Club Car Carryall 1500 Manual
2015
Carryall 1500/1700 and XRT 1550
Maintenance and Service
Manual
Carryall 1500/1700, XRT 1550/1550 SE Gasoline, Diesel and
IntelliT ach V ehicles
ManualNumber105157210
EditionCode0814A00000
FOREWORD
Club Car vehicles are designed and built to provide the ultimate in performance ef îšżciency; however , proper
maintenance and repair are essential for achieving maximum service life and continued safe and reliable operation.
Thismanualprovidesdetailedinformationforthemaintenanceandrepairof2015Carryall1500,Carryall1700,XRT
1550, XR T 1550 SE and IntelliT ach vehicles, and should be thoroughly reviewed prior to servicing the vehicles. The
procedures provided must be properly implemented, and the DANGER, W ARNING, and CAUTION statements
must be heeded.
This manual was written for the trained technician who already possesses knowledge and skills in electrical and
mechanical repair . If the technician does not have such knowledge and skills, attempted service or repairs to the
vehicle may render the vehicle unsafe. 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 of Club Car , LLC to assist its distributors and dealers in continually updating their service knowledge
and facilities so they can provide prompt and ef îšżcient service for vehicle owners. Regional technical representatives,
periodic service bulletins, maintenance and service manuals, and other service publications also represent Club Car ’ s
continuing commitment to customer support.
Club Car of fers a full line of training and continuing education classes for technicians who want to learn more about
our products. For more information, contact your local dealer or Club Car ’ s T echnical Services department for a
list of upcoming classes.
This manual covers all aspects of typical vehicle service; however , unique situations sometimes occur when servicing a
vehicle. If it appears that a service question is not answered in this manual, please contact your nearest authorized
Club Car dealer or distributor for assistance. Y ou may also write to us at: Club Car , LLC; P .O. Box 204658; Augusta,
GA 30917 - 4658 USA, Attention: T echnical Services.
Copyright ©2014 Club Car , LLC
Club Car , Carryall, and ArmorFlex
are registered trademarks of Club Car , LLC
ThismanualeffectiveSeptember1,2014
2015Carryall1500/1700andXRT1550MaintenanceandServiceManual Page i
FOREWORD
WARNING
•ReadSafetyonpage1-1beforeattemptinganyserviceonthisvehicle.
•Beforeservicingvehicle,readcompletesection(s)andanyreferencedinformationthatmaybe
relevanttotheserviceorrepairtobeperformed.
NOTE:Thismanualrepresentsthemostcurrentinformationatthetimeofpublication.Themanufactureriscontinually
workingtofurtherimproveitsvehiclesandotherproducts.Theseimprovementsmayaffectservicing
procedures.Anymodiîšżcationand/orsigniîšżcantchangeinspeciîšżcationsorprocedureswillbeforwardedtoall
dealersandwill,whenapplicable,appearinfutureeditionsofthismanual.
Damagetoavehicleorcomponentthereofnotresultingfromadefectorthatoccursduetounreasonable
orunintendeduse,overloading,abuse,orneglect(includingfailuretoprovidereasonableornecessary
maintenanceasinstructedinthevehicleowner’smanual),accidentoralteration,includingincreasingvehicle
speedbeyondfactoryspeciîšżcationsormodiîšżcationsthataffectthestabilityofthevehicleortheoperation
thereof,willvoidthewarranty.
Themanufacturerreservestherighttochangespeciîšżcationsanddesignsatanytimewithoutnoticeand
withoutincurringanyobligationorliabilitywhatsoever.
Therearenowarrantiesexpressedorimpliedinthismanual.Seethelimitedwarrantyfoundinthevehicle
owner’smanualorwritetoClubCar,LLC,P .O.Box204658,Augusta,GA30917-4658USA,Attention:
WarrantyDepartment.
CONTENTS
SECTION 1 – SAFETY ...................................................................................................................................... 1 -1
Safety Details ................................................................................................................................................ 1 -1
Personal Safety ......................................................................................................................................... 1 -1
Machine Safety .......................................................................................................................................... 1 -1
Information ................................................................................................................................................ 1 -2
General W arnings .......................................................................................................................................... 1 -2
Disabling the V ehicle .................................................................................................................................. 1 -3
Disconnecting the Battery – Gasoline/Diesel V ehicles .................................................................................. 1 -3
Connecting the Battery – Gasoline/Diesel V ehicles ...................................................................................... 1 -4
Recycling Lead -Acid Batteries .................................................................................................................... 1 -4
International safety symbols on batteries ..................................................................................................... 1 -5
SECTION 2 – VEHICLE SPECIFICA TIONS ........................................................................................................ 2 -1
1500/1700 and 1550/1550 SE Speciîšżcations ............................................................................................... 2 -1
Intellitach Speciîšżcations ............................................................................................................................. 2 -4
SECTION 3 – GENERAL INFORMA TION ........................................................................................................... 3 -1
Model Identiîšżcation ........................................................................................................................................ 3 -3
Identiîšżcation Numbers ............................................................................................................................... 3 -3
Storage ......................................................................................................................................................... 3 -5
Preparing the V ehicle for Extended Storage ................................................................................................ 3 -6
Returning the Stored V ehicle to Service ...................................................................................................... 3 -6
Lifting The V ehicle ......................................................................................................................................... 3 -7
Lifting Only The Front ................................................................................................................................ 3 -7
Lifting Only The Rear ................................................................................................................................. 3 -7
Lifting The Entire V ehicle ............................................................................................................................ 3 -8
Using A Booster Battery (Jump Starting) ......................................................................................................... 3 -9
SECTION 4 – BODY AND TRIM ......................................................................................................................... 4 -1
General Information ....................................................................................................................................... 4 -1
Cleaning the V ehicle ...................................................................................................................................... 4 -1
Seat Cleaning ............................................................................................................................................ 4 -1
Front Body Repair ......................................................................................................................................... 4 -2
Light Scratches .......................................................................................................................................... 4 -2
Abrasions and Haze .................................................................................................................................. 4 -2
Large Scratches and Abrasions .................................................................................................................. 4 -3
Front Body Components ................................................................................................................................ 4 -3
Instrument Panel Removal ......................................................................................................................... 4 -3
Instrument Panel Installation ...................................................................................................................... 4 -3
Front Fascia Removal ................................................................................................................................ 4 -4
Front Fascia Installation ............................................................................................................................. 4 -4
Hood Removal .......................................................................................................................................... 4 -4
Hood Installation ........................................................................................................................................ 4 -4
Center Cowl Panel Removal ....................................................................................................................... 4 -4
Center Cowl Panel Installation .................................................................................................................... 4 -5
Side Cowl Panel (Fender) Removal ............................................................................................................ 4 -5
Side Cowl Panel (Fender) Installation ......................................................................................................... 4 -5
Front Fender Flare Removal ....................................................................................................................... 4 -6
Front Fender Flare Installation .................................................................................................................... 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 -10
2015Carryall1500/1700andXRT1550MaintenanceandServiceManual Page iii
Seat Support Removal ............................................................................................................................. 4 -10
Seat Support Installation .......................................................................................................................... 4 -10
Seat Belts ................................................................................................................................................... 4 -10
Bench Seat Belt Removal ......................................................................................................................... 4 -10
Bench Seat Belt Installation .......................................................................................................................4 -1 1
Cargo Bed – Electric Lift ................................................................................................................................4 -1 1
T esting the Bed Lift Motor ..........................................................................................................................4 -1 1
Bed Lift Motor Removal .............................................................................................................................4 -1 1
Bed Lift Motor Installation ......................................................................................................................... 4 -12
Cargo Bed Removal ................................................................................................................................ 4 -12
Cargo Bed Installation .............................................................................................................................. 4 -12
Cargo Bed – Manual Lift ............................................................................................................................... 4 -13
Cargo Bed Removal ................................................................................................................................ 4 -13
