Club Car Carryall 295 2007 Owner'S Manual Download

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Owner’s Manual

2007

All-wheel Drive Vehicles

Gasoline and Diesel

Carryall 295

Carryall 295 SE

XRT 1550

XRT 1550 SE

Summary of Contents for Carryall 295 2007

Page 1: ...Owner s Manual 2007 All wheel Drive Vehicles Gasoline and Diesel Carryall 295 Carryall 295 SE XRT 1550 XRT 1550 SE ...

Page 2: ......

Page 3: ...rom the use of the material in this manual This manual contains proprietary information that is protected by copyright All rights are reserved No part of this manual may be photocopied reproduced or translated to another language without the written consent of Club Car Inc The information contained in this document is subject to change without notice Club Car reserves the right to make design chan...

Page 4: ...hers we recommend that you ask them to read this manual before they operate the vehicle Club Car products are backed by a customer support system designed to offer you fast courteous service In the event that your Club Car vehicle needs repairs or service we recommend that your local authorized Club Car representative perform them For the name and address of the Club Car representative nearest you...

Page 5: ... Inspection 20 Driving Instructions 21 Bed Latch and Prop Rod 24 Loading and Unloading Cargo 25 Vehicle Load Capacities 25 Towing with the Vehicle 27 Transporting on a Trailer 27 Storage 28 Maintenance 30 Periodic Service Schedule 31 Periodic Lubrication Schedule 34 Brake Fluid Reservoir 36 Engine Oil 36 Gearcase Lubrication 43 Engine Coolant Diesel Vehicles 44 Air Intake System 45 Fueling Instruc...

Page 6: ...DECAL ON ENGINE VALVE COVER ROTATING PARTS AND HOT MANIFOLD DECAL ON DRIVER SIDE VEHICLE FRAME FRAME GROUND WARNING DECAL ON VEHICLE FRAME NEAR BATTERY OPERATING INSTRUCTIONS ON INSTRUMENT PANEL HOT SURFACE WARNING DECAL ON COOLANT PIPES AND UNDERSIDE OF BOTH SEATS WINCH CABLE WARNING DECAL ON FRONT BODY FOR VEHICLES WITH WINCH ACCESSORY GASOLINE WARNING DECAL GASOLINE VEHICLES ONLY ON PASSENGER S...

Page 7: ...t jump from vehicle Keep away from drop offs steep slopes and unstable surfaces CCI 102961201 WARNING UNDERAGE WARNING DECAL CERTIFICATION NOTICE AND WARNING DECAL DRIVER PASSENGER WARNING DECAL ROTATING PARTS DECAL GAS UNDER SEAT ON DRIVER SIDE FRAME TRAILER HITCH DECAL ON REAR RECEIVER HITCH BED LATCH WARNING DECAL SERIAL NUMBER DECAL CRUSH AREA DECAL ON DRIVER SIDE AND PASSENGER SIDE VEHICLE LO...

Page 8: ...ACE WARNING DECAL ON COOLANT PIPES AND UNDERSIDE OF BOTH SEATS WINCH CABLE WARNING DECAL FOR VEHICLES WITH WINCH ACCESSORY ON FRONT BODY FRAME GROUND WARNING DECAL ON VEHICLE FRAME ROTATING PARTS AND HOT MANIFOLD WARNING DECAL ON DRIVER SIDE VEHICLE FRAME ROTATING PARTS DECAL DIESEL UNDER SEAT ON DRIVER SIDE FRAME ROTATING PARTS DECAL GAS UNDER SEAT ON DRIVER SIDE FRAME GASOLINE WARNING DECAL GASO...

Page 9: ...ttempt repair Use seat belts during operation Do not jump from vehicle Keep away from drop offs steep slopes and unstable surfaces CCI 102961201 WARNING UNDERAGE WARNING DECAL CERTIFICATION NOTICE AND WARNING DECAL DRIVER PASSENGER WARNING DECAL ON INSTRUMENT PANEL SERIAL NUMBER DECAL FALLING OFF WARNING DECAL CRUSH AREA DECAL ON DRIVER SIDE AND PASSENGER SIDE BED LOAD WARNING VEHICLE LOADING DECA...

