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Carryall 295 2014
Club Car Carryall 295 2014 Manuals
Manuals and User Guides for Club Car Carryall 295 2014. We have
1
Club Car Carryall 295 2014 manual available for free PDF download: Maintenance And Service Manual
Club Car Carryall 295 2014 Maintenance And Service Manual (428 pages)
Gasoline, Diesel and IntelliTach Vehicles
Brand:
Club Car
| Category:
Golf Cars
| Size: 35.39 MB
Table of Contents
Table of Contents
5
SECTION 1 - Safety
15
Safety Details
15
Personal Safety
15
Machine Safety
15
Information
15
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
Intellitach Specifications
24
SECTION 3 - General Information
27
Model Identification
29
Identification Numbers
29
Storage
31
Preparing the Vehicle for Extended Storage
32
Returning the Stored Vehicle to Service
33
Lifting the Vehicle
33
Lifting Only the Front
33
Lifting Only the Rear
34
Lifting the Entire Vehicle
35
Using a Booster Battery (Jump Starting)
35
SECTION 4 - Body and Trim
37
General Information
37
Cleaning the Vehicle
37
Seat Cleaning
37
Front Body Repair
38
Light Scratches
38
Abrasions and Haze
38
Large Scratches and Abrasions
38
Front Body Components
39
Instrument Panel Removal
39
Instrument Panel Installation
39
Front Fascia Removal
40
Front Fascia Installation
40
Hood Removal
40
Hood Installation
40
Center Cowl Panel Removal
40
Center Cowl Panel Installation
40
Side Cowl Panel (Fender) Removal
41
Side Cowl Panel (Fender) Installation
41
Front Fender Flare Removal
41
Front Fender Flare Installation
42
Roll-Over Protective Structure (ROPS)
42
ROPS Removal
43
ROPS Installation
44
Seat
45
Seat Removal
45
Seat Adjustment
45
Seat Installation
45
Seat Support Removal
46
Seat Support Installation
46
Seat Belts
46
Bench Seat Belt Removal
46
Bench Seat Belt Installation
47
Cargo Bed - Electric Lift
47
Testing the Bed Lift Motor
47
Bed Lift Motor Removal
47
Bed Lift Motor Installation
48
Cargo Bed Removal
48
Cargo Bed Installation
48
Cargo Bed - Manual Lift
48
Cargo Bed Removal
49
Cargo Bed Installation
49
Rear Fender
50
Rear Fender Removal
50
Rear Fender Installation
50
SECTION 5 - Accelerator and Brake Pedal Assemblies
53
Accelerator Pedal
53
Accelerator Pedal Removal
53
Accelerator Pedal Installation
54
Brake Pedal
55
Brake Pedal Removal
55
Brake Pedal Installation
55
Brake Pedal Adjustment
55
Park Brake Pedal
56
Park Brake Pedal Assembly Removal
56
Park Brake Pedal Assembly Installation
56
SECTION 6 - Hydraulic and Park Brake Systems
59
Brake System Inspection
59
Brake Pedal Inspection
59
Master Cylinder Inspection
60
Brake Line Inspection
61
Park Brake Inspection
61
Brake Disc and Pad Inspection
61
Brake System Troubleshooting
62
Brake Pads and Caliper
64
Brake Pad and Caliper Removal
64
Brake Pad and Caliper Installation
65
Brake Discs
68
Disc Removal
68
Disc Installation
68
Hydraulic Line Replacement
69
Front Brake Line Removal
69
Front Brake Line Installation
69
Rear Brake Line Removal
70
Rear Brake Line Installation
71
Master Cylinder and Reservoir
72
Filling the Hydraulic System
72
Master Cylinder Removal
72
Master Cylinder Installation
72
Bleeding the Hydraulic Brake System
73
Bleeding Brakes on a DOT 5 Fluid Filled System
73
Purging the Hydraulic System
75
Park Brake System
76
Park Brake Adjustment - at Rear Calipers
76
Front Park Brake Cable Adjustment - Cable Only System
76
Park Brake Wheel Cables
77
Front Park Brake Cable Removal - Cable Only System
79
Front Park Brake Cable Installation - Cable Only System