Cargo Bed Installation .............................................................................................................................. 4 -13
Rear Fender ................................................................................................................................................ 4 -14
Rear Fender Removal .............................................................................................................................. 4 -14
Rear Fender Installation ........................................................................................................................... 4 -14
SECTION 5 – ACCELERA T OR AND BRAKE PEDAL ASSEMBLIES ................................................................... 5 -1
Accelerator Pedal .......................................................................................................................................... 5 -1
Accelerator Pedal Removal ........................................................................................................................ 5 -1
Accelerator Pedal Installation ..................................................................................................................... 5 -2
Brake Pedal .................................................................................................................................................. 5 -3
Brake Pedal Removal ................................................................................................................................ 5 -3
Brake Pedal Installation ............................................................................................................................. 5 -3
Brake Pedal Adjustment ............................................................................................................................. 5 -3
Park Brake Pedal ........................................................................................................................................... 5 -4
Park Brake Pedal Assembly Removal ......................................................................................................... 5 -4
Park Brake Pedal Assembly Installation ...................................................................................................... 5 -4
SECTION 6 – HYDRAULIC AND P ARK BRAKE SYSTEMS ................................................................................ 6 -1
Brake System Inspection ................................................................................................................................ 6 -1
Brake Pedal Inspection .............................................................................................................................. 6 -1
Master Cylinder Inspection ......................................................................................................................... 6 -2
Brake Line Inspection ................................................................................................................................ 6 -3
Park Brake Inspection ................................................................................................................................ 6 -3
Brake Disc and Pad Inspection ................................................................................................................... 6 -3
Brake System T roubleshooting ....................................................................................................................... 6 -4
Brake Pads and Caliper ................................................................................................................................. 6 -6
Brake Pad and Caliper Removal ................................................................................................................. 6 -6
Brake Pad and Caliper Installation .............................................................................................................. 6 -7
Brake Discs ................................................................................................................................................. 6 -10
Disc Removal .......................................................................................................................................... 6 -10
Disc Installation ....................................................................................................................................... 6 -10
Hydraulic Line Replacement ..........................................................................................................................6 -1 1
Front Brake Line Removal .........................................................................................................................6 -1 1
Front Brake Line Installation ......................................................................................................................6 -1 1
Rear Brake Line Removal ........................................................................................................................ 6 -12
Rear Brake Line Installation ...................................................................................................................... 6 -13
Master Cylinder and Reservoir ..................................................................................................................... 6 -14
Filling the Hydraulic System ..................................................................................................................... 6 -14
Master Cylinder Removal ......................................................................................................................... 6 -14
Master Cylinder Installation ...................................................................................................................... 6 -14
Bleeding the Hydraulic Brake System ........................................................................................................... 6 -15
Bleeding Brakes on a DOT 5 Fluid Filled System ....................................................................................... 6 -15
Purging the Hydraulic System ................................................................................................................... 6 -17
Park Brake System ...................................................................................................................................... 6 -18
Park Brake Adjustment – At Rear Calipers ................................................................................................ 6 -18
Front Park Brake Cable Adjustment – Cable Only System .......................................................................... 6 -18
Park Brake Wheel Cables ........................................................................................................................ 6 -19
Front Park Brake Cable Removal – Cable Only System ............................................................................. 6 -20
Front Park Brake Cable Installation – Cable Only System ........................................................................... 6 -21
Page iv 2015Carryall1500/1700andXRT1550MaintenanceandServiceManual
Park Brake Equalizer Removal – Cable Only System ................................................................................. 6 -21
Park Brake Equalizer Installation – Cable Only System .............................................................................. 6 -22
SECTION 7 – STEERING AND FRONT SUSPENSION ....................................................................................... 7 -1
Steering Wheel .............................................................................................................................................. 7 -1
Steering Wheel Removal ............................................................................................................................ 7 -1
Steering Wheel Installation ......................................................................................................................... 7 -2
Steering Column ............................................................................................................................................ 7 -2
Steering Column Removal .......................................................................................................................... 7 -2
Steering Column Installation ....................................................................................................................... 7 -3
Rack and Pinion ............................................................................................................................................ 7 -3
Rack and Pinion Inspection ........................................................................................................................ 7 -4
Rack and Pinion Removal .......................................................................................................................... 7 -4
Rack and Pinion Installation ....................................................................................................................... 7 -4
Rack and Pinion Disassembly .................................................................................................................... 7 -5
Rack and Pinion Assembly ......................................................................................................................... 7 -9
Front Suspension ........................................................................................................................................ 7 -10
Wheel Alignment ..................................................................................................................................... 7 -10
Front Suspension Components ..................................................................................................................... 7 -14
Steering Upright Removal ........................................................................................................................ 7 -14
Steering Upright Installation ...................................................................................................................... 7 -16
Upper A -Arm Removal ............................................................................................................................. 7 -16
Upper A -Arm Installation .......................................................................................................................... 7 -18
Lower A -Arm Removal ............................................................................................................................. 7 -18
Lower A -Arm Installation .......................................................................................................................... 7 -19
Front Coil -Over Shock Absorber Removal ................................................................................................. 7 -20
Front Coil -Over Shock Absorber Installation .............................................................................................. 7 -21
SECTION 8 – WHEELS, TIRES AND HUBS ....................................................................................................... 8 -1
General Information ....................................................................................................................................... 8 -1
Wheels ......................................................................................................................................................... 8 -2
Wheel Removal ......................................................................................................................................... 8 -2
Wheel Installation ...................................................................................................................................... 8 -2
T ires ............................................................................................................................................................. 8 -2
T ire Removal ............................................................................................................................................. 8 -2
T ire Installation .......................................................................................................................................... 8 -3
Front Hubs .................................................................................................................................................... 8 -3
Front Hub Removal .................................................................................................................................... 8 -3
Front Hub Installation ................................................................................................................................. 8 -5
