Club Car IntelliTach XRT 1550 Maintenance And Service Manual Download Page 157

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TROUBLESHOOTING AND ELECTRICAL SYSTEM: KAWASAKI POWERED GASOLINE VEHICLES

Troubleshooting Guide

2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual

Page 11a-3

11A

Loss of engine power.

Exhaust valve is restricted with carbon
deposit

See the Kawasaki FH680D engine
manual (CCI P/N 103351201).

Muffler or exhaust pipe restricted with
carbon or other substance

Exhaust System on page 13a-6

Ignition coil failure

Test Procedure 15 – Ignition Spark on
page 11a-26

Air filter is dirty or clogged

Air Filter Replacement on page 13a-23

Governor is improperly adjusted

Fuel System on page 13a-9

Throttle linkage out of adjustment

Engine Control Linkages on page 13a-18

Low cylinder compression

See the Kawasaki FH680D engine
manual (CCI P/N 103351201).

Spark plug failed

Spark Plugs on page 10b-12

Restricted fuel flow

Fuel System on page 13a-9

Clutches are not backshifting properly

Clutches on page 13a-27

Spark plug fouls repeatedly.

Incorrect plug

Spark Plugs on page 10b-12

Unsuitable fuel, or incorrect (rich) fuel
mixture

Fuel System on page 13a-9

Spark plug wire is damaged

See the Kawasaki FH680D engine
manual (CCI P/N 103351201).

Dirt entering combustion chamber

Fuel System on page 13a-9

Ignition coil failed

See the Kawasaki FH680D engine
manual (CCI P/N 103351201).

Rings are heavily worn, low cylinder
pressure

See the Kawasaki FH680D engine
manual (CCI P/N 103351201).

Carburetor floods.

Inlet valve or seat is leaking,
dirty, worn, or damaged

See the Kawasaki FH680D engine
manual (CCI P/N 103351201).

Float is damaged and filled with gasoline

See the Kawasaki FH680D engine
manual (CCI P/N 103351201).

Carburetor vent is clogged

See the Kawasaki FH680D engine
manual (CCI P/N 103351201).

Float needle valve not functioning
properly

See the Kawasaki FH680D engine
manual (CCI P/N 103351201).

Starter fails to operate.

Starter control circuit is
not operating

Test Procedure 5 – Starter Control Circuit
on page 11a-14

Start relay failure

Test Procedure 6 – Start Relay on
page 11a-15

Fuse is blown

Test Procedure 2 – Fuse on page 11a-12

Battery is dead

Test Procedure 1 – Battery on page 11a-9

Charge coil failed

Test Procedure 13 – Charge Coil on
page 11a-25

Troubleshooting Guide continued on next page...

TROUBLESHOOTING GUIDE

SYMPTOM

POSSIBLE CAUSES

REFER TO

Summary of Contents for IntelliTach XRT 1550

Page 1: ...Manual Number 103209114 Edition Code 1006F1208E Gasoline Diesel and IntelliTach and Homologated Vehicles 2007 Carryall 295 295SE and XRT 1550 1550SE Maintenance and Service Manual...

Page 2: ......

Page 3: ...For this reason Club Car advises that all repairs and or service be performed by an authorized Club Car distributor dealer representative or by a Club Car factory trained technician It is the policy...

Page 4: ...le appear in future editions of this manual Damage to a vehicle or component thereof not resulting from a defect or that occurs due to unrea sonable or unintended use overloading abuse or neglect incl...

Page 5: ...AS KUBOTA DIESEL POWERED 295 295 SE and 1550 1550 SE Specifications 2b 1 295 Homologated Specifications 2b 3 IntelliTach Specifications 2b 5 SECTION 3 GENERAL INFORMATION General Information 3 1 Model...

Page 6: ...tion 4 6 Roll Over Protective Structure ROPS 4 6 ROPS Removal 4 7 ROPS Installation 4 8 Seat 4 9 Seat Removal 4 9 Seat Adjustment 4 9 Seat Installation 4 9 Seat Support Removal 4 10 Seat Support Insta...

Page 7: ...t Brake Pad and Caliper Removal 6 5 Front Brake Pad and Caliper Installation 6 7 Rear Brake Pad and Caliper Removal 6 8 Rear Brake Pad and Caliper Installation 6 9 Brake Disc and Hub 6 10 Front Wheel...

Page 8: ...2 Steering Column 7 2 Steering Column Removal 7 2 Steering Column Installation 7 3 Rack and Pinion 7 3 Rack and Pinion Removal 7 3 Rack and Pinion Installation 7 4 Rack and Pinion Disassembly 7 5 Rack...

Page 9: ...ne Engine 10a 7 Engine Oil Level Check 10a 8 Engine Oil and Filter Change 10a 8 Oil Viscosity 10a 12 Gearcase Lubrication 10a 13 Lubrication Level Check for Front Differential Transmission and Rear Di...

Page 10: ...ic System Intellitach Vehicle 10b 15 Engine Coolant Diesel Vehicles 10b 16 Engine Coolant Level Check 10b 16 Fueling Instructions 10b 16 Draining Water from Fuel Filter 10b 17 Battery 10b 18 SECTION 1...

Page 11: ...a 10 Fuse 12a 10 Reverse Warning Buzzer If Equipped 12a 11 Reverse Warning Buzzer Limit Switch If Equipped 12a 12 Front Differential Limit Switch 12a 13 Fuel Level Sending Unit 12a 14 Ignition Coil an...

Page 12: ...and Starter Solenoid 12c 1 Relays 12c 1 Neutral Switch 12c 2 Fuel Solenoid 12c 2 60 Amp Fusible Link 12c 3 Warning Lights 12c 5 Fuel Gauge Hour Meter 12c 6 Key Switch 12c 7 12 Volt Accessory Receptac...

Page 13: ...0 Fuel Pump 13a 10 Carburetor 13a 10 Fuel Level Sending Unit 13a 11 Fuel Tank 13a 14 Fuel Shut Off Valve 13a 17 Engine Control Linkages 13a 18 Accelerator Cable 13a 18 Choke Cable 13a 20 Engine Govern...

Page 14: ...9 Fuel Tank 13b 12 Fuel Shut Off Valve 13b 15 Oil Filter Hoses 13b 16 Engine Control Linkages 13b 16 Accelerator Cable 13b 16 Governor Guard 13b 19 Governor Cable 13b 19 Accelerator Cable Retention C...

Page 15: ...anifold Pipe Installation 13c 6 Intermediate Pipe Installation 13c 6 Muffler Installation 13c 7 Fuel System 13c 8 Fuel Lines 13c 9 Fuel Filter Replacement 13c 9 Draining Water from the Secondary Fuel...

Page 16: ...7 Rear Receiver Hitch 14 7 Rear Receiver Hitch Removal 14 7 Rear Receiver Hitch Installation 14 7 Rear Axle 14 8 Rear Axle Removal 14 8 Rear Axle Installation 14 10 Rear Driveshaft 14 11 Rear Drivesh...

Page 17: ...TACHMENT SYSTEM Model Identification 16 1 Relieving Hydraulic System Pressure 16 1 To Relieve Hydraulic Fluid Pressure 16 1 Attachment Interface 16 2 Inspection 16 2 Removing and Installing the Attach...

Page 18: ...29 Cylinder Assembly 16 32 Cylinder Bushings If Equipped 16 37 Angle Frame Bushings 16 39 Snow Blade Angle Frame 16 39 Whisk Broom Angle Frame 16 40 Front Mount 16 41 Front Mount Removal 16 41 Front M...

Page 19: ...ge GENERAL WARNING The following safety statements must be heeded whenever the vehicle is being operated repaired or ser viced Service technicians should become familiar with these safety statements w...

Page 20: ...ng the vehicle Moving parts Do not attempt to service the vehicle while it is running Hot Do not attempt to service hot engine or exhaust system Failure to heed this warning could result in severe bur...

Page 21: ...e is equipped with a prop rod ensure that it is securely engaged while bed is raised Do not close bed until all persons are clear of cargo bed area Keep hands clear of all crush areas Do not drop carg...

Page 22: ...1...

Page 23: ...ion Transmission Forward and reverse with neutral 4 98 1 forward 7 79 1 reverse Electrical system 12 volt 500 cca at 0 F 17 8 C 650 at 32 F 0 C 105 minute reserve capacity and 35 amp charging capacity...

Page 24: ...surface only 1200 lb 544 kg High capacity option 1450 lb 658 kg 1600 lb 725 5 kg Maximum gross vehicle weight fully loaded vehicle including accessories 2750 lb 1247 kg High capacity option 3012 lb 1...

Page 25: ...ers 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 Box tube aluminu...

Page 26: ...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 5 oz...

Page 27: ...smission Forward and reverse with neutral 5 39 1 forward 7 79 1 reverse Electrical system 12 volt 500 cca at 0 F 17 8 C 650 at 32 F 0 C 105 minute reserve capacity and 35 amp charging capacity Torque...

Page 28: ...surface only 1200 lb 544 kg High capacity option 1450 lb 658 kg 1600 lb 725 5 kg Maximum gross vehicle weight fully loaded vehicle including accessories 2750 lb 1247 kg High capacity option 3012 lb 1...

Page 29: ...lic brake system brake pads and discs on each wheel with separate foot operated park brake BODY CHASSIS Frame Chassis Box tube aluminum Side and rear body All aluminum Cargo bed Powder coated steel or...

Page 30: ...rake fluid 8 oz 240 ml Fuel tank diesel grade no 2 with cetane rating of 45 or higher 6 5 gallons 24 6 L TIRE PRESSURE All terrain tread and mud tires 20 22 psi 1 38 1 52 Bars VEHICLE MASS Standard op...

Page 31: ...rbers 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 Box tube alumi...

Page 32: ...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 5...

Page 33: ...tions Towing with the Vehicle Transporting on a Trailer Engine Oil and Filter Change Accessory Equipment Subsequent Owner Registration Warranties MODEL IDENTIFICATION The serial number of each vehicle...

Page 34: ...each of children Do not siphon fuel from the vehicle WARNING Turn the key switch to the OFF position remove the key and leave the Forward Reverse handle in the NEUTRAL position during storage This is...

Page 35: ...t oil through each of the two spark plug holes Rotate the engine crankshaft by hand several times then install both spark plugs Diesel vehicles NOTE If biodiesel fuel is used See Fueling Instructions...

Page 36: ...e 3 4 Page 3 5 Ensure that the valve is fully open A partially closed fuel shut off valve combined with the use of the choke can result in a fouled spark plug and engine failure Figure 3 6 Page 3 5 5...

Page 37: ...nnecting or disconnecting cables to the battery Never lean over battery while boosting testing or charging If it is necessary to use a booster battery to start the engine BE CAREFUL 1 Turn the key swi...

Page 38: ...of the booster battery Connect the other end of the same cable 2 to the positive terminal of the vehicle battery See DANGER Battery Explo sive gases in General Warning Section 1 Page 1 1 6 Connect the...

Page 39: ...th a sponge or soft cloth The Geloy XTW body panel material is the same material used in various automotive applications Automotive cleaning polishing products are available at automotive specialty an...

Page 40: ...adily over small area so as not to heat surface as this may cause warping or melting of plastic Buff sanded area until all sanding scratches have disap peared Use as much buffing compound as necessary...

Page 41: ...curing the top potion of the instrument panel located inside the glove box 9 Pull the top of the instrument panel towards the rear of the vehicle to access the rear of panel 10 Disconnect the wiring f...

Page 42: ...the lighting wire harness from each light at connectors 4 Separate the front fascia from front fenders and remove from vehicle FRONT FASCIA INSTALLATION 1 Position the fascia on the vehicle taking ca...

Page 43: ...ter cowl panel See Center Cowl Panel Removal on page 4 4 4 Disengage the three tabs securing the top of the side cowl panel from the three slots in the under hood inner structure of the fender flare 5...

Page 44: ...wer outboard end of the instrument panel 6 Remove the three hex head screws securing the front fender flare to the frame and remove front fender flare FRONT FENDER FLARE INSTALLATION 1 Position the fr...

Page 45: ...ur flanged nuts 6 that secure the two side supports 4 to the seat support 7 and the front cowl supports 8 3 2 passenger vehicles Remove the two side supports 4 See following NOTE NOTE It may facilitat...

Page 46: ...support tubes 2 Position the top structure 3 to the top of the side support tubes 4 and secure with hex head bolts 1 and flanged lock nuts 2 Do not tighten hardware at this time See following NOTE NOT...

Page 47: ...seat 2 1 Lift the seat bottom up 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 bucke...

Page 48: ...t webbing or hardware Inspect the safety belt system periodically Check for cuts fraying and loose parts Replace damaged parts immediately Do not disassemble or modify the system Keep safety belts cle...

Page 49: ...ESTING THE BED LIFT MOTOR Gasoline Vehicles See Test Procedure 29 Section 11a Page 11a 39 Diesel Vehicles See Test Procedure 34 Section 11c Page 11c 51 BED LIFT MOTOR REMOVAL 1 Make sure the key switc...

Page 50: ...he bed lift motor to the bed frame bracket 4 1 Repeat steps 3 1 through 3 4 for the rod end of the bed lift motor 4 2 Attach a lockwasher and nylon locknut and tighten to 23 ft lb 31 N m 5 Tighten the...

Page 51: ...the hinges Remove the hinge bolts 9 6 Raise the rear edge of the bed approximately 6 inches 15 2 cm and pull the bed assembly toward the rear of the vehicle approximately 3 inches 7 6 cm to release be...

Page 52: ...TRIM Cargo Bed Manual Lift Page 4 14 2007 Carryall 295 295 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual 4 Figure 4 4 Cargo Bed 4 3 17 11 5 2 7 6 16 16 13 12 1 13 10 TYPICAL 2 PLACES...

