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Club Car Carryall 1500 2016, Maintenance And Service Manual

Get the most out of your Club Car Carryall 1500 2016 with the Maintenance And Service Manual. This essential manual covers all maintenance and service procedures to keep your vehicle running smoothly. Download it for free from manualshive.com and ensure your Club Car is always in top condition.

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Model Identification

GENERAL INFORMATION

830

Figure 3-5

Gasoline Engine Serial Number Location

831

Figure 3-6

Diesel Engine Serial Number Location

2703

Figure 3-7

Differential Serial Number Location

Page 3-4

2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual

Summary of Contents for Carryall 1500 2016

Page 1: ...2016 Carryall 1500 1700 and XRT 1550 Maintenance and Service Manual Carryall 1500 1700 XRT 1550 1550 SE Gasoline Diesel and IntelliTach Vehicles Manual Number 105334710 Edition Code B...

Page 2: ......

Page 3: ...ers Regional technical representatives vehicle service seminars periodic service bulletins maintenance and service manuals and other service publications also represent Club Car s continuing commitmen...

Page 4: ...e EP NLGI Grade 2 commercially available Fuel Filter 675 cc gas CC PN 102003201 Dry Moly Lube CC PN 1012151 Engine Oil Filter 719 cc diesel CC PN 102703301 Spark Plug 675 cc gas CC PN AM1232301 Engine...

Page 5: ...ge 3 6 Returning the Stored Vehicle to Service 3 7 Lifting The Vehicle 3 7 Lifting Only The Front 3 7 Lifting Only The Rear 3 8 Lifting The Entire Vehicle 3 9 Using A Booster Battery Jump Starting 3 9...

Page 6: ...mbly Installation 5 4 SECTION 6 Hydraulic Brake and Park Brake Systems 6 1 General Information 6 1 Brake System Inspection 6 1 Brake Pedal Inspection 6 1 Master Cylinder Inspection 6 2 Brake Hose Insp...

Page 7: ...Front Suspension Components 7 18 Steering Upright Removal 7 18 Steering Upright Installation 7 20 Upper A Arm Removal 7 20 Upper A Arm Installation 7 22 Lower A Arm Removal 7 22 Lower A Arm Installati...

Page 8: ...nly 10 20 Draining Water from Fuel Filter 10 21 Battery 10 22 SECTION 11 Troubleshooting and Electrical System Gasoline Vehicles 11 1 Troubleshooting Guide 11 1 Wiring Diagram 11 6 Test Procedures 11...

Page 9: ...g Buzzer Removal 13 12 Reverse Warning Buzzer Installation 13 13 Reverse Warning Buzzer Limit Switch If Equipped 13 13 Testing the Reverse Warning Buzzer Limit Switch 13 13 Reverse Warning Buzzer Limi...

Page 10: ...e Hour Meter Removal 14 7 Fuel Gauge Hour Meter Installation 14 7 Key Switch 14 7 Testing the Key Switch 14 7 Key Switch Removal 14 7 Key Switch Installation 14 7 12 Volt Accessory Receptacle 14 8 Tes...

Page 11: ...14 18 Thermostat Switch Installation 14 19 Fan 14 19 Testing the Fan Motor 14 19 Fan Removal 14 19 Fan Installation 14 20 Wire Harness Diodes 14 20 Testing the Wire Harness Diodes 14 20 Wire Harness D...

Page 12: ...stallation 16 6 Intermediate Pipe Installation 16 6 Muffler Installation 16 6 Fuel System 16 8 Fuel Lines 16 9 Bleeding Air From Fuel System 16 9 Fuel Filter Replacement 16 9 Fuel Pump 16 11 Fuel Leve...

Page 13: ...iator 18 4 Radiator Removal 18 4 Radiator Installation 18 5 Coolant Pipe Weldment 18 6 Coolant Pipe Weldment Removal 18 6 Coolant Pipe Weldment Installation 18 6 Fan 18 7 Fan Removal 18 7 Fan Installa...

Page 14: ...Broom Angle Frame 19 40 Front Mount 19 41 Front Mount Removal 19 41 Front Mount installation 19 42 Hydraulic Pump Assembly 19 42 Fluid Level Inspection 19 43 Fluid Change 19 43 Pump Assembly 19 43 Res...

Page 15: ...ndicates an immediate hazard that will result in severe personal injury or death The color associated with Danger is RED WARNING A WARNING indicates an immediate hazard that could result in severe per...

Page 16: ...moving the air or loosening the tire on the rim breaking the bead will NOT eliminate the hazard This condition can exist whether tires are inflated or deflated The tire MUST be completely removed from...

Page 17: ...nnecting the Battery Gasoline Diesel Vehicles on page 1 3 See Top Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 4 Frame ground Do not allow tools or other metal objects to...

Page 18: ...plug s TOP POST BATTERY DISCONNECTING THE BATTERY GASOLINE DIESEL VEHICLES 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 Remove positive terminal cover 3 Disconnect the battery cables...

Page 19: ...oth water and soil causing environmental damage and personal injury Lead acid batteries are identified by the symbol shown below and should be properly recycled Figure 1 4 They cannot be disposed as m...

Page 20: ...le battery or batteries _ 1 Shield eyes 3 No smoking no open flames no sparks 5 Battery acid hazard 2 Read and follow operating instructions 4 Keep away from children 6 Explosive gas hazard Refer to G...

Page 21: ...r Kawasaki engine internal to engine centrifugal ball Governor internal to engine mechanical centrifugal ball Ignition Transistorized magneto Ignition Compression Transmission Forward and reverse with...

Page 22: ...t brush guard 2 passenger diesel with electric bed lift mud tires and brush guard 4 passenger gasoline with all terrain tires 4 passenger diesel with all terrain tires 1450 lb 657 6 kg 1597 lb 724 2 k...

Page 23: ...erential Mobil 424 Exxon Hydraul 560 or Esso Hydraul 56 lubricant CC P N AM1245401 20 oz 600 mL Transmission Mobil 424 Exxon Hydraul 560 or Esso Hydraul 56 lubricant CC P N AM1245401 20 oz 600 mL Engi...

Page 24: ...ndependent four link suspension with coil over shock absorbers Steering Self adjusting rack and pinion Ackerman Brakes Hydraulic brake system brake pads and discs on each wheel with separate foot oper...

Page 25: ...ries 3200 lb 1451 kg Standard seating capacity 2 LIQUID CAPACITIES Engine crankcase with filter SAE 10W 30 API classification CF 3 qt 2 8 L Front differential Mobil 424 Exxon Hydraul 560 or Esso Hydra...

Page 26: ...Pagination Page 2 General Warnings VEHICLE SPECIFICATIONS Page 2 6 2016 Carryall 1500 1700 and XRT 1550 Maintenance and Service Manual...

Page 27: ...Refer to the owner s manual provided with the vehicle for information on the following topics Safety Decal Identification Controls and Indicators Driving Instructions Towing with the Vehicle Transpor...

Page 28: ...d lift only 6 Engine Compartment Battery Fuel Tank under seat for four passenger model engine compartment is under rear seat 7 Seat 8 Brake Fluid Reservoir under hood 9 Radiator and Coolant Reservoir...

Page 29: ...ild code 4 is a five digit number that appears on the vehicle serial number decal The build code exists to enable the user to identify the correct owner s manual for a vehicle This owner s manual is v...

Page 30: ...ION 830 Figure 3 5 Gasoline Engine Serial Number Location 831 Figure 3 6 Diesel Engine Serial Number Location 2703 Figure 3 7 Differential Serial Number Location Page 3 4 2016 Carryall 1500 1700 and X...

Page 31: ...hicle 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...

Page 32: ...e fuel tank 4 1 Fill the tank with fresh fuel 4 2 Following the manufacturer s directions add a commercially available fuel stabilizer such as Sta Bil Run the engine in a well ventilated area to allow...

Page 33: ...10 24 2 1 Remove the plug from the fuel tank vent 2 2 Connect the vent tube to the fuel tank vent 3 Connect battery and spark plug Gas only wires See Side Post Battery Connecting the Battery Gasoline...

Page 34: ...ls 3 Disconnect battery See Side Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 3 See Top Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 4 4 If re...

Page 35: ...wing WARNING WARNING To prevent possible injury from pulling the vehicle off the front jack stands while lifting the rear perform the following Position floor jack wheels in the direction the jack wil...

Page 36: ...gases in General Warnings on page 1 2 6 Connect the end of the second cable 3 to the negative terminal of the booster battery Connect the other end of the same cable 4 to the battery frame ground 7 Si...

Page 37: ...trical components to moisture Moisture entering electrical components can result in water damage and subsequent component failure Normal residential water pressure is adequate for exterior cleaning Fo...

Page 38: ...a wool cutting pad 3M 5711 or equivalent on buffer and spread approx 1 2 tsp 2ml of compound 3M 05955 or equivalent Buff slowly and steadily over small area so as not to heat surface as this may cause...

Page 39: ...awasaki Powered Gasoline vehicles Remove the choke cable from the engine choke lever See Choke Cable Removal on page 15 22 12 Remove instrument panel from vehicle INSTRUMENT PANEL INSTALLATION 1 Posit...

Page 40: ...n page 4 4 2 The center cowl panel is held in place by four exposed Tuflok plastic locking fasteners and four metal body trim clips that are hidden from view on the top underside of the panel Carefull...

Page 41: ...Ensure that the top rear inside corner of the side cowl panel is engaged in the fender retaining notch in the instrument panel structural support and that the ROPS cowl support if equipped passes thr...

Page 42: ...panel fender See Side Cowl Panel Fender Installation on page 4 5 6 Reinstall center cowl panel See Center Cowl Panel Installation on page 4 4 7 Replace lower and secure hood See Hood Installation on...

Page 43: ...re 4 1 Page 4 7 2 Remove the the four bolts 5 and four flanged nuts 6 that secure the two side supports 4 to the seat support 7 and the front cowl supports 8 3 2 passenger vehicles Remove the two side...

Page 44: ...g decal is visible to the driver 3 Tighten all hardware to 33 ft lb 45 N m See following WARNING and NOTE NOTE If any ROPS joints remain loose apply additional torque up to 40 ft lb 54 N m WARNING Exc...

Page 45: ...from the bottom of the seat mounting plate 1 3 Align the mounting plate holes with the holes in the seat to achieve the desired seat position 1 4 Install the washers and bolts and tighten the hardwar...

Page 46: ...clean and dry If cleaning is necessary use a solution of mild soap and lukewarm water Do not use bleach dye or abrasive cleaners as they may severely weaken the safety belts Do not insert coins clips...

Page 47: ...nings Section 1 Page 1 2 TESTING THE BED LIFT MOTOR Gasoline Vehicles See Test Procedure 35 Bed Lift Motor on page 11 39 BED LIFT MOTOR REMOVAL 1 Make sure the key switch is OFF and the Forward Revers...

Page 48: ...red and yellow to yellow 5 Connect battery See Side Post Battery Connecting the Battery Gasoline Diesel Vehicles on page 1 4 See Top Post Battery Connecting the Battery Gasoline Diesel Vehicles on pag...

Page 49: ...nches 15 2 cm and pull the bed assembly toward the rear of the vehicle approximately 3 inches 7 6 cm to release bed latch 10 from the latch plate 11 Lift the bed from the vehicle CARGO BED INSTALLATIO...

Page 50: ...from the frame 3 Remove the two Phillips head screws and washers retaining the fender to the side of rear frame 4 Remove the fender 5 Repeat steps 1 through 4 to remove the remaining rear fender if n...

Page 51: ...BODY AND TRIM Rear Fender 4 4 3 17 11 5 2 7 6 16 16 13 12 1 13 10 8 15 14 9 1884 Figure 4 4 Cargo Bed 2016 Carryall 1500 1700 and XRT 1550 Maintenance and Service Manual Page 4 15...

