2008-2012 Club Car Carryall 295, 295 SE, XRT 1550, 1550 SE Diesel IntelliTach Service Manual

Description

This Official 2008-2012 Club Car Carryall 295/295 SE, XRT 1550/1550 SE Diesel and IntelliTach Golf Cart Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 2008, 2009, 2010, 2011, and 2012 Carryall 295/295 SE, XRT 1550/1550 SE Diesel and IntelliTach golf carts.

Table of Contents

SECTION 1 – SAFETY
Safety Details
Personal Safety
Machine Safety
Information
General Warnings
Disabling the Vehicle
Disconnecting the Battery – Gasoline/Diesel Vehicles
Connecting the Battery – Gasoline/Diesel Vehicles
Recycling Lead-Acid Batteries
International safety symbols on batteries

SECTION 2 – VEHICLE SPECIFICATIONS
295/295 SE and 1550/1550 SE Specifications
295 Homologated Specifications
Intellitach Specifications

SECTION 3 – GENERAL INFORMATION
Model Identification – Domestic
Identification Numbers
Model Identification – Homologated
Identification Numbers
Storage
Preparing the Vehicle for Extended Storage
Returning the Stored Vehicle to Service
Lifting The Vehicle
Lifting Only The Front
Lifting Only The Rear
Lifting The Entire Vehicle
Using A Booster Battery (Jump Starting)

SECTION 4 – BODY AND TRIM
General Information
Cleaning the Vehicle
Seat Cleaning
Front Body Repair
Light Scratches
Abrasions and Haze
Large Scratches and Abrasions
Front Body Components
Instrument Panel Removal
Instrument Panel Installation
Front Fascia Removal
Front Fascia Installation
Hood Removal
Hood Installation
Center Cowl Panel Removal
Center Cowl Panel Installation
Side Cowl Panel (Fender) Removal
Side Cowl Panel (Fender) Installation
Front Fender Flare Removal
Front Fender Flare Installation
Roll-Over Protective Structure (ROPS)
ROPS Removal
ROPS Installation
Seat
Seat Removal
Seat Adjustment
Seat Installation
Seat Support Removal
Seat Support Installation
Seat Belts
Bench Seat Belt Removal – 2008 Models
Bench Seat Belt Installation – 2008 Models
Bench Seat Belt Removal – 2009 and Newer Models
Bench Seat Belt Installation – 2009 and Newer Models
Seat Belt Removal – Homologated Models
Seat Belt Installation – Homologated Models
Cargo Bed – Electric Lift
Testing the Bed Lift Motor
Bed Lift Motor Removal
Bed Lift Motor Installation
Cargo Bed Removal
Cargo Bed Installation
Cargo Bed – Manual Lift
Cargo Bed Removal
Cargo Bed Installation
Rear Fender
Rear Fender Removal
Rear Fender Installation

SECTION 5 – ACCELERATOR AND BRAKE PEDAL ASSEMBLIES
Accelerator Pedal – Through Early 2010 Model Year
Accelerator Pedal Removal – Through Early 2010 Model Year
Accelerator Pedal Installation – Through Early 2010 Model Year
Accelerator Pedal and RPM Adjustment – Through Early 2010 Model Year
Accelerator Pedal – From Late 2010 Model Year
Accelerator Pedal Removal – From Late 2010 Model Year
Accelerator Pedal Installation – From Late 2010 Model Year
Brake Pedal
Brake Pedal Removal
Brake Pedal Installation
Brake Pedal Adjustment
Park Brake Pedal
Park Brake Pedal Assembly Removal – Bell Crank System
Park Brake Pedal Assembly Installation – Bell Crank System
Park Brake Pedal Assembly Removal – Cable Only System
Park Brake Pedal Assembly Installation – Cable Only System

