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Club Car Carryall XRT 1550, Maintenance And Service Manual

The Club Car Carryall XRT 1550 is a versatile utility vehicle designed for tough terrain. Make sure you keep it running smoothly with the Maintenance And Service Manual, available for free download from manualshive.com. This manual is essential for proper care and maintenance of your Club Car.

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11

Troubleshooting Guide

TROUBLESHOOTING AND ELECTRICAL

SYSTEM: GASOLINE VEHICLES

TROUBLESHOOTING GUIDE

SYMPTOM

POSSIBLE CAUSES

REFER TO

Spark plug is fouled or in poor condition

Spark Plugs on page 10-15

Spark plug wire is damaged or loose

See the Kawasaki FH680D engine manual

(CC P/N 103351201).

Intermittent ignition coil failure

Test Procedure 21 – Ignition Spark on page

11-26, Test Procedure 22 – Engine Kill Wire

on page 11-26, and Test Procedure 23 –

Grounded Kill Wire on page 11-27

Water or dirt in the fuel system and/or

carburetor; dirty or clogged fuel filter

Fuel System on page 15-8

Engine starts but does not run smoothly.

Fuel pump malfunction; fuel pressure to

carburetor too low

Fuel System on page 15-8

Fuel tank is empty

Fuel System on page 15-8

Fuel line or filters clogged

Fuel System on page 15-8

Fouled spark plug

Spark Plugs on page 10-15

Spark plug wire damaged or loose

See Section 15 – Gasoline Engine, Muffler,

Fuel System, and Clutches.

Engine flooded with fuel as result of 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

11-26, Test Procedure 22 – Engine Kill Wire

on page 11-26, and Test Procedure 23 –

Grounded Kill Wire on page 11-27

Kill circuit grounded

Test Procedure 23 – Grounded Kill Wire on

page 11-27

Carburetor solenoid failure

Test Procedure 27 – Carburetor Solenoid

Circuit on page 11-29

Engine turns but fails to start.

Improper idle governor adjustment

Engine Control Linkages on page 15-20

Fan screen is partially blocked or plugged

See the Kawasaki FH680D engine manual

(CC P/N 103351201).

Governor is improperly adjusted

Engine Control Linkages on page 15-20

Engine overheats.

Carburetor is too lean; check main jet size

Carburetor on page 15-9

Excessive carbon deposits on piston head or

in combustion chamber

See the Kawasaki FH680D engine manual

(CC P/N 103351201).

Spark plug heat range is incorrect

Spark Plugs on page 10-15

Engine pre-ignites.

Unsuitable or contaminated fuel

Fuel System on page 15-8

TABLE CONTINUED ON NEXT PAGE

Page 11-2

2013 Carryall 295/XRT 1550 Maintenance and Service Manual

Summary of Contents for Carryall XRT 1550

Page 1: ...2013 Carryall 295 XRT 1550 Maintenance and Service Manual Carryall 295 295 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach Vehicles Manual Number 103997711 Edition Code 0613A00000...

Page 2: ......

Page 3: ...of Club Car LLC to assist its distributors and dealers in continually updating their service knowledge and facilities so they can provide prompt and efficient service for vehicle owners Regional tech...

Page 4: ...amage to a vehicle or component thereof not resulting from a defect or that occurs due to unreasonable or unintended use overloading abuse or neglect including failure to provide reasonable or necessa...

Page 5: ...Stored Vehicle to Service 3 7 Lifting The Vehicle 3 8 Lifting Only The Front 3 8 Lifting Only The Rear 3 8 Lifting The Entire Vehicle 3 9 Using A Booster Battery Jump Starting 3 10 SECTION 4 BODY AND...

Page 6: ...Brake Pedal 5 4 Park Brake Pedal Assembly Removal Cable Only System 5 4 Park Brake Pedal Assembly Installation Cable Only System 5 4 SECTION 6 HYDRAULIC AND PARK BRAKE SYSTEMS 6 1 Brake System Inspect...

Page 7: ...pension Components 7 14 Steering Upright Removal 7 14 Steering Upright Installation 7 16 Upper A Arm Removal 7 16 Upper A Arm Installation 7 18 Lower A Arm Removal 7 18 Lower A Arm Installation 7 19 F...

Page 8: ...TROUBLESHOOTING AND ELECTRICAL SYSTEM GASOLINE VEHICLES 11 1 Troubleshooting Guide 11 1 Wiring Diagram 11 6 Test Procedures 11 8 SECTION 12 TROUBLESHOOTING AND ELECTRICAL SYSTEM DIESEL VEHICLES 12 1...

Page 9: ...Warning Buzzer Limit Switch If Equipped 13 13 Testing the Reverse Warning Buzzer Limit Switch 13 13 Reverse Warning Buzzer Limit Switch Removal 13 13 Reverse Warning Buzzer Limit Switch Installation 1...

Page 10: ...7 Key Switch Removal 14 7 Key Switch Installation 14 7 12 Volt Accessory Receptacle 14 8 Testing the 12 Volt Accessory Receptacle 14 8 12 Volt Accessory Receptacle Removal 14 8 12 Volt Accessory Recep...

Page 11: ...ion 14 20 Wire Harness Diodes 14 20 Testing the Wire Harness Diodes 14 20 Wire Harness Diode Removal 14 20 Wire Harness Diode Installation 14 21 Battery 14 21 General Information 14 21 Testing the Bat...

Page 12: ...6 6 Fuel System 16 8 Fuel Lines 16 8 Bleeding Air From Fuel System 16 9 Fuel Filter Replacement 16 9 Fuel Pump 16 12 Fuel Level Sending Unit 16 12 Fuel Tank 16 15 Engine Control Linkages 16 18 General...

Page 13: ...t 18 6 Coolant Pipe Weldment Removal 18 6 Coolant Pipe Weldment Installation 18 6 Fan 18 7 Fan Removal 18 7 Fan Installation 18 7 SECTION 19 HYDRAULIC ATTACHMENT SYSTEM 19 1 Model Identification 19 1...

Page 14: ...9 Front Mount Removal 19 39 Front Mount installation 19 40 Hydraulic Pump Assembly 19 40 Fluid Level Inspection 19 41 Fluid Change 19 41 Pump Assembly 19 42 Reservoir 19 44 Motor 19 45 Pump 19 46 Prim...

Page 15: ...ury or death Contact your dealer DANGER A DANGER indicates an immediate hazard that will result in severe personal injury or death The color associated with Danger is RED WARNING A WARNING indicates a...

Page 16: ...until the tire is completely removed Inflated tires can generate a gas mixture with the air that can be ignited by high temperatures from welding procedures performed on the wheel or rim Removing the...

Page 17: ...e and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation To avoid unintentionally starting the vehic...

Page 18: ...corrosion 4 Gasoline Vehicles Only Connect the spark plug wire s to the spark plug s RECYCLING LEAD ACID BATTERIES WARNING Lead acid batteries contain lead Pb other metals acids and other compounds I...

Page 19: ...SAFETY General Warnings 1 1403 Figure 1 3 Dispose of Lead acid Batteries Properly 2013 Carryall 295 XRT 1550 Maintenance and Service Manual Page 1 5...

Page 20: ...le battery or batteries 1 2 3 4 5 6 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...

Page 21: ...engine centrifugal ball Governor internal to engine mechanical centrifugal ball Ignition Transistorized magneto Ignition Compression Transmission Forward and reverse with neutral 5 39 1 forward 7 79 1...

Page 22: ...ithout 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 72...

Page 23: ...differential 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...

Page 24: ...rman Suspension Front Independent double A arms with coil over shock absorbers Rear Semi independent four link suspension with coil over shock absorbers Brakes Hydraulic brake system brake pads and di...

Page 25: ...in Sound level external per 74 151 EEC Annex VI as amended by 2006 96 EC Variant Version All Moving 79 9 dB A Stationary 73 9 dB A Engine Speed 2 700 min Vibration at driver s seat per 78 764 EEC 1 24...

Page 26: ...over shock absorbers Steering Self adjusting rack and pinion Ackerman Brakes Hydraulic brake system brake pads and discs on each wheel with separate foot operated park brake BODY CHASSIS Frame Chassis...

Page 27: ...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 Hydraul 56 lubricant CC...

Page 28: ......

Page 29: ...r 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 Transporting...

Page 30: ...diator and Coolant Reservoir under hood diesel engine model only 1630 Figure 3 2 Vehicle Components North America Vehicle 3 2 4 5 6 10 7 1 9 11 8 1 Hood 2 ROPS 3 Fuel Fill Cap 4 Cargo Bed 5 Engine Com...

Page 31: ...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 valid for the bu...

Page 32: ...L INFORMATION 830 Figure 3 6 Gasoline Engine Serial Number Location 831 Figure 3 7 Diesel Engine Serial Number Location 2703 Figure 3 8 Differential Serial Number Location Page 3 4 2013 Carryall 295 X...

Page 33: ...ithin a given model year See following NOTE NOTE Have the vehicle serial number available when ordering parts or making inquiries Build Code The build code 4 is a five digit number that appears on the...

Page 34: ...key and leave the Forward Reverse handle in the NEUTRAL position during storage This is to prevent unintentionally starting the vehicle or a fire hazard Gasoline vehicles only Turn fuel shut off valve...

Page 35: ...k 6 1 Fill the fuel tank with fresh fuel 6 2 Disconnect the fuel vent line from the fuel tank vent nipple Figure 10 24 Page 10 20 6 3 Plug the fuel tank vent nipple so that it is air tight The manufac...

Page 36: ...6 Perform the Pre Operation and Daily Safety Checklist See the Pre Operation and Daily Safety Checklist in the vehicle owner s manual LIFTING THE VEHICLE See General Warnings on page 1 2 LIFTING ONLY...