Page 52: ...Pagination Page 4 Rear Fender BODY AND TRIM Page 4 16 2016 Carryall 1500 1700 and XRT 1550 Maintenance and Service Manual...

Page 53: ...ttery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 4 2 Disconnect the Z shaped end of the accelerator cable from the pedal Figure 5 1 Page 5 1 1 2 4 3 5 4 6 Items 4 and 5 used only on...

Page 54: ...eck return spring length and adjust if necessary Figure 5 3 Page 5 2 3 Tighten pedal pivot bolt 1 and locknut 2 to 30 ft lb 68 N m 4 Connect battery and spark plug wire s See Side Post Battery Connect...

Page 55: ...eplace if necessary 1888 Figure 5 4 Clevis and Rue Pin BRAKE PEDAL INSTALLATION 1 Position the brake pedal between the frame brackets 2 Install the allen head shoulder bolt and locknut Tighten the har...

Page 56: ...bly 1 by removing the bow tie locking pin 2 Figure 5 5 Page 5 4 4 Loosen the park brake cable jam nuts 3 that secure the cable sheath to the pedal and remove cable 4 5 Remove the three bolts 5 and loc...

Page 57: ...ng pin 1 5 Connect battery See Side Post Battery Connecting the Battery Gasoline Diesel Vehicles on page 1 4 See Top Post Battery Connecting the Battery Gasoline Diesel Vehicles on page 1 4 6 Adjust t...

Page 58: ...Pagination Page 5 Park Brake Pedal ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Page 5 6 2016 Carryall 1500 1700 and XRT 1550 Maintenance and Service Manual...

Page 59: ...brake pedal several times If noise or binding occurs the brake pedal or hydraulic brake system may require service Pedal movement should be smooth and when the pedal is released it should return quick...

Page 60: ...Brake Hose Replacement on page 6 14 Turn the steering wheel all the way from left to right and back again Contact between the brake hoses and any other moving components especially the wheels or half...

Page 61: ...13 Grommet 2 Master Cylinder 6 Driver Side P Clamp 10 Mid Brake Hydraulic Hose 14 P Clamp 3 Front Brake Hydraulic Hose 7 Brake Pedal 11 Anchor 15 Rear Brake Hydraulic Hose 4 T Bracket 8 Passenger Side...

Page 62: ...nside of the wheel rim and the brake calipers Pressure washing or equivalent is recommended to remove such accumulation from the calipers WARNING Long term operation of a vehicle with material packed...

Page 63: ...approved DOT 5 silicone brake fluid See Purging the Hydraulic System on page 6 20 Weak bulging brake hoses that expand under pressure Check the master cylinder and brake hoses for leaks or bulges Rep...

Page 64: ...8 3 or Rear Axle Tubes Axle Shafts and Wheel Bearings on page 17 16 Decreasing brake pedal travel Sticking caliper piston Replace the caliper See Brake Pads and Caliper on page 6 7 Bent damaged or in...

Page 65: ...mponents Failure to bleed the brakes could result in decreased braking performance due to air being trapped in the hydraulic system Use only DOT 5 brake fluid See Bleeding the Hydraulic Brake System o...

Page 66: ...ubricant manufacturer s directions WARNING To reduce the possibility of diminished brake performance or failure never use petroleum based lubricants on brake system components and ensure lubricant doe...

Page 67: ...w the caliper and brake hose assembly to catch brake fluid when the brake hose and caliper body are separated 3 If the caliper will be used again plug the banjo bolt hole to prevent dirt and debris en...

Page 68: ...ction on page 6 1 REAR BRAKE PAD AND CALIPER REMOVAL WARNING Due to piston size 2 passenger and 4 passenger vehicles have different rear calipers Be careful not to interchange parts If at any point in...

Page 69: ...the brakes must be bled after the correct reinstallation of the brake components Failure to bleed the brakes could result in decreased braking performance due to air being trapped in the hydraulic sys...

Page 70: ...ee following WARNING WARNING Use the top bleeding port on each caliper to bleed that respective rear wheel Ensure hydraulic hoses cannot contact any moving parts that will cause wear and damage 5 Repe...

Page 71: ...he frame so that it does not hang suspended by the hydraulic brake hose 2 Slide the disc off the wheel studs to remove DISC INSTALLATION WARNING If at any point in this procedure the hydraulic system...

Page 72: ...ing NOTE NOTE Place a plastic bag around the master cylinder to catch brake fluid before the brake hose is removed Wrap the bag around the master cylinder to prevent debris from entering the brake hos...

Page 73: ...RNING Use the top bleeding port on each caliper to bleed that respective front wheel 8 Close hood MID BRAKE HOSE REMOVAL 1 Chock the front wheels and set the park brake 2 Open hood 3 Use a flare nut w...

Page 74: ...id Place a plastic bag around each caliper to prevent debris from entering the brake hose ports Do not allow brake fluid to contact the brake pads and disc 3 Remove the banjo bolt and copper washers f...

Page 75: ...in from the brake pedal and push rod clevis Figure 6 7 Page 6 18 5 Remove the two bolts and locknuts that secure the master cylinder to the frame 6 Remove the master cylinder from the vehicle MASTER C...

Page 76: ...to the front portion of the master cylinder and the rear wheels to the rear portion One or both sub systems may require bleeding depending on where the hydraulic system was opened Pressure or vacuum b...

Page 77: ...ction of gently moving fluid through the system to displace the air and contaminants that have accumulated It is important to have the vehicle sitting level and safely supported on jack stands before...

Page 78: ...mal pedal pressure should be used 6 8 Repeat this process at each brake caliper starting at the next caliper farthest from the master cylinder 7 After bleeding fill the master cylinder reservoir to th...

Page 79: ...ction 1 Page 1 2 NOTE The park brake pads are not replaceable Once pads are worn the park brake caliper and pad assembly must be replaced as a unit 3 4 2 1 7 6 8 10 13 12 11 5 9 2742a Figure 6 8 Park...

Page 80: ...wheels and release the park brake 2 Remove the seat bottom 3 Unload and raise the cargo bed 4 Remove bow tie clip 9 and clevis pin 10 securing park brake cable 11 to caliper 7 Figure 6 8 Page 6 21 5...

Page 81: ...ed 15 Install seat bottom PARK BRAKE ADJUSTMENT 1 Chock the rear wheels and release the park brake 2 Remove the seat bottom 3 Unload and raise the cargo bed 4 Loosen jam nuts securing park brake cable...

Page 82: ...d install the park brake switch 3 Remove the screws 1 washers 2 and 3 and barrel nuts 4 Figure 6 9 4 Label the wires 5 5 Disconnect the wires 6 Remove the park brake switch 6 Park Brake Switch Install...

Page 83: ...g wheel 3 Figure 7 1 Page 7 2 5 Loosen and remove the steering wheel retaining bolt 4 6 Remove the steering wheel See following NOTE NOTE The steering wheel has a tapered hex fitting A steering wheel...

Page 84: ...ning bolt 4 and tighten to 37 ft lb 50 N m 3 Place cover 2 onto steering wheel and secure with two screws 1 Tighten screws to 15 in lb 1 7 N m 4 Connect battery See Side Post Battery Connecting the Ba...

Page 85: ...3 Remove Steering Column from Rack and Pinion 8 Remove the three locknuts 3 from the steering column mount bolts Figure 7 4 NOTE Bolts are pressed into the steering column mount bracket 3 000070 006B...

Page 86: ...B Figure 7 5 Hole in Splash Guard STEERING COLUMN INSTALLATION 1 Install the steering column assembly through the column mounting bracket frame opening and down through the hole 1 in the splash guard...

Page 87: ...ure 7 8 4 Loosen the bolt 5 on the top yoke 4 5 000070 006D Figure 7 8 Install Steering Column onto Rack and Pinion 5 Install the steering column 6 onto the column mounting bracket 7 Figure 7 9 Page 7...

Page 88: ...ccelerator pivot bolt Figure 7 10 The clearance at this point must be more than 0 060 in 10 If the clearance is less than 0 060 in 10 1 Loosen the bolts 9 and locknuts 10 on the passengers side of the...

Page 89: ...e 7 14 If obvious visible damage is found such as a bent tie rod check the steering gear for abnormal free play noise binding or clunking while it is under a load With the steering system fully assemb...

Page 90: ...int 4 Install the universal bolt on the pinion shaft and tighten to 18 ft lb 24 N m See following NOTE NOTE Be sure to tighten the bolt at the universal joint on the rack and pinion shaft before tight...

Page 91: ...al clamp remove the clamp Do not reuse the clamp when the rack and pinion is reassembled Use a plastic wire tie to secure the dust seal bellows 2050 Figure 7 15 Dust Bellows Clamp 5 Remove the two hex...

Page 92: ...inion Gear 3 Bearing 2053 Figure 7 18 Remove Pinion from Housing 2054 Figure 7 19 Remove Pinion Gear 12 Inspect the bushing 17 and needle bearing 14 for excessive wear If wear is excessive replace the...

Page 93: ...Rack and Pinion 7 14 Remove the rack 2 from the housing 1 Figure 7 22 Page 7 12 2055 Figure 7 20 Secure Racks 2056 Figure 7 21 Remove Inner Ball Joints 2016 Carryall 1500 1700 and XRT 1550 Maintenance...

Page 94: ...Pinion STEERING AND FRONT SUSPENSION 13 4 15 17 3 16 2 23 12 19 12 11 10 24 9 5 6 8 7 1 14 2057 Figure 7 22 Steering Gear Assembly Page 7 12 2016 Carryall 1500 1700 and XRT 1550 Maintenance and Servi...

Page 95: ...ly into the housing The gear teeth or the small bearing could be damaged 4 Install the snap ring 4 5 Use a socket to apply pressure evenly and press in a new dust seal Figure 7 23 Page 7 13 1 2 3 1 Ru...

Page 96: ...e bellows with new bellows clamps or wire ties 16 Apply a light coat of anti seize lubricating compound to the inner ball joint threads to minimize corrosion 17 Loosely install and advance the two nut...

Page 97: ...See following NOTE NOTE The front measurement must be greater than the rear measurement 1186 Figure 7 27 Measure Toe Out 1187 Figure 7 28 Adjust Toe Out 4 Subtract the rear face tire measurement from...

Page 98: ...Page 7 16 2 Rotate both of the drag links equally To increase the toe in rotate both drag links counterclockwise To decrease the toe in rotate both drag links clockwise Maintain an equal distance from...

Page 99: ...m zero to 0 275 inch 7 0 mm maximum See following NOTE NOTE A good average dimension for this specification is 5 32 inch 4 mm negative camber on each wheel Camber Adjustment 1 Locate the bolts that se...

Page 100: ...icle and remove the wheel See Lifting The Vehicle on page 3 7 6 Remove the axle spindle nut and washer See following NOTE NOTE A new spindle nut will be required during assembly 7 2WD only Remove stub...

Page 101: ...Page 7 19 2065 Figure 7 36 Drag Link Ball Joint 12 Remove the lower and upper ball joint locknuts 13 Remove the lower ball joint from the upright Figure 7 37 Page 7 19 See NOTE and CAUTION below 1897...

Page 102: ...age 7 19 Use a new nylon locknut and tighten locknut to 70 ft lb 95 N m 8 Install brake disc onto hub 9 Inspect the brake pads for wear and replace if necessary NOTE If brake pads are replaced on one...

Page 103: ...l joint 1 2 Push or drive out the ball joint on the threaded shaft side See following NOTE NOTE The ball joint is press fit and secured with 641 Loctite and requires approximately 250 lb 113 4 kg of f...

Page 104: ...bolts washers and new flanged locknuts in both the front and rear frame attachments Tighten the hardware to 40 ft lb 54 N m 5 Secure the brake line bracket to the A arm and tighten the hardware to 11...