SECTION 6 – HYDRAULIC AND PARK BRAKE SYSTEMS
Brake System Inspection
Brake Pedal Inspection
Master Cylinder Inspection
Brake Line Inspection
Park Brake Inspection
Brake Disc and Pad Inspection
Brake System Troubleshooting
Brake Pads and Caliper – 2008-2011 Models
Front Brake Pad and Caliper Removal
Front Brake Pad and Caliper Installation
Rear Brake Pad and Caliper Removal
Rear Brake Pad and Caliper Installation
Brake Disc and Hub – 2008-2011 Models
Front Wheel Disc and Hub Removal
Front Wheel Disc and Hub Installation
Rear Wheel Disc Removal
Rear Wheel Disc Installation
Brake Pads and Caliper-2012 Model Year
Brake Pad and Caliper Removal
Brake Pad and Caliper Installation
Brake Discs – 2012 Model Year
Disc Removal
Disc Installation
Hydraulic Line Replacement
Front Brake Line Removal
Front Brake Line Installation
Rear Brake Line Removal
Rear Brake Line Installation
Master Cylinder and Reservoir
Filling the Hydraulic System
Master Cylinder Removal
Master Cylinder Installation
Bleeding the Hydraulic Brake System
Bleeding Brakes on a DOT 5 Fluid Filled System
Purging the Hydraulic System
Park Brake System
Park Brake Adjustment – At Rear Calipers
Front Park Brake Cable Adjustment – Bell Crank System
Front Park Brake Cable Adjustment – Cable Only System
Park Brake Wheel Cables
Front Park Brake Cable Removal – Bell Crank System
Front Park Brake Cable Installation – Bell Crank System
Front Park Brake Cable Removal – Cable Only System
Front Park Brake Cable Installation – Cable Only System
Park Brake Equalizer Removal – Bell Crank System
Park Brake Equalizer Installation – Bell Crank System
Park Brake Equalizer Removal – Cable Only System
Park Brake Equalizer Installation – Cable Only System

SECTION 7 – STEERING AND FRONT SUSPENSION
Steering Wheel
Steering Wheel Removal
Steering Wheel Installation
Steering Column
Steering Column Removal
Steering Column Installation
Rack and Pinion
Rack and Pinion Inspection
Rack and Pinion Removal
Rack and Pinion Installation
Rack and Pinion Disassembly
Rack and Pinion Assembly
Front Suspension
Wheel Alignment
Front Suspension Components
Steering Upright Removal
Steering Upright Installation
Upper A-Arm Removal
Upper A-Arm Installation
Lower A-Arm Removal
Lower A-Arm Installation
Front Coil-Over Shock Absorber Removal
Front Coil-Over Shock Absorber Installation

SECTION 8 – WHEELS, TIRES AND HUBS
General Information
Wheels
Wheel Removal
Wheel Installation
Tires
Tire Removal
Tire Installation
Front Flubs (2012 Model Year Only)
Front Flub Removal
Front Hub Installation
Rear Hubs (2012 Model Year Only)
Rear Hub Removal
Rear Hub Installation

SECTION 9 – REAR SUSPENSION
Rear Coil-Over Shock Absorber – 2008-2011 Models
Rear Shock Absorber Removal
Rear Shock Absorber Installation
Swing Arms – 2008-2011 Models
Swing Arm Removal
Swing Arm Installation
Rear Coil-Over Shock Absorber – 2012 Model Year
Rear Shock Absorber Removal
Rear Shock Installation
Trailing Arms and Lateral Links – 2012 Model Year
Lateral Link Removal
Lateral Link Installation
Trailing Arm Removal
Trailing Arm Installation