Page 37: ...k the front or rear wheels and loosen the lug nuts 4 If removing wheels loosen the lug nuts 5 Release the park brake and lift the front of the vehicle with a chain hoist or floor jack See preceding WA...

Page 38: ...ry 3 Access the engine compartment by raising the cargo bed See WARNING For vehicles with cargo beds in General Warnings on page 1 2 4 Locate the vehicle battery on the driver s side of the vehicle un...

Page 39: ...GENERAL INFORMATION Using A Booster Battery Jump Starting 3 POS NEG P O S N E G 2 3 1 4 435 Figure 3 13 Jump Starting 2013 Carryall 295 XRT 1550 Maintenance and Service Manual Page 3 11...

Page 40: ......

Page 41: ...l or aluminum The manufacturer does not recommend any type of pressure washing or steam cleaning Such a process will expose electrical components to moisture Moisture entering electrical components ca...

Page 42: ...aired area dry and visually inspect to be sure that the originial scratch has completely disappeared 3 Repeat step 2 using 1500 grit sandpaper until all 1200 grit scratches are removed paying close at...

Page 43: ...plastic cap to gain access to the bolt head Gain access to the rear nut and washer by raising hood and reaching up inside rear of instrument panel 8 Loosen and remove the hex bolt securing the top po...

Page 44: ...he three hex head screws that secure the front fascia to the frame 3 Disconnect the lighting wire harness from each light at connectors 4 Separate the front fascia from front fenders and remove from v...

Page 45: ...stallation on page 4 4 SIDE COWL PANEL FENDER REMOVAL 1 Remove Roll over Protective Structure ROPS if equipped See ROPS Removal on page 4 7 2 Remove hood See Hood Removal on page 4 4 3 Remove center c...

Page 46: ...ead screws securing the front fender flare to the floorboard and the lower outboard end of the instrument panel 6 Remove the three hex head screws securing the front fender flare to the frame and remo...

Page 47: ...id of an assistant and a rubber mallet 1 Remove the upper four bolts 1 and four flanged nuts 2 that secure the top structure 3 to the two side supports 4 and remove the top structure Figure 4 1 Page 4...

Page 48: ...nd secure with hex head bolts 1 and flanged lock nuts 2 Do not tighten hardware at this time See following NOTE NOTE Orient the top structure 3 so the grab handle is on the passenger side and the warn...

Page 49: ...and forward to raise it 2 2 Remove the seat by lifting the front edge hinges from the vehicle frame hinge slots SEAT ADJUSTMENT 1 Stationary driver and passenger bucket seats 1 1 Remove the seat from...

Page 50: ...ELTS See General Warnings Section 1 Page 1 2 CAUTION Be careful not to damage the safety belt webbing or hardware Inspect the safety belt system periodically Check for cuts fraying and loose parts Rep...

Page 51: ...side of the ROPS seat support with the shoulder bolt and a new lock nut Figure 4 2 Page 4 11 Orient the assembly with the tang end pointed up slightly and tighten the new lock nut to 35 ft lb 47 5 N m...

Page 52: ...th the shoulder bolt and a new lock nut Figure 4 2 Page 4 11 Orient the assembly with the tang end pointed up slightly and tighten the new lock nut to 33 ft lb 44 7 N m CARGO BED ELECTRIC LIFT See Gen...

Page 53: ...m 3 Tighten the locknut on the bed lift motor base to 30 ft lb 41 N m 4 Attach the two electric wire connectors red to red and yellow to yellow 5 Connect battery See Connecting the Battery Gasoline D...

Page 54: ...ch plate 11 Lift the bed from the vehicle CARGO BED INSTALLATION NOTE Cargo bed removal and installation will be easier with the aid of an assistant 1 Place the front edge of the bed onto the vehicle...

Page 55: ...peat steps 1 through 4 to remove the remaining rear fender if necessary REAR FENDER INSTALLATION 1 Lift bed 2 Put fender in place 3 Install the three Tuflok plastic fasteners to secure the top of the...

Page 56: ...4 Rear Fender BODY AND TRIM 4 3 17 11 5 2 7 6 16 16 13 12 1 13 10 8 15 14 9 1884 Figure 4 5 Cargo Bed Page 4 16 2013 Carryall 295 XRT 1550 Maintenance and Service Manual...

Page 57: ...g the Battery Gasoline Diesel Vehicles Section 1 Page 1 3 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 AWD vehicle...

Page 58: ...if worn ACCELERATOR PEDAL INSTALLATION 1 Installation is reverse of removal procedure 2 Check return spring length and adjust if necessary Figure 5 3 Page 5 2 3 Tighten pedal pivot bolt 1 and locknut...

Page 59: ...n the frame brackets 2 Install the allen head shoulder bolt and locknut Tighten the hardware to 4 8 ft lb 6 5 N m 3 Install the master cylinder rod and threaded clevis pin assembly 4 Install the clevi...

Page 60: ...assembly by removing the bow tie locking pin 1 and clevis pin 2 Figure 5 5 Page 5 4 4 Remove the three bolts 3 and locknuts 4 that secure both the park brake pedal assembly and the cable anchor bracke...

Page 61: ...to 15 ft lb 20 N m 3 Connect the cable end to the park brake pedal assembly with bow tie locking pin 1 and clevis pin 2 4 Connect battery See Connecting the Battery Gasoline Diesel Vehicles Section 1...

Page 62: ......

Page 63: ...from side to side to check for worn parts Excessive side movement indicates loose or worn pedal mounting parts If worn parts are found replace the worn parts then adjust the brake pedal See Brake Ped...

Page 64: ...he vent holes in the reservoir cap and clean or replace as necessary Check the diaphragm inside the reservoir cap and replace if damaged A A 1 2 3 4 6 7 10 16 5 8 9 10 15 14 12 11 13 11 1 Brake Fluid...

Page 65: ...RAKE DISC AND PAD INSPECTION Inspect each brake disc They should not be warped or have excessive scores or heat checks Each disc should be at least 0 150 inches 3 8 mm at the thinnest point Inspect ea...

Page 66: ...ed DOT 5 silicone brake fluid See Purging the Hydraulic System on page 6 17 Weak bulging brake hoses that expand under pressure Check the master cylinder brake lines and hoses for leaks or bulges Repl...

Page 67: ...ge 7 1 Decreasing brake pedal travel Sticking caliper piston Replace the caliper See Brake Pads and Caliper on page 6 6 Bent damaged or incorrect brake pads Replace the brake pads See Brake Pads and C...

Page 68: ...Bleeding the Hydraulic Brake System on page 6 15 Prior to servicing hydraulic brakes thoroughly clean the vehicle paying particular attention to areas immediately surrounding hydraulic connections to...

Page 69: ...d 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 system Use only DOT 5 bra...

Page 70: ...ongy brake pedal it is possible that the service caused the leak as described above There are three likely scenarios for this condition 1 The bolt was backed out too far and was not re adjusted proper...

Page 71: ...ic system See Bleeding the Hydraulic Brake System on page 6 15 See following WARNING WARNING Use the top bleeding port on each caliper to bleed that respective front wheel Ensure hydraulic hoses canno...

Page 72: ...n this procedure the hydraulic system is opened the brakes must be bled after the correct reinstallation of the brake components Failure to bleed the brakes could result in decreased braking performan...

Page 73: ...entering the brake line port 4 Remove the front brake lines banjo bolts and copper washers at each front wheel caliper assembly NOTE Place a pan under each caliper assembly to collect brake fluid Pla...

Page 74: ...he hydraulic system See Bleeding the Hydraulic Brake System on page 6 15 8 Inspect the brake system See Brake System Inspection on page 6 1 See following WARNING WARNING Use the top bleeding port on e...

Page 75: ...TION 1 Feed a new brake line from the rear of the vehicle and position it in line with the frame clamps and up to the master cylinder See following NOTE NOTE If a heavy nylon string was used to remove...

Page 76: ...pin from the brake pedal and push rod clevis Figure 6 9 Page 6 15 5 Remove the two bolts and locknuts that secure the master cylinder to the frame 6 Remove the master cylinder from the vehicle MASTER...

Page 77: ...ire bleeding depending on where the hydraulic system was opened Pressure or vacuum bleeding with preference given to the pressure bleeding method is the recommended way to remove air from a brake syst...

Page 78: ...ands before the manual bleeding procedure is performed See following WARNING WARNING Do not bleed brakes with only one end of the vehicle raised To place vehicle on four jack stands lift only one end...

Page 79: ...h brake caliper starting at the next caliper farthest from the master cylinder 7 After bleeding fill the master cylinder reservoir to the MAX level with DOT 5 brake fluid 8 Tighten the cap on the mast...

Page 80: ...k brake lever 3 Figure 6 10 Page 6 18 4 Carefully thread in and finger tighten the adjustment bolt 2 Then back adjustment bolt out 1 2 turn 5 Once resistance is felt stop and hold the adjustment bolt...

Page 81: ...before the vehicle is returned to service See Brake System Inspection on page 6 1 9 Verify brakes do not drag when park brake is released PARK BRAKE WHEEL CABLES Right Rear Cable Removal 1 Chock the...

Page 82: ...tside hole Figure 6 12 Page 6 19 6 Attach cable end to the equalizer 2 7 Use the nuts on the threaded end 6 to adjust the cable end Both cables should be equal in length Tighten the nuts to 40 ft lb 5...

Page 83: ...racket 7 and anchor the cable ferrule into bracket Figure 6 15 Page 6 21 2 Connect the cable end to the park brake pedal assembly with bow tie locking pin 5 and clevis pin 6 3 Connect the cable to the...

Page 84: ...he cup washer 4 against the equalizer 2 followed by the cone washer 3 and two nuts 1 in their original positions and orientation Tighten the hex nut closest to the equalizer until the cable is taut 4...