Page 105: ...of the ball joint Once the Loctite is applied slide the ball joint into the lower control arm slide adjuster Make sure the ball joint is seated up to the shoulder and wipe off any excess Loctite 2 In...

Page 106: ...hicle on page 3 7 2 Place a floor jack under the lower A arm at the lower ball joint and raise the jack just enough to allow the A arm assembly to rest on the jack 3 Remove the flange head bolt Separa...

Page 107: ...ock mount on the vehicle frame with a bolt and flange head locknut Tighten the hardware to 62 ft lb 84 N m Figure 7 46 Page 7 24 See previous NOTES 2 Install the bottom of the shock mount on the upper...

Page 108: ...Pagination Page 7 Front Suspension Components STEERING AND FRONT SUSPENSION Page 7 26 2016 Carryall 1500 1700 and XRT 1550 Maintenance and Service Manual...

Page 109: ...s are mounted on the wheels with regard to which side of the vehicle they will be used on The arrow molded on the sidewall indicates designed rotation when vehicle is moving forward Figure 8 1 Page 8...

Page 110: ...muddy terrain install all four tires as shown Figure 8 1 Page 8 1 2 Lower the vehicle and use a crisscross pattern to finish tightening the lug nuts to 85 ft lb 115 N m 3 Inspect the brake hoses at th...

Page 111: ...NT HUBS See General Warnings Section 1 Page 1 2 FRONT HUB REMOVAL 1 Remove the upright assembly from the vehicle See Steering Upright Removal on page 7 18 2 Remove the hub from the bearing and upright...

Page 112: ...1 1 10 10 5 7 0 5 in 12 mm Press ram 0 281 in 7 mm Radius 2 835 in 72 cm 2 909 in Max 73 9 cm Max 2030 Figure 8 3 Bearing Removal 3 2 Shim the ball joint arms with steel blocks 2 and 3 to provide a l...

Page 113: ...utside bearing race to press the bearing into the bearing cavity until it bottoms out See following CAUTION CAUTION Press against the entire bearing surface Bearing must seat completely in cavity Ther...

Page 114: ...s only See Side Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 3 See Top Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 4 2 Loosen the lug nuts 3...

Page 115: ...5 does not slide easily from the axle shaft use a two or four jaw wheel puller to remove the hub Figure 8 8 Page 8 7 2 1 3 4 5 2560 Figure 8 7 Rear Hub Exploded View 2561 Figure 8 8 Puller Removing Re...

Page 116: ...e lug nuts 10 Lower the rear of the vehicle 11 Tighten the axle nut 3 to 80 ft lb 108 N m Position the locking cap 2 and install new cotter pin 1 12 Install rubber dust cap onto wheel 13 Tighten the l...

Page 117: ...avy duty rear shock absorbers Ensure that the correct rear shock absorbers and coil over springs are used for the vehicle s load service option when the rear shock absorbers are removed and replaced R...

Page 118: ...installed ensure both shock absorbers have identical part numbers 1 Installation is the reverse of removal 2 Tighten the upper and lower hardware using new lock nuts to 73 ft lb 99 N m 3 If detached...

Page 119: ...rnings on page 1 2 1 Disconnect battery and spark plug wire s See Side Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 3 See Top Post Battery Disconnecting the Battery Gasoli...

Page 120: ...9 Trailing Arms and Lateral Links REAR SUSPENSION 2 1 3 2495 Figure 9 2 Rear Suspension Components 4 Link Page 9 4 2016 Carryall 1500 1700 and XRT 1550 Maintenance and Service Manual...

Page 121: ...ce Schedule and the Periodic Lubrication Schedule must be followed to keep the vehicle in optimum operating condition _ PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Pre Operation and Daily Safet...

Page 122: ...wash dirt from casing check electrolyte level on side post battery only Add distilled water if necessary See Battery on page 13 18 gasoline vehicles or Battery on page 14 21 diesel vehicles Front whe...

Page 123: ...ange on page 18 1 Radiator Diesel vehicles Check clamps for tightness check hoses for cracks Replace if necessary Replace air filter element See Air Filter Replacement on page 15 27 Engine air intake...

Page 124: ...on page 10 11 Diesel vehicles Check engine coolant add if necessary See Engine Coolant Level Check on page 10 19 Engine Clean debris from radiator Fuel filters Diesel vehicles Drain water from fuel f...

Page 125: ...sel vehicles Check the v belt for proper tension or damage Adjust or replace if necessary Engine Diesel vehicles Change engine coolant See Radiator and Cooling System Section in the maintenance and se...

Page 126: ...or trained technician or every 50 hours of operation whichever comes first Rear suspension 2 fittings Chassis Lube EP NLGI Grade 2 First change 50 hours additional change every 100 hours of operation...

Page 127: ...PERIODIC MAINTENANCE Periodic Lubrication Schedule 10 200 Figure 10 2 Lubrication Points Diesel Vehicles 2016 Carryall 1500 1700 and XRT 1550 Maintenance and Service Manual Page 10 7...

Page 128: ...hours of operation whichever comes first Attachment Arm and Interface 8 fittings Chassis Lube EP NLGI Grade 2 First change 50 hours additional change every 100 hours of operation or annually whichever...

Page 129: ...year whichever occurs first or whenever the attachment arm and interface are removed and reinstalled on the vehicle Lubricate the following locations as shown Figure 10 4 1 Attachment Interface Cylin...

Page 130: ...rvoir Figure 10 6 Also brake fluid should be clean with no residue in the bottom of the reservoir or other evidence of contamination CAUTION Use only DOT 5 silicone brake fluid Use of any other type b...

Page 131: ...vel See following CAUTION CAUTION Do not exceed recommended oil capacity Doing so will decrease engine performance or result in damage to the engine 1 Full Level 2 Safe Level 3 Low Level 1 Full Level...

Page 132: ...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...

Page 133: ...ner up and under the oil filter before removal Position the port of the plastic container so oil will be directed into the oil pan A drip guard can be made by folding a piece of cardboard thin metal o...

Page 134: ...t battery and spark plug Gas only wires See Side Post Battery Connecting the Battery Gasoline Diesel Vehicles on page 1 4 See Top Post Battery Connecting the Battery Gasoline Diesel Vehicles on page 1...

Page 135: ...Oil Viscosity Chart Diesel Vehicles SPARK PLUGS SPARK PLUG CLEANING AND INSPECTION 1 Carefully pull the plug wire from the spark plug and remove the spark plug 2 If the plug is oily or has carbon bui...

Page 136: ...pair leak and refill with specified oil type and volume See Lubrication Change for Front Differential Transmission and Rear Differential on page 10 16 LUBRICATION CHANGE FOR FRONT DIFFERENTIAL TRANSMI...

Page 137: ...on with new lubricant Figure 10 19 Tighten drain plug to 96 in lb 11 N m Remove fill plug 3 and lubricant level indicator plug 1 Using a funnel fill transmission to the bottom of the level indicator h...

Page 138: ...e cargo box 2 Turn the start key to the ON position but DO NOT start the engine 3 Press the joystick ON OFF switch to ON 4 Move the joystick 1 back and raise the attachment arm fully Figure 10 21 Page...

Page 139: ...not pour fuel into the fuel tank when the engine is hot or while it is running To avoid electric arc caused by static electricity the fuel storage pumping device must be grounded If the pump is not gr...

Page 140: ...d problems such as plugged fuel filters and deteriorated fuel lines during testing of biodiesel Biodiesel can damage painted surfaces Be sure to remove all spilled fuel immediately to help prevent dam...

Page 141: ...maintenance cleaning and fuel line replacement are required more frequently for engines that are operated with biodiesel DRAINING WATER FROM FUEL FILTER Diesel Vehicles Only Water should be drained fr...

Page 142: ...igure 10 25 Fuel Filter with Water Separator BATTERY For periodic battery maintenance see Battery on page 13 18 gasoline vehicles or page 14 21 diesel vehicles Page 10 22 2016 Carryall 1500 1700 and X...

Page 143: ...e manual CC P N 103351201 Intermittent ignition coil failure See the Kawasaki FH680D engine manual CC P N 103351201 Low cylinder compression See the Kawasaki FH680D engine manual CC P N 103351201 Wate...

Page 144: ...excess choking See owner s manual Controls and Indicators See Choke Fuel pump malfunction or failure Fuel System on page 15 8 Ignition coil failure Test Procedure 21 Ignition Spark on page 11 29 Test...

Page 145: ...not backshifting properly Clutches on page 15 29 Incorrect plug Spark Plugs on page 10 15 Unsuitable fuel or incorrect rich fuel mixture Fuel System on page 15 8 Spark plug wire is damaged See the Kaw...

Page 146: ...ure 15 Neutral Switch Transmission on page 11 24 Starter fails to operate Transmission shifter linkage is binding or is out of adjustment Forward Reverse Shifter Cable Adjustment on page 17 11 Loose o...

Page 147: ...FH680D engine manual CC P N 103351201 Low oil warning light stays on Shorted wire harness wire s Test Procedure 28 Low Oil Warning Light Circuit on page 11 33 Failed low oil warning light or oil pres...

Page 148: ...ELECTRICAL SYSTEM GASOLINE VEHICLES WIRING DIAGRAM WD1033057A7 L NOTE AWD diagram shown 2 wheel drive vehicle uses same harness Figure 11 1 Wiring Diagram Front Page 11 6 2016 Carryall 1500 1700 and X...

Page 149: ...SYSTEM GASOLINE VEHICLES Wiring Diagram 11 WD1033057A7 R NOTE AWD diagram shown 2 wheel drive vehicle uses same harness Figure 11 2 Wiring Diagram Rear 2016 Carryall 1500 1700 and XRT 1550 Maintenanc...

Page 150: ...OUBLESHOOTING AND ELECTRICAL SYSTEM GASOLINE VEHICLES 000662 005 2 1 1 Diodes Figure 11 3 Sonic Weld and Diode Locations Approximate Gasoline Page 11 8 2016 Carryall 1500 1700 and XRT 1550 Maintenance...

Page 151: ...oil 20 Voltage Regulator 21 Ignition Spark 22 Engine Kill Wire 23 Grounded Kill Wire 24 Key Switch Engine Kill Circuit 25 Reverse Warning Buzzer Limit Switch If Equipped 26 Reverse Warning Buzzer If E...

Page 152: ...ON CAUTION Do not allow battery acid from battery caps or hydrometer to drip onto the vehicle body Battery acid will cause permanent damage Wash off immediately 1 Disable the vehicle See Disabling the...

Page 153: ...210 50 1 160 to 1 180 25 If the difference between the cells is 0 020 or more the low cell should be suspected of poor performance It may require a catch up charge or it may be a weak cell When the va...

Page 154: ...6 VDC 6 If the battery voltage is acceptable or if the electrical problem continues after the battery has been replaced test the electrical circuits 7 If the voltage reading exceeds 9 6 volts at 70 F...

Page 155: ...11 7 Page 11 14 Repair or replace as required 3 Check the negative battery terminal 6 gauge black wire w202 and the two 12 gauge black wires w112 and w132 for damage Repair or replace as required 4 C...

Page 156: ...nd is tight If it is not repair or replace as necessary 3 Remove the key switch See Key Switch Removal on page 13 8 4 Set the multimeter to 200 ohms 5 Turn the key switch ON Place the red probe of the...

Page 157: ...reading should indicate continuity If the reading does not indicate continuity replace the key switch Figure 11 9 Page 11 14 Place the red probe of the multimeter on the B terminal and the black probe...

Page 158: ...starter motor has failed See the Kawasaki FH680D engine manual CC P N 103351201 TEST PROCEDURE 7 Start Relay See General Warnings Section 1 Page 1 2 1 Disable the vehicle See Disabling the Vehicle on...

Page 159: ...e relay clicks the contacts have failed Replace the relay 2085 Figure 11 11 Start Relay Coil Circuit Test 2086 Figure 11 12 Start Relay Contact Test 8 If the reading obtained in step 5 is not 12 VDC w...