Rear Hubs ..................................................................................................................................................... 8 -6
Rear Hub Removal .................................................................................................................................... 8 -6
Rear Hub Installation ................................................................................................................................. 8 -7
SECTION 9 – REAR SUSPENSION ................................................................................................................... 9 -1
Rear Coil -Over Shock Absorber ...................................................................................................................... 9 -1
Rear Shock Absorber Removal ................................................................................................................... 9 -1
Rear Shock Installation .............................................................................................................................. 9 -2
T railing Arms and Lateral Links ....................................................................................................................... 9 -3
Lateral Link Removal ................................................................................................................................. 9 -3
Lateral Link Installation .............................................................................................................................. 9 -3
T railing Arm Removal ................................................................................................................................. 9 -3
T railing Arm Installation .............................................................................................................................. 9 -3
SECTION 10 – PERIODIC MAINTENANCE ...................................................................................................... 10 -1
Periodic Service Schedule ............................................................................................................................ 10 -1
Periodic Service Schedule – IntelliT ach ......................................................................................................... 10 -4
Periodic Lubrication Schedule ...................................................................................................................... 10 -6
Periodic Lubrication Schedule – IntelliT ach .................................................................................................... 10 -8
Lubricating the Attachment Arm and Interface – IntelliT ach ............................................................................. 10 -9
Brake Fluid Reservoir .................................................................................................................................10 -10
2015Carryall1500/1700andXRT1550MaintenanceandServiceManual Page v
Brake Fluid .............................................................................................................................................10 -10
Engine Oil ..................................................................................................................................................10 -10
Oil Pressure – Gasoline Engine ............................................................................................................... 10 -1 1
Engine Oil Level Check ...........................................................................................................................10 -1 1
Engine Oil and Filter Change ...................................................................................................................10 -1 1
Oil V iscosity ...........................................................................................................................................10 -14
Spark Plugs ................................................................................................................................................10 -15
Spark Plug Cleaning And Inspection ........................................................................................................10 -15
Spark Plug Gap Inspection ......................................................................................................................10 -15
Gearcase Lubrication ..................................................................................................................................10 -15
Lubrication Level Check for Front Dif ferential, T ransmission and Rear Dif ferential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15
Lubrication Change for Front Dif ferential, T ransmission and Rear Dif ferential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 16
Hydraulic System – IntelliT ach V ehicle .........................................................................................................10 -18
Engine Coolant – Diesel V ehicles ................................................................................................................10 -19
Engine Coolant Level Check ...................................................................................................................10 -19
Fueling Instructions .....................................................................................................................................10 -19
Biodiesel Fuel (Diesel V ehicles Only) .......................................................................................................10 -20
Draining W ater from Fuel Filter ................................................................................................................10 -21
Battery .......................................................................................................................................................10 -22
SECTION 1 1 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES .............................1 1 -1
T roubleshooting Guide ..................................................................................................................................1 1 -1
Wiring Diagram .............................................................................................................................................1 1 -6
T est Procedures ...........................................................................................................................................1 1 -9
SECTION 12 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES ................................. 12 -1
T roubleshooting Guide ................................................................................................................................. 12 -1
Wiring Diagram ............................................................................................................................................ 12 -6
T est Procedures .......................................................................................................................................... 12 -9
SECTION 13 – ELECTRICAL COMPONENTS: GASOLINE VEHICLES ............................................................. 13 -1
Starter and Starter Solenoid ......................................................................................................................... 13 -1
Relays ........................................................................................................................................................ 13 -1
T esting the Relay ..................................................................................................................................... 13 -1
Relay Removal ........................................................................................................................................ 13 -2
Relay Installation ..................................................................................................................................... 13 -2
Neutral Switch ............................................................................................................................................. 13 -2
T esting the Neutral Switch ........................................................................................................................ 13 -2
Neutral Switch Removal ........................................................................................................................... 13 -2
Neutral Switch Installation ........................................................................................................................ 13 -2
Carburetor Solenoid ..................................................................................................................................... 13 -3
T esting the Carburetor Solenoid ................................................................................................................ 13 -3
Carburetor Solenoid Removal ................................................................................................................... 13 -3
Carburetor Solenoid Installation ................................................................................................................ 13 -3
Carburetor Heater ........................................................................................................................................ 13 -4
Carburetor Heater Removal ...................................................................................................................... 13 -4
Carburetor Heater Installation ................................................................................................................... 13 -4
V oltage Regulator ........................................................................................................................................ 13 -5
T esting the V oltage Regulator ................................................................................................................... 13 -5
V oltage Regulator Removal ...................................................................................................................... 13 -5
V oltage Regulator Installation ................................................................................................................... 13 -5
W arning Lights ............................................................................................................................................ 13 -6
T esting the W arning Lights ....................................................................................................................... 13 -6
W arning Light Removal ............................................................................................................................ 13 -6
W arning Light Installation ......................................................................................................................... 13 -6
Fuel Gauge/Hour Meter ............................................................................................................................... 13 -7
T esting the Fuel Gauge/Hour Meter .......................................................................................................... 13 -7
Fuel Gauge/Hour Meter Removal ............................................................................................................. 13 -7
Fuel Gauge/Hour Meter Installation ........................................................................................................... 13 -8
Key Switch .................................................................................................................................................. 13 -8
T esting the Key Switch ............................................................................................................................. 13 -8
Page vi 2015Carryall1500/1700andXRT1550MaintenanceandServiceManual
Key Switch Removal ................................................................................................................................ 13 -8
Key Switch Installation ............................................................................................................................. 13 -8
12 -V olt Accessory Receptacle ...................................................................................................................... 13 -9
T esting the 12 -V olt Accessory Receptacle ................................................................................................. 13 -9
12 -V olt Accessory Receptacle Removal .................................................................................................... 13 -9
12 -V olt Accessory Receptacle Installation ................................................................................................. 13 -9