Page 85: ...ering wheel retaining bolt 4 6 Remove the steering wheel See following NOTE NOTE The steering wheel has a tapered hex fitting A steering wheel puller CC P N 102061201 may be required to remove the ste...

Page 86: ...ge 1 2 STEERING COLUMN REMOVAL 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 Disconnect battery See Disconnecting the Battery Gasoline Diesel Vehicles Section 1 Page 1 3 3 Remove the s...

Page 87: ...t lb 24 N m NOTE Be sure to tighten the bolt at the universal joint on the rack and pinion shaft before tightening the steering column coupling bolt 5 Tighten the steering column coupling bolt to 18 f...

Page 88: ...ots Listen for unusual noises Replace the rack and pinion as an assembly if any is found RACK AND PINION REMOVAL 1 Lift and support the front of vehicle and remove the wheels See Lifting The Vehicle o...

Page 89: ...ghtened during alignment 7 Install the outer drag link ball joints on each upright and tighten the hardware to 70 ft lb 95 N m Figure 7 5 Page 7 4 8 Align the front wheels See Wheel Alignment on page...

Page 90: ...nut 8 rack guide screw 7 rack guide pressure spring 6 and the rack guide 5 Figure 7 16 Page 7 8 7 Remove the dust seal Figure 7 10 Page 7 6 8 Remove the snap ring 4 Figure 7 11 Page 7 6 4 16 2051 Figu...

Page 91: ...gure 7 16 Page 7 8 If either is excessively worn replace both ball joints 13 1 Secure the rack and housing assembly in a vise Figure 7 14 Page 7 7 See following CAUTION CAUTION Use wood blocks between...

Page 92: ...ck and 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 16 Steering Gear Assembly Page 7 8 2013 Carryall 295 XRT 1550 Maintenance and Service Ma...

Page 93: ...assembly 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 17 Page 7 9 1 2...

Page 94: ...a light coat of anti seize lubricating compound to the inner ball joint threads to minimize corrosion 17 Loosely install and advance the two nuts and drag links to the inner ball joint Figure 7 8 Page...

Page 95: ...f wheel revolution until the marks appear on the forward facing surfaces of the tires at the same height as the center of each hub Measure the distance between the marks Figure 7 21 Page 7 11 See foll...

Page 96: ...t Toe Out 4 Subtract the rear face tire measurement from the front face tire measurement Proper toe out is 3 16 to 1 4 inch 4 8 to 6 35 mm 3 16 inch 4 8 mm Toe Out Adjustment S N 1309 347765 and Great...

Page 97: ...with dimension A being less than dimension B 5 The negative camber for this vehicle should be from zero to 0 275 inch 7 0 mm maximum See following NOTE NOTE A good average dimension for this specifica...

Page 98: ...EMOVAL 1 Disconnect battery and spark plug wire s gasoline vehicles only See Disconnecting the Battery Gasoline Diesel Vehicles on page 1 3 2 Loosen the lug nuts 3 Remove the rubber spindle nut cover...

Page 99: ...on page 6 15 10 Remove brake disc from hub 11 Remove the outer drag link ball joints from the upright assemblies Figure 7 30 Page 7 15 2065 Figure 7 30 Drag Link Ball Joint 12 Remove the lower and upp...

Page 100: ...age 7 15 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 See Brake Disc and Pad Inspection on pa...

Page 101: ...the top of the ball 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 2...

Page 102: ...new 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 t...

Page 103: ...face 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...

Page 104: ...he Vehicle on page 3 8 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 S...

Page 105: ...he shock mount on the vehicle frame with a bolt and flange head locknut Tighten the hardware to 62 ft lb 84 N m Figure 7 40 Page 7 20 See previous NOTES 2 Install the bottom of the shock mount on the...

Page 106: ......

Page 107: ...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 1 Dire...

Page 108: ...e on 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...

Page 109: ...2 FRONT 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 14 2 Remove the hub from the bearing and up...

Page 110: ...4 3 2 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 provid...

Page 111: ...ut large enough to engage the outside 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...

Page 112: ...hicles on page 1 3 2 Loosen the lug nuts 3 Remove the rubber dust cap 4 Remove and discard the cotter pin 1 Figure 8 7 Page 8 7 5 Remove nut locking cap 2 and loosen the axle nut 3 on the axle shaft 6...

Page 113: ...Exploded View 2561 Figure 8 8 Puller Removing Rear Hub If Necessary REAR HUB INSTALLATION 1 Clean the spline and threaded portion of the axle shaft 2 Apply anti seize compound to both the axle shaft...

Page 114: ...er tighten the 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...

Page 115: ...sorbers is different from the part number for heavy 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...

Page 116: ...rence See following NOTE NOTE When shock absorbers are installed ensure both shock absorbers have identical part numbers 1 Installation is the reverse of removal 2 Tighten the upper and lower hardware...

Page 117: ...ear axle 4 Remove the hardware securing the lateral link 1 to the chassis Figure 9 2 Page 9 4 5 Remove the hardware securing the lateral link 1 to the rear axle LATERAL LINK INSTALLATION 1 Installatio...

Page 118: ...9 Trailing Arms and Lateral Links REAR SUSPENSION 2 1 3 2495 Figure 9 2 Rear Suspension Components 4 Link Page 9 4 2013 Carryall 295 XRT 1550 Maintenance and Service Manual...

Page 119: ...ove the hardware securing the front of the trailing arm to the chassis and remove the trailing arm TRAILING ARM INSTALLATION 1 Installation is the reverse of removal Figure 9 2 Page 9 4 Orient hardwar...

Page 120: ......

Page 121: ...chedule 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 Safety Chec...

Page 122: ...park brake cables for damage replace if necessary Semiannual service by trained technician only or every 50 hours of operation whichever comes first Brake system Check brake pads and discs replace if...

Page 123: ...e and tighten if necessary Fuel filters Replace Dispose of used filters properly Safety decals Check safety decals Replace if damaged or illegible Every 200 hours of operation by trained technician on...

Page 124: ...engine oil level add if necessary Diesel vehicles Check engine coolant add if necessary Engine Clean debris from radiator Fuel filters Diesel vehicles Drain water from fuel filter Brakes Check brake...

Page 125: ...tc Diesel 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...

Page 126: ...wner 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 opera...

Page 127: ...PERIODIC MAINTENANCE Periodic Lubrication Schedule 10 5 6 3 1 4 2 2 3 200 Figure 10 2 Lubrication Points Diesel Vehicles 2013 Carryall 295 XRT 1550 Maintenance and Service Manual Page 10 7...

Page 128: ...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 comes...

Page 129: ...mes a 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...

Page 130: ...ragm located in the cap should not have holes or other damage BRAKE FLUID Brake fluid level should be within 1 4 inch 6 mm from the top of the reservoir Figure 10 6 Also brake fluid should be clean wi...

Page 131: ...while engine is running 2 Check oil level by fully inserting the dipstick into the tube and immediately removing it 3 If the oil level is at or below the low level mark on the dipstick gauge add oil t...

Page 132: ...lowing WARNING WARNING Do not attempt to change engine oil when the engine is hot or even warm Hot engine oil can cause skin burns Wear safety glasses or approved eye protection when servicing the veh...

Page 133: ...re 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 or plastic under the oil filter formi...

Page 134: ...wires See Connecting the Battery Gasoline Diesel Vehicle on page 1 4 5 With the Forward Reverse handle in the NEUTRAL position start and run the engine for three minutes and check for leaks Observe bo...

Page 135: ...park plug 2 If the plug is oily or has carbon built up on it clean the plug using a high flash point solvent and a wire brush or other suitable tool 3 If the spark plug electrodes are corroded or dama...

Page 136: ...16 LUBRICATION CHANGE FOR FRONT DIFFERENTIAL TRANSMISSION AND REAR DIFFERENTIAL NOTE Metal particles may be discovered in the fluid or on the magnetic drain plug when changing the differential or tran...

Page 137: ...transmission 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 i...

Page 138: ...ey 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 10 18 5 Move the joystick 1 t...

Page 139: ...caused by static electricity the fuel storage pumping device must be grounded If the pump is not grounded the vehicle must be grounded to the pump before and during the fueling operation To avoid the...

Page 140: ...ll be used in the Kubota D722 engine be sure that it meets the following requirements The fuel blend should contain no more than 5 biodiesel by volume The petroleum portion of the fuel blend must meet...

Page 141: ...om the fuel filter daily The fuel filter is mounted on a plate by the lower seat support panel Figure 10 25 1 Position a pan under the fuel filter 2 Lift the passenger side seat 3 Locate the valve 1 o...

Page 142: ...ry PERIODIC MAINTENANCE BATTERY For periodic battery maintenance see Battery on page 13 18 gasoline vehicles or page 14 21 diesel vehicles Page 10 22 2013 Carryall 295 XRT 1550 Maintenance and Service...

Page 143: ...1 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 Water or dirt in the fuel sy...

Page 144: ...sult of 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...

Page 145: ...are not backshifting properly Clutches on page 15 28 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 th...

Page 146: ...rocedure 15 Neutral Switch Transmission on page 11 23 Starter fails to operate Transmission shifter linkage is binding or is out of adjustment Forward Reverse Shifter Cable Adjustment on page 17 13 Lo...

Page 147: ...awasaki 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 30 Failed low oil warning light or o...

Page 148: ...ICLES WIRING DIAGRAM G M 6 7 1 4 2 DIODE 1 DIODE 2 DIODE 3 FRONT DIFFERENT IAL LIMITSWITCH WD1033057 7 L NOTE AWD diagram shown 2 wheel drive vehicle uses same harness Figure 11 1 Wiring Diagram Front...

