Club car Intellitach carryall 295 Manual

2008-2012 All-Wheel Drive

Maintenance and Service

Manual

Carryall 295/295 SE, XRT 1550/1550 SE and IntelliT ach

Gasoline and Diesel V ehicles

Manual Number 1033731 17

Edition Code 1007F081 1E

FOREWORD

ClubCarvehiclesaredesignedandbuilttoprovidetheultimateinperformanceefciency;however,proper

maintenanceandrepairareessentialforachievingmaximumservicelifeandcontinuedsafeandreliableoperation.

ThismanualprovidesdetailedinformationforthemaintenanceandrepairofCarryall295,Carryall295SE,XRT

1550,XRT1550SEandIntelliT achvehicles,andshouldbethoroughlyreviewedpriortoservicingthevehicles.The

proceduresprovidedmustbeproperlyimplemented,andtheDANGER,WARNING,andCAUTIONstatements

mustbeheeded.

Thismanualwaswrittenforthetrainedtechnicianwhoalreadypossessesknowledgeandskillsinelectricaland

mechanicalrepair.Ifthetechniciandoesnothavesuchknowledgeandskills,attemptedserviceorrepairstothe

vehiclemayrenderthevehicleunsafe.Forthisreason,ClubCaradvisesthatallrepairsand/orservicebeperformed

byanauthorizedClubCardistributor/dealerrepresentativeorbyaClubCarfactorytrainedtechnician.

ItisthepolicyofClubCar,LLCtoassistitsdistributorsanddealersincontinuallyupdatingtheirserviceknowledge

andfacilitiessotheycanprovidepromptandefcientserviceforvehicleowners.Regionaltechnicalrepresentatives,

periodicservicebulletins,maintenanceandservicemanuals,andotherservicepublicationsalsorepresentClubCar’s

continuingcommitmenttocustomersupport.

ClubCaroffersafulllineoftrainingandcontinuingeducationclassesfortechnicianswhowanttolearnmoreabout

ourproducts.Formoreinformation,contactyourlocaldealerorClubCar’sTechnicalServicesdepartmentfora

listofupcomingclasses.

Thismanualcoversallaspectsoftypicalvehicleservice;however,uniquesituationssometimesoccurwhenservicinga

vehicle.Ifitappearsthataservicequestionisnotansweredinthismanual,pleasecontactyournearestauthorized

ClubCardealerordistributorforassistance.Y oumayalsowritetousat:ClubCar,LLC;P .O.Box204658;Augusta,

GA30917-4658USA,Attention:TechnicalServices.

ClubCar,Carryall,andArmorFlex

areregisteredtrademarksofClubCar,LLC

ThismanualeffectiveApril4,2008

2008-2012All-WheelDriveMaintenanceandServiceManualPagei

FOREWORD

WARNING

•ReadSeeSection1–Safety.beforeattemptinganyserviceonthisvehicle.

•Beforeservicingvehicle,readcompletesection(s)andanyreferencedinformationthatmaybe

relevanttotheserviceorrepairtobeperformed.

NOTE:Thismanualrepresentsthemostcurrentinformationatthetimeofpublication.Themanufactureriscontinually

workingtofurtherimproveitsvehiclesandotherproducts.Theseimprovementsmayaffectservicing

procedures.Anymodicationand/orsignicantchangeinspecicationsorprocedureswillbeforwardedtoall

dealersandwill,whenapplicable,appearinfutureeditionsofthismanual.

Damagetoavehicleorcomponentthereofnotresultingfromadefectorthatoccursduetounreasonable

orunintendeduse,overloading,abuse,orneglect(includingfailuretoprovidereasonableornecessary

maintenanceasinstructedinthevehicleowner’smanual),accidentoralteration,includingincreasingvehicle

speedbeyondfactoryspecicationsormodicationsthataffectthestabilityofthevehicleortheoperation

thereof,willvoidthewarranty.

Themanufacturerreservestherighttochangespecicationsanddesignsatanytimewithoutnoticeand

withoutincurringanyobligationorliabilitywhatsoever.

