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TROUBLESHOOTING AND ELECTRICAL SYSTEM: KAWASAKI POWERED GASOLINE VEHICLES

Test Procedures

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

Page 11a-15

11A

6. If the readings differ from those described in step 5, perform the following test procedures:

•

Check the battery.

See Test Procedure 1 – Battery on page 11a-9.

•

Check the 25-amp fuse at the fuse block.

See Test Procedure 2 – Fuse on page 11a-12.

•

Check the start relay.

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

•

Check diode 5.

See Test Procedure 8E – Diode 5 on wire 131 and 129 on page 11a-22.

•

Check the neutral switch on the transmission housing.

See Test Procedure 9 – Neutral Switch

(Transmission) on page 11a-22.

•

Check for continuity of the wire harness on wires 127, 129, 128, 124, and 125.

See Wiring Diagram

on page 11a-6.

7. If none of the previous steps resolves the problem, the starter solenoid and/or starter motor has failed.

See the Kawasaki 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 wheels.

2. Disconnect the 16-gauge green wire (w127) from the starter solenoid coil to prevent the vehicle from

unintentionally starting

(Figure 11a-10, Page 11a-15)

See following WARNING.

WARNING

• Failure to disconnect the wire from the solenoid coil could result in an unexpected engine

start when performing this test.

3. Set the multimeter to 20 VDC.

4. Place the probes to measure the voltage between the 16-gauge light green start relay wire (w110) ter-

minal and the frame ground

(Figure 11a-11, Page 11a-16)

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 and the relay
should click.

See following NOTE.

NOTE:

The carburetor heater and accessory relays (if equipped with accessory relay) may be removed to
isolate the sound of the start relay click.

Figure 11a-10 Solenoid Coil Wire (w127) Removed

Содержание IntelliTach XRT 1550

Страница 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...

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 22: ...1...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 54: ...4...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 60: ...5...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 90: ...6...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 114: ...8...

Страница 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...

Страница 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...

Страница 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...

Страница 118: ...9...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 196: ...11A...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 290: ...11C...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 468: ...13C...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 490: ...14...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 498: ...15...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 548: ...16...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 560: ...Club Car R NOTES...

Страница 561: ...Club Car R NOTES...

Страница 562: ...Club Car R NOTES...

Страница 563: ......

Страница 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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