Page 10: ...Page 8 2007 Carryall 295 295 SE and XRT 1550 1550 SE Gasoline Diesel Vehicle Owner s Manual ...

Page 11: ...sential and must be followed If any of the operation or warning decals on the vehicle become damaged have been removed or cannot be easily read they should be replaced immediately to avoid possible property damage personal injury or death Contact your Club Car dealer ý DANGER A DANGER indicates an immediate hazard that will result in severe personal injury or death ý WARNING A WARNING indicates an...

Page 12: ...ertaining to child safety The driver and passenger must be restrained at all times with the safety belts provided to help prevent injury in the event of sudden braking collision or roll over No more than one person per bucket seat at one time No more than two persons per bench seat at one time Do not allow people to ride in any part of the vehicle that is not equipped with a seat and a safety belt...

Page 13: ...ts to contact frame when disconnecting battery cables or other electrical wiring Do not allow a positive wire to touch the vehicle frame engine or any other metal component Wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when s...

Page 14: ...ing inquiries CONTROLS AND INDICATORS See General Warnings on page 10 ý WARNING Before allowing anyone to drive the vehicle make sure the driver is familiar with all controls and operating procedures Do not tamper with the high idle speed setting on the diesel vehicle Doing so will void the warranty as well as damage the engine and other components and could result in property damage personal inju...

Page 15: ...e Owner s Manual Page 13 Figure 4 Instrument Panel Gasoline Vehicles Figure 5 Instrument Panel Diesel Vehicles OPERATING INSTRUCTIONS ON OFF START 0 1 2 1 1 10 9 6 11 1 3 2 B A C 7 8 13 4 5 12 15 14 OPERATING INSTRUCTIONS ON OFF START PREHEAT 0 1 2 1 1 10 9 6 11 1 3 2 B A C 7 10 8 13 4 5 12 15 ...

Page 16: ...d the key in the PREHEAT position longer than 20 seconds To preheat the glow plugs in cold weather turn the key to the PREHEAT position and hold it there for 10 15 seconds Then turn the key to the START position and hold it there until the engine starts If the engine does not start after 10 15 seconds turn the key to the OFF position and repeat the procedure Once the engine starts release the key ...

Page 17: ...rolling STEERING ADJUSTMENT LOCK The steering wheel position is adjustable To adjust the steering wheel position press down on the steering adjustment lock lever 5 then move the steering wheel to the desired position Figure 4 and Figure 5 Page 13 While holding the steering wheel in the desired position pull up on the steering adjustment lock lever to firmly lock the steering column in position See...

Page 18: ...EADLIGHT CONTROL The headlight control 12 is located on the left side of the instrument panel Figure 4 and Figure 5 Page 13 Press the headlight rocker switch to turn the headlights on or off See following NOTE NOTE Using the headlights for extended periods while the engine is either off or idling will discharge the battery ELECTRIC BED LIFT Vehicles with Electric Bed Lift Option The electric bed l...

Page 19: ...den stop It also may lock if the occupant leans forward too quickly A slow easy motion will allow the belt to extend and the occupant can move freely If the safety belt cannot be pulled out of the retractor firmly pull the belt and release it It should then pull smoothly out of the retractor To release the safety belt press the buckle release button 1 and allow the belt to retract Figure 7 If the ...

Page 20: ... a passenger to hold a child in his or her lap while the vehicle is moving The Club Car vehicle is not designed to meet child seat compatibility requirements Children requiring a child safety seat must not ride on the vehicle Comply with state and local laws pertaining to child safety ý CAUTION Be careful not to damage the safety belt webbing or hardware Inspect the safety belt system periodically...

Page 21: ...le has been thoroughly inspected and adjusted at the factory however upon receiving your new vehicle s you should become familiar with the controls indicators and operation Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery Use the following list as a guide to inspect the vehicle This list should be used daily and in conjunction with the Perfo...