Therearenowarrantiesexpressedorimpliedinthismanual.Seethelimitedwarrantyfoundinthevehicle

owner’smanualorwritetoClubCar,LLC,P .O.Box204658,Augusta,GA30917-4658USA,Attention:

WarrantyDepartment.

CONTENTS

SECTION1–SAFETY......................................................................................................................................1-1

SafetyDetails................................................................................................................................................1-1

PersonalSafety.........................................................................................................................................1-1

MachineSafety..........................................................................................................................................1-1

Information................................................................................................................................................1-2

GeneralWarnings..........................................................................................................................................1-2

DisablingtheVehicle..................................................................................................................................1-3

DisconnectingtheBattery–Gasoline/DieselVehicles..................................................................................1-3

ConnectingtheBattery–Gasoline/DieselVehicles......................................................................................1-4

RecyclingLead-AcidBatteries....................................................................................................................1-4

Internationalsafetysymbolsonbatteries.....................................................................................................1-5

SECTION2–VEHICLESPECIFICATIONS........................................................................................................2-1

295/295SEand1550/1550SESpecications.............................................................................................2-1

295HomologatedSpecications.................................................................................................................2-4

IntellitachSpecications.............................................................................................................................2-6

SECTION3–GENERALINFORMATION...........................................................................................................3-1

ModelIdentication–Domestic......................................................................................................................3-2

IdenticationNumbers...............................................................................................................................3-3

ModelIdentication–Homologated................................................................................................................3-5

IdenticationNumbers...............................................................................................................................3-5

Storage.........................................................................................................................................................3-7

PreparingtheVehicleforExtendedStorage................................................................................................3-8

ReturningtheStoredVehicletoService......................................................................................................3-8

LiftingTheVehicle.........................................................................................................................................3-9

LiftingOnlyTheFront................................................................................................................................3-9

LiftingOnlyTheRear.................................................................................................................................3-9

LiftingTheEntireVehicle..........................................................................................................................3-10

UsingABoosterBattery(JumpStarting)........................................................................................................3-11

SECTION4–BODYANDTRIM.........................................................................................................................4-1

CleaningtheVehicle......................................................................................................................................4-1

SeatCleaning............................................................................................................................................4-1

FrontBodyRepair.........................................................................................................................................4-2

LightScratches..........................................................................................................................................4-2

AbrasionsandHaze..................................................................................................................................4-2

LargeScratchesandAbrasions..................................................................................................................4-2

FrontBodyComponents................................................................................................................................4-3

InstrumentPanelRemoval.........................................................................................................................4-3

InstrumentPanelInstallation......................................................................................................................4-3

FrontFasciaRemoval................................................................................................................................4-4

FrontFasciaInstallation.............................................................................................................................4-4

HoodRemoval..........................................................................................................................................4-4

HoodInstallation........................................................................................................................................4-4

CenterCowlPanelRemoval.......................................................................................................................4-4

CenterCowlPanelInstallation....................................................................................................................4-5

SideCowlPanel(Fender)Removal............................................................................................................4-5

SideCowlPanel(Fender)Installation.........................................................................................................4-5

FrontFenderFlareRemoval.......................................................................................................................4-6

FrontFenderFlareInstallation....................................................................................................................4-6

Roll-OverProtectiveStructure(ROPS)............................................................................................................4-6

ROPSRemoval.........................................................................................................................................4-6

ROPSInstallation......................................................................................................................................4-8

Seat..............................................................................................................................................................4-9

SeatRemoval............................................................................................................................................4-9

2008-2012All-WheelDriveMaintenanceandServiceManualPageiii

SeatAdjustment........................................................................................................................................4-9

SeatInstallation.........................................................................................................................................4-9

SeatSupportRemoval...............................................................................................................................4-9

SeatSupportInstallation..........................................................................................................................4-10

SeatBelts...................................................................................................................................................4-10

BenchSeatBeltRemoval–2008Models..................................................................................................4-10

BenchSeatBeltInstallation–2008Models................................................................................................4-11

BenchSeatBeltRemoval–2009andNewerModels..................................................................................4-11

BenchSeatBeltInstallation–2009andNewerModels..............................................................................4-12

SeatBeltRemoval–HomologatedModels................................................................................................4-12