Bed Lift Switch ...........................................................................................................................................13 -10
T esting the Bed Lift Switch ......................................................................................................................13 -10
Bed Lift Switch Removal .........................................................................................................................13 -10
Bed Lift Switch Installation .......................................................................................................................13 -10
Bed Lift Circuit Breaker ...............................................................................................................................13 -10
T esting the Bed Lift Circuit Breaker ..........................................................................................................13 -10
Bed Lift Circuit Breaker Removal .............................................................................................................13 -10
Bed Lift Circuit Breaker Installation .......................................................................................................... 13 -1 1
Light Switch ................................................................................................................................................13 -1 1
T esting the Light Switch ..........................................................................................................................13 -1 1
Light Switch Removal ............................................................................................................................. 13 -1 1
Light Switch Installation ........................................................................................................................... 13 -1 1
Fuse .......................................................................................................................................................... 13 -1 1
T esting the Fuse .....................................................................................................................................13 -12
Fuse Removal ........................................................................................................................................13 -12
Fuse Installation .....................................................................................................................................13 -12
Reverse W arning Buzzer (If Equipped) .........................................................................................................13 -12
T esting the Reverse W arning Buzzer ........................................................................................................13 -12
Reverse W arning Buzzer Removal ..........................................................................................................13 -12
Reverse W arning Buzzer Installation ........................................................................................................13 -13
Reverse W arning Buzzer Limit Switch (If Equipped) ......................................................................................13 -13
T esting the Reverse W arning Buzzer Limit Switch .....................................................................................13 -13
Reverse W arning Buzzer Limit Switch Removal ........................................................................................13 -13
Reverse W arning Buzzer Limit Switch Installation .....................................................................................13 -14
Front Dif ferential Limit Switch ......................................................................................................................13 -14
T esting the Front Dif ferential Limit Switch .................................................................................................13 -15
Front Dif ferential Limit Switch Removal ....................................................................................................13 -15
Front Dif ferential Limit Switch Installation .................................................................................................13 -15
Fuel Level Sending Unit ..............................................................................................................................13 -16
T esting the Fuel Level Sending Unit .........................................................................................................13 -16
Fuel Level Sending Unit Removal ............................................................................................................13 -16
Fuel Level Sending Unit Installation .........................................................................................................13 -16
Ignition Coil and Charge Coil .......................................................................................................................13 -16
T esting the Ignition Coil ...........................................................................................................................13 -16
Ignition Coil and/or Charge Coil Removal .................................................................................................13 -16
Oil Pressure Sensor ....................................................................................................................................13 -17
Headlights ..................................................................................................................................................13 -17
T esting the Headlight Bulb and Socket .....................................................................................................13 -17
Headlight Bulb Removal ..........................................................................................................................13 -17
Headlight Bulb Installation .......................................................................................................................13 -17
Wire Harness Diodes ..................................................................................................................................13 -18
T esting the Wire Harness Diodes .............................................................................................................13 -18
Wire Harness Diode Removal ..................................................................................................................13 -18
Wire Harness Diode Installation ...............................................................................................................13 -18
Battery .......................................................................................................................................................13 -19
General Information ................................................................................................................................13 -19
T esting the Battery ..................................................................................................................................13 -19
Preventive Maintenance ..........................................................................................................................13 -19
Self -Discharge ........................................................................................................................................13 -20
W ater Level ............................................................................................................................................13 -20
V ibration Damage ...................................................................................................................................13 -20
Mineral Content ......................................................................................................................................13 -20
Battery Removal .....................................................................................................................................13 -21
Charging the Battery ...............................................................................................................................13 -21
Battery Installation ..................................................................................................................................13 -21
Battery Storage ......................................................................................................................................13 -22
Charging a Dead Battery .........................................................................................................................13 -22
2015Carryall1500/1700andXRT1550MaintenanceandServiceManual Page vii
SECTION 14 – ELECTRICAL COMPONENTS: DIESEL VEHICLES .................................................................. 14 -1
Starter and Starter Solenoid ......................................................................................................................... 14 -1
Relays ........................................................................................................................................................ 14 -1
T esting the Relay ..................................................................................................................................... 14 -1
Relay Removal ........................................................................................................................................ 14 -2
Relay Installation ..................................................................................................................................... 14 -2
Neutral Switch ............................................................................................................................................. 14 -2
T esting the Neutral Switch ........................................................................................................................ 14 -2
Neutral Switch Removal ........................................................................................................................... 14 -2
Neutral Switch Installation ........................................................................................................................ 14 -2
Fuel Solenoid .............................................................................................................................................. 14 -3
T esting the Fuel Solenoid ......................................................................................................................... 14 -3
Fuel Solenoid Removal ............................................................................................................................ 14 -3
Fuel Solenoid Installation ......................................................................................................................... 14 -3
60 -Amp Fusible Link .................................................................................................................................... 14 -4
T esting the 60 -Amp Fusible Link ............................................................................................................... 14 -4
60 -Amp Fusible Link Removal .................................................................................................................. 14 -4
60 -Amp Fusible Link Installation ............................................................................................................... 14 -4
W arning Lights ............................................................................................................................................ 14 -5
T esting the W arning Lights ....................................................................................................................... 14 -5
W arning Light Removal ............................................................................................................................ 14 -5
W arning Light Installation ......................................................................................................................... 14 -5
Fuel Gauge/Hour Meter ............................................................................................................................... 14 -6
T esting the Fuel Gauge/Hour Meter .......................................................................................................... 14 -6
Fuel Gauge/Hour Meter Removal ............................................................................................................. 14 -7
Fuel Gauge/Hour Meter Installation ........................................................................................................... 14 -7