Page 53: ...FENDER INSTALLATION 1 Lift bed 2 Put fender in place 3 Install the three Tuflok plastic fasteners to secure the top of the fender to the frame 4 Install the two Phillips head screws and washers to se...

Page 54: ...4...

Page 55: ...d See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 1 3 Disconnect the cable strain relief from the pedal bracket 4 Disconnect the Z shaped end 1 of the accelerator cab...

Page 56: ...screw to 3 4 inches 19 mm as shown Figure 5 3 Page 5 2 3 Turn the key switch to start the engine See following DANGER DANGER The engine produces carbon monoxide which is an odorless deadly poison Do...

Page 57: ...bles as instructed See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 1 3 Remove the rue pin and the clevis pin Separate the clevis from the brake pedal Figure 5 4 Page...

Page 58: ...e the Forward Reverse handle in NEUTRAL Remove the key and chock the rear wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section...

Page 59: ...Page 5 5 5 3 Install the cable end on the pedal bracket stud and secure with washer and E clip 4 Connect the battery cables positive cable first and tighten the hardware to 144 in lb 16 N m Coat term...

Page 60: ...5...

Page 61: ...essive 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 Pedal Adjustment Section 5 Page 5 4 Apply heavy p...

Page 62: ...he steering wheel all the way from left to right and back again Contact between the brake hoses and any other components especially the wheels or half shafts will damage the brake hoses Check the back...

Page 63: ...here should be at least 0 020 inches 0 5 mm of brake pad material at the thinnest point See follow ing WARNING WARNING Use only approved replacement brake pads designed for your vehicle Use only DOT 5...

Page 64: ...od Replace master cylinder See Master Cylinder and Reservoir on page 6 20 Over aggressive braking Incorrect or distorted brake pads Replace the brake pads See Brake Pads and Caliper on page 6 5 Vehicl...

Page 65: ...n brake pads Replace the brake pads See Brake Disc and Hub on page 6 10 Brake discs are cracked or scored Replace the brake discs See Brake Disc and Hub on page 6 10 All brakes drag Binding brake peda...

Page 66: ...and front wheel Front Brake Pad Removal 1 Remove the two socket head slide pin bolts securing the top and bottom of the two brake pads Figure 6 3 Page 6 7 2 Remove the brake pads Front Brake Caliper R...

Page 67: ...hers Tighten to 13 ft lb 18 N m See following CAUTION CAUTION The banjo bolts are metric Use only metric thread replacements 3 Bleed the brake line at the top bleed port on the caliper body Tighten th...

Page 68: ...to areas immediately surrounding hydraulic connections to prevent dirt or debris from entering system 1 Chock the front wheels release the park brake loosen the rear wheel lug nuts and lift the rear o...

Page 69: ...njo bolt and new copper washers Tighten the hardware to 13 ft lb 18 N m See following NOTE and CAUTION NOTE Position the brake line so it is perpendicular to the caliper assembly and pointing directly...

Page 70: ...n 1 Page 1 1 FRONT WHEEL DISC AND HUB REMOVAL WARNING If at any point in this procedure the hydraulic system is opened the brakes must be bled after the correct reinstallation of the brake components...

Page 71: ...the frame so that it does not hang suspended by the hydraulic brake hose 6 Remove the outer tie rod end from the upright 7 Remove the lower ball joint from the upright Figure 6 9 Page 6 11 8 Remove th...

Page 72: ...uire the use of a hydraulic press 10 1 Place 2 x 2 inch or larger steel blocks 1 onto the platen bars of a hydraulic press Figure 6 11 Page 6 12 10 2 Position the disc 6 and upright 5 between the bloc...

Page 73: ...re 6 13 Page 6 13 12 2 Position a new bearing 7 into the bearing cavity of the upright 12 3 Use a bar or rod 8 slightly smaller than the outside diameter of the bearing but large enough to engage the...

Page 74: ...t 14 The disc and hub shaft should be approximately 3 32 inch 2 38 mm below the bearing inner race sur face Figure 6 15 Page 6 14 FRONT WHEEL DISC AND HUB INSTALLATION WARNING If at any point in this...

Page 75: ...crisscross pattern to tighten the lug nuts to 85 ft lb 115 N m 13 Tighten the flanged spindle nut to 150 ft lb 203 N m 14 Inspect the brake systems See Brake System Inspection on page 6 1 REAR WHEEL...

Page 76: ...n the spline and threaded portion of the axle 2 Apply anti seize compound to both the axle and wheel hub splined area See following CAUTION CAUTION Do not allow anti seize compound to contact the brak...

Page 77: ...ntering system NOTE The brake lines are provided as assemblies without separating unions other than those at the wheels and master cylinder FRONT BRAKE LINE REMOVAL 1 Chock the rear wheels and set the...

Page 78: ...l upright Tighten the hardware to 13 ft lb 18 N m See following CAUTION CAUTION Ensure that the hydraulic lines cannot contact any portion of the half shafts or CV boot The banjo bolts are metric Use...

Page 79: ...ne until it clears the rear of the vehicle During replacement tie the flare nut end of the new brake line to the nylon string and use it to pull the new brake line into position and to the master cyli...

Page 80: ...both hose ends are in a container remove the reservoir cap to allow fluid to drain freely from reservoir container 4 Remove the hoses at the reservoir NOTE If hoses are cracked or show signs of aged d...

Page 81: ...ct the brake fluid After both hose ends have been placed in a con tainer remove the reservoir cap and allow fluid to drain freely from the reservoir container If hoses are cracked or show signs of det...

Page 82: ...to bleed the brakes as instructed in this manual will result in decreased braking performance due to air being trapped in the hydraulic system Use only DOT 5 brake fluid to fill the master cylinder N...

Page 83: ...in the master cylinder reservoir to fall below the MIN level mark at any time during the brake bleeding procedure 5 8 With the vacuum still running tighten the two top front brake bleeder valves to 2...

Page 84: ...ure that no brake fluid gets on the brake rotors or pads If fluid gets on the brake rotors they should be cleaned with brake cleaner If fluid gets on the pads they should be replaced as brake fluid ca...

Page 85: ...stem Inspec tion on page 6 1 PARK BRAKE CABLE ADJUSTMENT CAUTION Perform the following procedure only on a level surface To avoid injury or property damage ensure that the path of the vehicle is clear...

Page 86: ...hock the rear wheels and release the park brake 2 Remove the P clamp and nylon wire tie securing the cable to the frame 3 Remove the C clip from the right rear cable sheath adjacent to the caliper 4 S...

Page 87: ...Route the cable to the inside of the air intake hose 5 Secure the cable with a P clamp and nylon wire tie to the frame 6 Secure the cable end to the equalizer bracket See Park Brake Equalizer Installa...

Page 88: ...racket Figure 6 24 Page 6 28 6 Install the conical nut with the cone oriented toward the equalizer and then install a jam nut onto the threaded portion of the cable end Advance both nuts a few turns 7...

Page 89: ...al nut to the cable with the cone oriented toward the equalizer Tighten the nut until the cable is drawn snugly through the equalizer bracket 4 Thread the jam nut onto the threaded portion of the equa...

Page 90: ...6...

Page 91: ...til wheel has been installed 5 Gently pry the center cap from the steering wheel center NOTE Pry from the bottom edge of the cap 6 Loosen and remove the steering wheel retaining bolt 18 Figure 7 1 Pag...

Page 92: ...MN See General Warning Section 1 Page 1 1 STEERING COLUMN REMOVAL 1 Turn the key switch OFF and place the Forward Reverse handle in the NEUTRAL position Chock the wheels 2 Disconnect the battery cable...

Page 93: ...n the rack and pinion shaft first 5 Tighten the steering column coupling bolt to 18 ft lb 24 N m 6 Install the instrument panel See Instrument Panel Installation Section 4 Page 4 3 7 Lower and secure...

Page 94: ...Position the rack and pinion base next to the mounting bracket and install the four bolts Tighten the hardware to 23 ft lb 31 N m Figure 7 6 Page 7 4 3 Slide the universal joint down over the pinion...

Page 95: ...wire ties Figure 7 9 Page 7 5 See following NOTE NOTE If the dust seal bellows are secured with a metal clamp remove the clamp Do not reuse the clamp when the rack and pinion is reassembled Use a plas...

Page 96: ...C type stop ring 16 Figure 7 11 Page 7 6 and use a press to remove the bearing Figure 7 13 Page 7 6 12 Inspect the bushing 17 and needle bearing 14 for excessive wear If wear is excessive replace the...

Page 97: ...7 7 CAUTION Use wood blocks between the rack and the jaws of the vise to protect the rack from damage 13 2 Tap the flange out of the notch in the rack Figure 7 15 Page 7 7 13 3 Remove the ball joint...

Page 98: ...nion Page 7 8 2007 Carryall 295 295 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual 7 Figure 7 16 Steering Gear Assembly 13 4 15 17 3 16 2 23 12 19 12 11 10 24 9 TYPICAL 2 PLACES 5 6 8...

Page 99: ...e necessary to rotate the rack slightly and lightly tap the pinion bearing assembly with a rubber mallet See following CAUTION CAUTION Do not force the pinion bearing assembly into the housing The gea...

Page 100: ...OTE NOTE When the nut 8 is tightened make sure the screw 7 adjustment does not change Figure 7 18 Page 7 9 14 Install the two dust seal bellows 10 Figure 7 9 Page 7 5 15 Secure the bellows with new be...

Page 101: ...that is facing the rear of the vehicle The marks should be at the same height as the center of each hub Measure the distance between the marks 3 Roll the vehicle forward one half wheel revolution unti...

Page 102: ...ide bead of the wheel rim Record that measurement See following NOTE NOTE Do not measure against the wheel rim edge or tire sidewall Both of these can have variations in their surfaces that will resul...

Page 103: ...Chock the rear wheels set the park brake loosen the front wheel lug nuts and lift the front of the vehicle with a chain hoist or floor jack See WARNING Lift only one end in General Warning Section 1...

Page 104: ...emove the lower and upper ball joint locknut 10 Swing the lower A arm down and separate the brake rotor and upright from the half shaft and the upper ball joint 11 Repeat steps 5 through 10 for the re...

Page 105: ...ame and bushings Upper Ball Joint Removal 1 Inspect the ball joint Replace the ball joint if it is worn loose or the rubber boot has been damaged 1 1 Remove the C clip from the top of the ball joint 1...

Page 106: ...in both the front and rear frame attachments Tighten the hardware to 40 ft lb 54 N m 5 Secure the brake line bracket to the A arm and tighten the hardware to 11 ft lb 15 N m 6 Repeat steps 1 through...

Page 107: ...ound the 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...

Page 108: ...lug nuts on both front wheels and lift the front of the vehicle with a chain hoist or floor jack See WARNING Lift only one end in General Warning Section 1 Page 1 2 2 Place jack stands under each end...

Page 109: ...b 118 N m 7 Repeat steps 1 through 6 for the remaining shock absorber STEERING UPRIGHT INSTALLATION 1 Slide the upright and wheel hub assembly onto the splined half shaft spindle See following NOTE NO...

Page 110: ...ck patch hex head bolts and tighten the hardware to 36 ft lb 49 N m See Front Brake Pad and Caliper Installation Section 6 Page 6 7 11 Install the tire and wheel and finger tighten the lug nuts 12 Low...

Page 111: ...different diameters on the vehicle The mud tread design is directional and the tires are mounted on the wheels with regard to which side of the vehicle they will be used on The arrow molded on the si...

Page 112: ...emove the wheel WHEEL INSTALLATION 1 Install the wheel s and use a crisscross pattern to tighten the lug nuts until they are snug See following NOTE NOTE Mud tires are directional For optimum performa...

Page 113: ...1 2 Install the valve core 3 On sidewall of tire locate the maximum pressure allowed to seat the bead of the tire and inflate to seat tire on wheel Do not exceed pressure noted on sidewall See followi...

Page 114: ...8...

Page 115: ...ver springs are used for the vehicle s load service option when the rear shock absorbers are removed and replaced Rear Shock Absorber Removal 1 Chock the front wheels and loosen both rear wheel lug nu...

Page 116: ...washer rubber grommet bracket and a new locknut Tighten the hardware to 73 ft lb 99 N m 3 Install the hydraulic line rubber grommet in the shock bracket 4 Install the rear tire and wheel Finger tighte...

Page 117: ...STP oil treatment on the outside surface of the urethane bushings to reduce friction during installation 4 Position the swing arm between the frame brackets and bracket bushings with the axle pad fac...

Page 118: ...9...

Page 119: ...Lubrication Schedule Both the Periodic Service Schedule and the Periodic Lubrication Schedule must be followed to keep the vehicle in optimum operating condition PERIODIC SERVICE SCHEDULE REGULAR INTE...

Page 120: ...onal every 100 hours of operation Engine Honda Adjust valve clearance See Honda GX620 Service Manual CCI P N 102615401 Semiannual service by trained technician only or every 50 hours of operation whic...

Page 121: ...s etc Gasoline vehicles Inspect clean and gap spark plug replace if necessary See authorized dealer or trained technician for service Diesel vehicles Check the v belt for proper tension or damage Adju...

Page 122: ...technician Driveshaft Chassis Lube EP NLGI Grade 2 Semiannually by owner or trained technician or every 50 hours of operation whichever comes first Check add brake fluid Use only DOT 5 silicone brake...

Page 123: ...hedule 2007 Carryall 295 295 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual Page 10a 5 10A Figure 10a 1 Lubrication Points Gasoline Vehicles Figure 10a 2 Lubrication Points Diesel Vehi...

Page 124: ...ly lubricant until extra grease shows Grease the 8 grease fittings every 50 hours of operation 2 times a year whichever occurs first or whenever the attachment arm and interface are removed and reinst...

Page 125: ...0a 7 Numbered sections indicate 1 Full Level 2 Safe Level and 3 Low Level Also brake fluid should be clean with no residue in the bottom of the reservoir or other evidence of contamination CAUTION Use...