SeatBeltInstallation–HomologatedModels.............................................................................................4-13

CargoBed–ElectricLift...............................................................................................................................4-13

TestingtheBedLiftMotor.........................................................................................................................4-13

BedLiftMotorRemoval............................................................................................................................4-13

BedLiftMotorInstallation.........................................................................................................................4-14

CargoBedRemoval................................................................................................................................4-14

CargoBedInstallation..............................................................................................................................4-14

CargoBed–ManualLift...............................................................................................................................4-15

CargoBedRemoval................................................................................................................................4-15

CargoBedInstallation..............................................................................................................................4-15

RearFender................................................................................................................................................4-17

RearFenderRemoval..............................................................................................................................4-17

RearFenderInstallation...........................................................................................................................4-17

SECTION5–ACCELERATORANDBRAKEPEDALASSEMBLIES...................................................................5-1

AcceleratorPedal–ThroughEarly2010ModelYear........................................................................................5-1

AcceleratorPedalRemoval–ThroughEarly2010ModelYear.....................................................................5-1

AcceleratorPedalInstallation–ThroughEarly2010ModelYear...................................................................5-2

AcceleratorPedalandRPMAdjustment–ThroughEarly2010ModelYear...................................................5-2

AcceleratorPedal–FromLate2010ModelYear.............................................................................................5-3

AcceleratorPedalRemoval–FromLate2010ModelYear...........................................................................5-3

AcceleratorPedalInstallation–FromLate2010ModelYear........................................................................5-3

BrakePedal..................................................................................................................................................5-5

BrakePedalRemoval................................................................................................................................5-5

BrakePedalInstallation.............................................................................................................................5-5

BrakePedalAdjustment.............................................................................................................................5-5

ParkBrakePedal...........................................................................................................................................5-6

ParkBrakePedalAssemblyRemoval–BellCrankSystem..........................................................................5-6

ParkBrakePedalAssemblyInstallation–BellCrankSystem.......................................................................5-6

ParkBrakePedalAssemblyRemoval–CableOnlySystem.........................................................................5-6

ParkBrakePedalAssemblyInstallation–CableOnlySystem......................................................................5-7

SECTION6–HYDRAULICANDPARKBRAKESYSTEMS................................................................................6-1

BrakeSystemInspection................................................................................................................................6-1

BrakePedalInspection..............................................................................................................................6-1

MasterCylinderInspection.........................................................................................................................6-2

BrakeLineInspection................................................................................................................................6-3

ParkBrakeInspection................................................................................................................................6-3

BrakeDiscandPadInspection...................................................................................................................6-3

BrakeSystemTroubleshooting.......................................................................................................................6-4

BrakePadsandCaliper–2008-2011Models..................................................................................................6-6

FrontBrakePadandCaliperRemoval........................................................................................................6-6

FrontBrakePadandCaliperInstallation.....................................................................................................6-7

RearBrakePadandCaliperRemoval.........................................................................................................6-8

RearBrakePadandCaliperInstallation......................................................................................................6-9

BrakeDiscandHub–2008-2011Models......................................................................................................6-10

FrontWheelDiscandHubRemoval.........................................................................................................6-10

FrontWheelDiscandHubInstallation.......................................................................................................6-14

RearWheelDiscRemoval.......................................................................................................................6-15

RearWheelDiscInstallation.....................................................................................................................6-16

BrakePadsandCaliper–Starting2012ModelYear......................................................................................6-17

BrakePadandCaliperRemoval...............................................................................................................6-17

Pageiv2008-2012All-WheelDriveMaintenanceandServiceManual

BrakePadandCaliperInstallation............................................................................................................6-18

BrakeDiscs–Starting2012ModelYear........................................................................................................6-19

DiscRemoval..........................................................................................................................................6-19

DiscInstallation.......................................................................................................................................6-20

HydraulicLineReplacement.........................................................................................................................6-20

FrontBrakeLineRemoval........................................................................................................................6-20

FrontBrakeLineInstallation.....................................................................................................................6-21

RearBrakeLineRemoval........................................................................................................................6-22

RearBrakeLineInstallation......................................................................................................................6-22

MasterCylinderandReservoir.....................................................................................................................6-23