SECTION 10 – PERIODIC MAINTENANCE
Periodic Service Schedule
Periodic Service Schedule – IntelliTach
Periodic Lubrication Schedule – 295/295 SE, 1550/1550 SE
Periodic Lubrication Schedule – IntelliTach
Lubricating the Attachment Arm and Interface – IntelliTach
Brake Fluid Reservoir
Brake Fluid
Engine Oil
Oil Pressure – Gasoline Engine
Engine Oil Level Check
Engine Oil and Filter Change
Oil Viscosity
Spark Plugs
Spark Plug Cleaning And Inspection
Spark Plug Gap Inspection
Gearcase Lubrication
Lubrication Level Check for Front Differential, Transmission, and Rear Differential
Lubrication Change for Front Differential, Transmission, and Rear Differential
Hydraulic System – IntelliTach Vehicle
Engine Coolant – Diesel Vehicles
Engine Coolant Level Check
Fueling Instructions
Biodiesel Fuel (Diesel Vehicles Only)
Draining Water from Fuel Filter
Battery

SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES
Troubleshooting Guide
Wiring Diagram
Test Procedures

SECTION 12 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES
Troubleshooting Guide
Wiring Diagram
Test Procedures

SECTION 13 – ELECTRICAL COMPONENTS: GASOLINE VEHICLES
Starter and Starter Solenoid
Relays
Testing the Relay
Relay Removal
Relay Installation
Neutral Switch
Testing the Neutral Switch
Neutral Switch Removal
Neutral Switch Installation
Carburetor Solenoid
Testing the Carburetor Solenoid
Carburetor Solenoid Removal
Carburetor Solenoid Installation
Carburetor Heater
Carburetor Heater Removal
Carburetor Heater Installation
Voltage Regulator
Testing the Voltage Regulator
Voltage Regulator Removal
Voltage Regulator Installation
Warning Lights
Testing the Warning Lights
Warning Light Removal
Warning Light Installation
Fuel Gauge/Hour Meter
Testing the Fuel Gauge/Hour Meter
Fuel Gauge/Hour Meter Removal
Fuel Gauge/Hour Meter Installation
Key Switch
Testing the Key Switch
Key Switch Removal
Key Switch Installation
12-Volt Accessory Receptacle
Testing the 12-Volt Accessory Receptacle
12-Volt Accessory Receptacle Removal
12-Volt Accessory Receptacle Installation
Bed Lift Switch
Testing the Bed Lift Switch
Bed Lift Switch Removal
Bed Lift Switch Installation
Bed Lift Circuit Breaker
Testing the Bed Lift Circuit Breaker
Bed Lift Circuit Breaker Removal
Bed Lift Circuit Breaker Installation
Light Switch
Testing the Light Switch
Light Switch Removal
Light Switch Installation
Fuse
Testing the Fuse
Fuse Removal
Fuse Installation
Reverse Warning Buzzer (If Equipped)
Testing the Reverse Warning Buzzer
Reverse Warning Buzzer Removal
Reverse Warning Buzzer Installation
Reverse Warning Buzzer Limit Switch (If Equipped)
Testing the Reverse Warning Buzzer Limit Switch
Reverse Warning Buzzer Limit Switch Removal
Reverse Warning Buzzer Limit Switch Installation
Front Differential Limit Switch
Testing the Front Differential Limit Switch
Front Differential Limit Switch Removal
Front Differential Limit Switch Installation
Fuel Level Sending Unit
Testing the Fuel Level Sending Unit
Fuel Level Sending Unit Removal
Fuel Level Sending Unit Installation
Ignition Coil and Charge Coil
Testing the Ignition Coil
Ignition Coil and/or Charge Coil Removal
Oil Pressure Sensor
Headlights
Testing the Headlight Bulb and Socket
Headlight Bulb Removal
Headlight Bulb Installation
Wire Harness Diodes
Testing the Wire Harness Diodes
Wire Harness Diode Removal
Wire Harness Diode Installation
Battery
General Information
Testing the Battery
Preventive Maintenance
Self-Discharge
Water Level
Vibration Damage
Mineral Content
Battery Removal
Charging the Battery
Battery Installation
Battery Storage
Charging a Dead Battery