Page 149: ...STEM GASOLINE VEHICLES Wiring Diagram 11 DIODE 5 DIODE 4 WD1033057 7 R NOTE AWD diagram shown 2 wheel drive vehicle uses same harness Figure 11 2 Wiring Diagram Rear 2013 Carryall 295 XRT 1550 Mainten...

Page 150: ...24 Key Switch Engine Kill Circuit 25 Reverse Warning Buzzer Limit Switch If Equipped 26 Reverse Warning Buzzer If Equipped 27 Carburetor Solenoid Circuit 28 Low Oil Warning Light Circuit 29 12 Volt Ac...

Page 151: ...ip onto the vehicle body Battery acid will cause permanent damage Wash off immediately 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 Check for loose or corroded battery terminal connec...

Page 152: ...charge or it may be a weak cell When the variations between cells reach 0 050 or more the battery should be replaced Voltage Test 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 Check f...

Page 153: ...9 6 volts at 70 F 21 C electrolyte temperature check the starter See the Kawasaki FH680D engine manual CC P N 103351201 See also the following NOTE NOTE Record the voltage reading at 70 F 21 C At low...

Page 154: ...epair or replace as required 4 Check the engine ground wire w203 located on the remote oil filter bracket for corrosion loose connections and or damage Figure 11 7 Page 11 13 Repair or replace as requ...

Page 155: ...ohms 5 Turn the key switch ON Place the red probe of the multimeter on the B terminal and the black probe on the L terminal of the key switch The reading should indicate continuity If the reading doe...

Page 156: ...e the key switch See Key Switch Removal on page 13 8 TEST PROCEDURE 6 Starter Control Circuit See General Warnings Section 1 Page 1 2 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 Disc...

Page 157: ...rt relay wire w110 terminal and the frame ground Figure 11 10 Page 11 16 5 Monitor the multimeter The reading should indicate 0 volts with the key in the OFF and ON positions The reading should indica...

Page 158: ...8 w110 and w43 See Wiring Diagram on page 11 6 TEST PROCEDURE 8 Carburetor Heater Relay See General Warnings Section 1 Page 1 2 NOTE Keep the battery connected during this test procedure The carbureto...

Page 159: ...4 If the multimeter indicates continuity while the key is in the ON position and the engine is off the contacts have failed closed Replace the relay 7 If the reading obtained in step 5 is not 12 VDC...

Page 160: ...0nA 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 500 20k 2...

Page 161: ...the key switch contacts Diode 4 w130 and w122 Carburetor solenoid coil flyback diode Closed The 10 amp fuse on w109 will blow repeatedly when key is in ON position until the diode has been replaced Op...

Page 162: ...over limit no continuity If the diode conducts current shows continuity with the meter probes connected as described the diode has failed and must be replaced See Wire Harness Diode Removal on page 13...

Page 163: ...e black probe of the multimeter to the frame ground 6 Connect the red probe of the multimeter to the female side of the carburetor solenoid bullet connector 7 The reading should indicate an over limit...

Page 164: ...note the reading The multimeter should indicate approximately 540 mV however a range of 400 to 700 mV is acceptable 10 If the readings obtained in the previous steps are incorrect replace the diode Se...

Page 165: ...ure 11 16 Page 11 23 3 Check for continuity on the switch contacts with the Forward Reverse handle in the FORWARD position Figure 11 17 Page 11 23 The multimeter should indicate no continuity 2090 Fig...

Page 166: ...ace the red probe on the terminal at one end of the wire Place the black probe on the other terminal end of the wire The reading should indicate continuity If the reading is incorrect repair or replac...

Page 167: ...Battery Gasoline Diesel Vehicles on page 1 3 2 Disconnect the two pin connector between the wire harness and the front drive gearcase located under the hood 3 Set the multimeter to 200 ohms 4 Measure...

Page 168: ...gnition Spark See General Warnings Section 1 Page 1 2 NOTE Keep the battery connected during this test procedure 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 Remove the spark plug wir...

Page 169: ...on 1 Page 1 2 NOTE Keep the battery connected during this test procedure 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 Disconnect the engine kill black wire of engine harness at the bu...

Page 170: ...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 Check for proper wiring and tight connections...

Page 171: ...art 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...

Page 172: ...t terminal 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 To...

Page 173: ...ngs 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 Disconnect battery and spark plug w...

Page 174: ...sition of the float but the reading on the fuel gauge hour meter is incorrect test the fuel gauge hour meter See Test Procedure 31 Fuel Gauge on page 11 32 TEST PROCEDURE 31 Fuel Gauge See General War...

Page 175: ...play It is powered by an internal battery and should always be on even with the engine off and the key removed 3 Start the engine and let it idle See following DANGER DANGER Do not operate vehicle in...

Page 176: ...14 gauge blue wire w113 from the light switch to the fuse block Check the fuse See Test Procedure 2 Fuse on page 11 11 If the wires and fuse show continuity and the readings are still incorrect repla...

Page 177: ...ue wire 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 th...

Page 178: ...are wired incorrectly Check the 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 c...

Page 179: ...7 5 14 Red w7 6 14 Yellow w5 8 14 Black w2 2104 Figure 11 35 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 whe...

Page 180: ......

Page 181: ...and fuel filter Fuel filter clogged Replace fuel filter See Fuel Filter Replacement on page 16 9 Fuel line or pipe s clogged Clean or replace fuel line and or pipe s See Fuel System on page 16 8 Fuel...

Page 182: ...ment on page 17 13 Engine does not start starter motor does not function Diode 1 2 5 or 6 failed closed Test Procedure 12 Wire Harness Diodes on page 12 24 Incorrect nozzle opening pressure Injection...

Page 183: ...Low oil pressure Improper engine oil Drain engine oil and refill with specified engine oil See owner s manual Oil level is low Add engine oil See owner s manual Failed radiator fan or radiator fan cir...

Page 184: ...th specified fuel See owner s manual Fuel filter clogged Replace fuel filter See Fuel Filter Replacement on page 16 9 Black or dark gray exhaust gas is observed Air cleaner clogged Replace air filter...

Page 185: ...est Procedure 1 Battery on page 12 10 Battery discharged 60 amp fusible link failed Test Procedure 22 60 Amp Fusible Link on page 12 31 Hour meter adds increments with key switch ON and engine not run...

Page 186: ...DIESEL VEHICLES WIRING DIAGRAM DIODE 2 DIODE 1 6 7 1 4 2 FRONT DIFFERENTIAL LIMIT SWITCH FUEL GAUGE HOUR METER WD1032775E7 L Figure 12 1 Wiring Diagram for Diesel Utility Vehicles Front Page 12 6 201...

Page 187: ...ECTRICAL SYSTEM DIESEL VEHICLES Wiring Diagram 12 DIODE 3 DIODE 4 LIGHTING RELAY WD1032775E7 R Figure 12 2 Wiring Diagram for Diesel Utility Vehicles Rear 2013 Carryall 295 XRT 1550 Maintenance and Se...

Page 188: ...iagram TROUBLESHOOTING AND ELECTRICAL SYSTEM DIESEL VEHICLES WD1033181B3 Figure 12 3 Main Light Wiring Diagram Carryall 295 Homologated Vehicle Page 12 8 2013 Carryall 295 XRT 1550 Maintenance and Ser...

Page 189: ...NESS PROV IDING P O W ER T O LOW BE AM HEA D LIGHTS CONNE CTS TO W39 IN MA I N LIG HT HA RNE SS PICKS UP B CONNE CTS TO GND SPADE ON HO RN CONNE CTS T O W 21 IN VEHICL E HARNE S S PICK UP B PO WER CON...

Page 190: ...60 Amp 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 Coi...

Page 191: ...nd 1 280 at 80 F 27 C Never add acid to the battery to obtain a higher specific gravity Figure 12 5 Page 12 12 See following CAUTION CAUTION Do not allow battery acid from battery caps or hydrometer t...

Page 192: ...charge or it may be a weak cell When the variations between cells reach 0 050 or more the battery should be replaced Voltage Test 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 Check fo...

Page 193: ...ing exceeds 9 6 volts at 70 F 21 C electrolyte temperature check the starter See the Kubota D722 diesel engine manual CC P N 103840201 See also the following NOTE NOTE Record the voltage reading at 70...

Page 194: ...ion damaged terminals and an excess of paint on the engine block under the starter where the two 6 gauge black wires w202 and w203 are connected Figure 12 9 Page 12 15 Repair or replace as required 5...

Page 195: ...or clips to connect the multimeter probes between the B and A terminals With the key switch in the START position the multimeter should indicate continuity Figure 12 10 Page 12 15 If the multimeter do...

Page 196: ...move the key switch See Key Switch Removal on page 14 7 4 Set the multimeter to 200 ohms 5 Check the B and I terminals 5 1 Use alligator clips to connect the multimeter probes between the B and I term...

Page 197: ...hould indicate approximately 12 VDC when the key is in the START position 2109 Figure 12 11 Solenoid Coil Wire w127 Removed 2110 Figure 12 12 Starter Circuit Test 6 If the readings differ from those d...

Page 198: ...position and the relay should click See following NOTE NOTE The fan and accessory relays may be removed to isolate the sound of the start relay click 6 If the reading is 12 VDC and the relay does not...

Page 199: ...icate 0 volts with the key in the OFF position If not check for a short or incorrect wiring between the yellow fan relay wire w146 terminal and the key switch 3 3 The reading should indicate approxima...

Page 200: ...F to 226 F 102 C to 108 C 185 F 85 C The fan relay activates the radiator fan when the engine coolant reaches a temperature range of 187 F to 198 F 86 C to 92 C and closes the fan thermostat switch Th...

Page 201: ...t switch 6 1 Place the thermostat switch in a kitchen pot as shown Figure 12 18 Page 12 22 6 2 Set a multimeter to 200 ohms 6 3 Use an alligator clip to connect the black probe to the thermostat switc...