FillingtheHydraulicSystem.....................................................................................................................6-23

MasterCylinderRemoval.........................................................................................................................6-23

MasterCylinderInstallation......................................................................................................................6-24

BleedingtheHydraulicBrakeSystem...........................................................................................................6-24

BleedingBrakesonaDOT5FluidFilledSystem.......................................................................................6-25

PurgingtheHydraulicSystem...................................................................................................................6-26

ParkBrakeSystem......................................................................................................................................6-27

ParkBrakeAdjustment–AtRearCalipers................................................................................................6-27

FrontParkBrakeCableAdjustment–BellCrankSystem...........................................................................6-27

FrontParkBrakeCableAdjustment–CableOnlySystem..........................................................................6-28

ParkBrakeWheelCables........................................................................................................................6-28

FrontParkBrakeCableRemoval–BellCrankSystem..............................................................................6-30

FrontParkBrakeCableInstallation–BellCrankSystem............................................................................6-31

FrontParkBrakeCableRemoval–CableOnlySystem.............................................................................6-31

FrontParkBrakeCableInstallation–CableOnlySystem...........................................................................6-32

ParkBrakeEqualizerRemoval–BellCrankSystem..................................................................................6-32

ParkBrakeEqualizerInstallation–BellCrankSystem...............................................................................6-32

ParkBrakeEqualizerRemoval–CableOnlySystem.................................................................................6-33

ParkBrakeEqualizerInstallation–CableOnlySystem..............................................................................6-33

SECTION7–STEERINGANDFRONTSUSPENSION.......................................................................................7-1

SteeringWheel..............................................................................................................................................7-1

SteeringWheelRemoval............................................................................................................................7-1

SteeringWheelInstallation.........................................................................................................................7-2

SteeringColumn............................................................................................................................................7-2

SteeringColumnRemoval..........................................................................................................................7-2

SteeringColumnInstallation.......................................................................................................................7-3

RackandPinion............................................................................................................................................7-3

RackandPinionInspection........................................................................................................................7-4

RackandPinionRemoval..........................................................................................................................7-4

RackandPinionInstallation.......................................................................................................................7-4

RackandPinionDisassembly....................................................................................................................7-5

RackandPinionAssembly.........................................................................................................................7-9

FrontSuspension........................................................................................................................................7-10

WheelAlignment.....................................................................................................................................7-10

FrontSuspensionComponents.....................................................................................................................7-12

SteeringUprightRemoval........................................................................................................................7-12

UpperA-ArmRemoval.............................................................................................................................7-14

UpperA-ArmInstallation..........................................................................................................................7-15

LowerA-ArmRemoval.............................................................................................................................7-15

LowerA-ArmInstallation..........................................................................................................................7-16

FrontCoil-OverShockAbsorberRemoval.................................................................................................7-17

FrontCoil-OverShockAbsorberInstallation..............................................................................................7-18

SteeringUprightInstallation......................................................................................................................7-18

SECTION8–WHEELSANDTIRES..................................................................................................................8-1

GeneralInformation.......................................................................................................................................8-1

Wheels.........................................................................................................................................................8-2

WheelRemoval.........................................................................................................................................8-2

WheelInstallation......................................................................................................................................8-2

Tires.............................................................................................................................................................8-2

TireRemoval.............................................................................................................................................8-2

2008-2012All-WheelDriveMaintenanceandServiceManualPagev

TireInstallation..........................................................................................................................................8-3

SECTION9–REARSUSPENSION...................................................................................................................9-1

RearCoil-OverShockAbsorber–2008-2011Models.......................................................................................9-1

RearShockAbsorberRemoval...................................................................................................................9-1

RearShockAbsorberInstallation................................................................................................................9-2

SwingArms–2008-2011Models....................................................................................................................9-3

SwingArmRemoval..................................................................................................................................9-3

SwingArmInstallation................................................................................................................................9-3

RearCoil-OverShockAbsorber–Starting2012ModelYear............................................................................9-4

RearShockAbsorberRemoval...................................................................................................................9-4

RearShockInstallation..............................................................................................................................9-5

TrailingArmsandLateralLinks–Starting2012ModelYear.............................................................................9-6