Key Switch .................................................................................................................................................. 14 -7
T esting the Key Switch ............................................................................................................................. 14 -7
Key Switch Removal ................................................................................................................................ 14 -7
Key Switch Installation ............................................................................................................................. 14 -7
12 -V olt Accessory Receptacle ...................................................................................................................... 14 -8
T esting the 12 -V olt Accessory Receptacle ................................................................................................. 14 -8
12 -V olt Accessory Receptacle Removal .................................................................................................... 14 -8
12 -V olt Accessory Receptacle Installation ................................................................................................. 14 -8
Bed Lift Switch ............................................................................................................................................ 14 -9
T esting the Bed Lift Switch ....................................................................................................................... 14 -9
Bed Lift Switch Removal .......................................................................................................................... 14 -9
Bed Lift Switch Installation ........................................................................................................................ 14 -9
Bed Lift Circuit Breaker ................................................................................................................................ 14 -9
T esting the Bed Lift Circuit Breaker ........................................................................................................... 14 -9
Bed Lift Circuit Breaker Removal .............................................................................................................. 14 -9
Bed Lift Circuit Breaker Installation ........................................................................................................... 14 -9
Light Switch ................................................................................................................................................14 -10
T esting the Light Switch ..........................................................................................................................14 -10
Light Switch Removal .............................................................................................................................14 -10
Light Switch Installation ...........................................................................................................................14 -10
Fuse ..........................................................................................................................................................14 -10
T esting the Fuse .....................................................................................................................................14 -10
Fuse Removal ........................................................................................................................................14 -10
Fuse Installation ..................................................................................................................................... 14 -1 1
Reverse W arning Buzzer (If Equipped) .........................................................................................................14 -1 1
T esting the Reverse W arning Buzzer ........................................................................................................ 14 -1 1
Reverse W arning Buzzer Removal .......................................................................................................... 14 -1 1
Reverse W arning Buzzer Installation ........................................................................................................14 -12
Reverse W arning Buzzer Limit Switch (If Equipped) ......................................................................................14 -12
T esting the Reverse W arning Buzzer Limit Switch .....................................................................................14 -12
Reverse W arning Buzzer Limit Switch Removal ........................................................................................14 -12
Reverse W arning Buzzer Limit Switch Installation .....................................................................................14 -13
Front Dif ferential Limit Switch ......................................................................................................................14 -13
T esting the Front Dif ferential Limit Switch .................................................................................................14 -14
Front Dif ferential Limit Switch Removal ....................................................................................................14 -14
Front Dif ferential Limit Switch Installation .................................................................................................14 -14
Fuel Level Sending Unit ..............................................................................................................................14 -15
Page viii 2015Carryall1500/1700andXRT1550MaintenanceandServiceManual
T esting the Fuel Level Sending Unit .........................................................................................................14 -15
Fuel Level Sending Unit Removal ............................................................................................................14 -15
Fuel Level Sending Unit Installation .........................................................................................................14 -15
Alternator ...................................................................................................................................................14 -15
T esting the Alternator ..............................................................................................................................14 -15
Alternator and V -belt Removal .................................................................................................................14 -15
Alternator and V -belt Installation ..............................................................................................................14 -16
Oil Pressure Sensor ....................................................................................................................................14 -18
Headlights ..................................................................................................................................................14 -18
T esting the Headlight Bulb and Socket .....................................................................................................14 -18
Headlight Bulb Removal ..........................................................................................................................14 -18
Headlight Bulb Installation .......................................................................................................................14 -18
Thermostat Switch ......................................................................................................................................14 -19
T esting the Thermostat Switch .................................................................................................................14 -19
Thermostat Switch Removal ....................................................................................................................14 -19
Thermostat Switch Installation .................................................................................................................14 -20
Fan ............................................................................................................................................................14 -20
T esting the Fan Motor .............................................................................................................................14 -20
Fan Removal ..........................................................................................................................................14 -20
Fan Installation .......................................................................................................................................14 -21
Wire Harness Diodes ..................................................................................................................................14 -21
T esting the Wire Harness Diodes .............................................................................................................14 -21
Wire Harness Diode Removal ..................................................................................................................14 -21
Wire Harness Diode Installation ...............................................................................................................14 -22
Battery .......................................................................................................................................................14 -22
General Information ................................................................................................................................14 -22
T esting the Battery ..................................................................................................................................14 -23
Preventive Maintenance ..........................................................................................................................14 -23
Self -Discharge ........................................................................................................................................14 -23
W ater Level ............................................................................................................................................14 -23
V ibration Damage ...................................................................................................................................14 -23
Mineral Content ......................................................................................................................................14 -23
Battery Removal .....................................................................................................................................14 -24
Charging the Battery ...............................................................................................................................14 -24
Battery Installation ..................................................................................................................................14 -25
Battery Storage ......................................................................................................................................14 -25
Charging a Dead Battery .........................................................................................................................14 -25
SECTION 15 – GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES ......................................... 15 -1
Gasoline Engine .......................................................................................................................................... 15 -1
Engine Removal ...................................................................................................................................... 15 -1
Engine Installation ................................................................................................................................... 15 -3
Oil Filter Hoses ........................................................................................................................................ 15 -5
Exhaust System .......................................................................................................................................... 15 -6
Muf er Removal ...................................................................................................................................... 15 -6
Intermediate Pipe Removal ...................................................................................................................... 15 -6
Intermediate Pipe Installation .................................................................................................................... 15 -7
Muf er Installation .................................................................................................................................... 15 -7