Page 126: ...ately removing it 3 If the oil level is at or below the low level mark on the dipstick gauge add oil until the level is between low and full levels safe level See following CAUTION CAUTION Do not fill...

Page 127: ...drain the engine oil into the pan See following 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 appro...

Page 128: ...NOTE An oil drip guard 1 can be used to prevent excess oil from dripping onto the engine base plate Use an empty quart one liter container and cut the bottom off at an angle then slide the open area...

Page 129: ...us or equivalent or new engine oil to the rubber seal around the outside surface of the filter before attaching it to the oil filter port Figure 10a 12 Page 10a 11 Install the new oil filter gas CCI P...

Page 130: ...05 3 With the Forward Reverse handle in the NEUTRAL position start and run the engine for a few minutes Observe both the drain plug and the oil filter from under the vehicle and watch for oil leaks If...

Page 131: ...rged meaning the gears are forged to a shape very close to the final gear size but the teeth are not finish machined prior to assembly The finish machining occurs when the gears make contact under loa...

Page 132: ...ential with new lubricant Figure 10a 19 Page 10a 14 Tighten the drain plug to 96 in lb 10 8 N m Use a funnel when filling the dif ferential through the lubricant level indicator hole 1 See Periodic Lu...

Page 133: ...2a 3 1 Lift the cargo box 2 Turn the start key to the ON position but DO NOT start the engine 3 Press the joystick ON OFF switch to ON 4 Move the joystick 1 back and raise the attachment arm fully Fi...

Page 134: ...is hot or while it is running To avoid electric arc caused by static electricity the fuel storage pumping device must be grounded If the pump is not grounded the vehicle must be grounded to the pump...

Page 135: ...used be sure to apply the following guidelines Ensure the fuel tank is as full as possible at all times to prevent moisture from collecting Ensure that the fuel tank cap is securely tightened to preve...

Page 136: ...or fire resulting in severe personal injury or death 5 Close the valve by rotating it counterclockwise until the valve is firmly sealed 6 To resupply the filter with fuel turn the key switch to the O...

Page 137: ...neral Warning Section 1 Page 1 1 WARNING Service repairs and adjustments must be made per instructions in this maintenance and service manual NOTE If the vehicle is constantly subjected to heavy use o...

Page 138: ...for grass and debris around the radiator Tires Check air pressure and adjust if necessary See Section 8 Wheels and Tires Transmission and differentials Check lubricant levels Add if necessary See Lub...

Page 139: ...asaki FH680D Service Manual Gasoline vehicles Inspect clean and gap spark plug replace if necessary See authorized dealer or trained technician for service See Spark Plugs on page 10b 12 Diesel vehicl...

Page 140: ...or trained technician Driveshaft Chassis Lube EP NLGI Grade 2 Semiannually by owner or trained technician or every 50 hours of operation whichever comes first Check add brake fluid Use only DOT 5 sil...

Page 141: ...Schedule 2007 Carryall 295 295 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual Page 10b 5 10B Figure 10b 1 Lubrication Points Gasoline Vehicles Figure 10b 2 Lubrication Points Diesel Ve...

Page 142: ...pply lubricant until extra grease shows Grease the 8 grease fittings every 50 hours of operation 2 times a year whichever occurs first or whenever the attachment arm and interface are removed and rein...

Page 143: ...bered sections indicate 1 Full Level 2 Safe Level and 3 Low Level Also brake fluid should be clean with no residue in the bottom of the reservoir or other evidence of contamination CAUTION Use only DO...

Page 144: ...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 until the level is between low and full level...

Page 145: ...ain plug 1 Turn the plug counterclockwise and drain the engine oil into the pan See following WARNING WARNING Do not attempt to change engine oil when the engine is hot or even warm Hot engine oil can...

Page 146: ...e engine oil filter Turn it counterclockwise and drain the residual oil in the filter port and filter into the oil drain pan See following NOTE NOTE Dispose of used oil according to the environmental...

Page 147: ...s for selection of oil grade Figure 10b 14 Page 10b 12 or Figure 10b 15 Page 10b 12 See following CAUTION CAUTION Do not exceed recommended oil capacity Doing so will decrease engine performance or re...

Page 148: ...flash point solvent and a wire brush or other suitable tool 3 If the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug with an OEM replacement Spark Plug Ty...

Page 149: ...ed for the first few fluid changes This is a result of the gears being net forged meaning the gears are forged to a shape very close to the final gear size but the teeth are not finish machined prior...

Page 150: ...Clean and install the drain plug 2 and washer before filling the rear differential with new lubricant Figure 10b 18 Page 10b 14 Tighten the drain plug to 96 in lb 10 8 N m Use a funnel when filling t...

Page 151: ...ge 2b 5 1 Lift the cargo box 2 Turn the start key to the ON position but DO NOT start the engine 3 Press the joystick ON OFF switch to ON 4 Move the joystick 1 back and raise the attachment arm fully...

Page 152: ...e is hot or while it is running To avoid electric arc caused by static electricity the fuel storage pumping device must be grounded If the pump is not grounded the vehicle must be grounded to the pump...

Page 153: ...used be sure to apply the following guidelines Ensure the fuel tank is as full as possible at all times to prevent moisture from collecting Ensure that the fuel tank cap is securely tightened to prev...

Page 154: ...n or fire resulting in severe personal injury or death 5 Close the valve by rotating it counterclockwise until the valve is firmly sealed 6 To resupply the filter with fuel turn the key switch to the...

Page 155: ...e 10b 12 Spark plug wire is damaged or loose See the Kawasaki FH680D engine manual CCI P N 103351201 Intermittent ignition coil failure See the Kawasaki FH680D engine manual CCI P N 103351201 Low cyli...

Page 156: ...ler 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 13a 9 Igniti...

Page 157: ...h fuel mixture Fuel System on page 13a 9 Spark plug wire is damaged See the Kawasaki FH680D engine manual CCI P N 103351201 Dirt entering combustion chamber Fuel System on page 13a 9 Ignition coil fai...

Page 158: ...Voltage Regulator on page 11a 26 Battery failure Test Procedure 1 Battery on page 11a 9 Transmission does not engage or disengage smoothly Transmission shifter linkage is binding or is out of adjustme...

Page 159: ...ge front wheels Failed front drive gearcase engagement coil Test Procedure 12 Front Drive Gearcase Coil on page 11a 25 Failed front differential switch Test Procedure 11 Front Differential Limit Switc...

Page 160: ...liTach M S Manual 11A WIRING DIAGRAM Figure 11a 1 Wiring Diagram Kawasaki Powered Gasoline Carryall 295 and XRT 1550 Vehicles Front FUEL GUAGE HOUR METER Style B See Detail for Previous Guage 18_BLK W...

Page 161: ...GASOLINE VEHICLES Wiring Diagram 2007 Carryall 295 295 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual Page 11a 7 11A Figure 11a 2 Wiring Diagram Kawasaki Powered Gasoline Carryall 295...

Page 162: ...al Switch Transmission 10 Wire Continuity 11 Front Differential Limit Switch 12 Front Drive Gearcase Coil 13 Charge Coil 14 Voltage Regulator 15 Ignition Spark 16 Engine Kill Wire 17 Grounded Kill Wir...

Page 163: ...ocedure 1A Hydrometer Test A hydrometer CCI P N 1011478 measures the specific gravity of battery electrolyte The higher the specific gravity the higher the state of charge of the battery A fully charg...

Page 164: ...ected for temperature For each 10 F 5 6 C above 80 F 27 C add 0 004 to the reading For each 10 F 5 6 C below 80 F 27 C subtract 0 004 from the reading Interpreting the Results of the Hydrometer Test U...

Page 165: ...forming the following test procedure 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Check for loose or corroded battery terminal connection...

Page 166: ...ct the probes of a multimeter set to 200 ohms to the fuse terminals The reading should be con tinuity If there is no continuity determine and repair the cause of the fuse failure Replace the fuse with...

Page 167: ...the readings are incor rect clean and tighten wire connections If the connections are good and the reading is incorrect repair or replace the wire TEST PROCEDURE 4 KEY SWITCH STARTER CIRCUIT See Gene...

Page 168: ...EDURE 5 STARTER CONTROL CIRCUIT See General Warning Section 1 Page 1 1 1 Turn the key switch OFF Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the 16 gauge green wire w127...

Page 169: ...awasaki FH680D engine manual CCI P N 103351201 TEST PROCEDURE 6 START RELAY See General Warning Section 1 Page 1 1 1 Turn the key switch OFF Place the Forward Reverse handle in NEUTRAL Chock the wheel...

Page 170: ...he relay clicks the contacts have failed Replace the relay 8 If the reading obtained in step 5 is not 12 VDC with the key in the START position perform the following test procedures Check battery See...

Page 171: ...imeter The multimeter should NOT indicate continuity with the key in the ON posi tion and the engine off The multimeter should indicate continuity when the engine starts 6 4 If the multimeter indicate...

Page 172: ...wire harness is equipped with several in line diodes The following table describes each diode s function in the electrical system the location in the wire harness and the symptom s of a diode failure...

Page 173: ...MMENT Diode 1 w32 and w35 Front differential coil flyback diode Open Will contribute to the premature failure of the limit switch Closed The 10 amp fuse on w109 will blow repeatedly with the key ON pe...

Page 174: ...multi pin connector located on the electrical component mounting plate 4 Disconnect the bullet connector in the carburetor solenoid green wire Figure 11a 16 Page 11a 20 5 Set the multimeter to the di...

Page 175: ...indicate an 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 Remova...

Page 176: ...be of the multimeter to the frame ground 8 Connect the red probe of the multimeter to the 16 gauge green wire w127 at the spade connector 9 The reading should indicate an over limit no continuity If t...

Page 177: ...The multimeter should indicate continuity 6 Check for continuity on the switch contacts with the Forward Reverse handle in the REVERSE position Figure 11a 20 Page 11a 23 The multimeter should indicate...

Page 178: ...ity of wires in the wire harness observe the polarity of diodes Testing con tinuity of certain wires will require the appropriate diode test procedure See Test Procedure 8 Wire Harness Diodes on page...

Page 179: ...ed under the hood 4 Set the multimeter to 200 ohms 5 Measure the resistance between the two wires at the two pin connector front drive gearcase side 6 The resistance should be 24 7 to 27 3 ohms 7 If t...

Page 180: ...ry voltage at the battery posts If the reading is between 14 0 and 15 0 volts the regulator is good If the reading is lower than 14 0 volts but rising steadily check the battery condition See Test Pro...

Page 181: ...TEST PROCEDURE 16 ENGINE KILL WIRE See General Warning Section 1 Page 1 1 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the ba...

Page 182: ...key switch is turned to the OFF position It will be necessary to pull and hold the choke handle until the engine stops running 4 Also check the key switch for proper operation See Test Procedure 18 Ke...

Page 183: ...ove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Check for proper wiring and tight connections at the reverse warning buzzer and the reverse warning buzzer limit switch Figur...

Page 184: ...21 CARBURETOR SOLENOID CIRCUIT See General Warning Section 1 Page 1 1 NOTE Keep the battery connected while performing this test procedure 1 Check the carburetor solenoid coil circuit 1 1 Turn the key...

Page 185: ...e Kawasaki FH680D engine manual CCI P N 103351201 If the low oil warning light does not illuminate and the vehicle is low on oil proceed to step 1 See following NOTE NOTE The low oil warning light sho...

Page 186: ...F and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Set the multimeter to 20 VDC 3 Measure the voltage between the center contact and the outer contact of the accessory...

Page 187: ...uel tank must be replaced See Fuel Tank Removal Section 13a Page 13a 14 7 If the readings are correct and the fuel gauge does not function correctly leave the battery disconnected and check the contin...

Page 188: ...om the fuel gauge hour meter 4 Set a multimeter to 20 volts DC and place the red probe on the positive post of the battery Place the black probe on the negative post of the battery Record the voltage...

Page 189: ...d black wires Figure 11a 33 Page 11a 35 7 The orange wire should remain disconnected for this step Place the black probe of the multimeter on the 1 terminal of the fuel gauge hour meter and place the...

Page 190: ...oduces carbon monoxide which is an odorless deadly poison 4 With engine idling the hour glass icon should flash slowly If not check the low oil warning light and the oil pressure switch See following...

Page 191: ...o 20 volts DC and place alligator clips on the multimeter probes Connect the red probe to the light switch terminal where the blue wire w03 is connected Figure 11a 35 Page 11a 37 4 Connect the black p...

Page 192: ...ht bulb 6 If there is no voltage reading at the wire harness check the continuity of the 16 gauge blue wires w01 and w03 from the headlight to the light switch 6 1 Set the multimeter to 20 VDC 6 2 Use...

Page 193: ...res from the bed lift motor Figure 11a 37 Page 11a 39 3 Set a multimeter for 20 VDC 4 Place the red probe in the bullet connector on the red wire wire harness side and place the black probe in the bul...

Page 194: ...r switch are wired incorrectly Check the wiring of the bed lift harness and bed lift switch See Wiring Diagram on page 11a 6 A reading of approximately 0 VDC indicates a failed bed lift switch failed...

Page 195: ...t Breaker Removal Section 12a Page 12a 9 2 Place the red probe of the multimeter on the circuit breaker terminals If the multimeter does not indicate continuity replace the circuit breaker See Bed Lif...

Page 196: ...11A...

Page 197: ...engine manual CCI P N 102615401 Spark plug wire is damaged or loose See the Honda GX620 engine manual CCI P N 102615401 Intermittent ignition coil failure See the Honda GX620 engine manual CCI P N 10...

Page 198: ...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...

Page 199: ...Unsuitable fuel or incorrect rich fuel mixture Fuel System on page 13b 7 Spark plug wire is damaged See the Honda GX620 engine manual CCI P N 102615401 Dirt entering combustion chamber Fuel System on...