Page 22: ...open surface accelerate the vehicle to moderate speed then apply the brakes under modest steady pres sure Repeat this procedure five times See following NOTE NOTE Perform the wear in procedure when the vehicle has been in operation for less than a week or when the brake pads or rotor have been replaced PERFORMANCE INSPECTION After you have familiarized yourself with the vehicle controls and have r...

Page 23: ... in reverse Governor Check maximum vehicle speed The vehicle should operate in forward at a maximum speed of 25 mph 40 km h on a level surface General Listen for any unusual noises such as squeaks or rattles Check the vehicle s ride and perfor mance Have a Club Car dealer or a trained technician investigate anything unusual DRIVING INSTRUCTIONS ý WARNING Only licensed drivers should be allowed to ...

Page 24: ...t be licensed for use on public roads The vehicle should be driven in only specified areas by trained drivers Do not drive while under the influence of alcohol drugs or medications Use brakes to reduce speed when coasting downhill Never attempt jumps Keep away from drop offs steep slopes and unstable surfaces Avoid extremely hard braking in reverse No one should drive the vehicle without first bei...

Page 25: ...r pedal partially when descending a hill With the accelerator pedal partially pressed the governor will cause the engine to assist the brakes in controlling downhill speed ALL WHEEL DRIVE AWD OPERATION All Carryall 295 295 SE and XRT 1550 1550 SE vehicles feature an all wheel drive AWD system The AWD system automatically directs power to the wheel or wheels that have the most traction providing op...

Page 26: ...gure 8 has an automatically engaging prop rod and prop rod track Figure 9 as standard features To lift the bed pull the bed latch handle toward the rear of the vehicle and lift the bed The prop rod will come to rest in one of the notches in the prop rod track To close the bed lift the bed so that the prop rod is no longer supported in one of the track notches Push the prop rod toward the front of ...

Page 27: ...uld never exceed 15 inches 38 cm above the bottom of the cargo bed The cargo s center of gravity may affect handling steering and braking of the vehicle When the vehicle is loaded reduce speed and drive slowly in turns Unload cargo bed before raising vehicle with a lift hoist or jack Avoid stopping on a hill when loaded If you must stop on a hill avoid sudden starts or rolling backwards and stoppi...

Page 28: ...st not be exceeded to maintain safe vehicle operation Maximum payload capacity must be reduced accordingly when any option or accessory is installed on the vehicle See following NOTE NOTE A standard vehicle with a cab accessory that weighs 235 lb 107 kg must reduce its maximum payload capacity by 235 lb 107 kg Refer to Figure 10 and Figure 11 for the following specifications CARRYALL 295 XRT 1550 ...

Page 29: ...urn fuel shut off valve to the closed OFF position Figure 12 Page 28 Do not allow riders in the trailer being towed Avoid sudden starts sudden stops and tight turns when towing Avoid stopping on a hill when towing If you must stop on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning could cause the vehicle to overturn possibly resulting in severe pe...

Page 30: ...he vehicle ý WARNING Turn the key switch to the OFF position remove the key and leave the Forward Reverse handle in the NEUTRAL position during storage This is to prevent unintentionally starting the vehicle or a fire hazard Gasoline vehicles only Turn fuel shut off valve to the closed OFF position Figure 12 Do not attempt to charge frozen batteries or batteries with bulged cases Discard the batte...

Page 31: ... fuel to replace untreated fuel in the carburetor 4 3 Disconnect the fuel vent line from the fuel tank vent nipple Figure 37 Page 46 4 4 Plug the fuel tank vent nipple so that it is air tight Club Car recommends using a slip on vinyl cap 5 Remove both spark plugs and pour 1 2 ounce 14 2 mL of SAE 10 weight oil through each of the two spark plug holes Rotate the engine crankshaft by hand several ti...