79
Park Brake Equalizer Removal - Cable Only System
79
Park Brake Equalizer Installation - Cable Only System
80
SECTION 7 - Steering and Front Suspension
81
Steering Wheel
81
Steering Wheel Removal
81
Steering Wheel Installation
82
Steering Column
82
Steering Column Removal
82
Steering Column Installation
84
Rack and Pinion
87
Rack and Pinion Inspection
87
Rack and Pinion Removal
87
Rack and Pinion Installation
88
Rack and Pinion Disassembly
88
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
117
Trailing Arm Installation
117
SECTION 10 - Periodic Maintenance
119
Periodic Service Schedule
119
Periodic Service Schedule - Intellitach
122
Periodic Lubrication Schedule
124
Periodic Lubrication Schedule - Intellitach
126
Lubricating the Attachment Arm and Interface - Intellitach
127
Brake Fluid Reservoir
128
Brake Fluid
128
Engine Oil
128
Oil Pressure - Gasoline Engine
128
Engine Oil Level Check
129
Engine Oil and Filter Change
129
Oil Viscosity
132
Spark Plugs
133
Spark Plug Cleaning and Inspection
133
Spark Plug Gap Inspection
133
Gearcase Lubrication
134
Lubrication Level Check for Front Differential, Transmission and Rear Differential
134
Lubrication Change for Front Differential, Transmission and Rear Differential
134
Hydraulic System - Intellitach Vehicle
136
Engine Coolant - Diesel Vehicles
137
Engine Coolant Level Check
137
Fueling Instructions
137
Biodiesel Fuel (Diesel Vehicles Only)
138
Draining Water from Fuel Filter
139
Battery
140
SECTION 11 - Troubleshooting and Electrical System: Gasoline Vehicles
141
Troubleshooting Guide
141
Wiring Diagram
146
Test Procedures
149
SECTION 12 - Troubleshooting and Electrical System: Diesel Vehicles
181
Troubleshooting Guide
181
Wiring Diagram
187
Test Procedures
190
SECTION 13 - Electrical Components: Gasoline Vehicles
227
Starter and Starter Solenoid
227
Relays
227
Testing the Relay
227
Relay Removal
228
Relay Installation
228
Neutral Switch
228
Testing the Neutral Switch
228
Neutral Switch Removal
228
Neutral Switch Installation
228
Carburetor Solenoid
228
Testing the Carburetor Solenoid
229
Carburetor Solenoid Removal
229
Carburetor Solenoid Installation
229
Carburetor Heater
229
Carburetor Heater Removal
230
Carburetor Heater Installation
230
Voltage Regulator
231
Testing the Voltage Regulator
231
Voltage Regulator Removal
231
Voltage Regulator Installation
231
Warning Lights
231
Testing the Warning Lights
232
Warning Light Removal
232
Warning Light Installation
232
Fuel Gauge/Hour Meter
233
Testing the Fuel Gauge/Hour Meter
233
Fuel Gauge/Hour Meter Removal
233
Fuel Gauge/Hour Meter Installation
233
Key Switch
233
Testing the Key Switch
233
Key Switch Removal
233
Key Switch Installation
234
12-Volt Accessory Receptacle
234
Testing the 12-Volt Accessory Receptacle
234
12-Volt Accessory Receptacle Removal
234
12-Volt Accessory Receptacle Installation
234
Bed Lift Switch
235
Testing the Bed Lift Switch
235
Bed Lift Switch Removal
235
Bed Lift Switch Installation
235
Bed Lift Circuit Breaker
235
Testing the Bed Lift Circuit Breaker
235
Bed Lift Circuit Breaker Removal
235
Bed Lift Circuit Breaker Installation
235
Light Switch
235
Testing the Light Switch
236
Light Switch Removal
236
Light Switch Installation
236
Fuse
236
Testing the Fuse
236
Fuse Removal
236
Fuse Installation
236
Reverse Warning Buzzer (if Equipped)
237
Testing the Reverse Warning Buzzer
237
Reverse Warning Buzzer Removal
237
Reverse Warning Buzzer Installation
237
Reverse Warning Buzzer Limit Switch (if Equipped)
237