Page 160: ...Page 11 18 6 3 Monitor the multimeter The multimeter should NOT indicate continuity with the key in the ON position and the engine off The multimeter should indicate continuity when the engine starts...

Page 161: ...A COM 200nA MAX 1000 750V FUSED 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m...

Page 162: ...n the ON position Open Difficult starting and engine will shut off shortly after key switch is moved from the START to ON position Diode 3 w45 and w39 Carburetor solenoid control powers carburetor sol...

Page 163: ...emoval on page 13 18 TEST PROCEDURE 11 Diode 2 on wire 40 and 41 See General Warnings Section 1 Page 1 2 1 Disconnect battery and spark plug wire s See Side Post Battery Disconnecting the Battery Gaso...

Page 164: ...e test function 8 Connect the black probe of the multimeter to the 18 gauge purple wire w47 at the key switch multi pin connector 9 Connect the red probe of the multimeter to the female side of the ca...

Page 165: ...battery and spark plug wire s See Side Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 3 See Top Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 4...

Page 166: ...Top Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 4 2 Disconnect the two pin connector between the neutral switch and the wire harness w138 and w143 Figure 11 17 Page 11 24...

Page 167: ...See Top Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 4 2 To test a wire for continuity disconnect either end from the electrical component to which it is attached 3 Set t...

Page 168: ...ch lever is activated If either reading is incorrect replace the switch See Front Differential Limit Switch Removal on page 13 14 TEST PROCEDURE 18 Front Drive Gearcase Coil See General Warnings Secti...

Page 169: ...Multi Pin Connector TEST PROCEDURE 20 Voltage Regulator See General Warnings Section 1 Page 1 2 NOTE Keep the battery connected during this test procedure 1 Disable the vehicle See Disabling the Vehi...

Page 170: ...oil on page 11 27 Also check for a loose connection at the voltage regulator 3 pin connector and check the continuity of each wire in the voltage regulator 3 pin connector 8 If the reading is more tha...

Page 171: ...ew spark plug set to the proper gap setting and test the engine for proper operation See Spark Plugs Section 10 Page 10 15 TEST PROCEDURE 22 Engine Kill Wire See General Warnings Section 1 Page 1 2 1...

Page 172: ...to the START position and release it after the engine starts If the engine starts and continues to idle check the kill wire for grounding See Test Procedure 22 Engine Kill Wire on page 11 29 See foll...

Page 173: ...ttery connected during this test procedure The reverse warning buzzer limit switch is located on the Forward Reverse handle under the hood 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2...

Page 174: ...when performing this test 1 4 Set the multimeter to 20 VDC 1 5 Place the probes to measure the voltage between the female side of the carburetor solenoid bullet connector green white wire w123 and the...

Page 175: ...minal 5 Leave the 18 gauge purple wire w42 connected to the low oil warning light 6 Place a jumper wire on the terminal of the low oil warning light where the blue white wire w17 was removed 7 Touch t...

Page 176: ...Level Sending Unit See General Warnings Section 1 Page 1 2 WARNING To avoid the possibility of fire or explosion make sure the fuel tank cap is securely in place while performing this test procedure 1...

Page 177: ...d and check the continuity of the following Orange wire w104 from the fuel level sending unit to the fuel gauge hour meter Blue wire w25 and purple wire w47 from the fuel gauge hour meter to the key s...

Page 178: ...2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 1 4 2 6 7 1 2 1 20 VDC Setting 2 Orange 481 Figure 11 29 Fuel Gauge Voltage Test Terminal...

Page 179: ...re is no voltage reading check the continuity of the 10 gauge red wire w126 from the fuse block to the starter solenoid Check the continuity of the 14 gauge yellow wire w07 and the 14 gauge blue wire...

Page 180: ...re terminal w01 of the wire harness If the multimeter reading is approximately 12 volts the blue wire has continuity 7 Check the continuity of the 16 gauge black wire w13 from the headlight to the fra...

Page 181: ...he wiring of the bed lift harness and bed lift switch See Wiring Diagram on page 11 6 A reading of approximately 0 VDC indicates a failed bed lift switch failed bed lift circuit breaker a poor connect...

Page 182: ...Red w7 6 14 Yellow w5 8 14 Black w2 2104 Figure 11 36 Bed Lift Switch Terminals _ BED LIFT SWITCH CONTINUITY Between Terminals 1 2 4 5 6 8 1 Cont when pushed DOWN 2 Cont when pushed DOWN Cont when pu...

Page 183: ...gs Section 1 Page 1 2 WARNING See General Warnings Section 1 Page 1 2 TROUBLESHOOTING GUIDE The following troubleshooting guide will be helpful in identifying operating difficulties should they occur...

Page 184: ...en nut See the Kubota D722 diesel engine manual CC P N 103840201 Air in fuel system Injection nozzle clogged Injection pump failed Fuel pump failure Incorrect injection timing Excessive valve clearanc...

Page 185: ...page 12 25 Incorrect nozzle opening pressure Injection nozzle clogged Failed injection pump Fuel overflow pipe clogged Fuel leak caused by loose injection pipe retaining nut See the Kubota D722 diese...

Page 186: ...d engine oil See owner s manual Failed radiator fan or radiator fan circuit Test Procedure 11 Fan Motor on page 12 23 Thermostat switch failure Test Procedure 10 Thermostat Switch on page 12 21 Fan re...

Page 187: ...ystem and Clutches Misaligned muffler mounting clamp Exhaust System on page 16 5 Damaged drive belt Clutches on page 16 24 Damaged drive clutch Clutches on page 16 24 Damaged driven clutch Clutches on...

Page 188: ...tch failed open See the Kubota D722 diesel engine manual CC P N 103840201 Failed low oil warning light or oil pressure sensor Test Procedure 29 Low Oil Warning Light Circuit on page 12 38 Oil pressure...

Page 189: ...AL SYSTEM DIESEL VEHICLES Wiring Diagram 12 WIRING DIAGRAM DIODE 2 DIODE 1 WD1032775E7 L Figure 12 1 Wiring Diagram for Diesel Utility Vehicles Front 2016 Carryall 1500 1700 and XRT 1550 Maintenance a...

Page 190: ...OUBLESHOOTING AND ELECTRICAL SYSTEM DIESEL VEHICLES DIODE 3 DIODE 4 WD1032775E7 R Figure 12 2 Wiring Diagram for Diesel Utility Vehicles Rear Page 12 8 2016 Carryall 1500 1700 and XRT 1550 Maintenance...

Page 191: ...ELECTRICAL SYSTEM DIESEL VEHICLES Wiring Diagram 12 000662 004 3 2 1 1 Diodes Figure 12 3 Sonic Weld and Diode Locations Approximate Diesel 2016 Carryall 1500 1700 and XRT 1550 Maintenance and Servic...

Page 192: ...p Fusible Link 23 Coolant Temperature Warning Light Circuit 24 Glow Plug Circuit 25 Reverse Warning Buzzer Limit Switch If Equipped 26 Reverse Warning Buzzer If Equipped 27 Fuel Solenoid Pull Coil Cir...

Page 193: ...0 F 27 C Never add acid to the battery to obtain a higher specific gravity Figure 12 4 Page 12 12 See following CAUTION CAUTION Do not allow battery acid from battery caps or hydrometer to drip onto t...

Page 194: ...10 50 1 160 to 1 180 25 If the difference between the cells is 0 020 or more the low cell should be suspected of poor performance It may require a catch up charge or it may be a weak cell When the var...

Page 195: ...pproximately 9 6 VDC 6 If the battery voltage is acceptable or if the electrical problem continues after the battery has been replaced test the electrical circuits 7 If the voltage reading exceeds 9 6...

Page 196: ...as required 3 Check the negative battery terminal and 6 gauge black wire w202 for damage Repair or replace as required 4 Check the engine ground for a loose connection damaged terminals and an excess...

Page 197: ...y and is tight If it is not repair or replace as necessary 4 Set the multimeter to 200 ohms 5 Check the B and A key switch terminals 5 1 Use alligator clips to connect the multimeter probes between th...

Page 198: ...tch Removal on page 14 7 7 2 If the multimeter indicates continuity between the B and S terminals with the key in any position other than START the key switch has failed and should be replaced See Key...

Page 199: ...y Switch Removal on page 14 7 4 Set the multimeter to 200 ohms 5 Check the B and A terminals 5 1 Use alligator clips to connect the multimeter probes between the B and A terminals With the key in the...

Page 200: ...indicate approximately 12 VDC when the key is in the START position 2109 Figure 12 10 Solenoid Coil Wire w127 Removed 2110 Figure 12 11 Starter Circuit Test 6 If the readings differ from those descri...

Page 201: ...itions The reading should indicate approximately 12 VDC when the key is in the START position and the relay should click See following NOTE NOTE The fan and accessory relays may be removed to isolate...

Page 202: ...8 gauge yellow fan relay wire w146 terminal and the frame ground Figure 12 14 Page 12 21 3 2 Monitor the multimeter The reading should indicate 0 volts with the key in the OFF position If not check fo...

Page 203: ...ack _ THERMOSTAT SWITCH CONTACT OPERATION WIRE COLOR FUNCTION CLOSE ON RISE OPEN White Radiator Fan 187 F to 198 F 86 C to 92 C 165 F 74 C Black Temperature Warning Light 216 F to 226 F 102 C to 108 C...

Page 204: ...ultimeter indicates continuity at room temperature replace the thermostat switch See Thermostat Switch Removal on page 14 18 G N I N R A W Y R U J N I E R E V E S E S U A C N A C T O H d l o f i n a M...

Page 205: ...g WARNING WARNING Allow surfaces to cool adequately before touching them 2116 Figure 12 17 Fan Thermostat Switch Test Setup TEST PROCEDURE 11 Fan Motor See General Warnings Section 1 Page 1 2 The fan...

Page 206: ...ition 10 Monitor the multimeter while turning the key switch to the ON position The multimeter should indicate 0 zero VDC with the key in the OFF position and approximately 12 VDC with the key switch...

Page 207: ...A COM 200nA MAX 1000 750V FUSED 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m...

Page 208: ...wire 32 See General Warnings Section 1 Page 1 2 1 Disconnect battery See Side Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 3 See Top Post Battery Disconnecting the Batter...

Page 209: ...iled and must be replaced See Wire Harness Diode Removal on page 14 20 8 Reverse the multimeter probes and note the reading The multimeter should indicate approximately 540 mV however a range of 400 t...

Page 210: ...40 mV however a range of 400 to 700 mV is acceptable 11 If the readings obtained in the previous steps are incorrect replace the diode See Wire Harness Diode Removal on page 14 20 TEST PROCEDURE 16 Di...

Page 211: ...IESEL VEHICLES Test Procedures 12 8 If the readings obtained in the previous steps are incorrect replace the diode See Wire Harness Diode Removal on page 14 20 2016 Carryall 1500 1700 and XRT 1550 Mai...

Page 212: ...the switch contacts with the Forward Reverse handle in the FORWARD position Figure 12 24 Page 12 30 The multimeter should indicate no continuity 4 Check for continuity on the switch contacts with the...

Page 213: ...rminal end of the wire The reading should indicate continuity If the reading is incorrect repair or replace the wire See following NOTE NOTE When checking continuity of wires in the wire harness obser...

Page 214: ...Differential Limit Switch Removal on page 14 13 TEST PROCEDURE 20 Front Drive Gearcase Coil See General Warnings Section 1 Page 1 2 1 Disconnect battery See Side Post Battery Disconnecting the Batter...

Page 215: ...7 If the reading is less than 14 2 volts and not rising or higher than 14 8 volts replace the alternator TEST PROCEDURE 22 60 Amp Fusible Link See General Warnings Section 1 Page 1 2 NOTE Keep the ba...