LateralLinkRemoval.................................................................................................................................9-6

LateralLinkInstallation..............................................................................................................................9-6

TrailingArmRemoval.................................................................................................................................9-8

TrailingArmInstallation..............................................................................................................................9-8

SECTION10–PERIODICMAINTENANCE......................................................................................................10-1

PeriodicServiceSchedule............................................................................................................................10-1

PeriodicLubricationSchedule......................................................................................................................10-4

PeriodicLubricationSchedule–Intellitach.....................................................................................................10-6

LubricatingtheAttachmentArmandInterface...............................................................................................10-7

BrakeFluidReservoir..................................................................................................................................10-8

BrakeFluid..............................................................................................................................................10-8

EngineOil...................................................................................................................................................10-8

OilPressure–GasolineEngine................................................................................................................10-9

EngineOilLevelCheck............................................................................................................................10-9

EngineOilandFilterChange....................................................................................................................10-9

OilViscosity...........................................................................................................................................10-12

SparkPlugs................................................................................................................................................10-13

SparkPlugCleaningAndInspection........................................................................................................10-13

SparkPlugGapInspection......................................................................................................................10-13

GearcaseLubrication..................................................................................................................................10-13

LubricationLevelCheckforFrontDifferential,Transmission,andRearDifferential......................................10-13

LubricationChangeforFrontDifferential,Transmission,andRearDifferential............................................10-14

HydraulicSystem–IntellitachVehicle..........................................................................................................10-15

EngineCoolant–DieselVehicles................................................................................................................10-16

EngineCoolantLevelCheck...................................................................................................................10-16

FuelingInstructions.....................................................................................................................................10-16

BiodieselFuel(DieselVehiclesOnly)...................................................................................................10-17

DrainingWaterfromFuelFilter................................................................................................................10-18

Battery.......................................................................................................................................................10-19

SECTION11–TROUBLESHOOTINGANDELECTRICALSYSTEM:GASOLINEVEHICLES.............................11-1

TroubleshootingGuide..................................................................................................................................11-1

WiringDiagram.............................................................................................................................................11-8

TestProcedures.........................................................................................................................................11-10

SECTION12–TROUBLESHOOTINGANDELECTRICALSYSTEM:DIESELVEHICLES.................................12-1

TroubleshootingGuide.................................................................................................................................12-1

WiringDiagram............................................................................................................................................12-8

TestProcedures.........................................................................................................................................12-12

SECTION13–ELECTRICALCOMPONENTS:GASOLINEVEHICLES.............................................................13-1

StarterandStarterSolenoid.........................................................................................................................13-1

Relays........................................................................................................................................................13-1

TestingtheRelay.....................................................................................................................................13-1

RelayRemoval........................................................................................................................................13-2

Pagevi2008-2012All-WheelDriveMaintenanceandServiceManual

RelayInstallation.....................................................................................................................................13-2

NeutralSwitch.............................................................................................................................................13-2

TestingtheNeutralSwitch........................................................................................................................13-2

NeutralSwitchRemoval...........................................................................................................................13-2

NeutralSwitchInstallation........................................................................................................................13-2

CarburetorSolenoid.....................................................................................................................................13-3

TestingtheCarburetorSolenoid................................................................................................................13-3

CarburetorSolenoidRemoval...................................................................................................................13-3

CarburetorSolenoidInstallation................................................................................................................13-3

CarburetorHeater........................................................................................................................................13-4

CarburetorHeaterRemoval......................................................................................................................13-4

CarburetorHeaterInstallation...................................................................................................................13-4

VoltageRegulator........................................................................................................................................13-5

TestingtheVoltageRegulator...................................................................................................................13-5

VoltageRegulatorRemoval......................................................................................................................13-5

VoltageRegulatorInstallation...................................................................................................................13-5

WarningLights............................................................................................................................................13-6

TestingtheWarningLights.......................................................................................................................13-6

WarningLightRemoval............................................................................................................................13-6

WarningLightInstallation.........................................................................................................................13-6

FuelGauge/HourMeter...............................................................................................................................13-7

TestingtheFuelGauge/HourMeter..........................................................................................................13-7