Page 202: ...ge yellow black wire in the connector 3 With the Forward Reverse handle still in the NEUTRAL position turn the key switch to the ON position The fan motor should run If not test voltage to fan motor V...

Page 203: ...key switch in the OFF position check the fan relay for proper wiring and function See Test Procedure 9 Fan Relay on page 12 19 12 If the voltage reading is not approximately 12 VDC with the key switc...

Page 204: ...20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 1 4 5 A B 6 2 1 2 2 1 2 3 1 1 VOM Black Lead 2 VOM Red Lead 3 Wiring Diagram Symbol with Diode Stripe Orientation 4 Good Dio...

Page 205: ...meter to the diode test function 4 Connect the black probe of the multimeter to the frame ground 5 Connect the red probe of the multimeter to the 18 gauge gray wire w35 on the two pin connector wire h...

Page 206: ...Wire Harness Diode Removal on page 14 20 TEST PROCEDURE 15 Diode 3 on wire 123 See General Warnings Section 1 Page 1 2 1 Disconnect battery See Disconnecting the Battery Gasoline Diesel Vehicles Secti...

Page 207: ...Removal on page 14 20 TEST PROCEDURE 16 Diode 4 on wire 129 See General Warnings Section 1 Page 1 2 1 Disconnect battery See Disconnecting the Battery Gasoline Diesel Vehicles Section 1 Page 1 3 2 Di...

Page 208: ...se handle in the FORWARD position Figure 12 25 Page 12 28 The multimeter should indicate no continuity 4 Check for continuity on the switch contacts with the Forward Reverse handle in the NEUTRAL posi...

Page 209: ...ndicate continuity If the reading is incorrect repair or replace the wire See following NOTE NOTE When checking continuity of wires in the wire harness observe the polarity of diodes Testing continuit...

Page 210: ...er reading is incorrect replace the switch See Front 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 ba...

Page 211: ...12 10 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 t...

Page 212: ...1 3 2 At driver side raise the seat and disconnect the two pin connector from the thermostat switch Figure 12 20 Page 12 23 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 213: ...See General Warnings Section 1 Page 1 2 NOTE Keep the battery connected during this test procedure 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 Set a multimeter to 20 VDC 3 Place the...

Page 214: ...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 215: ...12 10 Key switch See Test Procedure 4 Key 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...

Page 216: ...itch to the ON position The low oil warning 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...

Page 217: ...float is at the surface of the fuel in the tank FLOAT POSITION RESISTANCE READING FUEL GAUGE READINGS Lower position tank empty 240 20 ohms Empty Center position tank half full 120 20 ohms Half full U...

Page 218: ...12 35 Page 12 38 6 Turn the key switch ON The voltage reading should be the same as the battery voltage reading recorded earlier If not check the continuity of the blue and black wires Figure 12 35 P...

Page 219: ...PROCEDURE 34 Light Switch See General Warnings Section 1 Page 1 2 NOTE The headlight circuit is protected by the 20 amp fuse Check the fuse before this procedure is performed See Test Procedure 2 Fus...

Page 220: ...the multimeter indicates approximately 12 volts replace the headlight bulb 6 If there is no voltage reading at the wire harness check the continuity of the 16 gauge blue wire w01 and w03 from the head...

Page 221: ...re wired incorrectly Check the wiring of the bed lift harness and bed lift switch See Wiring Diagram on page 12 6 A reading of approximately 0 VDC indicates a failed bed lift switch failed bed lift ci...

Page 222: ...d Lift Switch Removal on page 14 9 2 Check continuity between the terminals Figure 12 42 Page 12 42 of the switch and compare the readings with the Bed Lift Switch Continuity Table If continuity readi...

Page 223: ...pushed 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...

Page 224: ......

Page 225: ...anual 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 component mounting...

Page 226: ...The neutral switch 1 is located on the transmission housing Figure 13 2 Page 13 1 TESTING THE NEUTRAL SWITCH See Test Procedure 15 Neutral Switch Transmission on page 11 23 NEUTRAL SWITCH REMOVAL 1 D...

Page 227: ...onnect the two pin connector from the carburetor solenoid Figure 13 3 Page 13 3 4 Remove the solenoid from the carburetor See the Kawasaki FH680D engine manual CC P N 103351201 2128 Figure 13 3 Carbur...

Page 228: ...r from the engine 3 Disconnect the green wire from the carburetor heater 1 Figure 13 4 Page 13 4 4 Remove the heater from the carburetor 2129 Figure 13 4 Carburetor Heater CARBURETOR HEATER INSTALLATI...

Page 229: ...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 230: ...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 231: ...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 time unless the key switch is in the ON p...

Page 232: ...rcuit on page 11 13 Also see Test Procedure 24 Key Switch Engine Kill Circuit on page 11 28 KEY SWITCH REMOVAL 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Diesel...

Page 233: ...E 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 sections in the receptacle threads Once aligned...

Page 234: ...er and secure the hood 4 Connect battery and spark plug wire s See Connecting the Battery Gasoline Diesel Vehicles Section 1 Page 1 4 BED LIFT CIRCUIT BREAKER TESTING THE BED LIFT CIRCUIT BREAKER See...

Page 235: ...onnector and switch 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 and spark plug wire s See Connecti...

Page 236: ...NG BUZZER IF EQUIPPED See General Warnings Section 1 Page 1 2 TESTING THE REVERSE WARNING BUZZER See Test Procedure 26 Reverse Warning Buzzer If Equipped on page 11 29 REVERSE WARNING BUZZER REMOVAL 1...

Page 237: ...itch If Equipped on page 11 28 REVERSE WARNING BUZZER LIMIT SWITCH REMOVAL 1 Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Diesel Vehicles on page 1 3 2 Raise the hoo...

Page 238: ...the 18 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 Connecting the Battery Gasoline Diesel Vehicles Section 1 Page...

Page 239: ...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 harness 4 C...

Page 240: ...e 19 Charge Coil on page 11 25 IGNITION COIL AND OR CHARGE COIL REMOVAL The ignition coils are located under the flywheel shroud of the engine and the charge coil is located behind the flywheel Replac...

Page 241: ...nnector 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 bulb Oil from finger tips can...

Page 242: ...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 into the plastic wire condu...

Page 243: ...ht Frayed or worn wires should be replaced After all cables have been connected and properly tightened to 80 in lb 9 N m coat terminals with Battery Terminal Protector Spray CC P N 1014305 to prevent...

Page 244: ...local water department to be sure mineral contents are below the levels listed in the following table See following NOTE NOTE Contact your local water department for mineral content analysis IMPURITY...

Page 245: ...tery to cool to room temperature and resume charging battery at a lower amp rate BATTERY INSTALLATION See General Warnings on page 1 2 1 Place the battery into the vehicle with the battery posts facin...

Page 246: ...recommended that the area be heated to at least 60 F 16 C prior to charging The battery will not charge effectively in cold temperatures for the same reasons that it does not discharge as rapidly in c...

Page 247: ...e manual CC P N 103840201 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 componen...

Page 248: ...eutral switch 1 is located on the transmission housing Figure 14 2 Page 14 1 TESTING THE NEUTRAL SWITCH See Test Procedure 17 Neutral Switch Transmission on page 12 28 NEUTRAL SWITCH REMOVAL 1 Disable...

Page 249: ...s securing 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...

Page 250: ...ehicles Section 1 Page 1 3 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 251: ...MOVAL 1 Disconnect battery See Disconnecting the Battery Gasoline Diesel Vehicles Section 1 Page 1 3 2 Raise the hood 3 Disconnect the wires from the warning light 1 Figure 14 6 Page 14 6 4 Press the...

Page 252: ...key 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 regi...

Page 253: ...d secure the hood 6 Connect battery See Connecting the Battery Gasoline Diesel Vehicles Section 1 Page 1 4 KEY SWITCH See General Warnings Section 1 Page 1 2 TESTING THE KEY SWITCH See Test Procedure...

Page 254: ...hood disconnect 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...

Page 255: ...sh the bed lift switch into the instrument panel until fully seated 3 Lower and secure the hood 4 Connect battery See Connecting the Battery Gasoline Diesel Vehicles Section 1 Page 1 4 BED LIFT CIRCUI...

Page 256: ...IGHT SWITCH INSTALLATION 1 Match the terminal numbers molded onto the connector and switch and reconnect the wire harness 2 Push the light switch into the instrument panel until fully seated 3 Lower a...

Page 257: ...Connecting the Battery Gasoline Diesel Vehicles Section 1 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 R...

Page 258: ...ARNING BUZZER LIMIT SWITCH See Test Procedure 25 Reverse Warning Buzzer Limit Switch If Equipped on page 12 34 REVERSE WARNING BUZZER LIMIT SWITCH REMOVAL 1 Disconnect battery See Disconnecting the Ba...

Page 259: ...ch lever is being properly activated 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 Connecting the Battery Gasoline Diese...

Page 260: ...nuts 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 h...

Page 261: ...onnect the 18 gauge purple wire from the alternator Figure 14 11 Page 14 15 3 Disconnect the 12 gauge blue fusible link from the alternator Figure 14 11 Page 14 15 Figure 14 12 Page 14 15 1 2 3 1 Purp...

Page 262: ...en the belt tension is adjusted 3 Place the V belt 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 ga...

Page 263: ...LB REMOVAL 1 Disconnect battery See Disconnecting the Battery Gasoline Diesel Vehicles Section 1 Page 1 3 2 From the front of the vehicle reach under the cowl and turn the connector harness halogen bu...

Page 264: ...est Procedure 10 Thermostat Switch on page 12 20 THERMOSTAT SWITCH REMOVAL 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 Disconnect the two pin connector between the thermostat switch...

