembly
410
Fluid Level Inspection
411
Fluid Change
411
Pump Assembly
412
Reservoir
414
Motor
415
Pump
416
Priming the Pump
416
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