Fuel System ................................................................................................................................................ 15 -8
Fuel Lines ............................................................................................................................................... 15 -9
Fuel Filter ................................................................................................................................................ 15 -9
Fuel Pump .............................................................................................................................................. 15 -9
Carburetor ............................................................................................................................................... 15 -9
Fuel Level Sending Unit ..........................................................................................................................15 -1 1
Fuel T ank ...............................................................................................................................................15 -15
Carbon Canister .....................................................................................................................................15 -18
Fuel Shut -Of f V alve .................................................................................................................................15 -19
Engine Control Linkages .............................................................................................................................15 -20
General Information ................................................................................................................................15 -20
Ground Speed ........................................................................................................................................15 -20
Accelerator Cable ...................................................................................................................................15 -20
Choke Cable ..........................................................................................................................................15 -21
Engine Governor Arm .............................................................................................................................15 -23
2015Carryall1500/1700andXRT1550MaintenanceandServiceManual Page ix
Engine RPM Adjustment .........................................................................................................................15 -24
Air Intake System .......................................................................................................................................15 -26
Air Filter Replacement .............................................................................................................................15 -26
Air Canister Removal ..............................................................................................................................15 -27
Air Canister Installation ...........................................................................................................................15 -27
Clutches .....................................................................................................................................................15 -28
Clutch T roubleshooting ...........................................................................................................................15 -28
Drive Belt ...............................................................................................................................................15 -29
Drive Clutch ...........................................................................................................................................15 -29
Driven Clutch .........................................................................................................................................15 -33
Clutch Cover ..........................................................................................................................................15 -36
SECTION 16 – DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES ............................................... 16 -1
Diesel Engine .............................................................................................................................................. 16 -1
Engine Removal ...................................................................................................................................... 16 -1
Engine Installation ................................................................................................................................... 16 -3
Exhaust System .......................................................................................................................................... 16 -5
Muf er Removal ...................................................................................................................................... 16 -5
Intermediate Pipe Removal ...................................................................................................................... 16 -5
Manifold Pipe Removal ............................................................................................................................ 16 -6
Manifold Pipe Installation ......................................................................................................................... 16 -6
Intermediate Pipe Installation .................................................................................................................... 16 -6
Muf er Installation .................................................................................................................................... 16 -6
Fuel System ................................................................................................................................................ 16 -8
Fuel Lines ............................................................................................................................................... 16 -9
Bleeding Air From Fuel System ................................................................................................................ 16 -9
Fuel Filter Replacement ........................................................................................................................... 16 -9
Fuel Pump ............................................................................................................................................. 16 -1 1
Fuel Level Sending Unit ..........................................................................................................................16 -1 1
Fuel T ank ...............................................................................................................................................16 -14
Engine Control Linkages .............................................................................................................................16 -18
General Information ................................................................................................................................16 -18
Ground Speed ........................................................................................................................................16 -18
Accelerator Cable ...................................................................................................................................16 -18
Engine RPM Adjustment .........................................................................................................................16 -19
Air Intake System .......................................................................................................................................16 -21
Air Filter Replacement .............................................................................................................................16 -21
Air Canister Removal ..............................................................................................................................16 -22
Air Canister Installation ...........................................................................................................................16 -23
Clutches .....................................................................................................................................................16 -24
Clutch T roubleshooting ...........................................................................................................................16 -24
Drive Belt ...............................................................................................................................................16 -24
Drive Clutch ...........................................................................................................................................16 -25
Driven Clutch .........................................................................................................................................16 -29
Clutch Cover ..........................................................................................................................................16 -32
SECTION 17 – DRIVETRAIN COMPONENTS .................................................................................................. 17 -1
Half Shafts .................................................................................................................................................. 17 -1
Half Shaft Removal .................................................................................................................................. 17 -1
Half Shaft Installation ............................................................................................................................... 17 -2
Front Dif ferential .......................................................................................................................................... 17 -3
Front Dif ferential Removal ........................................................................................................................ 17 -3
Front Dif ferential Installation ..................................................................................................................... 17 -5
Front Driveshaft ........................................................................................................................................... 17 -5
Front Driveshaft Removal ......................................................................................................................... 17 -5
Front Driveshaft Installation ...................................................................................................................... 17 -5
T ransmission ............................................................................................................................................... 17 -6
T ransmission Removal ............................................................................................................................. 17 -6
T ransmission Installation .......................................................................................................................... 17 -7
Forward/Reverse Shifter Cable ................................................................................................................. 17 -9
Forward/Reverse Shifter Handle .............................................................................................................. 17 -1 1
Rear Driveshaft ..........................................................................................................................................17 -12
Page x 2015Carryall1500/1700andXRT1550MaintenanceandServiceManual
Rear Driveshaft Removal ........................................................................................................................17 -12
Rear Driveshaft Installation .....................................................................................................................17 -12
Rear Axle ...................................................................................................................................................17 -12
Rear Axle Removal .................................................................................................................................17 -12
Rear Axle Installation ..............................................................................................................................17 -14
Rear Axle T ubes, Axle Shafts and Wheel Bearings .......................................................................................17 -14