Page 200: ...l on page 11b 26 25 amp fuse is blown Test Procedure 2 Fuse on page 11b 12 Voltage Regulator failure Test Procedure 14 Voltage Regulator on page 11b 27 Battery failure Test Procedure 1 Battery on page...

Page 201: ...pressure switch failed open See the Honda GX620 engine manual CCI P N 102615401 Front differential does not engage front wheels Failed front drive gearcase engagement coil Test Procedure 12 Front Dri...

Page 202: ...HICLES Wiring Diagram Page 11b 6 2007 Carryall 295 295 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual 11B WIRING DIAGRAM Figure 11b 1 Wiring Diagram Honda Powered Gasoline Carryall 295...

Page 203: ...E VEHICLES Wiring Diagram 2007 Carryall 295 295 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual Page 11b 7 11B Figure 11b 2 Wiring Diagram Honda Powered Gasoline Carryall 295 and XRT 15...

Page 204: ...ntial Relay 9 Wire Harness Diodes 10 Neutral Switch Transmission 11 Wire Continuity 12 Front Drive Gearcase Coil 13 Charge Coil 14 Voltage Regulator 15 Ignition Spark 16 Engine Kill Wire 17 Grounded K...

Page 205: ...cedure 1A Hydrometer Test A hydrometer CCI P N 1011478 measures the specific gravity of battery electrolyte The higher the specific gravity the higher the state of charge of the battery A fully charge...

Page 206: ...be corrected for temperature For each 10 F 5 6 C above 80 F 27 C add 0 004 to the reading For each 10 F 5 6 C below 80 F 27 C subtract 0 004 from the reading Interpreting the Results of the Hydromete...

Page 207: ...forming the following test procedure 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Check for loose or corroded battery terminal connection...

Page 208: ...ecessary 5 Remove the fuse to be tested from the fuse block 6 Connect the probes of a multimeter set to 200 ohms to the fuse terminals The reading should be con tinuity If there is no continuity deter...

Page 209: ...y terminal and the frame 8 Check for continuity between the 6 gauge wire w202 terminal disconnected from the negative bat tery terminal and the engine 9 The readings obtained in the previous steps sho...

Page 210: ...nuity If either reading does not indicate continuity replace the key switch See Key Switch Removal Section 12b Page 12b 6 TEST PROCEDURE 5 KEY SWITCH ACCESSORY TERMINAL See General Warning Section 1 P...

Page 211: ...11b 15 5 Monitor the multimeter The reading should indicate 0 volts with the key in the OFF and ON positions The reading should indicate approximately 12 VDC when the key is in the START position 6 If...

Page 212: ...the key in the OFF and ON positions The reading should indicate approximately 12 VDC when the key is in the START position and the relay should click See following NOTE NOTE The differential and acces...

Page 213: ...w141 w138 w110 and w43 See Wiring Diagram on page 11b 6 TEST PROCEDURE 8 DIFFERENTIAL RELAY See General Warning Section 1 Page 1 1 The differential relay activates the front differential when the key...

Page 214: ...uity while the key is in the ON position and the relay clicks the con tacts have failed closed Replace the relay 8 If the reading obtained in step 5 is not 12 VDC with the key in the ON position perfo...

Page 215: ...or solenoid control powers carburetor solenoid when key switch is in the ON position Open Difficult starting and engine will shut off shortly after key switch is moved from the START to ON position Cl...

Page 216: ...V however a range of 400 700 mV is acceptable 9 If the readings obtained in the previous steps are incorrect replace the diode See Wire Harness Diode Removal Section 12b Page 12b 14 Test Procedure 9B...

Page 217: ...auge hour meter 6 Remove the differential relay and the accessory relay from the multi pin connector located on the elec trical component mounting plate 7 Set the multimeter to the diode test function...

Page 218: ...t be replaced See Wire Harness Diode Removal Section 12b Page 12b 14 9 Reverse the multimeter probes and note the reading The multimeter should indicate approximately 540 mV however a range of 400 700...

Page 219: ...Page 1 1 3 Raise the hood and disconnect the multi pin connector from the key switch 4 Disconnect the multi pin connector between the voltage regulator and the wire harness 5 Set the multimeter to the...

Page 220: ...however a range of 400 700 mV is acceptable 11 If the readings obtained in the previous steps are incorrect replace the diode See Wire Harness Diode Removal Section 12b Page 12b 14 TEST PROCEDURE 10...

Page 221: ...instructed See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 1 3 To test a wire for continuity disconnect either end from the electrical component to which it is attach...

Page 222: ...in General Warning Section 1 Page 1 1 3 Disconnect the multi pin connector between the voltage regulator and the wire harness 4 Measure the resistance of the charge coil on the two blue wires at the v...

Page 223: ...the continuity of each wire in the voltage regulator multi pin connector 8 If the reading is more than 15 0 volts and continues to rise replace voltage regulator See Voltage Reg ulator Removal Sectio...

Page 224: ...RAL position insert the key and turn the key switch to the ON position Note the multimeter reading Turn the key and hold it in the START position Note the mul timeter reading 6 There should be no cont...

Page 225: ...proceed to Test Procedure 15 Ignition Spark on page 11b 27 TEST PROCEDURE 18 KEY SWITCH ENGINE KILL CIRCUIT See General Warning Section 1 Page 1 1 1 Turn the key switch OFF and remove the key Place t...

Page 226: ...n place the red probe of the multimeter on one terminal and the black probe on the other terminal of the limit switch With the lever fully released the reading should be no continuity 5 Place the Forw...

Page 227: ...frame ground 1 6 Monitor the multimeter The reading should indicate 0 volts with the key in the OFF position The reading should indicate approximately 12 VDC when the key is in the ON and START positi...

Page 228: ...wire w17 from the low oil warning light 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 t...

Page 229: ...ponent mounting plate See Test Procedure 2 Fuse on page 11b 12 5 If the fuse is good check the continuity of the wires connected to the accessory receptacle TEST PROCEDURE 24 FUEL LEVEL SENDING UNIT S...

Page 230: ...g unit and at the fuel gauge hour meter See Fuel Gauge Hour Meter Removal Section 12b Page 12b 6 8 If the readings are correct according to the position of the float but the reading on the fuel gauge...

Page 231: ...least 6 minutes the meter records in 6 minute increments See following DANGER DANGER Do not operate vehicle in an enclosed area without proper ventilation The engine produces carbon monoxide which is...

Page 232: ...witch in the OFF position the reading should indicate 0 volts With the light in the ON posi tion the reading should indicate between 11 and 12 5 volts If the there is no voltage reading check the cont...

Page 233: ...2 Use an alligator clip to attach the black probe onto the negative battery terminal and place the red probe into the blue wire terminal of the wire harness If the multimeter reading is approx imatel...

Page 234: ...es from the bed lift motor Figure 11b 32 Page 11b 38 3 Set a multimeter for 20 VDC 4 Place the red probe in the bullet connector on the red wire wire harness side and place the black probe in the bull...

Page 235: ...d to step 8 A reading of approximately positive 12 VDC indicates that the bed lift harness or switch are wired incorrectly Check the wiring of the bed lift harness and bed lift switch See Wiring Diagr...

Page 236: ...Breaker Removal Section 12b Page 12b 8 2 Place the red probe of the multimeter on the circuit breaker terminals If the multimeter does not indicate continuity replace the circuit breaker See Bed Lift...

Page 237: ...l and engine oil See owner s manual Water in fuel system Replace fuel and fuel filter Air in fuel system See the Kubota D722 diesel engine manual CCI P N 102615501 Fuel filter clogged Replace fuel fil...

Page 238: ...13D Diode 4 on wire 141 on page 11c 32 One or both 30 amp fuses blown Test Procedure 2 Fuse on page 11c 16 Neutral switch failure failed open Test Procedure 14 Neutral Switch Transmission on page 11c...

Page 239: ...r clogged See the Kubota D722 diesel engine manual CCI P N 102615501 Oil filter clogged Relief valve clogged with dirt Relief valve spring is weak or broken Excessive clearance or crankshaft bearing E...

Page 240: ...1 Incorrect injection timing Cylinder compression leak Black or dark gray exhaust gas is observed Vehicle is overloaded Do not overload vehicle See owner s manual Low grade fuel Drain fuel and refill...

Page 241: ...battery Test Procedure 1 Battery on page 11c 13 60 amp fusible link failed Test Procedure 19 60 Amp Fusible Link on page 11c 38 Engine can be started while Forward Reverse handle is in the FOWARD or R...

Page 242: ...ing Diagram Page 11c 6 2007 Carryall 295 295 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual 11C WIRING DIAGRAM Figure 11c 1 Wiring Diagram 2 Piece Harness for Diesel Carryall 295 and X...

Page 243: ...Wiring Diagram 2007 Carryall 295 295 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual Page 11c 7 11C Figure 11c 2 Wiring Diagram 2 Piece Harness for Diesel Carryall 295 and XRT 1550 Veh...

Page 244: ...Diagram Page 11c 8 2007 Carryall 295 295 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual 11C Figure 11c 3 Wiring Diagram 1 Piece Harness for Diesel Carryall 295 and XRT 1550 Vehicles Fr...

Page 245: ...ESEL VEHICLES Wiring Diagram 2007 Carryall 295 295 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual Page 11c 9 11C Figure 11c 4 Wiring Diagram 1 Piece Harness for Diesel Carryall 295 and...

Page 246: ...LECTRICAL SYSTEM DIESEL VEHICLES Wiring Diagram Page 11c 10 2007 Carryall 295 295 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual 11C Figure 11c 5 Main Light Wiring Diagram Carryall 295...

Page 247: ...WITCH THREE POSITION SWITCH AND FLASHER UNIT CONNECTS TO W31 IN MAIN LIGHT HARNESS PICKS UP POWER FROM THREE POSITION SWITCH LOW BEAM POSITION CONNECTS TO W3 IN VEHICLE HARNESS PROVIDING POWER TO LOW...

Page 248: ...Harness Diodes 14 Neutral Switch Transmission 15 Wire Continuity 16 Front Differential Limit Switch 17 Front Drive Gearcase Coil 18 Alternator 19 60 Amp Fusible Link 20 Coolant Temperature Warning Li...

Page 249: ...A Hydrometer Test A hydrometer CCI P N 1011478 measures the specific gravity of battery electrolyte The higher the specific gravity the higher the state of charge of the battery A fully charged batter...

Page 250: ...temperature For each 10 F 5 6 C above 80 F 27 C add 0 004 to the reading For each 10 F 5 6 C below 80 F 27 C subtract 0 004 from the reading Interpreting the Results of the Hydrometer Test Use the fol...

Page 251: ...ing test procedure 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Check for loose or corroded battery terminal connections Clean tighten an...

Page 252: ...Page 1 1 3 Remove the electrical component cover 4 Ensure the wires are connected correctly and are tight If they are not rewire or tighten as necessary 5 Remove the fuse to be tested from the fuse b...

Page 253: ...w202 for damage Repair or replace as required 5 Check the engine ground for a loose connection damaged terminals and an excess of paint on the engine block under the starter where the two 6 gauge blac...

Page 254: ...ey Switch Removal Section 12c Page 12c 7 6 2 If the multimeter indicates continuity between the BATT and ST terminals with the key in any posi tion other than START the key switch has failed and shoul...

Page 255: ...ld indicate continuity Figure 11c 12 Page 11c 18 If the multimeter does not indicate continuity the key switch has failed and should be replaced See Key Switch Removal Section 12c Page 12c 7 6 2 If th...

Page 256: ...or the multimeter The reading should indicate 0 volts with the key in the OFF and ON positions The reading should indicate approximately 12 VDC when the key is in the START position 6 If the readings...

Page 257: ...ts with the key in the OFF and ON positions The reading should indicate approximately 12 VDC when the key is in the START position and the relay should click See following NOTE NOTE The differential i...

Page 258: ...page 11c 6 TEST PROCEDURE 9 DIFFERENTIAL RELAY The differential relay is only used on early 2007 vehicles equipped with the two piece wire harness See General Warning Section 1 Page 1 1 The different...

Page 259: ...he ON position perform the following test procedures Check the battery See Test Procedure 1 Battery on page 11c 13 Check the 30 amp fuse on w125 See Test Procedure 2 Fuse on page 11c 16 Check the key...

Page 260: ...mostat switch See Test Procedure 11 Thermostat Switch on page 11c 25 4 If the reading is 12 VDC with key in the ON position check relay function 4 1 At the relay place the meter probes to check contin...

Page 261: ...G Hot Coolant system is pressurized Do not remove thermostat switch while engine is hot 3 Disconnect the two pin connector between the thermostat switch and the wire harness Figure 11c 21 Page 11c 26...

Page 262: ...t Switch Removal Section 12c Page 12c 17 6 6 Fill the kitchen pot with water so that approximately half of the thermostat housing is submerged as shown Figure 11c 22 Page 11c 27 6 7 Place the kitchen...

Page 263: ...re 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 perform Test Procedure 12B Voltage to Fan Mot...

Page 264: ...failure in closed condition See Test Procedure 13B Diode 2 on wire 40 on page 11c 31 Fan relay for proper wiring and function See Test Procedure 10 Fan Relay on page 11c 23 Both 30 amp fuses on wires...

Page 265: ...contribute to the premature failure of the differential relay or limit switch contacts Closed With key switch ON the 30 amp fuse on w125 will blow repeatedly until the diode has been replaced Diode 2...

Page 266: ...de conducts current shows continuity with the meter probes connected as described the diode has failed and must be replaced See Wire Harness Diode Removal Section 12c Page 12c 20 8 Reverse the multime...

Page 267: ...eter probes and note the reading The multimeter should indicate approximately 540 mV however a range of 400 700 mV is acceptable 10 If the readings obtained in the previous steps are incorrect replace...