Page 216: ...y connected during this test procedure 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 At driver side raise the seat and disconnect the two pin connector from the thermostat switch Figur...

Page 217: ...e continuity for wires w117 w45 w29 w37 w24 w125 and w126 See Test Procedure 18 Wire Continuity on page 12 31 TEST PROCEDURE 24 Glow Plug Circuit See General Warnings Section 1 Page 1 2 NOTE Keep the...

Page 218: ...terminal and the black probe on the other terminal of the limit switch With the limit switch lever fully released the reading should be no continuity 5 Place the Forward Reverse handle in the REVERSE...

Page 219: ...Switch Starter Circuit on page 12 15 Starter solenoid See the Kubota D722 diesel engine manual CC P N 103840201 Wire continuity of w135 See Test Procedure 18 Wire Continuity on page 12 31 TEST PROCEDU...

Page 220: ...light should illuminate 9 If the low oil warning light does not illuminate when the key switch is in the ON position check the 18 gauge purple wire w42 for continuity between the terminal at the low...

Page 221: ...l tank The resistance reading will vary according to the exact position of the float The following table may be used as a guideline to determine if the fuel level sending unit is operating correctly M...

Page 222: ...e hour meter w22 See Fuel Gauge Hour Meter Removal on page 14 7 7 If the readings are correct according to the position of the float but the reading on the fuel gauge hour meter is incorrect test the...

Page 223: ...20 volts DC and place the red probe on the 2 terminal of the fuel gauge hour meter where the blue wire w25 is connected Place the black probe on the 1 terminal of the fuel gauge hour meter with the bl...

Page 224: ...not operate vehicle in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison 4 With engine idling the hour glass icon should flash If not...

Page 225: ...XL V V V A COM 200nA MAX 1000 750V FUSED 1130 Figure 12 36 Light Switch Test TEST PROCEDURE 35 Voltage at Headlight Socket See General Warnings Section 1 Page 1 2 NOTE Keep the battery connected durin...

Page 226: ...the black wire wire harness side Figure 12 39 Page 12 45 5 Have an assistant press the bed lift switch in the UP position and monitor the multimeter A reading of approximately positive 12 VDC indicate...

Page 227: ...ition 2103 Figure 12 40 Bed Lift Motor Voltage Reading with Switch in DOWN position TEST PROCEDURE 37 Bed Lift Switch 1 Remove the bed lift switch See Bed Lift Switch Removal on page 14 9 2 Check cont...

Page 228: ...ed DOWN Cont when pushed UP 8 Cont when pushed UP TEST PROCEDURE 38 Bed Lift Circuit Breaker 1 Remove the bed lift circuit breaker See Bed Lift Circuit Breaker Removal on page 14 9 2 Place the red pro...

Page 229: ...FH680D engine manual CC P N 103351201 RELAYS See General Warnings Section 1 Page 1 2 The start relay 1 carburetor heater relay 2 and accessory relay optional not shown are housed on the electrical com...

Page 230: ...est Procedure 15 Neutral Switch Transmission on page 11 24 NEUTRAL SWITCH REMOVAL 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 Disconnect the two pin connector between the neutral swi...

Page 231: ...See the Kawasaki FH680D engine manual CC P N 103351201 2128 Figure 13 3 Carburetor Solenoid Connector CARBURETOR SOLENOID INSTALLATION 1 Install the carburetor solenoid and tighten to 168 in lb 19 N m...

Page 232: ...uretor heater 1 Figure 13 4 Page 13 4 4 Remove the heater from the carburetor 2129 Figure 13 4 Carburetor Heater CARBURETOR HEATER INSTALLATION 1 Install the carburetor heater and tighten to 65 in lb...

Page 233: ...he voltage regulator VOLTAGE REGULATOR INSTALLATION 1 Position the voltage regulator on the mounting plate and install the mounting screw Tighten screw to 30 in lb 3 4 N m Figure 13 5 Page 13 5 2 Conn...

Page 234: ...the wires from the warning light 1 Figure 13 6 Page 13 7 4 Press the retaining tabs and remove the warning light from the instrument panel WARNING LIGHT INSTALLATION 1 Push a new warning light into th...

Page 235: ...he fuel gauge initially registers full before indicating the actual fuel level The hour meter displays the number of hours of use in increments of 0 1 one tenth hour but does not record additional tim...

Page 236: ...est Procedure 5 Key Switch Starter Circuit on page 11 15 Also see Test Procedure 24 Key Switch Engine Kill Circuit on page 11 31 KEY SWITCH REMOVAL 1 Disconnect battery and spark plug wire s See Side...

Page 237: ...the accessory receptacle See following NOTE NOTE The retainer works like a nut but can be removed quickly by turning only enough to align the two small patches of retainer threads with the two smooth...

Page 238: ...he bed lift switch into the instrument panel until fully seated 3 Lower and secure the hood 4 Connect battery and spark plug wire s See Side Post Battery Connecting the Battery Gasoline Diesel Vehicle...

Page 239: ...onnect the wire harness 2 Push the light switch into the instrument panel until fully seated 3 Lower and secure the hood 4 Connect battery and spark plug wire s See Side Post Battery Connecting the Ba...

Page 240: ...y Connecting the Battery Gasoline Diesel Vehicles on page 1 4 REVERSE WARNING BUZZER IF EQUIPPED See General Warnings Section 1 Page 1 2 TESTING THE REVERSE WARNING BUZZER See Test Procedure 26 Revers...

Page 241: ...ee General Warnings Section 1 Page 1 2 TESTING THE REVERSE WARNING BUZZER LIMIT SWITCH See Test Procedure 25 Reverse Warning Buzzer Limit Switch If Equipped on page 11 31 REVERSE WARNING BUZZER LIMIT...

Page 242: ...gauge red and 18 gauge red white wires to the limit switch 8 Lower and secure the hood 9 Connect battery and spark plug wire s See Side Post Battery Connecting the Battery Gasoline Diesel Vehicles on...

Page 243: ...rtightened the switch could become damaged 2 Move the accelerator pedal back and forth to ensure that the switch lever is being properly activated 3 Connect wire leads of switch to wire harness 4 Conn...

Page 244: ...0 For charge coil testing see Test Procedure 19 Charge Coil on page 11 27 IGNITION COIL AND OR CHARGE COIL REMOVAL The ignition coils are located under the flywheel shroud of the engine and the charge...

Page 245: ...the retaining tabs on the connector and remove the halogen bulb 1 2 3 1165 Figure 13 11 Headlight Bulb HEADLIGHT BULB INSTALLATION NOTE When handling halogen bulbs do not touch the glass portion of b...

Page 246: ...k tubing over the diode and ensure that it will after being activated adequately cover the uninsulated diode leads 4 Activate the heatshrink by carefully applying heat to the tubing 5 Bundle the wires...

Page 247: ...5 to prevent future corrosion 2 The battery should be kept clean and dry to prevent self discharge Dirt grime and acid spillage should be removed Wash the battery with a bristle brush and a solution o...

Page 248: ...um oxides 40 0 Iron 5 0 Ammonia 8 0 Organic matter 50 0 Nitrates 10 0 Nitrites 5 0 Chloride 5 0 BATTERY REMOVAL See General Warnings on page 1 2 1 Disconnect battery and spark plug wire s See Top Post...

Page 249: ...t Battery Connecting the Battery Gasoline Diesel Vehicles on page 1 4 BATTERY STORAGE See General Warnings on page 1 2 1 Keep the battery clean and free of corrosion See Preventive Maintenance on page...

Page 250: ...ot designed to charge a dead battery If the vehicle battery has become discharged it must be charged with a properly rated automotive type charger See following WARNING WARNING Do not jump start a dea...

Page 251: ...01 RELAYS See General Warnings Section 1 Page 1 2 The start relay 1 differential relay 2 fan relay 3 and accessory relay optional not shown are housed on the electrical component mounting plate locate...

Page 252: ...NEUTRAL SWITCH See Test Procedure 17 Neutral Switch Transmission on page 12 30 NEUTRAL SWITCH REMOVAL 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 Disconnect the two pin connector be...

Page 253: ...ecuring the wire lead bracket and the two bolts securing the fuel solenoid to the engine Pull the solenoid and o ring from the engine Figure 14 4 Page 14 3 1 2 3 1 Bracket 2 Fuel Solenoid 3 O ring 213...

Page 254: ...iesel Vehicles on page 1 4 2 Move the terminal cover 2 and remove the nut 3 that secures the fusible link wire assembly 1 to the alternator Figure 14 5 Page 14 4 2 1 3 2138 Figure 14 5 60 Amp Fusible...

Page 255: ...cles on page 1 3 See Top Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 4 2 Raise the hood 3 Disconnect the wires from the warning light 1 Figure 14 6 Page 14 6 4 Press the...

Page 256: ...switch in the OFF position the fuel gauge field is blank however the hour meter field is always ON When the key switch is turned to ON the fuel gauge field activates The fuel gauge initially registers...

Page 257: ...cles on page 1 4 See Top Post Battery Connecting the Battery Gasoline Diesel Vehicles on page 1 4 KEY SWITCH See General Warnings Section 1 Page 1 2 TESTING THE KEY SWITCH See Test Procedure 4 Key Swi...

Page 258: ...sconnect the wires from the accessory receptacle 12 Figure 14 6 Page 14 6 5 Reach under the instrument panel to remove the retainer 13 securing the accessory receptacle See following NOTE NOTE The ret...

Page 259: ...he bed lift switch into the instrument panel until fully seated 3 Lower and secure the hood 4 Connect battery See Side Post Battery Connecting the Battery Gasoline Diesel Vehicles on page 1 4 See Top...

Page 260: ...tch and reconnect the wire harness 2 Push the light switch into the instrument panel until fully seated 3 Lower and secure the hood 4 Connect battery See Side Post Battery Connecting the Battery Gasol...

Page 261: ...y Connecting the Battery Gasoline Diesel Vehicles on page 1 4 REVERSE WARNING BUZZER IF EQUIPPED See General Warnings Section 1 Page 1 2 TESTING THE REVERSE WARNING BUZZER See Test Procedure 26 Revers...

Page 262: ...e General Warnings Section 1 Page 1 2 TESTING THE REVERSE WARNING BUZZER LIMIT SWITCH See Test Procedure 25 Reverse Warning Buzzer Limit Switch If Equipped on page 12 36 REVERSE WARNING BUZZER LIMIT S...

Page 263: ...ted 7 Connect the 18 gauge red and 18 gauge red white wires to the limit switch 8 Lower and secure the hood 9 Connect battery See Side Post Battery Connecting the Battery Gasoline Diesel Vehicles on p...

Page 264: ...ts are overtightened the switch could become damaged 2 Move the accelerator pedal back and forth to ensure that the switch lever is being properly activated 3 Connect wire leads of switch to wire harn...

Page 265: ...See Top Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 4 2 Disconnect the 18 gauge purple wire from the alternator Figure 14 11 Page 14 15 3 Disconnect the 12 gauge blue fu...

Page 266: ...on the alternator pulley 4 Place a belt tension gauge on the V belt and use a pry bar to increase the belt tension Use a Krikit brand belt tension gauge to measure the belt tension The belt tension ad...

Page 267: ...Disconnecting the Battery Gasoline Diesel Vehicles on page 1 3 See Top Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 4 2 From the front of the vehicle reach under the cowl...

Page 268: ...e 1 2 TESTING THE THERMOSTAT SWITCH See Test Procedure 10 Thermostat Switch on page 12 21 THERMOSTAT SWITCH REMOVAL 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 Disconnect the two pin...

Page 269: ...the level reaches the FULL mark See Engine Coolant Diesel Vehicles Section 10 Page 10 19 5 Connect battery See Side Post Battery Connecting the Battery Gasoline Diesel Vehicles on page 1 4 See Top Pos...