Rear Axle T ube and Axle Shaft Removal ..................................................................................................17 -14
Rear Axle T ube and Axle Shaft Installation ...............................................................................................17 -15
Rear Wheel Bearing Removal .................................................................................................................17 -16
Rear Wheel Bearing Installation ...............................................................................................................17 -16
SECTION 18 – RADIA T OR AND COOLANT SYSTEM (DIESEL) ....................................................................... 18 -1
General Information ..................................................................................................................................... 18 -1
Engine Coolant Level Check .................................................................................................................... 18 -1
Engine Coolant Change ........................................................................................................................... 18 -1
Coolant Reservoir ........................................................................................................................................ 18 -3
Coolant Reservoir Removal ...................................................................................................................... 18 -3
Coolant Reservoir Installation ................................................................................................................... 18 -4
Radiator ...................................................................................................................................................... 18 -4
Radiator Removal .................................................................................................................................... 18 -4
Radiator Installation ................................................................................................................................. 18 -5
Coolant Pipe W eldment ................................................................................................................................ 18 -6
Coolant Pipe W eldment Removal ............................................................................................................. 18 -6
Coolant Pipe W eldment Installation ........................................................................................................... 18 -6
Fan ............................................................................................................................................................. 18 -7
Fan Removal ........................................................................................................................................... 18 -7
Fan Installation ........................................................................................................................................ 18 -7
SECTION 19 – HYDRAULIC A TT ACHMENT SYSTEM ...................................................................................... 19 -1
Model Identiîšżcation .................................................................................................................................. 19 -1
Relieving Hydraulic System Pressure ............................................................................................................ 19 -1
T o Relieve Hydraulic Fluid Pressure .......................................................................................................... 19 -1
Attachment Interface .................................................................................................................................... 19 -2
Inspection ............................................................................................................................................... 19 -2
Removing and Installing the Attachment Arm Mechanism ........................................................................... 19 -3
Electrical ..................................................................................................................................................... 19 -8
Joystick ..................................................................................................................................................19 -10
Joystick ON/OFF Switch .........................................................................................................................19 -12
Attachment Arm Float Switch ...................................................................................................................19 -13
Auxiliary Hydraulic Switch .......................................................................................................................19 -15
Relays ...................................................................................................................................................19 -16
Solenoid .................................................................................................................................................19 -18
Circuit Breaker .......................................................................................................................................19 -18
Control V alves ........................................................................................................................................19 -19
Hoses ........................................................................................................................................................19 -21
Hose Routing .........................................................................................................................................19 -21
Hose Removal ........................................................................................................................................19 -22
Hose Installation .....................................................................................................................................19 -22
Quick Connect Fittings (Auxiliary Hydraulic Circuit only) ................................................................................19 -23
Quick Connect Removal ..........................................................................................................................19 -23
Quick Connect Installation .......................................................................................................................19 -23
Cylinders ....................................................................................................................................................19 -24
V ehicle Mounted Cylinders ......................................................................................................................19 -24
Auxiliary Cylinder (Optional) ....................................................................................................................19 -25
Cylinder Disassembly .............................................................................................................................19 -27
Cylinder Assembly ..................................................................................................................................19 -30
Cylinder Bushings (If Equipped) ...............................................................................................................19 -36
Angle Frame Bushings ................................................................................................................................19 -37
Snow Blade Angle Frame ........................................................................................................................19 -37
Whisk Broom Angle Frame ......................................................................................................................19 -38
Front Mount ................................................................................................................................................19 -39
Front Mount Removal .............................................................................................................................19 -39
2015Carryall1500/1700andXRT1550MaintenanceandServiceManual Page xi
Front Mount installation ...........................................................................................................................19 -40
Hydraulic Pump Assembly ...........................................................................................................................19 -40
Fluid Level Inspection .............................................................................................................................19 -41
Fluid Change ..........................................................................................................................................19 -41
Pump Assembly .....................................................................................................................................19 -42
Reservoir ...............................................................................................................................................19 -44
Motor .....................................................................................................................................................19 -45
Pump .....................................................................................................................................................19 -46
Priming the Pump ...................................................................................................................................19 -46
SECTION i –INDEX
Page xii 2015Carryall1500/1700andXRT1550MaintenanceandServiceManual
SECTION 1 – SAFETY
1
SAFETY DET AILS
W ARNING
• This owner ’ s manual should be read completely before attempting to drive or service the vehicle.
Failure to follow the instructions in this manual could result in property damage, severe personal
injury , or death.
PERSONAL SAFETY
It is important to note that some vital statements throughout this manual and on the decals af îšżxed to the vehicle are
preceded by the words DANGER, W ARNING, or CAUTION. For your protection, we recommend that you take special
notice of these safety precautions. Safety precautions are essential and must be followed.
If any of the operation or warning decals on the vehicle become damaged, have been removed, or cannot be easily
read, they should be replaced immediately to avoid possible property damage, personal injury , or death. Contact
your dealer .
DANGER
• A DANGER indicates an immediate hazard that will result in severe personal injury or death. The
color associated with Danger is RED.
W ARNING
• A W ARNING indicates an immediate hazard that could result in severe personal injury or death.
The color associated with W arning is ORANGE.
CAUTION
• A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in
minor personal injury . The color associated with Caution is YELLOW .
MACHINE SAFETY
CAUTION
• A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could
result in property damage.
A CAUTION, without the safety alert symbol, is intended for machine and property safety . It is used throughout this
manual followed by speciîšżc instructions to prevent machine or property damage. Failure to follow these CAUTION
messages could result in machine or property damage.
2015Carryall1500/1700andXRT1550MaintenanceandServiceManual Page 1-1
1
General W arnings SAFETY
INFORMA TION
NOTE: Instructions that clarify steps, procedures, or other information in this manual.
GENERAL W ARNINGS
The following safety statements must be heeded whenever the vehicle is being operated, repaired, or serviced. Other
speciîšżc safety statements appear throughout this manual and on the vehicle.
DANGER
• Battery – Explosive gases! Do not smoke. Keep sparks and ames away from the vehicle and service
area. V entilate when charging or operating vehicle in an enclosed area. W ear a full face shield and
rubber gloves when working on or near batteries.
• Gasoline/Diesel – Flammable! Explosive! Do not smoke. Keep sparks and ames away from the
vehicle and service area. Service only in a well - ventilated area.
• Do not operate engine in an enclosed area without proper ventilation. The engine produces carbon
monoxide, which is an odorless, deadly poison that can quickly accumulate in an enclosed cab. Do
not run the engine in a parked vehicle without proper cab ventilation. Move to fresh air if you feel
nausea, headache, dizziness, drowsiness or weakness.
• The vehicle will not provide protection from lightning, ying objects, or other storm - related hazards.
If caught in a storm while driving this vehicle, exit the vehicle and seek shelter in accordance with
applicable safety guidelines for your location.