Testing the Reverse Warning Buzzer Limit Switch
238
Reverse Warning Buzzer Limit Switch Removal
238
Reverse Warning Buzzer Limit Switch Installation
238
Front Differential Limit Switch
239
Testing the Front Differential Limit Switch
239
Front Differential Limit Switch Removal
239
Front Differential Limit Switch Installation
240
Fuel Level Sending Unit
240
Testing the Fuel Level Sending Unit
240
Fuel Level Sending Unit Removal
240
Fuel Level Sending Unit Installation
240
Ignition Coil and Charge Coil
240
Testing the Ignition Coil
241
Ignition Coil And/Or Charge Coil Removal
241
Oil Pressure Sensor
241
Headlights
241
Testing the Headlight Bulb and Socket
241
Headlight Bulb Removal
241
Headlight Bulb Installation
242
Wire Harness Diodes
242
Testing the Wire Harness Diodes
242
Wire Harness Diode Removal
242
Wire Harness Diode Installation
243
Battery
243
General Information
243
Testing the Battery
244
Preventive Maintenance
244
Self-Discharge
244
Water Level
244
Vibration Damage
244
Mineral Content
244
Battery Removal
245
Charging the Battery
245
Battery Installation
246
Battery Storage
246
Charging a Dead Battery
246
SECTION 14 - Electrical Components: Diesel Vehicles
249
Starter and Starter Solenoid
249
Relays
249
Testing the Relay
249
Relay Removal
249
Relay Installation
250
Neutral Switch
250
Testing the Neutral Switch
250
Neutral Switch Removal
250
Neutral Switch Installation
250
Fuel Solenoid
251
Testing the Fuel Solenoid
251
Fuel Solenoid Removal
251
Fuel Solenoid Installation
251
60-Amp Fusible Link
252
Testing the 60-Amp Fusible Link
252
60-Amp Fusible Link Removal
252
60-Amp Fusible Link Installation
252
Warning Lights
253
Testing the Warning Lights
253
Warning Light Removal
253
Warning Light Installation
253
Fuel Gauge/Hour Meter
254
Testing the Fuel Gauge/Hour Meter
254
Fuel Gauge/Hour Meter Removal
255
Fuel Gauge/Hour Meter Installation
255
Key Switch
255
Testing the Key Switch
255
Key Switch Removal
255
Key Switch Installation
255
12-Volt Accessory Receptacle
256
Testing the 12-Volt Accessory Receptacle
256
12-Volt Accessory Receptacle Removal
256
12-Volt Accessory Receptacle Installation
256
Bed Lift Switch
256
Testing the Bed Lift Switch
256
Bed Lift Switch Removal
256
Bed Lift Switch Installation
257
Bed Lift Circuit Breaker
257
Testing the Bed Lift Circuit Breaker
257
Bed Lift Circuit Breaker Removal
257
Bed Lift Circuit Breaker Installation
257
Light Switch
257
Testing the Light Switch
257
Light Switch Removal
257
Light Switch Installation
257
Fuse
258
Testing the Fuse
258
Fuse Removal
258
Fuse Installation
258
Reverse Warning Buzzer (if Equipped)
258
Testing the Reverse Warning Buzzer
258
Reverse Warning Buzzer Removal
258
Reverse Warning Buzzer Installation
259
Reverse Warning Buzzer Limit Switch (if Equipped)
259
Testing the Reverse Warning Buzzer Limit Switch
259
Reverse Warning Buzzer Limit Switch Removal
259
Reverse Warning Buzzer Limit Switch Installation
260
Front Differential Limit Switch
260
Testing the Front Differential Limit Switch
261
Front Differential Limit Switch Removal
261
Front Differential Limit Switch Installation
261
Fuel Level Sending Unit
262
Testing the Fuel Level Sending Unit
262
Fuel Level Sending Unit Removal
262
Fuel Level Sending Unit Installation
262
Alternator
262
Testing the Alternator
262
Alternator and V-Belt Removal
262
Alternator and V-Belt Installation
263
Oil Pressure Sensor
265
Headlights
265
Testing the Headlight Bulb and Socket
265
Headlight Bulb Removal
265
Headlight Bulb Installation