Page 268: ...itch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning...

Page 269: ...avoid unintentionally starting in General Warning Section 1 Page 1 1 3 Raise the hood 4 Disconnect the multi pin connector from the key switch Figure 11c 27 Page 11c 33 See following NOTE NOTE Failur...

Page 270: ...g Section 1 Page 1 1 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid uninte...

Page 271: ...tor between the neutral switch and the wire harness w143 and w142 Figure 11c 26 Page 11c 32 4 Check for continuity on the switch contacts with the Forward Reverse handle in the FORWARD position Figure...

Page 272: ...he 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 con tinuity of certain wires wil...

Page 273: ...OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the battery as instructed See WARNING To avoid unintentionally starting in General Warning Section 1 Pa...

Page 274: ...Warning Section 1 Page 1 1 NOTE Keep the battery connected during this test procedure 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Raise...

Page 275: ...the thermostat switch See following NOTE NOTE Keep the battery connected during this test procedure 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the w...

Page 276: ...the ON posi tion check the following 30 amp fuse on wire w125 See Test Procedure 2 Fuse on page 11c 16 Key switch See Test Procedure 5 Key Switch ON Position on page 11c 19 Connections and wire contin...

Page 277: ...and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Check for proper wiring and tight connections at the reverse warning buzzer and the reverse warning buzzer limit swit...

Page 278: ...20 VDC 4 Place the red probe on the 14 gauge blue wire w135 of the three pin connector at the fuel solenoid wire harness side 5 Place the black probe on the frame or engine block ground 6 The multimet...

Page 279: ...15 Wire Continuity on page 11c 36 TEST PROCEDURE 26 FUEL PUMP CIRCUIT See General Warning Section 1 Page 1 1 NOTE Keep the battery connected during this test procedure 1 Turn the key switch OFF Place...

Page 280: ...ition 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 continuity between...

Page 281: ...w104 from the center post of the fuel level sending unit 4 With a multimeter set to 2k ohms place the red probe on the center post of the sending unit Place the black probe on the ground connection of...

Page 282: ...hour meter is incorrect test the fuel gauge hour meter See Test Procedure 30 Fuel Gauge on page 11c 46 TEST PROCEDURE 30 FUEL GAUGE See General Warning Section 1 Page 1 1 Two fuel gauges were used for...

Page 283: ...EUTRAL Chock the wheels 2 Raise the hood 3 Disconnect the orange wire w104 from the fuel gauge hour meter 4 Set a multimeter to 20 volts DC and place the red probe on the positive post of the battery...

Page 284: ...appears 3 Start the engine and let it idle See following DANGER DANGER Do not operate vehicle in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless de...

Page 285: ...ning Section 1 Page 1 1 NOTE The headlight circuit is protected by the 20 amp fuse Check the fuse before this procedure is per formed See Test Procedure 2 Fuse on page 11c 16 Keep the battery connecte...

Page 286: ...lace 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 headlight to the light switch 6 1 Set the multimeter to...

Page 287: ...ed probe in the bullet connector on the red wire wire harness side and place the black probe in the bullet connector on the black wire wire harness side Figure 11c 49 Page 11c 51 5 Have an assistant p...

Page 288: ...g of approximately positive 12 VDC indicates that the bed lift harness or switch are wired incorrectly Check the wiring of the bed lift harness and bed lift switch See Wiring Diagram on page 11c 6 A r...

Page 289: ...Removal Section 12c Page 12c 9 2 Place the red probe of the multimeter on the circuit breaker terminals If the multimeter does not indicate continuity replace the circuit breaker See Bed Lift Circuit...

Page 290: ...11C...

Page 291: ...for testing removal disassembly and installation procedures See the Kawasaki FH680D engine manual CCI P N 103351201 RELAYS See General Warning Section 1 Page 1 1 The start relay 1 carburetor heater re...

Page 292: ...eutral Switch See Test Procedure 9 Section 11a Page 11a 22 Neutral Switch Removal 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect...

Page 293: ...N 103351201 2 Connect the two pin connector to the carburetor solenoid Figure 12a 3 Page 12a 3 3 Install the engine front cover 4 Connect the battery cables positive cable first and tighten the termi...

Page 294: ...Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally in General W...

Page 295: ...Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 2 3 Raise the hood 4 Disconne...

Page 296: ...hour meter field is always ON When the key switch is turned to ON the fuel gauge field activates All 2007 vehicles The fuel gauge initially registers full before indicating the actual fuel level The h...

Page 297: ...in lb 28 N m Place one drop of Loctite on each hex nut Do not allow Loctite to come into con tact with the fuel gauge hour meter casing 2 2 Late 2007 vehicles Force the mounting clip 14 onto the back...

Page 298: ...Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 2 3 Raise the hood 4 From under the hood disconnect the...

Page 299: ...d Lift Switch Installation 1 Match the terminal numbers molded onto the connector and switch and reconnect the wire harness 2 Push the bed lift switch into the instrument panel until fully seated 3 Lo...

Page 300: ...ect the wire harness 2 Push the light switch into the instrument panel until fully seated 3 Lower and secure the hood 4 Connect the battery cables positive cable first and tighten the terminals to 144...

Page 301: ...everse handle in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 2 3 Raise the hood 4 Remove th...

Page 302: ...from the reverse warning buzzer limit switch Figure 12a 7 Page 12a 11 5 Remove the screws nuts washers and lockwashers that secure the limit switch 6 Remove the limit switch Reverse Warning Buzzer Li...

Page 303: ...Terminal Protector Spray CCI P N 1014305 10 Turn the key switch to the ON position With the Forward Reverse handle in REVERSE the buzzer should sound FRONT DIFFERENTIAL LIMIT SWITCH See General Warni...

Page 304: ...re replacing the unit Testing the Fuel Level Sending Unit See Test Procedure 24 Section 11a Page 11a 32 Fuel Level Sending Unit Removal See Fuel Level Sending Unit Removal Section 13a Page 13a 11 Fuel...

Page 305: ...e the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 2 3 From the fr...

Page 306: ...by removing the wire conduit and tracing the wire 4 Note the polarity of the diode as indicated by the silver stripe on one end of the diode and mark the wire on the side of the silver stripe 5 Cut t...

Page 307: ...ecommends a group 70 side post battery CCI P N 1012328 with a 650 cranking amp rating at 32 F 0 C 500 CCA at 0 F 17 8 C and a reserve capacity of at least 105 minutes The group 70 classification indic...

Page 308: ...keep the battery from bouncing Battery life may be severely shortened if the clamp is too loose Excessive vibration shortens the life of the battery It may also cause acid to leak from the vent caps...

Page 309: ...or fluid boils from vents stop charging immediately Failure to stop charging battery when any of these conditions are present could result in an explosion personal injury and or damage to the battery...

Page 310: ...e container is bulged discard battery A frozen battery can explode 6 The frequency of recharging required depends on the temperature of the storage area but it is recom mended that the battery be moni...

Page 311: ...anual for testing removal disassembly and installation procedures See the Honda GX620 engine manual CCI P N 102615401 RELAYS See General Warning Section 1 Page 1 1 The start relay 1 differential relay...

Page 312: ...tral Switch See Test Procedure 10 Section 11b Page 11b 24 Neutral Switch Removal 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect...

Page 313: ...carburetor and install the carburetor See the Honda GX620 engine manual CCI P N 102615401 2 Install the intake hose on the carburetor intake adapter 3 Connect the 18 gauge yellow wire w39 from the ca...

Page 314: ...inals to 144 in lb 16 N m Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 4 With the Forward Reverse handle in NEUTRAL start the engine and check the regulator for proper func tio...

Page 315: ...or Spray CCI P N 1014305 FUEL GAUGE HOUR METER See General Warning Section 1 Page 1 1 Testing the Fuel Gauge Hour Meter See Test Procedure 25 Section 11b Page 11b 34 Also see Test Procedure 26 Hour Me...

Page 316: ...in lb 28 N m Place one drop of Loctite on each hex nut Do not allow Loctite to come into contact with the fuel gauge hour meter cas ing 3 Connect the wires to the fuel gauge hour meter See Wiring Dia...

Page 317: ...ock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 2 3 Raise the hood 4 From under the hood disconnect the w...

Page 318: ...Lift Switch Installation 1 Match the terminal numbers molded onto the connector and switch and reconnect the wire harness 2 Push the bed lift switch into the instrument panel until fully seated 3 Low...

Page 319: ...t the wire harness 2 Push the light switch into the instrument panel until fully seated 3 Lower and secure the hood 4 Connect the battery cables positive cable first and tighten the terminals to 144 i...

Page 320: ...in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 2 3 Raise the hood 4 Remove the plastic riv...

Page 321: ...erse warning buzzer limit switch Figure 12b 6 Page 12b 10 5 Remove the screws nuts washers and lockwashers that secure the limit switch 6 Remove the limit switch Reverse Warning Buzzer Limit Switch In...

Page 322: ...vel sending unit before replacing the unit Testing the Fuel Level Sending Unit See Test Procedure 24 Section 11b Page 11b 33 Fuel Level Sending Unit Removal See Fuel Level Sending Unit Removal Section...

Page 323: ...additional testing removal disassembly and installation procedures See the Honda GX620 engine manual CCI P N 102615401 HEADLIGHTS See General Warning Section 1 Page 1 1 Testing the Headlight Bulb and...

Page 324: ...44 in lb 16 N m Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 WIRE HARNESS DIODES See General Warning Section 1 Page 1 1 The wire harness is equipped with several in line diodes...

Page 325: ...r gloves when working around a battery Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or using in an enclosed space Wear a f...

Page 326: ...ot weather also has an effect on a battery s self discharge rate The higher the temperature the quicker a battery will discharge Therefore the battery should be checked more often in hotter climates W...

Page 327: ...General Warning Section 1 Page 1 1 and DANGER on page 12b 15 1 Charge the battery with an automotive type 12 volt battery charger Follow all warnings and procedures supplied by the battery charger man...

Page 328: ...ttery 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 batter...

Page 329: ...installation procedures See the Kubota D722 diesel engine manual CCI P N 102615501 RELAYS See General Warning Section 1 Page 1 1 The start relay 1 differential relay 2 fan relay 3 and accessory relay...

Page 330: ...tch Removal 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the two pin connector between the neutral switch and the wire harness...

Page 331: ...firmly 3 Connect the three pin connector from the fuel solenoid to the wire harness Figure 12c 3 Page 12c 3 4 Connect the battery cables positive cable first and tighten the terminals to 144 in lb 16...

Page 332: ...5 Remove the nut and lock washer that secures the red wires to the starter solenoid and pull the fusible link wire assembly from vehicle and discard 60 Amp Fusible Link Installation 1 Attach the red...

Page 333: ...handle in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 2 3 Raise the hood 4 Disconnect the w...

Page 334: ...nd remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 1...

Page 335: ...the hood 4 From under the hood remove the multi pin connector from the key switch 5 Reach under the instrument panel to hold the key switch and remove the key switch nut 7 Figure 12c 6 Page 12c 5 Pull...

Page 336: ...d secure the hood 4 Connect the battery cables positive cable first and tighten the terminals to 144 in lb 16 N m Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 BED LIFT SWITCH T...

Page 337: ...ng Section 1 Page 1 1 Testing the Light Switch See Test Procedure 32 Section 11c Page 11c 49 Light Switch Removal 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTR...

Page 338: ...ary repairs before installing a new fuse Use the appropriately rated fuse if a fuse with a higher amp rating is used damage to the vehicle electrical system may occur 2 Install the electrical componen...

Page 339: ...Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 REVERSE WARNING BUZZER LIMIT SWITCH IF EQUIPPED See General Warning Section 1 Page 1 1 Testing the Reverse Warning Buzzer Limit Sw...

Page 340: ...the limit switch in position and tighten the mounting screws and nuts to 4 in lb 0 5 N m See fol lowing CAUTION CAUTION Do not overtighten the retaining nuts If the nuts are overtightened the limit sw...

Page 341: ...es of the wire harness Figure 12c 10 Page 12c 13 5 Remove the nuts 2 and screws 3 that secure the switch 1 and remove the switch Front Differential Limit Switch Installation 1 Install the front differ...

Page 342: ...Section 13c Page 13c 12 FUEL LEVEL SENDING UNIT See General Warning Section 1 Page 1 1 Thoroughly test the fuel level sending unit before replacing the unit Testing the Fuel Level Sending Unit See Te...

Page 343: ...he belt shield and the alternator from the engine compartment 8 If necessary remove the V belt Alternator and V belt Installation 1 Place the alternator and belt shield on the engine and insert the al...

Page 344: ...nnect the 12 gauge blue fusible link to the alternator Figure 12c 12 Page 12c 15 Tighten the nut to 84 in lb 9 5 N m 8 Connect the 18 gauge purple wire to the alternator Figure 12c 11 Page 12c 15 9 Co...

Page 345: ...n the bulb assembly counterclockwise one quarter turn 4 Connect the battery cables positive cable first and tighten the terminals to 144 in lb 16 N m Coat terminals with Battery Terminal Protector Spr...

Page 346: ...the engine block the radiator fan will not function and the high temperature warning lamp will not illuminate Thus the engine will over heat and the operator will not be alerted to the potential engi...

Page 347: ...assembly to shroud and remove the fan by pulling it through opening between driver side front tire and underside of fender flare Figure 12c 17 Page 12c 19 See follow ing NOTE NOTE To aid reassembly no...

Page 348: ...of the silver stripe 5 Cut the wires attached to each side of the diode and discard the diode Wire Harness Diode Installation 1 Slide a piece of heatshrink tubing over one of the wire ends where the d...

Page 349: ...a group 70 side post battery CCI P N 1012328 with a 650 cranking amp rating at 32 F 0 C 500 CCA at 0 F 17 8 C and a reserve capacity of at least 105 minutes The group 70 classification indicates batte...