• Do not weld to a wheel or rim until the tire is completely removed. Inated tires can generate a gas
mixture with the air that can be ignited by high temperatures from welding procedures performed on
the wheel or rim. Removing the air or loosening the tire on the rim (breaking the bead) will NOT
eliminate the hazard. This condition can exist whether tires are inated or deated. The tire MUST
be completely removed from the wheel or rim prior to welding the wheel or rim. Failure to comply
will result in death or serious injury .
W ARNING
• Follow the procedures exactly as stated in this manual, and heed all DANGER, W ARNING, and
CAUTION statements in this manual as well as those on the vehicle.
• This vehicle is not intended to be used where risk of falling objects exist. If your vehicle will be used in
such an environment, contact your local dealer .
• Do not leave children unattended on vehicle.
• Children requiring a child safety seat must not ride on the vehicle. Comply with state and local laws
pertaining to child safety .
• The driver and passenger must be restrained at all times with the seat belts provided to help prevent
injury in the event of sudden braking, collision, or roll - over .
• No more than one person per bucket seat at one time. No more than two persons per bench seat at
one time. Do not allow people to ride in any part of the vehicle that is not equipped with a seat and a
seat belt. Do not allow a passenger to hold a child in his or her lap while the vehicle is moving.
W ARNING CONTINUED ON NEXT P AGE
Page 1-2 2015Carryall1500/1700andXRT1550MaintenanceandServiceManual
SAFETY General W arnings
1
W ARNING
• Prior to leaving the vehicle unattended or servicing the vehicle, place attachment on the ground, set
the park brake, place the Forward/Reverse handle in the NEUTRAL position, turn the key switch to the
OFF position, and remove the key . Chock the wheels when servicing the vehicle.
• Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle
performance, severe personal injury , or death.
• Any modication or change to the vehicle that affects the electrical system, stability or handling
of the vehicle, or increases maximum vehicle speed beyond factory speciîšżcations, could result in
severe personal injury or death.
• Check the vehicle for proper location of all vehicle safety and operation decals and make sure they are
in place and are easy to read.
• For vehicles with cargo beds, remove all cargo (including accessories) before raising the bed or
servicing the vehicle. If the vehicle 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 cargo bed; lower gently and keep entire body clear . Failure to heed this
warning could result in severe personal injury or death.
• Only trained technicians should service or repair the vehicle. Anyone doing even simple repairs or
service should have knowledge and experience in electrical and mechanical repair . The appropriate
instructions must be used when performing maintenance, service, or accessory installation.
• T o avoid unintentionally starting the vehicle, disconnect battery and spark plug (Gas only) wires. See
Disconnecting the Battery – Gasoline/Diesel V ehicles on page 1 - 3 .
• Frame ground – Do not allow tools or other metal objects to contact frame when disconnecting battery
cables or other electrical wiring. Do not allow a positive wire to touch the vehicle frame, engine, or
any other metal component.
• W ear safety glasses or approved eye protection when servicing the vehicle. W ear a full face shield and
rubber gloves when working on or near batteries.
• Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the vehicle.
• Use insulated tools when working near batteries or electrical connections. Use extreme caution to
avoid shorting of components or wiring.
• When servicing the vehicle with part of the vehicle on jack stands, do not operate the engine with the
Forward/Reverse handle in either the FOR W ARD or REVERSE position. The all - wheel drive system will
engage any wheel(s), front or rear , with traction ( Figure 1 - 2 , Page 1 - 4 ) .
DISABLING THE VEHICLE
1. Set the park brake.
2. T urn the key switch OFF and remove the key .
3. Place the Forward/Reverse control in the NEUTRAL position.
4. In addition, chock the wheels if servicing or repairing the vehicle.
DISCONNECTING THE BA TTER Y – GASOLINE/DIESEL VEHICLES
1. Disable the vehicle. See Disabling the V ehicle on page 1 - 3 .
2015Carryall1500/1700andXRT1550MaintenanceandServiceManual Page 1-3
1
General W arnings SAFETY
2. Disconnect the battery cables, negative (–) cable rst, as shown ( Figure 1 - 1 ) .
3. Gasoline V ehicles Only: Disconnect the spark plug wire(s) from the spark plug(s).
NEG
PO S
1
2
(–)
(+)
1. Remove negative battery cable.
2. Remove positive battery cable.
Connect battery cables in reverse order .
188
Figure 1 - 1 Battery Cable Removal
189
Figure 1 - 2 All - Wheel Drive W arning
CONNECTING THE BA TTER Y – GASOLINE/DIESEL VEHICLES
1. Connect the battery cables, positive (+) cable îšżrst.
2. T ighten battery terminals to 80 in - lb (9 N·m).
3. Coat terminals with Battery T erminal Protector Spray (CC P/N 1014305) to minimize corrosion.
4. Gasoline V ehicles Only: Connect the spark plug wire(s) to the spark plug(s).
RECYCLING LEAD-ACID BA TTERIES
W ARNING
• Lead - acid batteries contain lead (Pb), other metals, acids and other compounds. If improperly handled,
they can contaminate both water and soil, causing environmental damage and personal injury .
Lead - acid batteries are identiîšżed by the symbol shown below and should be properly recycled ( Figure 1 - 3 ) . They
cannot be disposed as municipal waste and must be collected separately . Responsibility for environmental protection
must be shared, not only by the manufacturers of the batteries, but by people who use the batteries as well. Please
contact your nearest dealer for information on how to properly recycle your batteries.
Page 1-4 2015Carryall1500/1700andXRT1550MaintenanceandServiceManual
SAFETY General W arnings
1
1403
Figure 1- 3 Dispose of Lead-acid Batteries Properly
INTERNA TIONAL SAFETY SYMBOLS ON BA TTERIES
Anyone using, repairing, or servicing the vehicle must understand and heed the safety symbols on the vehicle battery
or batteries.
123456
1. Shield eyes. 3. No smoking, no open ames, no sparks. 5. Battery acid hazard.
2. Read and follow operating instructions. 4. Keep away from children. 6. Explosive gas hazard.
Refer to General W arnings for more information.
1642
Figure 1-
4 International Safety Symbols on Batteries
2015Carryall1500/1700andXRT1550MaintenanceandServiceManual Page 1-5
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