265
Thermostat Switch
266
Testing the Thermostat Switch
266
Thermostat Switch Removal
266
Thermostat Switch Installation
266
Fan
267
Testing the Fan Motor
267
Fan Removal
267
Fan Installation
268
Wire Harness Diodes
268
Testing the Wire Harness Diodes
268
Wire Harness Diode Removal
268
Wire Harness Diode Installation
268
Battery
269
General Information
269
Testing the Battery
270
Preventive Maintenance
270
Self-Discharge
270
Water Level
270
Vibration Damage
270
Mineral Content
270
Battery Removal
271
Charging the Battery
271
Battery Installation
272
Battery Storage
272
Charging a Dead Battery
272
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
283
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
319
Bleeding Air from Fuel System
319
Fuel Filter Replacement
319
Fuel Pump
321
Fuel Level Sending Unit
321
Fuel Tank
324
Engine Control Linkages
327
General Information
327
Ground Speed
327
Accelerator Cable
327
Engine RPM Adjustment
328
Air Intake System
331
Air Filter Replacement
331
Air Canister Removal
332
Air Canister Installation
332
Clutches
333
Clutch Troubleshooting
333
Drive Belt
334
Drive Clutch
334
Driven Clutch
338
Clutch Cover
341
SECTION 17 - Drivetrain Components
343
Half Shafts
343
Half Shaft Removal
343
Half Shaft Installation
344
Front Differential
345
Front Differential Removal
345
Front Differential Installation
347
Front Driveshaft
347
Front Driveshaft Removal
347
Front Driveshaft Installation
348
Transmission
349
Transmission Removal
349
Transmission Installation
350
Forward/Reverse Shifter Cable
351
Forward/Reverse Shifter Handle
354
Rear Driveshaft
355
Rear Driveshaft Removal
355
Rear Driveshaft Installation
355
Rear Axle
355
Rear Axle Removal
355
Rear Axle Installation
357
Rear Axle Tubes, Axle Shafts and Wheel Bearings
358
Rear Axle Tube and Axle Shaft Removal
358
Rear Axle Tube and Axle Shaft Installation
359
Rear Wheel Bearing Removal
359
Rear Wheel Bearing Installation
360
SECTION 18 - Radiator and Coolant System (Diesel)
361
General Information
361
Engine Coolant Level Check
361
Engine Coolant Change
361
Coolant Reservoir
363
Coolant Reservoir Removal
363
Coolant Reservoir Installation
364
Radiator
364
Radiator Removal
364
Radiator Installation
365
Coolant Pipe Weldment
366
Coolant Pipe Weldment Removal
366
Coolant Pipe Weldment Installation
366
Fan
367
Fan Removal
367
Fan Installation
367
SECTION 19 - Hydraulic Attachment System
369
Model Identification
369
Relieving Hydraulic System Pressure
369
To Relieve Hydraulic Fluid Pressure
369
Attachment Interface
370
Inspection
370
Removing and Installing the Attachment Arm Mechanism
371
Electrical
376
Joystick
378
Joystick ON/OFF Switch
380
Attachment Arm Float Switch
381
Auxiliary Hydraulic Switch
383
Relays
384
Solenoid
386
Circuit Breaker
386
Control Valves
387
Hoses
389
Hose Routing
389
Hose Removal
390
Hose Installation
390
Quick Connect Fittings (Auxiliary Hydraulic Circuit Only)
391
Quick Connect Removal
391
Quick Connect Installation
391
Cylinders
392
Vehicle Mounted Cylinders
392
Auxiliary Cylinder (Optional)
393
Cylinder Disassembly
395
Cylinder Assembly
399
Cylinder Bushings (if Equipped)
404
Angle Frame Bushings
405
Snow Blade Angle Frame
405
Whisk Broom Angle Frame
407
Front Mount
408
Front Mount Removal
408
Front Mount Installation
409
Hydraulic Pump Assembly
409
Fluid Level Inspection
410
Fluid Change
410
Pump Assembly
410
Reservoir
413
Motor
414
Pump
415
Priming the Pump
415
Index
417
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