Page 350: ...ght enough to keep the battery from bouncing Battery life may be severely shortened if the clamp is too loose Excessive vibration shortens the life of the battery It may also cause acid to leak from t...

Page 351: ...2 C or more emits gases or fluid boils from vents stop charging immediately Failure to stop charging battery when any of these conditions are present could result in an explosion personal injury and o...

Page 352: ...r is bulged discard battery A frozen battery can explode 6 The frequency of recharging required depends on the temperature of the storage area but it is recom mended that the battery be monitored mont...

Page 353: ...lean the engine 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintention...

Page 354: ...EL SYSTEM AND CLUTCHES Gasoline Engine Page 13a 2 2007 Carryall 295 295 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual 13A Figure 13a 1 Engine Removal and Installation Components 9 10...

Page 355: ...he starter solenoid See following NOTE NOTE Mark or tape together for identification the connectors on the starter solenoid posts 21 Drain the engine oil See Engine Oil and Filter Change Section 10b P...

Page 356: ...3a 1 Page 13a 2 Tighten the hard ware to 21 ft lb 28 N m 7 Install the clutch inner cover 6 See Clutch Inner Cover Installation on page 13a 38 8 Tighten the engine mounting bolts 8 to 39 ft lb 53 N m...

Page 357: ...ne Oil and Filter Change Section 10b Page 10b 8 25 Check the engine oil level See Engine Oil Level Check Section 10b Page 10b 8 26 Connect the battery cables positive cable first and tighten the hardw...

Page 358: ...l filter and the outlet port of the oil filter is connected to the inlet port on the engine Use new clamps when the hoses are replaced 3 Fill the engine with engine oil See Engine Oil Filling Section...

Page 359: ...t bolts 2 Remove the springs from the intermediate pipe and muffler inlet See following WARNING and NOTE WARNING Always wear eye protection when springs are removed or installed NOTE Shift the end of...

Page 360: ...ate pipe with new springs See following WARNING and NOTE WARNING Always wear eye protection when springs are removed or installed NOTE Shift the end of the muffler inlet and intermediate pipe from sid...

Page 361: ...should be kept clean See following NOTE and WARNING NOTE Use only 1 4 inch hoses with SAE J30R7 rating to replace the fuel lines WARNING Make sure fuel lines are the correct length and are properly ro...

Page 362: ...ondition See the Kawasaki FH680D engine manual CCI P N 103351201 Air filter element See Air Filter Replacement on page 13a 23 Fuel filters See Fuel Filter on page 13a 10 Choke and air intake system fo...

Page 363: ...es See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 1 4 Remove the passenger seat See Seat Removal Section 4 Page 4 9 5 Remove the rubber boot 8 from the center post o...

Page 364: ...DANGER Gasoline Flammable Explosive Do not smoke Keep sparks and flames away from the vehicle and service area 1 Place a new rubber gasket on the fuel tank with the notch 2 centered between the flange...

Page 365: ...holes could result in an incomplete seal between the fuel level sending unit and the fuel tank NOTE The fuel level sending unit mounts to the fuel tank only one way If the unit does not fit on the fu...

Page 366: ...ank Removal 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally...

Page 367: ...orage or Disposal 1 Remove the cap from the tank and thoroughly rinse it with water The cap may be discarded or kept as a spare 2 Use a well ventilated area and flush the fuel tank with water to remov...

Page 368: ...ate fuel to the fuel tank 13 Ensure the fuel shut off valve on top of the fuel tank is in the open ON position Figure 13a 12 Page 13a 17 and Figure 13a 13 Page 13a 17 14 Connect the battery cables pos...

Page 369: ...Page 13a 17 Fully Open Position To open the valve fully it must be turned approximately 120 from the closed OFF position until it cannot be turned any further Figure 13a 12 Page 13a 17 If the valve be...

Page 370: ...handle in NEUTRAL Remove the key Chock the rear wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 2 3 Raise the ho...

Page 371: ...2 1 Feed the pedal end and governor end of the accelerator cable up into place from under the vehicle on the passenger side See following NOTE NOTE Tie the nylon cord routed during removal to the engi...

Page 372: ...RNING To avoid unintentionally starting in General Warning Section 1 Page 1 1 3 Remove seat s 4 Remove the center seat plate bucket seat vehicles only 5 Remove the engine top cover 6 Remove the choke...

Page 373: ...rews tightened to 54 in lb 6 N m Figure 13a 19 Page 13a 21 5 Feed the Z shaped cable end 2 of the choke cable through the engine front cover Figure 13a 19 Page 13a 21 6 Push the cable sheath strain re...

Page 374: ...16112 close to the spark plug wire and plug 2 Hold the throttle lever against the stop screw and adjust the carburetor idle screw 1 on the carburetor until the tachometer displays 1125 50 RPM Figure 1...

Page 375: ...the event of a loss of power sluggish acceleration or a roughly running engine with excessive black exhaust service the air filter immediately CAUTION Do not drill into the driver side frame Failure t...

Page 376: ...Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 1 3 Remove the air filter cartridge See Air Filter Removal on page 13a 23...

Page 377: ...ves as a duct to carry air from a location at the top of the front of the vehicle CAUTION Do not drill holes or attach anything to the driver side of the frame A penetrating fastener will create passa...

Page 378: ...ry Terminal Protector Spray CCI P N 1014305 AIR FILTER OUTLET HOSE REMOVAL 1 Turn the key switch OFF and remove the key Set the park brake Place the Forward Reverse handle in NEUTRAL 2 Disconnect the...

Page 379: ...01 Driven clutch service tools Spring compression base CCI P N 102603501 Spring compression collar CCI P N 102605201 Spring compression nut CCI P N 102606101 CLUTCH TROUBLESHOOTING See General Warning...

Page 380: ...rning Section 1 Page 1 1 The drive belt should be inspected periodically for wear and glazing If it is excessively worn frayed or glazed replace the belt As the drive belt wears the engine RPM will in...

Page 381: ...the hardware to 144 in lb 16 N m Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 DRIVE CLUTCH See General Warning Section 1 Page 1 1 CAUTION Be very careful with the clutches A cl...

Page 382: ...r clutch operation Use only a dry cloth and lightly wipe the shaft of the fixed face assembly 15 Figure 13a 30 Page 13a 33 Do not use a brush or steel wool These abrasives will damage the surface of t...

Page 383: ...in 9 and allow the rollers 7 to slide out of the spider 6 1 2 Install new rollers and secure the rollers with pins 2 Inspect the rollers 10 and weights 11 There should be no noticeable wear If the rol...

Page 384: ...2 4 Place the drive clutch assembly on the crankshaft taper 5 Install the mounting washer and retaining bolt Tighten the hardware to 39 ft lb 53 N m 6 Install the drive belt as instructed See Drive Be...

Page 385: ...E MUFFLER FUEL SYSTEM AND CLUTCHES Clutches 2007 Carryall 295 295 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual Page 13a 33 13A Figure 13a 30 Drive Clutch Assembly 2 3 4 5 6 10 13 12...

Page 386: ...l Warning Section 1 Page 1 2 4 Remove the top air filter hose from the filter canister 5 Remove the clutch outer cover See Clutch Outer Cover Removal on page 13a 37 6 Remove the drive belt as instruct...

Page 387: ...gh to release the pressure on the snap ring 4 Use snap ring pliers to remove the snap ring 1 Figure 13a 32 Page 13a 36 5 Slowly remove the spring compression nut The collar will then rise and release...

Page 388: ...he cup Figure 13a 31 Page 13a 35 5 Tighten the spring compression nut just enough to enable the snap ring to be installed 6 Use snap ring pliers to install the snap ring Driven Clutch Installation 1 T...

Page 389: ...void unintentionally starting in General Warning Section 1 Page 1 2 4 Remove the top air filter hose from the filter canister 5 Remove the self threading screws and remove the clutch outer cover See f...

Page 390: ...lt holes 2 Loosely install one bolt and washer in each transmission and engine mounting hole 3 Finger tighten the bolts and washers NOTE Mounting holes in the clutch inner cover have close tolerances...

Page 391: ...rse handle in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally in General Warning Section 1 Page 1 2 3 Remove the cargo bed See Cargo Bed Rem...

Page 392: ...20 Remove the electrical connectors 20 1 Disconnect the two ground wires on the frame from the starter case 20 2 Disconnect the two female bullet connectors from the charge coil 20 3 Disconnect the o...

Page 393: ...engine ports with new clamps See Oil Filter Hose Installation on page 13b 16 4 Loosely install new flange head bolts and flange head locknuts on the engine base slotted mounts See following NOTE NOTE...

Page 394: ...m on page 13b 23 18 Feed the fuel line through the grommet in the engine name plate Secure the fuel line to the in line filter on the engine with a new clamp See following DANGER DANGER Gasoline Flamm...

Page 395: ...to the intermediate pipe Figure 13b 2 Page 13b 5 See following NOTE NOTE Shift the end of the muffler inlet and intermediate pipe from side to side to relax and disconnect the springs 5 Remove the two...

Page 396: ...Replace 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 13...

Page 397: ...T 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual Page 13b 7 13B FUEL SYSTEM Figure 13b 3 Fuel System Honda Powered Gasoline Vehicles FUEL LINE No ROUTING 1 2 Fuel tank to fuel filter Vent tub...

Page 398: ...emoval and installation can be found in the engine manual See the Honda GX620 engine manual CCI P N 102615401 CARBURETOR See General Warning Section 1 Page 1 1 Before suspecting the carburetor as the...

Page 399: ...rse handle in NEUTRAL Chock the wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 1 3 Disconnect the spark plug wir...

Page 400: ...install the fuel level sending unit Failure to heed this warning could result in a fire or explosion DANGER Gasoline Flammable Explosive Do not smoke Keep sparks and flames away from the vehicle and s...

Page 401: ...e 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 in an incomplete seal b...

Page 402: ...ge 1 1 WARNING If the fuel tank is damaged replace it Do not attempt to repair it See the following tank removal and disposal procedure Fuel Tank Removal 1 Turn the key switch OFF and remove the key P...

Page 403: ...rap end below the passenger seat area 15 Lift the strap end and remove the opposite end from the slotted bracket 16 Remove the passenger side bed latch bracket from the frame 17 Remove the fuel tank F...

Page 404: ...ed nylon locknut Tighten the hardware to 20 ft lb 27 N m 9 Install the seat frame on the vehicle frame Secure the seat side plates with bolts flat washers and flanged locknuts Tighten the nut to 37 ft...

Page 405: ...Figure 13b 7 Page 13b 13 The fuel shut off valve should always be turned to the closed OFF position during vehicle storage towing or trailering and mainte nance and service Figure 13b 9 Page 13b 15 Fu...

Page 406: ...meter to the larger nozzle 1 Replace the oil hoses with like hoses See following NOTE NOTE One oil hose is 3 8 inch 9 5 mm equivalent and the other is 5 16 inch 7 9 mm equivalent Both oil hoses are ra...

Page 407: ...n the accelerator cable from the pedal Figure 13b 12 Page 13b 17 6 Release the retention clip at the pedal bracket Figure 13b 13 Page 13b 17 7 Disconnect the accelerator cable 5 from the engine Figure...

Page 408: ...TE Tie the nylon cord routed during removal to the engine end of the cable Pull the nylon cord to help feed the cable back through the instrument panel area and engine compartment 2 Secure the cable t...

Page 409: ...r Guard Installation 1 Slide the rear of the governor guard onto the bolts that extend through the transmission case 2 Install the front cable side governor guard bolts 1 Figure 13b 16 Page 13b 19 Tig...

Page 410: ...on page 13b 24 Incorrect adjustment may result in severe personal injury or death 1 Secure the spring loop on the engine end of the cable to the engine bracket Figure 13b 19 Page 13b 20 2 Slide the ca...

Page 411: ...Page 13b 22 Incorrect adjustment may result in severe personal injury or death NOTE This procedure may require the aid of an assistant 1 Remove the governor guard See Governor Guard Removal on page 13...

Page 412: ...Linkages Page 13b 22 2007 Carryall 295 295 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual 13B Figure 13b 21 Engine Honda and Transmission Figure 13b 22 Pin Measurement at Transmission...

Page 413: ...governor cable is inserted into the loop in the governor wire 9 Insert the idle spring 13 into the engine governor arm 6 and stretch it to insert it into the idle adjuster 14 6 Ensure the engine gover...

Page 414: ...ys 3825 25 RPM Figure 13b 23 Page 13b 24 See following NOTE NOTE Turn the screw counterclockwise to raise the RPM and clockwise to lower the RPM 4 Release the accelerator pedal CHOKE AND AIR INTAKE SY...

Page 415: ...op center of the canister Figure 13b 24 Page 13b 25 3 Use both tab locks on the sides of the cap to secure the canister cap CHOKE CABLE REMOVAL 1 Turn the key switch OFF and remove the key Set the par...

Page 416: ...on the choke control at the carburetor 5 Secure the cable sheath strain relief to the choke cable bracket on the engine 6 Install the engine cover plate 6 1 Tighten the two front bolts to 35 in lb 4 N...

Page 417: ...nals with Battery Terminal Protector Spray CCI P N 1014305 AIR FILTER INTAKE HOSE REMOVAL The air filter intake hose fits between the driver side frame and the inlet port on the air filter canister Th...

Page 418: ...se under the filter canister inlet port Figure 13b 29 Page 13b 28 See fol lowing NOTE NOTE Ensure the hose is positioned against the port surfaces and the clamps are positioned between the port bead a...

Page 419: ...and secure it with a clamp 2 Connect the air filter outlet hose to the carburetor inlet port and secure it with a clamp 3 Connect the battery cables positive cable first and tighten the hardware to 1...