Page 32: ... CCI P N 1014305 4 Gasoline vehicles only Completely open the fuel shut off valve Figure 13 Page 29 Ensure the valve is fully open A partially closed fuel shut off valve combined with the use of the choke can result in a fouled spark plug and engine failure Figure 14 Page 29 5 Place the Forward Reverse handle in the NEUTRAL position Crank the engine until fuel is pumped into the carburetor gasolin...

Page 33: ...ands clear of all crush areas Do not drop cargo bed lower gently and keep entire body clear Failure to heed this warning could result in severe personal injury or death Do not work on vehicle powertrain or under cargo bed when it is loaded Gasoline vehicles only Turn fuel shut off valve to the closed OFF position Figure 13 Page 28 To avoid unintentionally starting the vehicle Disconnect battery ca...

Page 34: ...ater from fuel filter See Draining Water from Fuel Filter on page 47 Brakes Check brake fluid add if necessary Check brake pedal for proper operation See Performance Inspection on page 20 Monthly service by owner or trained technician Engine Check engine circulating air passage visually inspect unshrouded area around engine exhaust for grass and debris and clean if necessary Diesel vehicles Check ...

Page 35: ...r brake wear in procedure see Hydraulic Brakes in the Pre Operation and Daily Safety Checklist on page 19 See also Section 6 Brake System in the appropriate maintenance and service manual Annual service by trained technician only or every 100 hours of operation whichever comes first Engine Check for leaks around gaskets fill plugs etc Kawasaki gasoline engines Adjust valve clearance See Kawasaki F...

Page 36: ...L with filter See Oil Viscosity on page 42 Monthly by owner or trained technician Driveshaft Chassis Lube EP NLGI Grade 2 Semiannually by owner or trained technician or every 50 hours of operation whichever comes first Check add brake fluid Use only DOT 5 silicone brake fluid Rear suspension 2 fittings Chassis Lube EP NLGI Grade 2 First change 50 hours additional change every 100 hours of operatio...

Page 37: ...edule 2007 Carryall 295 295 SE and XRT 1550 1550 SE Gasoline Diesel Vehicle Owner s Manual Page 35 Figure 15 Lubrication Points Gasoline Vehicles Figure 16 Lubrication Points Diesel Vehicles 6 7 4 1 3 5 2 2 4 6 7 4 1 3 5 2 2 4 ...

Page 38: ...due in the bottom of the reservoir or other evidence of contamination ý CAUTION Use only DOT 5 silicone brake fluid Use of any other type brake fluid is not recommended ENGINE OIL Even though the low oil warning light on the instrument panel should illuminate if the oil level becomes low the engine oil level should be checked daily The vehicle should be on a level surface when the oil is checked D...

Page 39: ...awasaki engine manual is 35 45 psi at idle however the remote filter design causes oil pressure to be 18 psi which is normal for this type of oil circula tion design ENGINE OIL LEVEL CHECK 1 Remove the oil level dipstick from the oil filler tube and wipe oil from the dipstick See Figure 19 Figure 20 Figure 21 and Figure 22 on page 38 See following CAUTION ý CAUTION Do not remove dipstick while eng...

Page 40: ... hours of operation After that the oil should be changed every 100 hours of operation or annually whichever comes first Figure 19 Engine Oil Level Check Honda Gasoline Vehicles Figure 20 Engine Oil Level Check Kawasaki Gasoline Vehicles Figure 21 Engine Oil Level Check Diesel Vehicles With Driver side Dipstick Figure 22 Engine Oil Level Check Diesel Vehicles With Passenger side Dipstick Full Low L...

Page 41: ... change engine oil when the engine is hot or even warm Hot engine oil can cause skin burns Wear safety glasses or approved eye protection when servicing the vehicle Wear rubber gloves when handling oil drain plug oil filter and oil drain pan 6 Clean the oil drain plug threads with solvent to remove oil and oil residue Make sure that the compres sion washer or sealing o ring remains on the drain pl...

Page 42: ...prevent excess oil from dripping onto the engine base plate Figure 27 Use an empty quart one liter container and cut the bot tom off at an angle then slide the open area of the container up and under the oil filter 2 before removal Position the port of the plastic container so oil will be directed into the oil pan 3 A drip guard can be made by folding a piece of cardboard thin metal or plastic und...