FuelGauge/HourMeterRemoval.............................................................................................................13-7

FuelGauge/HourMeterInstallation...........................................................................................................13-8

KeySwitch..................................................................................................................................................13-8

TestingtheKeySwitch.............................................................................................................................13-8

KeySwitchRemoval................................................................................................................................13-8

KeySwitchInstallation.............................................................................................................................13-8

12-VoltAccessoryReceptacle......................................................................................................................13-9

Testingthe12-VoltAccessoryReceptacle.................................................................................................13-9

12-VoltAccessoryReceptacleRemoval....................................................................................................13-9

12-VoltAccessoryReceptacleInstallation.................................................................................................13-9

BedLiftSwitch...........................................................................................................................................13-10

TestingtheBedLiftSwitch......................................................................................................................13-10

BedLiftSwitchRemoval.........................................................................................................................13-10

BedLiftSwitchInstallation.......................................................................................................................13-10

BedLiftCircuitBreaker...............................................................................................................................13-10

TestingtheBedLiftCircuitBreaker..........................................................................................................13-10

BedLiftCircuitBreakerRemoval.............................................................................................................13-10

BedLiftCircuitBreakerInstallation..........................................................................................................13-11

LightSwitch................................................................................................................................................13-11

TestingtheLightSwitch..........................................................................................................................13-11

LightSwitchRemoval.............................................................................................................................13-11

LightSwitchInstallation...........................................................................................................................13-11

Fuse..........................................................................................................................................................13-11

TestingtheFuse.....................................................................................................................................13-11

FuseRemoval........................................................................................................................................13-12

FuseInstallation.....................................................................................................................................13-12

ReverseWarningBuzzer(IfEquipped).........................................................................................................13-12

TestingtheReverseWarningBuzzer........................................................................................................13-12

ReverseWarningBuzzerRemoval..........................................................................................................13-12

ReverseWarningBuzzerInstallation........................................................................................................13-13

ReverseWarningBuzzerLimitSwitch(IfEquipped)......................................................................................13-13

TestingtheReverseWarningBuzzerLimitSwitch.....................................................................................13-13

ReverseWarningBuzzerLimitSwitchRemoval........................................................................................13-13

ReverseWarningBuzzerLimitSwitchInstallation.....................................................................................13-14

FrontDifferentialLimitSwitch......................................................................................................................13-14

TestingtheFrontDifferentialLimitSwitch.................................................................................................13-15

FrontDifferentialLimitSwitchRemoval....................................................................................................13-15

FrontDifferentialLimitSwitchInstallation.................................................................................................13-15

FuelLevelSendingUnit..............................................................................................................................13-16

TestingtheFuelLevelSendingUnit.........................................................................................................13-16

FuelLevelSendingUnitRemoval............................................................................................................13-16

FuelLevelSendingUnitInstallation.........................................................................................................13-16

2008-2012All-WheelDriveMaintenanceandServiceManualPagevii

IgnitionCoilandChargeCoil.......................................................................................................................13-16

TestingtheIgnitionCoil...........................................................................................................................13-16

IgnitionCoiland/orChargeCoilRemoval.................................................................................................13-16

OilPressureSensor....................................................................................................................................13-17

Headlights..................................................................................................................................................13-17

TestingtheHeadlightBulbandSocket.....................................................................................................13-17

HeadlightBulbRemoval..........................................................................................................................13-17

HeadlightBulbInstallation.......................................................................................................................13-17

WireHarnessDiodes..................................................................................................................................13-18

TestingtheWireHarnessDiodes.............................................................................................................13-18

WireHarnessDiodeRemoval..................................................................................................................13-18

WireHarnessDiodeInstallation...............................................................................................................13-18

Battery.......................................................................................................................................................13-19

GeneralInformation................................................................................................................................13-19

TestingtheBattery..................................................................................................................................13-19

PreventiveMaintenance..........................................................................................................................13-19

Self-Discharge........................................................................................................................................13-20

WaterLevel............................................................................................................................................13-20

VibrationDamage...................................................................................................................................13-20

MineralContent......................................................................................................................................13-20

BatteryRemoval.....................................................................................................................................13-21

ChargingtheBattery...............................................................................................................................13-21