Page 270: ...SS DIODES See General Warnings Section 1 Page 1 2 The wire harness is equipped with several in line diodes TESTING THE WIRE HARNESS DIODES See Test Procedure 12 Wire Harness Diodes on page 12 25 WIRE...

Page 271: ...gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or using in an enclosed space Wear a full face shield and rubber gloves when working on or nea...

Page 272: ...ept clean Hot weather also has an effect on a battery s self discharge rate The higher the temperature the quicker a battery will discharge Therefore the battery should be checked more often in hotter...

Page 273: ...yte leakage Tipping the battery beyond a 45 angle in any direction can allow a small amount of electrolyte to leak out of the vent hole Do not exceed this 45 angle when lifting carrying or installing...

Page 274: ...ng the Battery Gasoline Diesel Vehicles on page 1 3 See Top Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 4 3 Fully charge the battery prior to storage 4 Store in a cool dr...

Page 275: ...TRICAL COMPONENTS DIESEL VEHICLES Battery 14 WARNING Do not jump start a dead battery with another battery and jumper cables 2016 Carryall 1500 1700 and XRT 1550 Maintenance and Service Manual Page 14...

Page 276: ...Pagination Page 14 Battery ELECTRICAL COMPONENTS DIESEL VEHICLES Page 14 26 2016 Carryall 1500 1700 and XRT 1550 Maintenance and Service Manual...

Page 277: ...l Vehicles on page 1 3 See Top Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 4 2 Remove the cargo bed See Cargo Bed Removal Section 4 Page 4 12 3 Remove seat s and remove t...

Page 278: ...ine GASOLINE ENGINE MUFFLER FUEL SYSTEM AND CLUTCHES 9 10 11 7 6 8 4 5 1 2 3 2573 Figure 15 1 Engine Removal and Installation Components Page 15 2 2016 Carryall 1500 1700 and XRT 1550 Maintenance and...

Page 279: ...and outlet hoses from the engine See Oil Filter Hose Removal on page 15 5 See also following NOTE NOTE Plug each line as it is removed from the engine Without plugs oil will leak from the lines 22 Rem...

Page 280: ...ne mounting bolts 8 to 39 ft lb 53 N m 9 Install the clutches 5 See Drive Clutch Installation on page 15 34 Also see Driven Clutch Installation on page 15 37 10 Install the drive belt See Drive Belt I...

Page 281: ...enter seat plate bucket seat vehicles only 29 Install seat s 30 Test drive the vehicle to ensure all systems are functional and adjusted correctly OIL FILTER HOSES Oil Filter Hose Removal 1 Drain the...

Page 282: ...ery Gasoline Diesel Vehicles on page 1 4 2 Loosen the muffler spring suspension bracket bolts 3 Remove the two springs that secure the muffler inlet to the intermediate pipe Figure 15 4 Page 15 6 See...

Page 283: ...pipe and tighten the muffler spring suspension bracket bolts to 21 ft lb 29 N m MUFFLER INSTALLATION NOTE Replace springs that show signs of brittleness broken coils or loss of tension 1 Loosely secu...

Page 284: ...closed area without proper ventilation FUEL SYSTEM 1 REF 1 2 6 4 7 8 5 3 FUEL LINE NO DIAMETER ROUTING 1 5 16 in 8 mm Fuel tank to fuel filter 6 2 5 16 in 8 mm Fuel filter 6 to fuel pump 3 1 4 in 6 35...

Page 285: ...hange to a 1 4 inch tank vent nipple eliminated the need for the flared end 2695 Figure 15 5 Fuel and Evaporative Emission System FUEL LINES See General Warnings Section 1 Page 1 2 The fuel lines must...

Page 286: ...P N 103351201 CARBURETOR See General Warnings Section 1 Page 1 2 WARNING The carburetor is equipped with an electric heater and must be grounded to the engine in order to prevent the risk of a spark...

Page 287: ...Electric Heater 1454 Figure 15 6 Carburetor Ground Wire Carburetor Jetting The Kawasaki FH680D engine is equipped with a carburetor that has fixed jets These fixed jets do not require adjustment The...

Page 288: ...vehicle and service area WARNING Do not use electrically powered tools to remove or install the fuel level sending unit Failure to heed this warning could result in a fire or explosion 1 Disconnect ba...

Page 289: ...ware 6 Carefully remove the sending unit and gasket 3 Feed the rheostat arm and float 4 through the fuel tank hole Immediately place the fuel level sending unit in a pan to catch fuel See following DA...

Page 290: ...nding unit rheostat arm and float 4 into the fuel tank Figure 15 7 Page 15 13 The rheostat arm and float should be positioned toward the passenger s side surface of the fuel tank Figure 15 9 Page 15 1...

Page 291: ...in lb 1 N m If the hardware cannot be tightened to 9 in lb 1 N m the fuel tank must be replaced See following CAUTION CAUTION Do not overtighten the screws Overtightening the screws will strip the mou...

Page 292: ...flanged locknuts from the seat frame seat side plates and engine cover plate 6 Turn the fuel shut off valve to the closed OFF position Figure 15 13 Page 15 20 7 Run the engine until all fuel in the ca...

Page 293: ...accordance with federal state and local laws and ordinances 4 Store the tank upside down with the cap installed in a well ventilated area Fuel Tank Installation 1 Install the fuel tank in the vehicle...

Page 294: ...NEUTRAL start the engine and allow it to idle Run the engine for a few minutes to ensure that the fuel lines are full of fuel See following DANGER DANGER The engine produces carbon monoxide which is a...

Page 295: ...3 2 Lift cargo bed and secure in raised position 3 Remove hose clamps securing three hoses to canister and disconnect hoses Figure 15 12 Page 15 19 4 Push pull the canister to force it from its mounti...

Page 296: ...valve should always be turned to the closed OFF position during vehicle storage towing or trailering and maintenance and service Figure 15 13 Page 15 20 1 2 3 1 Fuel Shut off Valve 2 Closed OFF 3 Open...

Page 297: ...nect battery and spark plug wire s See Side Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 3 See Top Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page...

Page 298: ...tery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 4 2 Remove seat s 3 Remove the center seat plate bucket seat vehicles only 4 Remove the engine top cover 5 Remove the choke cable retu...

Page 299: ...he choke cable through the engine front cover Figure 15 16 Page 15 23 6 Push the cable sheath strain relief 3 into the engine front cover 4 until it snaps into place Figure 15 17 Page 15 23 7 Insert a...

Page 300: ...Hold in this position 3 Insert small allen wrench into shaft 3 and rotate shaft counterclockwise CCW until it stops Hold in this position 4 Tighten nut 1 2 1 3 2503 Figure 15 18 Governor Arm Engine G...

Page 301: ...Adjustment Screws Idle RPM Adjustment DANGER Do not operate the engine in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison 1 Place Fo...

Page 302: ...ngine produces carbon monoxide which is an odorless deadly poison 1 With engine at operating temperature press the accelerator pedal all the way to the floor 2 Measure the engine RPM with a tachometer...

Page 303: ...riodic Service Schedule Section 10 Page 10 1 More frequent service may be required in extremely dirty operating environments In the event of a loss of power sluggish acceleration or a roughly running...

Page 304: ...om the canister 4 Remove the top outlet hose from the canister 5 Remove the two bolts and park brake cable from the canister and remove the canister 2041 Figure 15 23 Air Filter Canister AIR CANISTER...

Page 305: ...RPM and governor adjustments If these adjustments are within specifications there is a clutch problem See Engine RPM Adjustment on page 15 25 If the clutches are not operating properly perform the fo...

Page 306: ...riven clutch by rotating the clutch clockwise See following CAUTION CAUTION Make sure your fingers are not underneath the belt when rolling the belt off the driven clutch Drive Belt Installation 1 Pos...

Page 307: ...arts See following CAUTION CAUTION Do not lubricate the drive clutch Lubricants attract dirt and dust which interfere with proper clutch operation Use only a dry cloth and lightly wipe the shaft of th...

Page 308: ...Clutches GASOLINE ENGINE MUFFLER FUEL SYSTEM AND CLUTCHES 2500 Figure 15 27 Using the Drive Clutch Service Tool Three Weight Page 15 32 2016 Carryall 1500 1700 and XRT 1550 Maintenance and Service Man...

Page 309: ...375x1 375 12 Moveable Sheave 3 Spring Compression 2 0 OD Black Or 8 Washer Flat 13 Locknut 10 24 4 Spacer Clutch 1 44x1 125x0 23 9 Button Torque Primary 14 Screw Shoulder Hex Socket 0 25x2 5 5 Spider...

Page 310: ...the moveable sheave upward and start threading bolts 1 into holes 6 Use a crisscross pattern to continue tightening the bolts to 113 in lb 12 7 N m Drive Clutch Installation 1 Place the drive clutch a...

Page 311: ...isassembly The following service tools are required to disassemble and assemble the driven clutch They are available from a service parts representative Spring compression base CC P N 102603501 Spring...

Page 312: ...X 2175 Figure 15 30 Driven Clutch Assembly Driven Clutch Assembly 1 Place the fixed sheave 5 onto the spring compression base and note the location of the X so the X on the moveable sheave 4 can be a...

Page 313: ...ore returning the vehicle to normal operation If the engine is operated with the clutch outer cover removed keep hands away from the clutches and belt Failure to heed this warning could result in seve...

Page 314: ...e clutch inner cover engine bolts and washers to 21 ft lb 28 5 N m 5 Tighten the transmission bolts and washers to 21 ft lb 28 5 N m 6 Install the driven clutch See Driven Clutch Installation on page...

Page 315: ...the Battery Gasoline Diesel Vehicles on page 1 3 See Top Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 4 3 Remove the cargo bed See Cargo Bed Removal Section 4 Page 4 12 4...

Page 316: ...l return line Figure 16 1 Page 16 2 See previous DANGER 11 Remove the accelerator cable 5 from the accelerator lever Figure 16 1 Page 16 2 12 Remove the accelerator cable sheath strain relief 6 from t...

Page 317: ...from the mounting plate 28 If replacing engine remove cvt adapter shaft from flywheel and retain for use on replacement engine ENGINE INSTALLATION See General Warnings Section 1 Page 1 2 1 If install...

Page 318: ...away from the vehicle and service area To prevent fuel from siphoning keep the fuel supply line above the fuel level in the fuel tank when removing the plug 20 Remove the plug and secure the fuel supp...

Page 319: ...at secure the muffler to the chassis and remove the muffler See following WARNING and NOTE WARNING Always wear eye protection when springs are removed or installed NOTE Replace springs that show signs...

Page 320: ...new bolts and flange head locknuts Tighten the hardware to 21 ft lb 28 5 N m Figure 16 6 Page 16 6 INTERMEDIATE PIPE INSTALLATION 1 Secure the intermediate pipe to the manifold pipe with new springs S...

Page 321: ...h the intermediate pipe and tighten the muffler spring bracket hardware to 21 ft lb 29 N m See previous NOTE and WARNING 2182 Figure 16 7 Muffler and Bracket 4 Connect battery See Side Post Battery Co...

Page 322: ...23 0 in 58 4 cm 2 5 16 in 8 mm Water separator to fuel pump 13 0 in 33 0 cm 3 3 16 in 5 mm Fuel return hose 29 0 in 73 5 cm 4 3 16 in 5 mm Vent tube fuel tank 22 0 in 55 8 cm Total 36 0 in 91 4 cm of...

Page 323: ...injury Bleed air from the fuel system in the following circumstances fuel tank runs empty after hoses and or components have been disconnected for service or maintenance prior to starting the engine...

Page 324: ...rotating it in the opposite direction until the valve is firmly sealed and detach the drain hose See following NOTE NOTE Dispose of water according to the environmental laws and regulations for your...

Page 325: ...e under the injector pump It only operates when the engine is rotating See the Kubota D722 diesel engine manual CC P N 103840201 Mechanical Fuel Pump Installation See the Kubota D722 diesel engine man...