Page 43: ...il to the rubber seal around the outside surface of the filter before attaching it to the oil filter port Figure 28 Page 41 Install the new oil filter gas CCI P N 1016467 diesel CCI PN 102703301 onto the engine oil filter port See following NOTE NOTE Use only Club Car oil filters designed for your engine 6 Tighten the oil filter by hand 2 3 turn after gasket contact Do not use a band wrench or cha...

Page 44: ...everse handle in the NEUTRAL position start and run the engine for a few minutes Observe both the drain plug and the oil filter from under the vehicle and watch for oil leaks If a leak is detected check the tightness of the oil filter and drain plug Tighten repair and or replace components as necessary See following NOTE NOTE Wait five minutes after turning off the engine before removing the dipst...

Page 45: ... preceding NOTE Metal particles may be discovered in the fluid or on the magnetic drain plug when changing the differential or transmission fluid These particles are normal and expected for the first few fluid changes This is a result of the gears being net forged meaning the gears are forged to a shape very close to the final gear size but the teeth are not finish machined prior to assembly The f...

Page 46: ... and washer before filling the rear differential with new lubricant Figure 35 Tighten the drain plug to 8 ft lb 10 8 N m Use a funnel to fill the differential through the lubricant level indicator hole 1 See Periodic Lubrication Schedule on page 34 Apply Loctite 567 to the threads of the level indicator plug and tighten to 21 ft lb 28 N m ENGINE COOLANT DIESEL VEHICLES ENGINE COOLANT LEVEL CHECK T...

Page 47: ...nments In the event of a loss of power sluggish acceleration or a roughly running engine service the air filter immediately Air Filter Removal 1 Raise the cargo bed and locate the air filter canister 2 Release both canister tab locks Figure 36 3 Pull the canister cap away from the canister 4 Remove the air filter cartridge 1 See following NOTE NOTE The air filter cartridge is specifically designed...

Page 48: ...d fuels and fuels that are blended with alcohol Diesel vehicles Use only diesel fuel grade no 2 with a cetane rating of 45 or higher 2 Replace the fuel cap Ensure that the cap is tightened securely 3 Clean any spilled fuel from the cap or around the fuel cap area Biodiesel Fuel Diesel Vehicles Only Biodiesel has unique qualities that should be considered before it is used in the Kubota D722 diesel...

Page 49: ...l tank Drain all water from the fuel filter daily before operating vehicle See Draining Water from Fuel Filter Check the engine oil level daily before the engine is started See Engine Oil Level Check on page 4 37 Before vehicle storage run the engine with conventional diesel fuel for at least 30 minutes to flush the biodiesel from the engine See Preparing the Vehicle for Extended Storage Section 4...

Page 50: ...ies Battery Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes External Flush with water Call a physician immediately Internal Drink large quantities of milk or water followed with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately Tools wires and metal objects can cause sparks wh...

Page 51: ...l the battery cells above the designated fill line Replace battery cell caps 6 Clean both battery terminals with a solution of baking soda and water 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse thoroughly Do not allow this solution to enter the battery Tighten battery terminals to 144 in lb 16 N m Let the terminals dry and then spray them with Battery Terminal Protector Spray CCI P N...

Page 52: ...is recommended but a deep cycle battery can be used if necessary 3 Access the engine compartment by raising the cargo bed See WARNING For vehicles with cargo beds on page 10 4 Locate the vehicle battery on the driver s side of the vehicle under the cargo bed Figure 42 5 Connect the end of the first cable 1 to the positive terminal of the booster battery Connect the other end of the same cable 2 to...

Page 53: ...service manual See following NOTE NOTE Dispose of waste water properly ACCESSORIES There is a complete line of accessory equipment available from Club Car and our dealers distributors You can obtain the name and phone number of your closest Club Car contact by visiting our web site at www clubcar com and clicking the Dealer Locator link Care should be taken that these accessories are properly inst...