BatteryInstallation..................................................................................................................................13-21

BatteryStorage......................................................................................................................................13-22

ChargingaDeadBattery.........................................................................................................................13-22

SECTION14–ELECTRICALCOMPONENTS:DIESELVEHICLES..................................................................14-1

StarterandStarterSolenoid.........................................................................................................................14-1

Relays........................................................................................................................................................14-1

TestingtheRelay.....................................................................................................................................14-1

RelayRemoval........................................................................................................................................14-2

RelayInstallation.....................................................................................................................................14-2

NeutralSwitch.............................................................................................................................................14-2

TestingtheNeutralSwitch........................................................................................................................14-2

NeutralSwitchRemoval...........................................................................................................................14-2

NeutralSwitchInstallation........................................................................................................................14-2

FuelSolenoid..............................................................................................................................................14-3

TestingtheFuelSolenoid.........................................................................................................................14-3

FuelSolenoidRemoval............................................................................................................................14-3

FuelSolenoidInstallation.........................................................................................................................14-3

60-AmpFusibleLink....................................................................................................................................14-4

Testingthe60-AmpFusibleLink...............................................................................................................14-4

60-AmpFusibleLinkRemoval..................................................................................................................14-4

60-AmpFusibleLinkInstallation...............................................................................................................14-4

WarningLights............................................................................................................................................14-5

TestingtheWarningLights.......................................................................................................................14-5

WarningLightRemoval............................................................................................................................14-5

WarningLightInstallation.........................................................................................................................14-5

FuelGauge/HourMeter...............................................................................................................................14-6

TestingtheFuelGauge/HourMeter..........................................................................................................14-6

FuelGauge/HourMeterRemoval.............................................................................................................14-7

FuelGauge/HourMeterInstallation...........................................................................................................14-7

KeySwitch..................................................................................................................................................14-7

TestingtheKeySwitch.............................................................................................................................14-7

KeySwitchRemoval................................................................................................................................14-7

KeySwitchInstallation.............................................................................................................................14-7

12-VoltAccessoryReceptacle......................................................................................................................14-8

Testingthe12-VoltAccessoryReceptacle.................................................................................................14-8

12-VoltAccessoryReceptacleRemoval....................................................................................................14-8

12-VoltAccessoryReceptacleInstallation.................................................................................................14-8

BedLiftSwitch............................................................................................................................................14-9

TestingtheBedLiftSwitch.......................................................................................................................14-9

BedLiftSwitchRemoval..........................................................................................................................14-9

Pageviii2008-2012All-WheelDriveMaintenanceandServiceManual

BedLiftSwitchInstallation........................................................................................................................14-9

BedLiftCircuitBreaker................................................................................................................................14-9

TestingtheBedLiftCircuitBreaker...........................................................................................................14-9

BedLiftCircuitBreakerRemoval..............................................................................................................14-9

BedLiftCircuitBreakerInstallation...........................................................................................................14-9

LightSwitch................................................................................................................................................14-10

TestingtheLightSwitch..........................................................................................................................14-10

LightSwitchRemoval.............................................................................................................................14-10

LightSwitchInstallation...........................................................................................................................14-10

Fuse..........................................................................................................................................................14-10

TestingtheFuse.....................................................................................................................................14-10

FuseRemoval........................................................................................................................................14-10

FuseInstallation.....................................................................................................................................14-11

ReverseWarningBuzzer(IfEquipped).........................................................................................................14-11

TestingtheReverseWarningBuzzer........................................................................................................14-11

ReverseWarningBuzzerRemoval..........................................................................................................14-11

ReverseWarningBuzzerInstallation........................................................................................................14-12

ReverseWarningBuzzerLimitSwitch(IfEquipped)......................................................................................14-12

TestingtheReverseWarningBuzzerLimitSwitch.....................................................................................14-12

ReverseWarningBuzzerLimitSwitchRemoval........................................................................................14-12

ReverseWarningBuzzerLimitSwitchInstallation.....................................................................................14-12

FrontDifferentialLimitSwitchdiesel.............................................................................................................14-13

TestingtheFrontDifferentialLimitSwitch.................................................................................................14-13