SECTION 14 – ELECTRICAL COMPONENTS: DIESEL VEHICLES
Starter and Starter Solenoid
Relays
Testing the Relay
Relay Removal
Relay Installation
Neutral Switch
Testing the Neutral Switch
Neutral Switch Removal
Neutral Switch Installation
Fuel Solenoid
Testing the Fuel Solenoid
Fuel Solenoid Removal
Fuel Solenoid Installation
60-Amp Fusible Link
Testing the 60-Amp Fusible Link
60-Amp Fusible Link Removal
60-Amp Fusible Link Installation
Warning Lights
Testing the Warning Lights
Warning Light Removal
Warning Light Installation
Fuel Gauge/Hour Meter
Testing the Fuel Gauge/Hour Meter
Fuel Gauge/Hour Meter Removal
Fuel Gauge/Hour Meter Installation
Key Switch
Testing the Key Switch
Key Switch Removal
Key Switch Installation
12-Volt Accessory Receptacle
Testing the 12-Volt Accessory Receptacle
12-Volt Accessory Receptacle Removal
12-Volt Accessory Receptacle Installation
Bed Lift Switch
Testing the Bed Lift Switch
Bed Lift Switch Removal
Bed Lift Switch Installation
Bed Lift Circuit Breaker
Testing the Bed Lift Circuit Breaker
Bed Lift Circuit Breaker Removal
Bed Lift Circuit Breaker Installation
Light Switch
Testing the Light Switch
Light Switch Removal
Light Switch Installation
Fuse
Testing the Fuse
Fuse Removal
Fuse Installation
Reverse Warning Buzzer (If Equipped)
Testing the Reverse Warning Buzzer
Reverse Warning Buzzer Removal
Reverse Warning Buzzer Installation
Reverse Warning Buzzer Limit Switch (If Equipped)
Testing the Reverse Warning Buzzer Limit Switch
Reverse Warning Buzzer Limit Switch Removal
Reverse Warning Buzzer Limit Switch Installation
Front Differential Limit Switch
Testing the Front Differential Limit Switch
Front Differential Limit Switch Removal
Front Differential Limit Switch Installation
Fuel Level Sending Unit
Testing the Fuel Level Sending Unit
Fuel Level Sending Unit Removal
Fuel Level Sending Unit Installation
Alternator
Testing the Alternator
Alternator and V-belt Removal
Alternator and V-belt Installation
Oil Pressure Sensor
Headlights
Testing the Headlight Bulb and Socket
Headlight Bulb Removal
Headlight Bulb Installation
Thermostat Switch
Testing the Thermostat Switch
Thermostat Switch Removal
Thermostat Switch Installation
Fan
Testing the Fan Motor
Fan Removal
Fan Installation
Wire Harness Diodes
Testing the Wire Harness Diodes
Wire Harness Diode Removal
Wire Harness Diode Installation
Battery
General Information
Testing the Battery
Preventive Maintenance
Self-Discharge
Water Level
Vibration Damage
Mineral Content
Battery Removal
Charging the Battery
Battery Installation
Battery Storage
Charging a Dead Battery

SECTION 15 – GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES
Gasoline Engine
Engine Removal
Engine Installation
Oil Filter Hoses
Exhaust System
Muffler Removal
Intermediate Pipe Removal
Intermediate Pipe Installation
Muffler Installation
Fuel System
Fuel Lines
Fuel Filter
Fuel Pump
Carburetor
Fuel Level Sending Unit
Fuel Tank
Carbon Canister
Fuel Shut-Off Valve
Engine Control Linkages
General Information
Ground Speed
Accelerator Cable
Choke Cable
Engine Governor Arm
Engine RPM Adjustment
Air Intake System
Air Filter Replacement
Air Canister Removal
Air Canister Installation
Air Filter Intake Hose Removal
Air Filter Intake Hose Installation
Air Filter Outlet Hose Removal
Air Filter Outlet Hose Installation
Clutches
Clutch Troubleshooting
Drive Belt
Drive Clutch
Driven Clutch
Clutch Cover