Page 54: ...following WARNING and CAUTION ý WARNING To avoid the risk of rollover when operating a vehicle equipped with mud tires on a paved surface reduce speed use extreme caution and drive slowly in turns The diameter of all tires on the vehicle must be equal otherwise the all wheel drive system will not operate as intended and could result in severe personal injury or death Never install tires of differe...

Page 55: ...e fuel pump Fuel system Mechanical injection fuel water separator fuel filters and elec tric fuel pump Governor Honda engine Automatic ground speed sensing internally geared in transmission Governor Kawasaki engine internal to engine centrifugal ball Governor internal to engine mechanical centrifugal ball Ignition Transistorized magneto Ignition Compression Transmission Forward and reverse with ne...

Page 56: ...ith all terrain tires 1450 lb 657 6 kg 1597 lb 724 2 kg 1630 lb 739 2 kg 1734 lb 786 4 kg Forward speed 25 mph 40 km h Governed RPM 3825 Turning Radius 138 in 350 5 cm 204 in 518 2 cm Load bed height 34 in 86 4 cm Load bed size box bed inside dimensions 48 0 x 49 8 x 10 9 in 122 x 127 x 28 cm 15 3 cubic feet Maximum payload capacity level surface only 800 lb 363 kg High capacity option 1050 lb 476...

Page 57: ...cant 20 oz 600 mL Engine coolant mixture of 55 propylene glycol and 45 water n a 2 gal 7 8 L n a 2 25 gal 8 5 L Brake fluid DOT 5 silicone brake fluid 8 oz 240 ml 17 9 oz 530 ml Fuel tank unleaded gasoline 6 5 gallons 24 6 L 6 5 gallons 24 6 L Fuel tank diesel grade no 2 with cetane rating of 45 or higher 6 5 gallons 24 6 L 6 5 gallons 24 6 L TIRE PRESSURE All terrain tread and mud tires 20 22 psi...

Page 58: ... items which deteriorate or fail due to exposure or ordinary wear and tear Batteries battery charger onboard computer and solid state speed controller are covered under separate CLUB CAR warranties Also excluded from any CLUB CAR warranty is damage to a vehicle or component resulting from a cause other than a defect including unreasonable or unintended strain or use improper installation of access...

Page 59: ...T WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY 7 NO CONSEQUENTIAL DAMAGES IN NO EVENT SHALL CLUB CAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS RELATED TO PROPERTY OTHER THAN THE VEHICLE LOSS OF USE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Some states allow neither limitation on the duration of an implied warranty nor exclusions or li...

Page 60: ...e For use at low alti tudes have your servicing dealer return the carburetor to original factory specifications Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound These gasolines are col lectively referred to as oxygenated fuels To meet clean air standards some areas of the United States and Canada use oxygenated fuels to help reduce emissions If you u...

Page 61: ...ause the engine to oper ate outside its design parameters Problems That May Affect Emissions If you are aware of any of the following symptoms have your engine inspected and repaired by your servicing dealer Hard starting or stalling after starting Rough idle Misfiring or backfiring under load After burning backfiring Black exhaust smoke or high fuel consumption Replacement Parts The emission cont...

Page 62: ...provisions herein warranty services or repairs will be provided at all of our distribution centers that are franchised to service the subject engines or equipment 6 The engine or equipment owner will not be charged for diagnostic labor that is directly associated with diagnosis of a defective emission related warranted part provided that such diagnostic work is performed at a warranty station 7 CL...

Page 63: ... Information 3 Clarity of Illustrations 4 Periodic Service and Periodic Lubrication Schedules Poor Fair Average Good Excellent Comments Suggestions In order to help us better serve you please rate this publication in the following catgories Your Comments Are Appreciated Please select your category Distributor Dealer Individual Owner Club Car Associate Representative Technician Golf Course Superint...

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Page 68: ...b Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Intl l 1 706 863 3000 Fax 1 706 863 5808 Publication Part Number 103218301 Edition Code 0606E0307D ...

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