Page 265: ...vel in the reservoir If the coolant level is at or below the LOW mark add pre mixed coolant until the level reaches the FULL mark See Engine Coolant Diesel Vehicles Section 10 Page 10 18 5 Connect bat...

Page 266: ...HARNESS 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 24...

Page 267: ...s 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 near batteries For added protection cover to...

Page 268: ...discharge the battery should always be kept 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 batter...

Page 269: ...sonal injury when accidentally coming in contact with the skin or eyes and could damage clothing CHARGING THE BATTERY See General Warnings on page 1 2 1 Charge the battery with an automotive type 12 v...

Page 270: ...stored at 0 F 17 8 C will discharge very little over a four month period A battery stored at 80 F 27 C will have to be recharged every few weeks 5 Check the state of charge periodically A battery tha...

Page 271: ...ELECTRICAL COMPONENTS DIESEL VEHICLES Battery 14 WARNING Do not jump start a dead battery with another battery and jumper cables 2013 Carryall 295 XRT 1550 Maintenance and Service Manual Page 14 25...

Page 272: ......

Page 273: ...Gasoline Diesel Vehicles on page 1 3 2 Remove the cargo bed See Cargo Bed Removal Section 4 Page 4 13 3 Remove seat s and remove the center seat plate bucket seat vehicles only 4 Remove the ROPS Roll...

Page 274: ...e Engine 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 2013 Carryall 295 XRT 1550 Maintenance and Servi...

Page 275: ...nlet 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 2...

Page 276: ...N m 9 Install the clutches 5 See Drive Clutch Installation on page 15 33 Also see Driven Clutch Installation on page 15 36 10 Install the drive belt See Drive Belt Installation on page 15 29 11 Instal...

Page 277: ...ilter Hose Removal 1 Drain the engine oil See Engine Oil on page 10 10 2 Place a pan under the oil filter hose connections on the engine See following NOTE NOTE It s best to disconnect the engine hose...

Page 278: ...ft the end of the muffler inlet and intermediate pipe from side to side to relax and disconnect the springs 4 Remove the two bolts and large flat washers that secure the muffler to the chassis and rem...

Page 279: ...e springs that show signs of brittleness broken coils or loss of tension 1 Loosely secure the muffler and spring suspension bracket to the chassis with two bolts and large flat washers Figure 15 4 Pag...

Page 280: ...k to Canister 7 4 3 16 in 5 mm Vent Tube Canister 7 to Air Filter Canister 8 5 5 16 in 8 mm Vent Tube Canister 7 to Atmosphere A 3 16 inch to 1 4 inch flared vent hose connected the fuel tank to the c...

Page 281: ...l CC P N 103351201 FUEL PUMP See General Warnings Section 1 Page 1 2 Procedures for inspection removal and installation can be found in the engine manual See the Kawasaki FH680D engine manual CC P N 1...

Page 282: ...tting The Kawasaki FH680D engine is equipped with a carburetor that has fixed jets These fixed jets do not require adjustment The size of the main jet is determined by the altitude where the engine wi...

Page 283: ...E KAWASAKI FH680 ENGINE MODEL REVISION CARBURETOR NUMBER 0 3300 FT 0 1000 M 3300 6600 FT 1000 2000 M 6600 FT AND HIGHER 2000 M AND HIGHER CS09 47050 DS09 to current 40755 Left 102 Right 104 99 99 96 9...

Page 284: ...soline Diesel Vehicles on page 1 3 2 Remove the passenger seat See Seat Removal Section 4 Page 4 9 3 Remove the rubber boot 8 from the center post on the fuel level sending unit Remove the nut 9 from...

Page 285: ...ing holes 1 is larger than the distance between any of the other mounting holes in the sending unit flange 5 Ensure the replacement gasket is rubber and that the mounting holes in the gasket are align...

Page 286: ...a crisscross pattern to tighten the hardware to 9 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 s...

Page 287: ...plates and engine cover plate 6 Turn the fuel shut off valve to the closed OFF position Figure 15 13 Page 15 19 7 Run the engine until all fuel in the carburetor fuel pump and fuel lines is used and...

Page 288: ...nk in 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 ve...

Page 289: ...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 an odorless deadly poison Do not operate t...

Page 290: ...ge 1 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 18 4 Push pull the canister to force it from its m...

Page 291: ...off 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 19 1 2 3 1 Fuel Shut off Valve 2 Closed OFF 3...

Page 292: ...attery Gasoline Diesel Vehicles Section 1 Page 1 3 Accelerator Cable Removal NOTE When the accelerator cable is replaced the high speed RPM must be adjusted See High Speed RPM Adjustment on page 15 25...

Page 293: ...ry and spark plug wire s See Disconnecting the Battery Gasoline Diesel Vehicles on page 1 3 2 Remove seat s 3 Remove the center seat plate bucket seat vehicles only 4 Remove the engine top cover 5 Rem...

Page 294: ...17 Page 15 22 5 Feed the Z shaped cable end 2 of the choke cable through the engine front cover Figure 15 16 Page 15 22 6 Push the cable sheath strain relief 3 into the engine front cover 4 until it...

Page 295: ...stops 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 Eng...

Page 296: ...504 Figure 15 19 Overview of RPM 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 o...

Page 297: ...The engine 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 tacho...

Page 298: ...e Periodic 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 runn...

Page 299: ...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 300: ...ngine RPM and governor adjustments If these adjustments are within specifications there is a clutch problem See Engine RPM Adjustment on page 15 24 If the clutches are not operating properly perform t...

Page 301: ...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 302: ...icate 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 15 28 Page 15...

Page 303: ...GASOLINE ENGINE MUFFLER FUEL SYSTEM AND CLUTCHES Clutches 15 2500 Figure 15 27 Using the Drive Clutch Service Tool Three Weight 2013 Carryall 295 XRT 1550 Maintenance and Service Manual Page 15 31...

Page 304: ...in 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 23 9 Button Torque Primary 14 Screw Shoulder Hex Socket 0 25x2 5 5 Sp...

Page 305: ...65301 to tighten the moveable sheave and spider to 265 ft lb 359 N m 3 Install the spacer 4 and spring 5 onto the shaft 4 Place the cover plate 2 onto the shaft 5 Pull the moveable sheave upward and s...

Page 306: ...ing CAUTION CAUTION Do not hit or tap the clutch with a hammer Do not pry the clutch These actions will damage the clutch Driven Clutch Disassembly The following service tools are required to disassem...

Page 307: ...retain the spacers for reassembly of the driven clutch 1 2 4 5 3 6 6 X X 2175 Figure 15 30 Driven Clutch Assembly Driven Clutch Assembly 1 Place the fixed sheave 5 onto the spring compression base an...

Page 308: ...away from the clutches and belt Failure to heed this warning could result in severe personal injury Clutch Outer Cover Installation 1 Align the mounting holes in the clutch cover with the mounting ho...

Page 309: ...hten the transmission bolts and washers to 21 ft lb 28 5 N m 6 Install the driven clutch See Driven Clutch Installation on page 15 36 7 Install the drive clutch See Drive Clutch Installation on page 1...

Page 310: ......

Page 311: ...seat frame assembly See ROPS Removal Section 4 Page 4 7 6 Drain the engine and radiator coolant system See Engine Coolant Change Section 18 Page 18 1 7 Release the clamps securing the upper 1 and low...

Page 312: ...ne bracket 13 Disconnect the three pin connector 7 on the fuel solenoid valve from the engine Figure 16 1 Page 16 2 14 Disconnect the thermostat switch connector 8 from the wire harness Figure 16 2 Pa...

Page 313: ...ft tabs on top of the engine to lift the engine from the mounting plate 28 If replacing engine remove cvt adapter shaft from flywheel and retain for use on replacement engine ENGINE INSTALLATION See G...

Page 314: ...mable Explosive Do not smoke Keep sparks and flames 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...

Page 315: ...move the muffler See following WARNING and NOTE WARNING Always wear eye protection when springs are removed or installed NOTE Replace springs that show signs of brittleness broken coils or loss of ten...

Page 316: ...EDIATE PIPE INSTALLATION 1 Secure the intermediate pipe to the manifold pipe with new springs See following WARNING and NOTE WARNING Always wear eye protection when springs are removed or installed NO...

Page 317: ...te 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 Connecting the Battery Gasoline Dies...

Page 318: ...fuel tank 22 0 in 55 8 cm Total 36 0 in 91 4 cm of 5 16 in 8 mm 29 0 in 73 5 cm of 3 16 in 5 mm 22 0 in 55 8 cm 2694 Figure 16 8 Fuel System Diesel Vehicles FUEL LINES See General Warnings Section 1...

Page 319: ...for a few seconds by turning key switch to the START position and hold for a few seconds 3 Loosen the air vent on top of the fuel filter assembly to allow air bubbles to escape Tighten vent once bubbl...

Page 320: ...r from the Fuel Filter above 1 Disconnect battery See Disconnecting the Battery Gasoline Diesel Vehicles Section 1 Page 1 3 2 Place a large pan under the fuel filter to catch fuel 3 Turn filter counte...

Page 321: ...CLUTCHES Fuel System 16 4 Verify the water separator drain valve is closed bleed air from the system and check for leaks See Bleeding Air From Fuel System on page 16 9 2013 Carryall 295 XRT 1550 Main...

Page 322: ...the Battery Gasoline Diesel Vehicles Section 1 Page 1 3 2 Remove the passenger seat See Seat Removal Section 4 Page 4 9 3 Remove the rubber boot 8 from the center post on the fuel level sending unit...

Page 323: ...is warning could result in a fire or explosion 1 Place a new rubber gasket 3 on the fuel tank with the notch 2 centered between the flange identification mounting holes 1 Figure 16 11 Page 16 14 See f...