SECTION 16 – DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES
Diesel Engine
Engine Removal
Engine Installation
Exhaust System
Muffler Removal
Intermediate Pipe Removal
Manifold Pipe Removal
Manifold Pipe Installation
Intermediate Pipe Installation
Muffler Installation
Fuel System
Fuel Lines
Bleeding Air From Fuel System
Fuel Filter Replacement
Fuel Pump
Fuel Level Sending Unit
Fuel Tank
Engine Control Linkages
General Information
Ground Speed
Accelerator Cable
Engine RPM Adjustment
Air Intake System
Air Filter Replacement
Air Canister Removal
Air Canister Installation
Air Filter Intake Hose Removal
Air Filter Intake Hose Installation
Air Filter Outlet Hose Removal
Air Filter Outlet Hose Installation
Clutches
Clutch Troubleshooting
Drive Belt
Drive Clutch
Driven Clutch
Clutch Cover

SECTION 17 – DRIVETRAIN COMPONENTS
Half Shafts
Half Shaft Removal
Half Shaft Installation
Front Differential
Front Differential Removal
Front Differential Installation
Front Driveshaft
Front Driveshaft Removal
Front Driveshaft Installation
Rear Receiver Hitch
Rear Receiver Hitch Removal
Rear Receiver Hitch Installation
Rear Axle – 2008-2011 Models
Rear Axle Removal
Rear Axle Installation
Rear Axle – 2012 Model Year
Rear Axle Removal
Rear Axle Installation
Rear Driveshaft
Rear Driveshaft Removal
Rear Driveshaft Installation
Transmission
Transmission Removal
Transmission Installation
Forward/Reverse Shifter Cable – 2008 to mid-2012 Model year
Forward/Reverse Shifter Handle – 2008 to mid-2012 Model year
Forward/Reverse Shifter Cable – From mid-2012 Model year
Forward/Reverse Shifter Handle – From mid-2012 Model year
Rear Axle Tubes, Axle Shafts and Wheel Bearings
Rear Axle Tube and Axle Shaft Removal
Rear Axle Tube and Axle Shaft Installation
Rear Wheel Bearing Removal
Rear Wheel Bearing Installation

SECTION 18 – RADIATOR AND COOLANT SYSTEM (DIESEL)
General Information
Engine Coolant Level Check
Engine Coolant Change
Coolant Reservoir
Coolant Reservoir Removal
Coolant Reservoir Installation
Radiator
Radiator Removal
Radiator Installation
Coolant Pipe Weldment
Coolant Pipe Weldment Removal
Coolant Pipe Weldment Installation
Fan
Fan Removal
Fan Installation

SECTION 19 – HYDRAULIC ATTACHMENT SYSTEM
Model Identification
Relieving Hydraulic System Pressure
To Relieve Hydraulic Fluid Pressure
Attachment Interface
Inspection
Removing and Installing the Attachment Arm Mechanism
Electrical
Joystick
Joystick ON/OFF Switch
Attachment Arm Float Switch
Auxiliary Hydraulic Switch
Relays
Solenoid
Circuit Breaker
Control Valves
Hoses
Hose Routing
Hose Removal
Hose Installation
Quick Connect Fittings (Auxiliary Hydraulic Circuit only)
Quick Connect Removal
Quick Connect Installation
Cylinders
Vehicle Mounted Cylinders
Auxiliary Cylinder (Optional)
Cylinder Disassembly
Cylinder Assembly
Cylinder Bushings (If Equipped)
Angle Frame Bushings
Snow Blade Angle Frame
Whisk Broom Angle Frame
Front Mount
Front Mount Removal
Front Mount installation
Hydraulic Pump Assembly
Fluid Level Inspection
Fluid Change
Pump Assembly
Reservoir
Motor
Pump
Priming the Pump

SECTION i – INDEX