Page 326: ...be positioned toward the passenger s side surface of the fuel tank 7 5 4 8 9 3 10 6 2153 Figure 16 10 Fuel Level Sending Unit Removal Fuel Level Sending Unit Installation DANGER Diesel fuel Flammable...

Page 327: ...the passenger s side surface of the fuel tank Figure 16 12 Page 16 14 3 Align the flange identification mounting holes 1 directly over the corresponding mounting holes in the gasket and fuel tank Fig...

Page 328: ...ill strip the mounting holes in the fuel tank 6 Secure the orange wire 7 to the center post with the nut 9 previously removed Figure 16 10 Page 16 12 Tighten the hardware to 17 in lb 1 9 N m and secur...

Page 329: ...E and DANGER NOTE The fuel line contains diesel fuel Squeeze the fuel line closed to prevent fuel flow after the fuel line is removed Plug or cap the fuel line DANGER Diesel fuel Flammable Explosive D...

Page 330: ...can drain Allow the tank to sit for 24 hours to dry See following WARNING WARNING Dispose of wastewater and fuel tank in accordance with federal state and local laws and ordinances 4 Store the tank u...

Page 331: ...Connecting the Battery Gasoline Diesel Vehicles on page 1 4 15 Install both seats 16 Place the Forward Reverse handle in NEUTRAL turn the key switch to start the engine and allow it to idle See follow...

Page 332: ...ble Removal 1 Disconnect battery See Side Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 3 See Top Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1...

Page 333: ...break in period If this condition persists beyond 15 hours of use go to step 2 2 Inspect the accelerator pedal and cable Check idle and high speed RPM See Idle RPM Adjustment on page 16 19 See High Sp...

Page 334: ...ssary to cut the wire attached to the adjustment screws The manufacturer recommends that a new wire be secured to the screws after new RPM settings are established 6 Turn the key switch to start and r...

Page 335: ...rn the key switch to start and allow the engine to idle Press the accelerator pedal all the way to the floor Measure the RPM with the tachometer and diesel probe attachment Note the RPM reading 6 Turn...

Page 336: ...02498601 Air Filter Installation 1 Push the new filter cartridge onto the inside canister nozzle 2 Place the canister cap marked TOP on the top center of the canister Figure 16 22 Page 16 22 3 Secure...

Page 337: ...vehicle frame bracket Tighten the bolts to 21 ft lb 28 5 N m 3 Secure the bottom inlet hose to the canister port 4 Secure the top outlet hose to the canister port 5 Install a new air filter cartridge...

Page 338: ...hill Check the engine RPM If engine speed is within manufacturer specifications there is a clutch problem See Engine RPM Adjustment on page 16 19 If the clutches are not operating properly perform the...

Page 339: ...the clutch clockwise Figure 16 26 Page 16 25 See following CAUTION CAUTION Make sure your fingers are not underneath the belt when rolling the belt off the driven clutch Drive Belt Installation 1 Posi...

Page 340: ...not lubricate the drive clutch Lubricants attract dirt and dust which interfere with proper clutch operation Use only a dry cloth and lightly wipe the shaft of the fixed face assembly 15 Figure 16 28...

Page 341: ...ESEL ENGINE MUFFLER FUEL SYSTEM AND CLUTCHES Clutches 16 2500 Figure 16 27 Using the Drive Clutch Service Tool Three Weight 2016 Carryall 1500 1700 and XRT 1550 Maintenance and Service Manual Page 16...

Page 342: ...0 375x1 375 12 Moveable Sheave 3 Spring Compression 2 0 OD Black Or 8 Washer Flat 13 Locknut 10 24 4 Spacer Clutch 1 44x1 125x0 15 9 Button Torque Primary 14 Screw Shoulder Hex Socket 0 25x2 5 5 Spide...

Page 343: ...onto the shaft 4 Place the cover plate 2 onto the shaft 5 Pull the moveable sheave upward and start threading bolts 1 into holes 6 Use a crisscross pattern to continue tightening the bolts to 113 in...

Page 344: ...clutch with a hammer Do not pry the clutch These actions will damage the clutch 1 3 2 2174 Figure 16 29 Driven Clutch Service Tools Driven Clutch Disassembly 1 Place the driven clutch onto the Spring...

Page 345: ...d sheave 5 and align the X s on both components 3 Place the spring 3 cup 2 and snap ring 1 onto the clutch 4 Place the spring compression collar onto the cup Figure 16 29 Page 16 30 5 Tighten the spri...

Page 346: ...rews and tighten the hardware to 72 in lb 8 N m 3 Install the top air filter hose on the filter canister 4 Connect battery See Side Post Battery Connecting the Battery Gasoline Diesel Vehicles on page...

Page 347: ...ch inner cover have close tolerances Align the engine and transmission carefully to ensure the mounting holes in the clutch inner cover match the threaded holes in the engine and transmission 5 Tighte...

Page 348: ...Pagination Page 16 Clutches DIESEL ENGINE MUFFLER FUEL SYSTEM AND CLUTCHES Page 16 34 2016 Carryall 1500 1700 and XRT 1550 Maintenance and Service Manual...

Page 349: ...vers from both front wheels 4 Loosen the axle spindle nuts Figure 17 1 Page 17 2 5 Lift and support the front of vehicle and remove the wheel s See Lifting The Vehicle on page 3 7 6 Remove both spindl...

Page 350: ...sion ring mates with a groove inside the differential Figure 17 4 Page 17 2 14 Repeat steps for the remaining half shaft 2194 Figure 17 3 Separate Half Shaft from Differential 2195 Figure 17 4 Compres...

Page 351: ...locknut Tighten the hardware to 73 ft lb 99 N m Figure 17 1 Page 17 2 9 Install the tire and wheel and finger tighten the lug nuts 10 Repeat steps 1 through 9 for the remaining half shaft and wheel 1...

Page 352: ...e differential at the connector behind the splash guard Figure 17 7 Page 17 5 See following NOTE NOTE It may be necessary to open one or two splash guard fasteners to access the connector 10 Remove th...

Page 353: ...frame support weldments with new flange head bolts Tighten the hardware to 23 ft lb 31 N m Figure 17 8 Page 17 5 5 Connect the electric clutch harness to the connector behind splash guard Figure 17 7...

Page 354: ...de the driveshaft 3 off the transmission through the oval shaped frame shield and remove from vehicle FRONT DRIVESHAFT INSTALLATION See General Warnings Section 1 Page 1 2 1 Apply a light coat of anti...

Page 355: ...h cover See Clutch Outer Cover Removal on page 15 37 gasoline vehicles See Clutch Outer Cover Removal on page 16 32 diesel vehicles 3 Remove the drive belt See Drive Belt Removal on page 15 30 gasolin...

Page 356: ...ll the new transmission Tighten the base bracket hardware to 39 ft lb 53 N m If the transmission is not replaced leave the base brackets attached to help stabilize the transmission during repair 13 Li...

Page 357: ...r driveshaft See Rear Driveshaft Installation on page 17 13 10 Attach the front driveshaft See Front Driveshaft Installation on page 17 6 11 Install the driven clutch See Driven Clutch Installation on...

Page 358: ...ifter handle bracket Figure 17 13 Page 17 11 NOTE Note the positions of the flanged nuts on the cable The nut farthest from the handle should be at the farthest end of the threaded portion of the cabl...

Page 359: ...from the handle end as far away from the handle end as the thread will allow 4 Advance the front flanged nut away from the rear nut Allow enough room to install the cable and two flanged nuts on the...

Page 360: ...3 4 2 1 5 4 6 2568 Figure 17 14 Shifter Handle Components Shifter Handle Removal 1 Disconnect battery and spark plug wire s gasoline vehicles only See Side Post Battery Disconnecting the Battery Gasol...

Page 361: ...See Top Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 4 3 Remove the lock nut 4 and bolt 5 securing the rear driveshaft 6 to the differential pinion shaft Figure 17 9 Page...

Page 362: ...e floor jack under the differential and raise the jack just enough to support the axle 7 Detach rear shock absorbers from axle See Rear Coil Over Shock Absorber on page 9 1 8 Detach rear driveshaft fr...

Page 363: ...nuts are not available clean existing bolts and add Loctite 2760 per instructions 4 Attach rear driveshaft to rear axle See Rear Driveshaft Installation on page 17 13 5 Secure shock absorbers to axle...

Page 364: ...move the rear axle and differential assembly to a clean location before disassembly 3 If removing only one axle tube 8 or shaft 3 Figure 17 16 Page 17 17 from vehicle clean that tube and hub in prepar...

Page 365: ...re installing new bolts Apply Loctite 2760 Threadlocker to the bolt threads 4 Apply a 3 16 inch wide bead of Three Bond No 1215 CC P N 101928701 to the mating surface of the differential 5 Secure axle...

Page 366: ...te the bore with anti seize compound Figure 17 18 Page 17 18 2 Using an appropriate sized bearing driver that fits the outer race drive in new bearing 3 until fully seated 3 Install retaining ring 2 4...

Page 367: ...rain pan under the radiator and engine drain plugs 4 Turn the drain valve at the radiator counterclockwise for one and one half turns only to drain coolant from radiator See following NOTE NOTE The ra...

Page 368: ...oir cap 14 Start and run the engine until it reaches operating temperature Monitor the coolant level in the reservoir 15 Stop the engine and allow the engine and coolant to cool See following WARNING...

Page 369: ...the radiator counterclockwise for one and one half turns only to drain enough coolant to empty the reservoir Once empty close radiator drain valve See following NOTE NOTE The radiator drain valve does...

Page 370: ...em is pressurized Do not remove radiator cap while engine is hot 9 If necessary remove reservoir cap and fill the reservoir to the FULL mark Replace cap See preceding WARNING 10 Lower and secure the h...

Page 371: ...hannel See preceding CAUTION 3 Install the two radiator support brackets over the studs of the rubber isolators and finger tighten flanged locknuts Secure brackets to chassis with flanged bolts tighte...

Page 372: ...hoses from pipes 5 Remove the flanged locknut securing the front of the weldment to the chassis Leave bolt in chassis 6 Remove the two flanged locknuts and bolts securing the rear of the weldment to t...

Page 373: ...t Coolant system is pressurized Do not remove radiator cap while engine is hot 9 If necessary remove reservoir cap and fill to the FULL mark Replace cap See preceding WARNING 10 Lower and secure the h...

Page 374: ...Pagination Page 18 Fan RADIATOR AND COOLANT SYSTEM DIESEL Page 18 8 2016 Carryall 1500 1700 and XRT 1550 Maintenance and Service Manual...

Page 375: ...misapplication of product If you have any questions about application please contact a local dealer Fluids should be contained and disposed of properly This section contains procedures for inspection...

Page 376: ...d position Failure to secure pins can allow attachment to come off and cause injury or death 2 1 2 2220 Figure 19 1 Hand Lever 2221 Figure 19 2 Attachment Pins 1 Move the locking hand lever 1 to engag...

Page 377: ...CHANISM When the attachment arm mechanism is not being used it can be removed from the vehicle NOTE Remove the bucket or the attachment before attempting to remove the attachment arm mechanism from th...

Page 378: ...achment arm cylinder fully by moving the joystick 1 back Figure 19 8 Page 19 4 7 Retract the attachment interface cylinder fully by moving the joystick 1 to the left 8 Turn the start key to the OFF po...

Page 379: ...the attachment arms Figure 19 12 Page 19 5 2 Stop the engine put the Forward Reverse Handle in NEUTRAL engage the park brake unfasten your seat belt and exit the vehicle 3 Remove the retaining rings...

Page 380: ...gure 19 14 Remove Retainer Pins from Both Cylinders 256 Figure 19 15 Joystick 2234 Figure 19 16 Raise Attachment Arm Install Pin and Retainer Ring 7 Swing the attachment interface cylinder down 8 Turn...