Page 420: ...ed governor and throttle settings See Governor Cable Installation on page 13b 20 2 Inspect both clutches for dirt and debris buildup on component parts Clean the exterior surfaces of both clutches wit...

Page 421: ...and remove the key Set the park brake Place the Forward Reverse handle in NEUTRAL 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Sectio...

Page 422: ...g CAUTION CAUTION Hold the clutch assembly firmly when the clutch removal tool is advanced Once loosened the clutch will drop quickly Do not allow the clutch to fall on a hard surface 9 Remove the dri...

Page 423: ...ure the Fixed sheave tool CCI P N 102601501 into a vise or mount the tool to a flat work surface Figure 13b 32 Page 13b 33 5 Place the fixed sheave of the drive clu 6 tch onto the service tool so that...

Page 424: ...ble sheave upward and start threading the bolts with washers into holes See following NOTE NOTE Keep the cover as square to the post as possible to minimize wear between the post and cover 6 Use a cri...

Page 425: ...MUFFLER FUEL SYSTEM AND CLUTCHES Clutches 2007 Carryall 295 295 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual Page 13b 35 13B Figure 13b 33 Drive Clutch Assembly 2 3 4 5 6 10 13 12 1...

Page 426: ...Warning Section 1 Page 1 2 4 Remove the top air filter hose from the filter canister 5 Remove the clutch outer cover See Clutch Outer Cover Removal on page 13b 39 6 Remove the drive belt as instructed...

Page 427: ...h to release the pressure on the snap ring 4 Use snap ring pliers to remove the snap ring 1 Figure 13b 35 Page 13b 38 5 Slowly remove the spring compression nut The collar will then rise and release t...

Page 428: ...cup Figure 13b 34 Page 13b 37 5 Tighten the spring compression nut just enough to enable the snap ring to be installed 6 Use snap ring pliers to install the snap ring Driven Clutch Installation 1 Tur...

Page 429: ...oid unintentionally starting in General Warning Section 1 Page 1 2 4 Remove the top air filter hose from the filter canister 5 Remove the self threading screws and remove the clutch outer cover See fo...

Page 430: ...holes 2 Loosely install one bolt and washer in each transmission and engine mounting hole 3 Finger tighten the bolts and washers NOTE Mounting holes in the clutch inner cover have close tolerances Al...

Page 431: ...e key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Remove both seats 3 Disconnect the battery cables as instructed See WARNING To avoid unintentionally in General Warning Section 1 P...

Page 432: ...elerator cable sheath strain relief 6 from the engine bracket 14 Disconnect the three pin connector 7 on the fuel solenoid valve from the engine Figure 13c 1 Page 13c 2 15 Disconnect the thermostat sw...

Page 433: ...of the engine to lift the engine from the mounting plate 29 If replacing engine remove cvt adapter shaft from flywheel and retain for use on replacement engine ENGINE INSTALLATION See General Warning...

Page 434: ...throttle lever 19 Remove the plug and secure the fuel return line 4 to the engine relief valve with a new clamp Figure 13c 1 Page 13c 2 See following DANGER DANGER Diesel fuel Flammable Explosive Do n...

Page 435: ...e pipe Figure 13c 5 Page 13c 5 See following NOTE NOTE Shift the end of the muffler inlet and intermediate pipe from side to side to relax and disconnect the springs 5 Remove the two bolts and large f...

Page 436: ...brush 2 Use a new high temperature flange gasket CCI P N 102422301 and align the manifold pipe so the bend directs the pipe in and slightly down 3 Install new bolts and flange head locknuts Tighten t...

Page 437: ...ed or installed NOTE Shift the end of the muffler inlet and intermediate pipe from side to side to relax and connect the springs 3 Align the muffler with the intermediate pipe and tighten the muffler...

Page 438: ...4 5 6 5 16 in 8 mm 5 16 in 8 mm 5 16 in 8 mm 5 16 in 8 mm 3 16 in 5 mm 3 16 in 5 mm Fuel tank to primary fuel filter Primary fuel filter to fuel pump Fuel pump to secondary fuel filter Secondary fuel...

Page 439: ...m contains two fuel filters A primary fuel filter 7 and a secondary fuel filter 8 with an inte grated water separator Figure 13c 8 Page 13c 8 Fuel filters fuel lines and the fuel tank vent 6 should be...

Page 440: ...e first filter to receive fuel from the fuel tank Figure 13c 8 Page 13c 8 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Disconnect the bat...

Page 441: ...o wipe the filter manifold surface clean where the fuel filter gasket seats 2 To help seal the new fuel filter to the manifold apply a light coat of new engine oil to the rubber seal before installing...

Page 442: ...from the right side of the fuel pump bracket and remove the fuel pump Fuel Pump Installation See General Warning Section 1 Page 1 1 1 Position a new fuel pump between the fuel filters Figure 13c 8 Pa...

Page 443: ...orange wire 7 Figure 13c 10 Page 13c 13 Retain the hardware 5 Remove the hex head plastic thread screw 10 securing the black ground wire 6 to the fuel level send ing unit and remove the black ground w...

Page 444: ...13c 11 Page 13c 14 See following NOTE NOTE The distance between the flange identification mounting holes 1 is larger than the distance between any of the other mounting holes in the sending unit flang...

Page 445: ...13 See following CAUTION CAUTION Use only the existing screws or new plastic thread screws made for plastics applications Do not use sheet metal screws as replacement hardware 5 Use a crisscross patte...

Page 446: ...ion 4 Page 4 10 6 Disconnect the fuel feed line 1 from the fuel tank to the primary fuel filter and raise the end of the hose above the fuel tank Plug the line Figure 13c 8 Page 13c 8 See following NO...

Page 447: ...nd flush the fuel tank with water to remove any remaining fuel 3 Set the tank upside down in a well ventilated area so that the water can drain Allow the tank to sit for 24 hours to dry See following...

Page 448: ...l to the fuel tank 14 Connect the battery cables positive cable first and tighten the hardware to 144 in lb 16 N m Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 15 Install both...

Page 449: ...ger seat See Seat Removal Section 4 Page 4 9 5 Disconnect the Z shaped end 1 of the accelerator cable from the pedal Figure 13c 15 Page 13c 19 6 Disconnect the cable strain relief at the pedal bracket...

Page 450: ...er on the engine Figure 13c 1 Page 13c 2 5 Secure the strain relief on the accelerator cable sheath to the engine bracket 6 Secure the accelerator cable to the rubber grommets under the passenger side...

Page 451: ...iesel probe instructions before any RPM adjustments are made 3 Secure the fuel line probe clamp to the clean area of the fuel injector line Figure 13c 20 Page 13c 21 4 Secure the negative line clamp t...

Page 452: ...adjustments are made 2 Secure the fuel line clamp to the clean area of the fuel injector line Figure 13c 20 Page 13c 21 3 Secure the negative line clamp to the negative battery post Figure 13c 21 Page...

Page 453: ...e frame Failure to heed this caution could damage the engine by allowing excessive contamination or water to enter the air intake system Air Filter Removal 1 Release both canister tab locks Figure 13c...

Page 454: ...racket Tighten the bolts to 21 ft lb 28 5 N m 3 Secure the bottom inlet hose to the canister port 4 Secure the top outlet hose to the canister port 5 Install a new air filter cartridge See Air Filter...

Page 455: ...cle body 5 Slide the air intake hose through the frame support bracket and remove the hose from the vehicle Figure 13c 26 Page 13c 25 AIR FILTER INTAKE HOSE INSTALLATION 1 Slide the air intake hose th...

Page 456: ...ee WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 1 3 Disconnect the air outlet hose from the air filter canister outlet port 4 Disconnect the air outlet hose from the c...

Page 457: ...g compression collar CCI P N 102605201 Spring compression nut CCI P N 102606101 CLUTCH TROUBLESHOOTING See General Warning Section 1 Page 1 1 Use a tachometer during vehicle operation to determine if...

Page 458: ...5 Check the drive clutch rollers and weights for wear DRIVE BELT See General Warning Section 1 Page 1 1 The drive belt should be inspected periodically for wear and glazing If it is excessively worn...

Page 459: ...tery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 2 3 Remove the top air filter hose outlet from the air filter canister 4 Remove the clutch o...

Page 460: ...disassemble the drive clutch and are available from a service parts representative Fixed sheave tool CCI P N 102601501 Spider tool CCI P N 102607501 1 Use a 7 16 inch socket to remove the four bolts 1...

Page 461: ...S Manual Page 13c 31 13C 6 Place the Spider tool CCI P N 102607501 on top of the spider 7 Use a 1 2 inch drive ratchet to disengage the moveable sheave 14 and spider 6 which will come off as an assemb...

Page 462: ...07501 to tighten the moveable sheave and spider to 225 ft lb 305 N m 3 Install the spring 5 onto the shaft 4 Install the cover 4 onto the shaft 5 Align the plate that has holes in the cover with the a...

Page 463: ...al Warning Section 1 Page 1 2 3 Remove the top air filter hose from the filter canister 4 Remove the clutch outer cover See Clutch Outer Cover Removal on page 13c 35 5 Remove the drive belt as instruc...

Page 464: ...P N 102603501 Figure 13c 33 Page 13c 33 2 Place the Spring compression collar CCI P N 102605201 onto the driven clutch 3 Thread the Spring compression nut CCI P N 102606101 down onto the threaded pos...

Page 465: ...tion on page 13c 29 6 Install the clutch outer cover and tighten the screws to 72 in lb 8 N m 7 Install the top air filter hose on the filter canister NOTE Ensure the hose is fully seated and the clam...

Page 466: ...NOTE NOTE When bolts are removed note any bolt length differences around the flywheel Some bolt holes have limited depth and require a specific length of bolt thread Ensure the studs remain on the eng...

Page 467: ...ion 5 Tighten the engine bolts and washers to 21 ft lb 28 5 N m 6 Tighten the engine stud bolt nuts to 21 ft lb 28 5 N m 7 Tighten the transmission bolts and washers to 21 ft lb 28 5 N m 8 Install the...

Page 468: ...13C...

Page 469: ...Turn the key switch OFF and remove the key Set the park brake Place the Forward Reverse handle in NEUTRAL Chock the rear wheels 2 Disconnect the battery cables as instructed See WARNING To avoid unint...

Page 470: ...CAUTION CAUTION Do not kink twist or damage the hydraulic brake lines 13 Remove the two flanged bolts and square nuts from the camber adjustment bar Figure 14 4 Page 14 2 14 Lift the wheel hub up and...

Page 471: ...the half shaft into the front 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...

Page 472: ...lug nuts on both front wheels to 85 ft lb 115 N m 13 Tighten both spindle locknuts to 150 ft lb 203 N m 14 Adjust the front wheel camber See Camber Adjustment Section 7 Page 7 12 15 Connect the batte...

Page 473: ...the frame support weldments Figure 14 11 Page 14 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...

Page 474: ...TE NOTE If the tube shows signs of cracking or splitting trim the end before the tube is connected or replaced 7 Drive a new roll pin into the differential pinion shaft and driveshaft universal joint...

Page 475: ...oll pin should 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 6 Connect the battery cables positive cable first and tighten...

Page 476: ...plug wires See WARNING To avoid unintentionally start ing in General Warning Section 1 Page 1 2 4 Loosen the lug nuts on the rear wheels and lift the rear of the vehicle with a chain hoist or floor j...

Page 477: ...ise the jack just enough to support the axle Figure 14 16 Page 14 10 14 Detach rear shock absorbers from axle See Rear Shock Absorber Removal Section 9 Page 9 1 15 Remove the rear receiver hitch See R...

Page 478: ...pin holes and drive a new roll pin into place See following NOTE NOTE The roll pin should be slightly below the surface on both sides of the coupling Use a 1 4 inch roll pin punch to drive the roll p...

Page 479: ...14 Install both rear wheels and finger tighten the lug nuts 15 Lift the rear of the vehicle with a chain hoist or floor jack and remove jack stands See WARNING Lift only one end in General Warning Sec...

Page 480: ...e a new roll pin into the differential pinion shaft and the driveshaft universal joint coupling See fol lowing NOTE NOTE The roll pin should be slightly below the surface on both sides of the coupling...

Page 481: ...arm 11 3 Remove the governor arm 12 Remove the transmission Forward Reverse shifter cable ball socket from the ball stud on the transmis sion shifter arm Figure 14 24 Page 14 17 13 Disconnect the neut...

Page 482: ...Cover Installation Section 13c Page 13c 36 See following NOTE NOTE Hole tolerances in the inner cover are very close in diameter to bolt sizes The inner cover is used to align the engine and transmis...

Page 483: ...hicles or Drive Belt Installation Section 13c Page 13c 29 diesel vehicles 13 Install the clutch outer cover See Clutch Outer Cover Installation Section 13b Page 13b 39 gas oline vehicles or Clutch Out...

Page 484: ...he nut farthest from the handle should be at the farthest end of the threaded portion of the cable 7 Remove the passenger seat 8 Note the positions of the wire ties that secure the cable between the d...

Page 485: ...install the cable and two flanged nuts on the Forward Reverse cable bracket on the dash frame 5 Adjust the shifter cable See Forward Reverse Shifter Cable Adjustment on page 14 17 Forward Reverse Shi...

Page 486: ...ulder bolt nylon spacer two large flat washers and nylon locknut from the shifter handle and frame bracket 7 Remove the shifter handle Shifter Handle Installation 1 Secure the shifter handle with a ne...

Page 487: ...See following CAUTION CAUTION The differential and axle tubes have been assembled with Loctite 2760 Threadlocker compound Use a non flammable heat source to heat the flange area and bolts during the...

Page 488: ...ew bolts Apply Loctite 2760 Threadlocker to the bolt threads 4 Apply a 3 16 inch wide bead of Three Bond No 1215 CCI P N 101928701 to the mating surfaces on each side of the differential 5 Secure the...