Page 324: ...and NOTE CAUTION Ensure all mounting holes in the fuel level sending unit gasket and fuel tank are aligned properly before hardware is installed Improper alignment of the mounting holes could result i...

Page 325: ...17 in lb 1 9 N m and secure the rubber boot 8 to the center post 7 Install the passenger seat See Seat Installation Section 4 Page 4 10 8 Connect battery See Connecting the Battery Gasoline Diesel Veh...

Page 326: ...he end of the hose above the fuel tank Plug the line See previous NOTE and DANGER 7 Loosen the clamp and remove the vent tube from the fuel tank 8 Remove the fuel tank cap 9 Use a siphon with a built...

Page 327: ...ttom of the frame Install a nylon locknut and tighten the nut to 40 in lb 4 5 N m 4 Connect the clear vent tube to the fuel tank vent and secure the tube with a new clamp 5 Connect the fuel line to th...

Page 328: ...es are not cracked cut or worn ENGINE CONTROL LINKAGES GENERAL INFORMATION For proper vehicle operation it is important the accelerator cable idle RPM and high speed RPM adjustments are done correctly...

Page 329: ...he cable allow the cord to travel from the engine under the frame and up to the dashboard This cord can be used to route the cable during installation 2362 Figure 16 15 Accelerator Cable At Pedal Z Sh...

Page 330: ...the Vehicle on page 1 3 2 Clean paint grease and dirt from one of the three fuel injector lines Figure 16 17 Page 16 20 See following NOTES NOTE It is very important that the line be cleaned enough to...

Page 331: ...ector lines Figure 16 17 Page 16 20 See following NOTE NOTE It is very important that the line be cleaned enough to expose the metal Read the tachometer and diesel probe instructions before any RPM ad...

Page 332: ...gine by allowing excessive contamination or water to enter the air intake system Air Filter Removal 1 Release both canister tab locks Figure 16 22 Page 16 22 2 Pull the canister cap away from the cani...

Page 333: ...LLATION 1 Position the canister next to the frame bracket with the tab lock released and oriented toward the passenger side 2 Install two bolts on the canister base bracket and vehicle frame bracket T...

Page 334: ...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 following 1 Check th...

Page 335: ...he driven clutch Drive Belt Installation 1 Position the new belt on the drive clutch and then start the belt over the top of the driven clutch 2 Rotate the driven clutch clockwise and roll the belt ov...

Page 336: ...he fixed face assembly 15 Do not use a brush or steel wool These abrasives will damage the surface of the shaft Do not use solvents Solvents will damage the lubricating characteristics of the bushings...

Page 337: ...DIESEL ENGINE MUFFLER FUEL SYSTEM AND CLUTCHES Clutches 16 2500 Figure 16 27 Using the Drive Clutch Service Tool Three Weight 2013 Carryall 295 XRT 1550 Maintenance and Service Manual Page 16 27...

Page 338: ...Pin 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...

Page 339: ...N m 3 Install the spacer 4 and spring 5 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...

Page 340: ...lace the driven clutch onto the Spring compression base CC P N 102603501 1 Figure 16 29 Page 16 30 2 Place the Spring compression collar CC P N 102605201 2 onto the driven clutch 3 Thread the Spring c...

Page 341: ...re 16 29 Page 16 30 5 Tighten the spring compression nut just enough to enable the snap ring to be installed 6 Use the snap ring pliers to install snap ring Driven Clutch Installation 1 Disconnect bat...

Page 342: ...y Gasoline Diesel Vehicles Section 1 Page 1 4 See following NOTE NOTE Ensure the hose clamp is tightly installed and positioned between the filter canister and canister port bead Clutch Inner Cover Re...

Page 343: ...pths on the engine block Mounting holes in the clutch inner cover have close tolerances Align the engine and transmission carefully to ensure the mounting holes in the clutch inner cover match the thr...

Page 344: ......

Page 345: ...s gasoline vehicles only See Disconnecting the Battery Gasoline Diesel Vehicles Section 1 Page 1 3 2 Loosen the lug nuts on both front wheels 3 Remove the rubber spindle nut covers from both front whe...

Page 346: ...up and away from the lower A frame to remove the half shaft spindle from the wheel hub and remove the camber bar from the lower A frame 1896 Figure 17 2 Front Caliper and Discs 2193 Figure 17 3 Camber...

Page 347: ...nt differential Advance the half shaft until the compression ring seats into the groove inside the differential housing 3 Lift the wheel hub and upper A frame Slide the half shaft spindle into the whe...

Page 348: ...ber See Camber Adjustment Section 7 Page 7 13 15 Connect battery See Connecting the Battery Gasoline Diesel Vehicles Section 1 Page 1 4 FRONT DIFFERENTIAL FRONT DIFFERENTIAL REMOVAL See General Warnin...

Page 349: ...ents Figure 17 10 Page 17 5 See following NOTE NOTE Do not remove the flange head bolts from the differential plate and differential housing 11 Pull the front differential and differential plate forwa...

Page 350: ...slightly below the surface on both sides of the coupling Use a 1 4 inch roll pin punch to drive the roll pin into place 8 Fill the front differential with the specified lubricant See Periodic Lubricat...

Page 351: ...uring the brake calipers to axle tubes Figure 17 11 Page 17 8 Discard bolts 6 Remove brake calipers from rear axle and temporarily hang them from the chassis with a piece of wire See following CAUTION...

Page 352: ...be slightly below the surface on both sides of the coupling Use a 1 4 inch roll pin punch to drive the roll pin into place 5 Secure axle to trailing arms and lateral links at four locations with bolts...

Page 353: ...n 1 Page 1 2 1 Push the car to a position that enables easy access to the roll pin securing the rear driveshaft to the differential pinion shaft Figure 17 12 Page 17 9 Chock the front wheels 2 Disconn...

Page 354: ...ch cover See Clutch Outer Cover Removal on page 15 36 gasoline vehicles 3 Remove the drive belt See Drive Belt Removal on page 15 29 gasoline vehicles 4 Remove the drive clutch See Drive Clutch Remova...

Page 355: ...in the inner cover are very close in diameter to bolt sizes The inner cover is used to align the engine and transmission and is the primary support for the transmission Allow the inner cover plate to...

Page 356: ...1 Disconnect battery and spark plug wire s gasoline vehicles only See Disconnecting the Battery Gasoline Diesel Vehicles Section 1 Page 1 3 2 Raise the hood 3 Disconnect cable end from Forward Reverse...

Page 357: ...frame down between the splash guard and frame under the vehicle body and up to the transmission Use care during cable installation and avoid bending the rigid tubular ends of the cable assembly 2 Att...

Page 358: ...fter handle is centered between those positions in the NEUTRAL position 8 Install the passenger seat 9 Lower and secure the hood 10 Gasoline vehicles Connect the spark plug wires 11 Connect battery Se...

Page 359: ...Clean debris from drain plug and area around it at the bottom of the differential Drain oil Install plug after draining 2 If removing entire rear axle from vehicle remove the rear axle and clean it in...

Page 360: ...ach thread location with a thread tap M12 x 1 75 pitch before 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 101928...

Page 361: ...bricate the bore with anti seize compound Figure 17 20 Page 17 17 2 Using an appropriate sized bearing driver that fits the outer race drive in new bearing 3 until fully seated 3 Install retaining rin...

Page 362: ......

Page 363: ...urized Remove caps slowly to relieve pressure Hot Coolant system is pressurized Do not remove radiator cap while engine is hot 3 Place a large drain pan under the radiator and engine drain plugs 4 Tur...

Page 364: ...in lb 16 N m 12 Continue adding to the reservoir until coolant reaches the radiator fill spout Replace the radiator cap 13 Fill the reservoir to the FULL mark with coolant and check for leaks Replace...

Page 365: ...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 not have a drain STOP position It can be...

Page 366: ...t system 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...

Page 367: ...t down into chassis to rest in the aluminum frame channel See preceding CAUTION 3 Install the two radiator support brackets over the studs of the rubber isolators and finger tighten flanged locknuts S...

Page 368: ...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 the chassis and remove the pipes See f...

Page 369: ...ot 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 hood FAN See General Warnings Section...

Page 370: ......

Page 371: ...t any stored energy for example pressure is released Also extended equipment or cylinders should be lowered and mechanically locked as required The manufacturer is not responsible for misuse or misapp...

Page 372: ...is in the OFF position and set the joystick ON OFF switch to OFF ATTACHMENT INTERFACE INSPECTION Hand Lever WARNING The pins must extend through the holes in attachment Lever must be fully engaged in...

Page 373: ...RM MECHANISM 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 fr...

Page 374: ...e attachment 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 O...

Page 375: ...with 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 r...

Page 376: ...in and Retainer Ring 7 Swing the attachment interface cylinder down 8 Turn the key to the ON position but DO NOT start the engine 9 Move the joystick 1 forward to extend the attachment arm cylinder Fi...

Page 377: ...ll the pin 3 and retaining ring 4 Figure 19 16 Page 19 6 13 Raise the attachment interface and align it with the cylinder Install the pin 2 and the retaining ring 1 Figure 19 17 Page 19 7 2225 Figure...

Page 378: ...l HYDRAULIC ATTACHMENT SYSTEM ELECTRICAL Diode 3 Diode 2 WD1027864C L Figure 19 18 Wiring Diagram for Hydraulic Attachment System Vehicles Front Page 19 8 2013 Carryall 295 XRT 1550 Maintenance and Se...

Page 379: ...LIC ATTACHMENT SYSTEM Electrical 19 Diode 4 Diode 1 WD1027864C R Figure 19 19 Wiring Diagram for Hydraulic Attachment System Vehicles Rear 2013 Carryall 295 XRT 1550 Maintenance and Service Manual Pag...