Page 381: ...the cylinders when extending or retracting the cylinders 12 Raise the attachment arm 1 and align it with the cylinder 2 Install the pin 3 and retaining ring 4 Figure 19 16 Page 19 6 13 Raise the atta...

Page 382: ...RAULIC ATTACHMENT SYSTEM ELECTRICAL Diode 3 Diode 2 WD1027864C L Figure 19 18 Wiring Diagram for Hydraulic Attachment System Vehicles Front Page 19 8 2016 Carryall 1500 1700 and XRT 1550 Maintenance a...

Page 383: ...TTACHMENT SYSTEM Electrical 19 Diode 4 Diode 1 WD1027864C R Figure 19 19 Wiring Diagram for Hydraulic Attachment System Vehicles Rear 2016 Carryall 1500 1700 and XRT 1550 Maintenance and Service Manua...

Page 384: ..._ORG Top Switch 8 W11_ORG Bottom Switch E Tilt Out Top Switch 9 W80_ORG Top Switch 10 W78_ORG Bottom Switch 11 W19_GRN Top Switch 12 W39_BLU Bottom Switch F Lift Up Top Switch 13 W13_GRN Top Switch 14...

Page 385: ...still does not work check the following items Fuse Joystick ON OFF switch Accessory relay Control valves See Control Valves on page 19 20 Continuity of the wires involved Key switch Joystick Removal...

Page 386: ...ur screws 4 Secure joystick harness to chassis with new wire tie Figure 19 22 Page 19 11 5 Connect battery See Side Post Battery Connecting the Battery Gasoline Diesel Vehicles on page 1 4 See Top Pos...

Page 387: ...oystick harness to chassis Figure 19 22 Page 19 11 4 Access the joystick ON OFF switch See Joystick Removal on page 19 11 5 Ensure the wires are connected correctly and are tight If they are not rewir...

Page 388: ...e still does not work check the following items Fuse Float and accessory relays Joystick switches Control valves See Control Valves on page 19 20 Continuity of the wires involved Float Switch Removal...

Page 389: ...2 red white wire w82 and terminal 1 gray wire w01 Between terminal 2 red white wire w82 and terminal 3 gray white wire w57 3 If switch does not work as stated in previous step replace switch See Auxil...

Page 390: ...ing 2243 Figure 19 27 Relay 2 Wiring and Testing Testing Float Relay 1 1 Test for continuity between terminal 85 black wire and terminal 86 brown wire Figure 19 26 Page 19 16 2 Test for no continuity...

Page 391: ...45 Figure 19 29 Accessory Relay Wiring and Testing 1 Test for continuity between terminal 85 black wire and terminal 86 orange wire Figure 19 29 Page 19 17 2 Test for no continuity between terminals 8...

Page 392: ...ad connected to the negative coil terminal The solenoid should click and show continuity between the two large terminals Solenoid Removal 1 Empty and raise cargo bed 2 Set the joystick ON OFF switch t...

Page 393: ...age 1 3 See Top Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 4 4 Disconnect wires from each post of circuit breaker 5 Remove hardware securing breaker to chassis and remov...

Page 394: ...r if necessary the following items The valve hot wire and ground wire Figure 19 19 Page 19 9 The switch controlling the valve See Electrical on page 19 8 The supplied voltage The continuity of the con...

Page 395: ...2 Position and Four Way 2 Position Valve and Coil Troubleshoot and repair these valves as follows Figure 19 33 Page 19 21 1 If the valve does not shift check and repair if necessary the following ite...

Page 396: ...lve does not return to the neutral or unshifted position check for dirt in the valve cartridge and repair as described above HOSES HOSE ROUTING 1 2 3 4 5 8 7 6 At Lift and Lower Cylinder 1 Green 2 Blu...

Page 397: ...rea around the ends of the hose being removed Figure 19 34 Page 19 22 5 If removing more than one hose at a time locate and note the hose factory color marking to ease reassembly See following NOTE NO...

Page 398: ...y Disconnecting the Battery Gasoline Diesel Vehicles on page 1 4 4 Thoroughly clean the fittings and the area around them 5 Mark hoses to ease reassembly and disconnect hoses from quick connect fittin...

Page 399: ...and disable vehicle See Disabling the Vehicle on page 1 3 3 Disconnect battery See Side Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 3 See Top Post Battery Disconnecting...

Page 400: ...following conditions exist Fluids are under pressure Flying debris or loose material is present Engine is running Tools are being used CAUTION When repairing hydraulic systems clean the work area befo...

Page 401: ...ulic cylinder and remove cylinder 1 2 2256 Figure 19 40 Remove Retaining Pin 2257 Figure 19 41 Remove Pivot Pin Auxiliary Cylinder Installation 1 Reverse the removal procedure to install the auxiliary...

Page 402: ...your hydraulic cylinder exactly as it appears but the internal assembly is the same 1 Case 5 O ring 9 Head 2 Nut 6 O ring 10 Oil Seal 3 Seal 7 Back up Ring 11 Dust Seal 4 Piston 8 O ring 12 Rod 2258 F...

Page 403: ...Wrench MEL1076 Cylinder Wrench Torque Multiplier See your Ingersoll Rand dealer NOTE The drawings may not show the cylinder exactly as it appears but the procedure is correct for all the cylinders 1...

Page 404: ...2 Figure 19 46 Pull Components from Rod 10 If the head has a seal remove the seal from the head Figure 19 47 Page 19 30 11 Remove the O ring and back up washer from the head Figure 19 48 Page 19 30 22...

Page 405: ...Remove Piston Seal 2268 Figure 19 52 Remove Piston O ring 16 Wash the cylinder parts in clean solvent and dry with compressed air NOTE While servicing the cylinder do not damage the parts Inspect for...

Page 406: ...e seal 2 Install the seal on the tool and stretch it until it fits the piston Figure 19 54 Page 19 32 Allow the O ring to stretch for 30 seconds before removing it from the tool 3 Install the seal on...

Page 407: ...l seal goes toward the inside of the cylinder 6 Install the oil seal in the head Figure 19 58 Page 19 33 2273 Figure 19 57 Rod Seal Tool 2274 Figure 19 58 Install Oil Seal in Head 7 Install the wiper...

Page 408: ...as you install it Damage to the seal may result 2277 Figure 19 61 Install O ring on Head 2278 Figure 19 62 Install Seal 13 Use a ring compressor to compress the seal to the correct size Figure 19 63 P...

Page 409: ...re 19 66 Install Cushion Sleeve If Equipped and Piston 16 Install and tighten nut to 150 to 185 ft lb 203 to 251 N m torque Figure 19 67 Page 19 36 17 Remove the rod from the vise 18 Install the cylin...

Page 410: ...od assembly in the cylinder case Figure 19 70 Page 19 36 22 Put oil on the seals and threads on the head Figure 19 71 Page 19 37 23 Use the adjustable gland nut wrench to tighten the head until the he...

Page 411: ...ing debris or loose material is present Engine is running Tools are being used 1 Remove bushing s 1 Figure 19 73 Page 19 37 from the base end of the hydraulic cylinder one bushing on each side of cyli...

Page 412: ...E FRAME BUSHINGS SNOW BLADE ANGLE FRAME Removal and Installation WARNING Wear safety glasses to prevent eye injury when any of the following conditions exist Fluids are under pressure Flying debris or...

Page 413: ...19 79 Page 19 39 from both ends of the angle frame 5 Apply LOCTITE 271 Red to the bushings before installing them into the angle frame Figure 19 80 Page 19 39 6 Install the four bushings 2 on both en...

Page 414: ...Apply LOCTITE and Install Pivot Bushings 1 Remove the two bushings 1 Figure 19 81 Page 19 40 from both sides of the angle frame 2 Apply LOCTITE 271 Red to the bushing before installing them into the a...

Page 415: ...ying debris or loose material is present Engine is running Tools are being used CAUTION When repairing hydraulic systems clean the work area before disassembly and keep all parts clean Always use caps...

Page 416: ...6 and bolts 7 securing top of mount to vehicle Figure 19 84 Page 19 41 13 Remove front mount pulling at bottom of front fascia as necessary to clear mount FRONT MOUNT INSTALLATION 1 Reverse the remova...

Page 417: ...ch to ON 10 Pump fluid out of the hoses by moving the joystick back and forth and side to side several times and pressing the auxiliary hydraulic switch if equipped to the right and left several times...

Page 418: ...ng the Battery Gasoline Diesel Vehicles on page 1 3 See Top Post Battery Disconnecting the Battery Gasoline Diesel Vehicles on page 1 4 5 Release the clamp securing the vent hose to top of clutch cove...

Page 419: ...1 Remove wire tie securing hoses wire harness to chassis Figure 19 89 Page 19 45 2305 Figure 19 89 Wire Tie to Chassis 2306 Figure 19 90 Pump To Cradle Bolts 12 Lift pump and cradle up and while guidi...

Page 420: ...clamp bolt to 60 in lb 6 4 N m 7 Tighten the small terminals of solenoid to 10 in lb 1 1 N m and 21 in lb 2 4 N m on the large terminals 8 Connect battery See Side Post Battery Connecting the Battery...

Page 421: ...19 93 Page 19 47 5 Grasp motor housing and armature and pull motor from pump See following NOTE NOTE The motor may require effort to remove because the bearing is also being pulled out of the base Fi...

Page 422: ...for Installing Modular Pump on Existing Unit following page 19 48 PRIMING THE PUMP 1 Fill reservoir to the Maximum Fluid Level line 2 Cycle pump and cylinders refilling reservoir as necessary until t...

Page 423: ...moval 7 23 ball joint upper installation 7 21 removal 7 21 battery diesel vehicles 14 21 charging 14 23 14 24 hydrometer test 12 11 installation 14 24 load test 12 13 maintenance 14 22 mineral content...

Page 424: ...21 cable forward reverse adjustment 17 11 installation 17 11 removal 17 10 camber adjustment 7 17 measurement 7 15 carbon canister gasoline vehicles installation 15 19 removal 15 19 carburetor gasoli...

Page 425: ...4 assembly three weight design 16 29 cleaning 16 26 disassembly three weight design 16 26 inspection 16 26 three weight design 16 29 installation 16 29 removal 16 26 troubleshooting 16 24 drive clutch...

Page 426: ...8 operation 13 7 removal 13 7 fuel level sending unit diesel vehicles installation 16 12 removal 16 11 testing 12 39 fuel level sending unit gasoline vehicles installation 15 13 removal 15 12 testing...

Page 427: ...9 11 testing 19 10 K key switch diesel vehicles glow plug circuit testing 12 17 installation 14 7 14 8 on position testing 12 16 removal 14 7 14 8 starter circuit testing 12 15 key switch gasoline veh...

Page 428: ...schedule 10 1 pump assembly hydraulic installation 19 46 removal 19 44 pump fuel diesel vehicles installation 16 12 pump fuel gasoline vehicles 15 10 pump fuel mechanical diesel vehicles installation...

Page 429: ...hedule 10 1 shock absorber front installation 7 25 removal 7 24 rear installation 9 2 removal 9 1 solenoid fuel diesel vehicles installation 14 3 removal 14 3 solenoid hydraulic attachment installatio...

Page 430: ...enoid pull coil circuit 12 37 28 fuel solenoid hold coil circuit 12 37 29 low oil warning light 12 38 3 ground cables 12 14 30 12 volt accessory receptacle 12 38 31 fuel level sending unit 12 39 32 fu...

Page 431: ...ubleshooting brake system 6 5 clutches diesel vehicles 16 24 clutches gasoline vehicles 15 29 diode troubleshooting guide gasoline vehicles 11 19 troubleshooting guide diesel vehicles 12 1 troubleshoo...

Page 432: ...NOTES...

Page 433: ...NOTES...

Page 434: ...NOTES...

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