Page 489: ...re new bearing will sit and lightly lubricate the bore with anti seize compound 2 Using an appropriate sized bearing driver that fits the outer race drive in new bearing until fully seated 3 Install t...

Page 490: ...14...

Page 491: ...eels 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in See General Warning Section 1 Page 1 1 3 Raise the hood and remove the reservoir cap See following W...

Page 492: ...45 water and 55 propylene glycol with anti corrosion additives 12 Apply Loctite 567 Liquid Thread Sealer to the threads of the block coolant plug Install the plug and tighten to 144 in lb 16 N m 13 C...

Page 493: ...E NOTE Do not remove the drain pan until the reservoir has been replaced and the hoses attached 5 Turn the drain valve at the radiator counterclockwise for one and one half turns only to drain enough...

Page 494: ...he engine and coolant to cool See following WARNING WARNING Coolant reservoir and radiator are pressurized Remove caps slowly to relieve pressure Hot Coolant system is pressurized Do not remove radiat...

Page 495: ...ator and remove the shroud RADIATOR INSTALLATION 1 Place fan shroud assembly on radiator and secure with four lock patch bolts Tighten the hardware to 48 in lb 5 N m 2 Carefully lower the radiator str...

Page 496: ...ing Section 1 Page 1 1 3 Drain the radiator reservoir and engine See Engine Coolant Change on page 15 1 See following WARNING WARNING Coolant reservoir and radiator are pressurized Remove caps slowly...

Page 497: ...positive cable first and tighten the hardware to 144 in lb 16 N m Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 7 Start and run the engine until it reaches operating temperature...

Page 498: ...15...

Page 499: ...rgy 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 misapplication of prod...

Page 500: ...OFF posi tion 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 the locke...

Page 501: ...TACHMENT ARM 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 me...

Page 502: ...r fully by moving the joystick 1 back Figure 16 8 Page 16 4 7 Retract the attachment interface cylinder fully by moving the joystick 1 to the left 8 Turn the start key to the OFF position 9 Rotate the...

Page 503: ...the retaining rings 2 and the pins 1 from the attachment arm both sides Figure 16 13 Page 16 6 4 Raise the attachment arms and align the holes in the attachment arms to the vehicle mounting holes Figu...

Page 504: ...right to extend the attachment interface cylinder 11 Turn the key to the OFF position NOTE When aligning the cylinders to the attachment arm and interface during installation the cylinders may need to...

Page 505: ...95 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual Page 16 7 16 13 Raise the attachment interface and align it with the cylinder Install the pin 2 and the retaining ring 1 Figure 16 17...

Page 506: ...T SYSTEM Electrical Page 16 8 2007 Carryall 295 295 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual 16 ELECTRICAL Figure 16 18 Wiring Diagram for Hydraulic Attachment System Vehicles Fr...

Page 507: ...ACHMENT SYSTEM Electrical 2007 Carryall 295 295 SE XRT 1550 1550 SE Gasoline Diesel and IntelliTach M S Manual Page 16 9 16 Figure 16 19 Wiring Diagram for Hydraulic Attachment System Vehicles Rear Di...

Page 508: ...uity with the joystick at rest and continuity with the joystick acting on the switch 3 If a switch 3 1 Does not work as stated in previous step replace switch 3 2 Does work as stated in previous step...

Page 509: ...al 1 Turn the key switch OFF and remove the key Place the Forward Reverse handle in NEUTRAL Chock the wheels 2 Set the joystick ON OFF switch to OFF and remove both seats 3 Disconnect the battery cabl...

Page 510: ...e 16 11 5 Connect the battery cables positive cable first and tighten the terminals to 144 in lb 16 N m Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 JOYSTICK ON OFF SWITCH See...

Page 511: ...stick ON OFF switch to OFF and remove both seats 3 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 1 4 Cut the wire tie se...

Page 512: ...rom motor solenoid and cover its ring terminal to prevent a short 3 3 Reconnect the battery cables positive cable first and turn the key switch ON 3 4 Switch the joystick ON OFF switch to ON 3 5 Push...

Page 513: ...tallation 1 With switch light oriented to the passenger side insert switch into control box cover until fully seated 2 Connect harness plug to switch 3 Install control box cover joystick assembly and...

Page 514: ...wheels 2 Set the joystick ON OFF switch to OFF and remove both seats 3 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 1...

Page 515: ...e and terminal 30 light blue wire Figure 16 27 Page 16 17 3 Apply 12 volts with the positive lead connected to terminal 86 and the negative lead connected to termi nal 85 The relay should click and sh...

Page 516: ...en terminal 85 black wire and terminal 86 orange wire Figure 16 29 Page 16 18 2 Test for no continuity between terminals 87 and 30 red wires Figure 16 29 Page 16 18 3 Apply 12 volts with the positive...

Page 517: ...purple wire Figure 16 30 Page 16 19 2 Test for no continuity between the two large terminals red wire and copper strap Figure 16 30 Page 16 19 3 Apply 12 volts with the positive lead connected to the...

Page 518: ...check again for continuity 3 If there is still no continuity replace the breaker Circuit Breaker Removal 1 Empty and raise cargo bed 2 Turn the key switch OFF and remove the key Place the Forward Reve...

Page 519: ...ground wire Figure 16 19 Page 16 9 The switch controlling the valve See Electrical on page 16 8 The supplied voltage The continuity of the control valve coil A bent valve stem Replace valve Any debri...

Page 520: ...be removed the cartridge will have to be replaced 2 If the valve does not return to the neutral or unshifted position check for either dirt in the valve cartridge or a bent stem Three Way 2 Position a...

Page 521: ...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 blow dr...

Page 522: ...g more than one hose at a time locate and note the hose factory color marking to ease reas sembly See following NOTE NOTE Mark hoses for correct installation if factory markings are not found 7 Discon...

Page 523: ...WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 1 5 Thoroughly clean the fittings and the area around them 6 Mark hoses to ease reassembly and disconnect hoses from quic...

Page 524: ...vehicle 4 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 1 Page 1 1 5 Thoroughly clean the cylinder hose fittings and the area aro...

Page 525: ...afety glasses to 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 CAUTION When...

Page 526: ...pin 2 Figure 16 41 Page 16 28 from the base end of the hydraulic cylinder and remove cylinder Auxiliary Cylinder Installation 1 Reverse the removal procedure to install the auxiliary hydraulic cylinde...

Page 527: ...any of the following conditions exist Fluids are under pressure Flying debris or loose material is present Engine is running Tools are being used Figure 16 42 Cylinder Exploded View 1 Case 2 Nut 3 Se...

Page 528: ...plier See your Ingersoll Rand dealer NOTE The drawings may not show the cylinder exactly as it appears but the procedure is correct for all the cylinders 1 Put the base end of the hydraulic cylinder i...

Page 529: ...Page 16 31 11 Remove the O ring and back up washer from the head Figure 16 48 Page 16 31 12 Remove the wiper seal Figure 16 49 Page 16 31 13 Remove the oil seal from the head Figure 16 50 Page 16 31...

Page 530: ...the O rings and seals and replace them with NEW O rings and seals CYLINDER ASSEMBLY WARNING Wear safety glasses to prevent eye injury when any of the following conditions exist Fluids are under press...

Page 531: ...5 Install the oil seal on the rod seal tool Figure 16 57 Page 16 34 NOTE The O ring side of the oil seal goes toward the inside of the cylinder 6 Install the oil seal in the head Figure 16 58 Page 16...

Page 532: ...nstall the O ring next to the back up ring as shown Figure 16 61 Page 16 35 10 If a seal was removed from the head use the following procedure to install a new seal 11 Install the guide with a pilot a...

Page 533: ...r the Teflon seal for five minutes 14 Install the head on the rod Figure 16 64 Page 16 35 15 Note piston type and install according to the following 15 1 For cylinders with a cushioned piston install...

Page 534: ...case Figure 16 68 Page 16 36 20 Put oil on the Teflon seal on the piston Figure 16 69 Page 16 37 21 Install the rod assembly in the cylinder case Figure 16 70 Page 16 37 22 Put oil on the seals and th...

Page 535: ...Fluids are under pressure Flying debris or loose material is present Engine is running Tools are being used 1 Remove bushing s 1 Figure 16 73 Page 16 38 from the base end of the hydraulic cylinder On...

Page 536: ...6 75 Page 16 38 from the rod end of the hydraulic cylinder 4 Apply LOCTITE 271 Red to the bushings 2 before installing them into the cylinder Figure 16 76 Page 16 38 Figure 16 73 Remove Bushings From...

Page 537: ...g used 1 Remove bushings 1 Figure 16 77 Page 16 39 from both sides of angle frame 2 Apply LOCTITE 271 Red to the bushings before installing them into the frame 3 Install bushings 2 Figure 16 78 Page 1...

Page 538: ...16 81 Page 16 40 from both sides of the angle frame 2 Apply LOCTITE 271 Red to the bushing before installing them into the angle frame 3 Install the two bushings 1 Figure 16 82 Page 16 40 on both side...

Page 539: ...ng used CAUTION When repairing hydraulic systems clean the work area before disassembly and keep all parts clean Always use caps and plugs on hoses tubelines and ports to keep dirt out Dirt can quickl...

Page 540: ...6 9 Loosen bottom of front fascia by removing two bolts securing it to vehicle Figure 16 83 Page 16 41 10 Remove four bolts 1 and washers 2 from lower part of mount under front of vehicle Figure 16 84...

Page 541: ...elieving Hydraulic System Pressure on page 16 1 3 Thoroughly clean the hose fittings and the area around the ends of the hoses being removed 4 Locate and note the hose factory color marking to ease re...

Page 542: ...rk area before disassembly and keep all parts clean Always use caps and plugs on hoses tubelines and ports to keep dirt out Dirt can quickly damage the system NOTE Mark hoses for correct installation...

Page 543: ...nd Figure 16 86 Page 16 45 10 Remove bolt securing the passenger side park brake cable to the chassis at the air filter and move cable forward Figure 16 87 Page 16 45 11 Cover edge of heat shield to p...

Page 544: ...See Solenoid Removal on page 16 19 16 Disconnect wire harness from control valve leads 17 Place drain pan under pump to catch fluid Slowly loosen and disconnect hoses at pump Cover all hose ends and f...

Page 545: ...end up into drain pan Remove filler cap to drain most of the fluid into pan 3 Clean and inspect filler cap Replace cap if damaged or unable to clean 4 Loosen band clamp and remove reservoir Figure 16...

Page 546: ...See following NOTE NOTE The motor may require effort to remove because the bearing is also being pulled out of the base Figure 16 94 Page 16 48 Motor Installation 1 Align slot in motor armature with...

Page 547: ...sting Unit following page 16 49 Pump Installation See Instructions for Installing Modular Pump on Existing Unit following page 16 49 PRIMING THE PUMP 1 Fill reservoir to the Maximum Fluid Level line 2...

Page 548: ...16...

Page 549: ...n 7 15 removal 7 15 battery diesel vehicles 12c 21 charging 12c 23 12c 24 hydrometer test 11c 13 installation 12c 23 load test 11c 15 maintenance 12c 21 mineral content 12c 22 removal 12c 22 self disc...

Page 550: ...20 brake system inspection 6 1 hydraulic brake system bleeding 6 22 filling 6 20 purging 6 24 master cylinder inspection 6 1 installation 6 21 removal 6 21 park brake see park brake troubleshooting 6...

Page 551: ...15 1 level check 10a 16 10b 16 cylinder auxiliary installation 16 28 removal 16 27 cylinder hydraulic assembly 16 32 bushings 16 37 disassembly 16 29 parts identification 16 29 cylinder vehicle mount...

Page 552: ...r diesel vehicles installation 12c 19 removal 12c 19 testing 11c 27 fan relay diesel vehicles testing 11c 23 fender front installation 4 6 removal 4 6 fender rear installation 4 15 removal 4 15 floor...

Page 553: ...sting 11c 16 fuse gasoline vehicles installation 12a 10 12b 9 removal 12a 10 12b 9 testing 11a 12 11b 12 fusible link diesel vehicles installation 12c 4 removal 12c 4 testing 11c 38 G gearcase lubrica...

Page 554: ...12b 7 removal 12a 7 12a 8 12b 6 12b 7 starter circuit testing 11a 13 11b 13 testing 11b 14 kill circuit engine gasoline vehicles testing 11a 28 11b 29 kill wire engine gasoline vehicles testing 11a 27...

Page 555: ...4 periodic service schedule 10a 1 10b 1 pump assembly hydraulic installation 16 46 removal 16 44 pump fuel diesel vehicles installation 13c 12 13c 13 removal 13c 11 pump fuel gasoline vehicles 13a 10...

Page 556: ...4 11 removal 4 10 seat adjustment 4 9 installation 4 9 removal 4 9 seat belt see safety belt seat frame installation 4 10 removal 4 10 serial number vehicle 3 1 service schedule see periodic service...

Page 557: ...1c 18 5 key switch on position 11c 19 6 key switch glow plug circuit 11c 19 7 starter control circuit 11c 20 8 start relay 11c 21 9 differential relay 11c 22 10 fan relay 11c 23 11 thermostat switch 1...

Page 558: ...sel vehicles installation 12c 18 removal 12c 17 testing 11c 25 throttle see accelerator pedal tire installation 8 3 removal 8 2 torque converter diesel vehicles 13c 27 torque converter gasoline vehicl...

Page 559: ...ormation 3 Clarity of Illustrations 4 Index Usability 5 Troubleshooting Chart Usability Poor Fair Average Good Excellent Comments Suggestions In order to help us better serve you please rate this publ...

Page 560: ...Club Car R NOTES...

Page 561: ...Club Car R NOTES...

Page 562: ...Club Car R NOTES...

Page 563: ......

Page 564: ...Club Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Int l 1 706 863 3000 Fax 1 706 863 5808...

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