Page 380: ...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 W37_YEL Bottom Switch 15 W79_ORG Top Switch 16 W77_ORG Bottom Switc...

Page 381: ...liary Switch 3 To ON OFF Swtich 4 Wire Tie 5 Relay 1 6 Relay 2 2237 Figure 19 21 Joystick Hardware 2238 Figure 19 22 Joystick Components 1 Set the joystick ON OFF switch to OFF and remove both seats 2...

Page 382: ...k w10 5 18 Red White w82 6 18 Red w16 2239 Figure 19 23 ON OFF Switch Test Rear View Testing the Joystick ON OFF Switch NOTE The control circuit is protected by a 20 amp fuse Check the fuse before thi...

Page 383: ...Insert switch into control box until fully seated 2 Connect harness plug to switch 3 Install control box cover joystick assembly and secure with the four screws 4 Secure joystick harness to chassis wi...

Page 384: ...rol Valves on page 19 19 Continuity of the wires involved Float Switch Removal 1 Set the joystick ON OFF switch to OFF and remove both seats 2 Disconnect battery See Disconnecting the Battery Gasoline...

Page 385: ...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 Auxi...

Page 386: ...6 2 Test for no continuity between terminal 87 orange white wire and terminal 30 light blue wire Figure 19 26 Page 19 16 3 Apply 12 volts with the positive lead connected to terminal 86 and the negati...

Page 387: ...nals 87 and 30 red wires Figure 19 29 Page 19 17 3 Apply 12 volts with the positive lead connected to terminal 86 and the negative lead connected to terminal 85 The relay should click and show continu...

Page 388: ...argo bed 2 Set the joystick ON OFF switch to OFF 3 Disconnect battery See Disconnecting the Battery Gasoline Diesel Vehicles Section 1 Page 1 3 4 Note wiring and disconnect wires and copper strap from...

Page 389: ...ion Normally Closed Valves 1 2 3 1 Two Way 2 Position Control Valves 2 Three Way 2 Position Control Valves 3 Four Way 2 Position Control Valves 2 1 2 1 2247 Figure 19 31 Control Valve Identification 2...

Page 390: ...ough bottom of cartridge to move plunger It will help to have the body filter removed See following NOTE NOTE The cartridge itself cannot be disassembled in the field as the proper tolerances cannot b...

Page 391: ...nite Click is heard when the valve in energized If it cannot be heard remove the cartridge from the valve body and blow compressed air through all parts to dislodge dirt Clean all parts in solvent blo...

Page 392: ...ved Figure 19 34 Page 19 21 5 If removing more than one hose at a time locate and note the hose factory color marking to ease reassembly See following NOTE NOTE Mark hoses for correct installation if...

Page 393: ...les Section 1 Page 1 3 4 Thoroughly clean the fittings and the area around them 5 Mark hoses to ease reassembly and disconnect hoses from quick connect fittings See following NOTE Cover hoses and fitt...

Page 394: ...the joystick ON OFF switch to OFF remove driver seat and disable vehicle See Disabling the Vehicle on page 1 3 3 Disconnect battery See Disconnecting the Battery Gasoline Diesel Vehicles Section 1 Pag...

Page 395: ...ids 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 before disassembly and keep all pa...

Page 396: ...der 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 hydraulic cylinder in the att...

Page 397: ...show 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 2...

Page 398: ...d Nut 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 cylinde...

Page 399: ...head has a seal remove the seal from the head Figure 19 47 Page 19 29 11 Remove the O ring and back up washer from the head Figure 19 48 Page 19 29 2263 Figure 19 47 Remove Seal 2264 Figure 19 48 Remo...

Page 400: ...cylinder do not damage the parts Inspect for nicks scratches or otherwise damaged or bent parts before assembling the cylinder Replace parts that appear damaged in any way The cylinder may not functio...

Page 401: ...ure 19 54 Page 19 31 Allow the O ring to stretch for 30 seconds before removing it from the tool 3 Install the seal on the piston Figure 19 55 Page 19 32 4 Use the ring compressor to compress the seal...

Page 402: ...he oil seal goes toward the inside of the cylinder 6 Install the oil seal in the head Figure 19 58 Page 19 32 2273 Figure 19 57 Rod Seal Tool 2274 Figure 19 58 Install Oil Seal in Head 7 Install the w...

Page 403: ...seal 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...

Page 404: ...Figure 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 35 17 Remove the rod from the vise 18 Install the...

Page 405: ...re 19 70 Page 19 35 22 Put oil on the seals and threads on the head Figure 19 71 Page 19 35 23 Use the adjustable gland nut wrench to tighten the head until the head is flush with the case Figure 19 7...

Page 406: ...end of the hydraulic cylinder one bushing on each side of cylinder 2 Apply LOCTITE 271 Red to the bushings 2 before installing them into the cylinder Figure 19 74 Page 19 36 1 2 2289 Figure 19 73 Remo...

Page 407: ...prevent eye injury when any of the following conditions exist Fluids are under pressure Flying debris or loose material is present Engine is running Tools are being used 1 Remove bushings 1 Figure 19...

Page 408: ...o the bushings before installing them into the angle frame Figure 19 80 Page 19 38 6 Install the four bushings 2 on both ends of the angle frame 1 2 2295 Figure 19 79 Remove Four Pivot Bushings 2296 F...

Page 409: ...38 on both sides of the angle frame FRONT MOUNT FRONT MOUNT REMOVAL 1 Front Mount Not Shown For Clarity 7 4 1 2 3 6 5 2299 Figure 19 83 Front Fascia Bolts 2300 Figure 19 84 Front Mount Hardware WARNIN...

Page 410: ...Mounted Cylinders on page 19 24 9 Loosen bottom of front fascia by removing two bolts securing it to vehicle Figure 19 83 Page 19 39 10 Remove four bolts 1 and washers 2 from lower part of mount unde...

Page 411: ...uipped quick connect fittings Allow cylinders to drain into pan and then cover cylinder and quick connect fittings to keep out debris See Vehicle Mounted Cylinders on page 19 24 See also Quick Connect...

Page 412: ...moval 1 Empty and remove cargo bed See Cargo Bed Removal Section 4 Page 4 13 2 Relieve pressure See Relieving Hydraulic System Pressure on page 19 1 3 Set the joystick ON OFF switch to OFF and remove...

Page 413: ...pump assembly from chassis Figure 19 88 Page 19 43 11 Remove wire tie securing hoses wire harness to chassis Figure 19 89 Page 19 43 2305 Figure 19 89 Wire Tie to Chassis 2306 Figure 19 90 Pump To Cr...

Page 414: ...radle hardware lock nuts to 33 5 ft lb 45 N m 5 Tighten the front cradle hardware lock nut to 21 ft lb 28 N m 6 Tighten the park brake cable clamp bolt to 60 in lb 6 4 N m 7 Tighten the small terminal...

Page 415: ...Remove two bolts and end cover from motor Figure 19 93 Page 19 45 5 Grasp motor housing and armature and pull motor from pump See following NOTE NOTE The motor may require effort to remove because the...

Page 416: ...tions for Installing Modular Pump on Existing Unit following page 19 46 PRIMING THE PUMP 1 Fill reservoir to the Maximum Fluid Level line 2 Cycle pump and cylinders refilling reservoir as necessary un...

Page 417: ...TANT Place a small amount of grease on the tang of the drive shaft This will help the tang slide past the shaft seal in the pump base without damaging it Carefully slide the pump into place 9 Align 4...

Page 418: ...NOTES...

Page 419: ...19 ball joint upper installation 7 17 removal 7 17 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 14 22 r...

Page 420: ...nt 15 24 jetting 15 10 troubleshooting 15 9 carburetor heater gasoline vehicles installation 13 4 removal 13 4 carburetor heater relay gasoline vehicles testing 11 16 carburetor solenoid gasoline vehi...

Page 421: ...e vehicles 15 28 assembly three weight design 15 33 cleaning 15 30 disassembly three weight design 15 30 inspection 15 30 three weight design 15 33 installation 15 33 removal 15 30 troubleshooting 15...

Page 422: ...shut off valve gasoline vehicles 15 19 fuel solenoid diesel vehicles hold coil circuit testing 12 35 installation 14 3 pull coil circuit testing 12 35 removal 14 3 fuel system diesel vehicles 16 8 fu...

Page 423: ...starter circuit testing 11 13 kill circuit engine gasoline vehicles testing 11 28 kill wire engine gasoline vehicles testing 11 26 L lateral link installation 9 3 removal 9 3 lifting jacking instruct...

Page 424: ...3 R rack and pinion 7 3 assembly 7 9 disassembly 7 5 installation 7 4 removal 7 4 radiator diesel vehicles coolant pipe installation 18 6 removal 18 6 electric fan and shroud installation 18 7 removal...

Page 425: ...ehicle 2 1 start relay diesel vehicles testing 12 18 start relay gasoline vehicles testing 11 15 starter control circuit diesel vehicles testing 12 17 starter control circuit gasoline vehicles testing...

Page 426: ...2 16 7 starter control circuit 12 17 8 start relay 12 18 9 fan relay 12 19 test procedures gasoline vehicles 1 battery 11 8 10 diode 1 11 19 11 diode 2 11 20 12 diode 3 11 20 13 diode 4 11 21 14 diode...

Page 427: ...t diesel vehicles installation 14 16 removal 14 15 voltage regulator gasoline vehicles installation 13 5 removal 13 5 testing 11 26 W wheel installation 8 2 removal 8 2 wheel bearing installation 17 1...

Page 428: ...NOTES...

Page 429: ...to help us better serve you please rate this publication in the following categories Poor Fair Average Good Excellent 5 If you are reviewing a Kit Instruction were all indicated parts included in you...

Page 430: ...NOTES...

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