FrontDifferentialLimitSwitchRemoval....................................................................................................14-13

FrontDifferentialLimitSwitchInstallation.................................................................................................14-14

FuelLevelSendingUnit..............................................................................................................................14-14

TestingtheFuelLevelSendingUnit.........................................................................................................14-14

FuelLevelSendingUnitRemoval............................................................................................................14-15

FuelLevelSendingUnitInstallation.........................................................................................................14-15

Alternator...................................................................................................................................................14-15

TestingtheAlternator..............................................................................................................................14-15

AlternatorandV-beltRemoval.................................................................................................................14-15

AlternatorandV-beltInstallation..............................................................................................................14-16

OilPressureSensor....................................................................................................................................14-17

Headlights..................................................................................................................................................14-17

TestingtheHeadlightBulbandSocket.....................................................................................................14-17

HeadlightBulbRemoval..........................................................................................................................14-17

HeadlightBulbInstallation.......................................................................................................................14-17

ThermostatSwitch......................................................................................................................................14-18

TestingtheThermostatSwitch.................................................................................................................14-18

ThermostatSwitchRemoval....................................................................................................................14-18

ThermostatSwitchInstallation.................................................................................................................14-19

Fan............................................................................................................................................................14-19

TestingtheFanMotor.............................................................................................................................14-19

FanRemoval..........................................................................................................................................14-19

FanInstallation.......................................................................................................................................14-20

WireHarnessDiodes..................................................................................................................................14-20

TestingtheWireHarnessDiodes.............................................................................................................14-20

WireHarnessDiodeRemoval..................................................................................................................14-20

WireHarnessDiodeInstallation...............................................................................................................14-21

Battery.......................................................................................................................................................14-21

GeneralInformation................................................................................................................................14-21

TestingtheBattery..................................................................................................................................14-22

PreventiveMaintenance..........................................................................................................................14-22

Self-Discharge........................................................................................................................................14-22

WaterLevel............................................................................................................................................14-22

VibrationDamage...................................................................................................................................14-22

MineralContent......................................................................................................................................14-22

BatteryRemoval.....................................................................................................................................14-23

ChargingtheBattery...............................................................................................................................14-23

BatteryInstallation..................................................................................................................................14-24

BatteryStorage......................................................................................................................................14-24

ChargingaDeadBattery.........................................................................................................................14-24

2008-2012All-WheelDriveMaintenanceandServiceManualPageix

SECTION15–GASOLINEENGINE,MUFFLER,FUELSYSTEM,ANDCLUTCHES.........................................15-1

GasolineEngine..........................................................................................................................................15-1

EngineRemoval......................................................................................................................................15-1

EngineInstallation...................................................................................................................................15-3

OilFilterHoses........................................................................................................................................15-5

ExhaustSystem..........................................................................................................................................15-6

MuferRemoval......................................................................................................................................15-6

IntermediatePipeRemoval......................................................................................................................15-6

IntermediatePipeInstallation....................................................................................................................15-7

MuferInstallation....................................................................................................................................15-7

FuelSystem................................................................................................................................................15-8

FuelLines...............................................................................................................................................15-8

FuelFilter...............................................................................................................................................15-10

FuelPump.............................................................................................................................................15-10

Carburetor..............................................................................................................................................15-10

FuelLevelSendingUnit..........................................................................................................................15-11

FuelTank...............................................................................................................................................15-14

CarbonCanister.....................................................................................................................................15-17

FuelShut-OffValve.................................................................................................................................15-18

EngineControlLinkages.............................................................................................................................15-19

AcceleratorCable...................................................................................................................................15-19

ChokeCable..........................................................................................................................................15-21

EngineGovernorArm.............................................................................................................................15-22

EngineRPMAdjustment.........................................................................................................................15-23

AirIntakeSystem.......................................................................................................................................15-26

AirFilterReplacement.............................................................................................................................15-26

AirCanisterRemoval..............................................................................................................................15-27

AirCanisterInstallation...........................................................................................................................15-27

AirFilterIntakeHoseRemoval................................................................................................................15-27

AirFilterIntakeHoseInstallation..............................................................................................................15-28

AirFilterOutletHoseRemoval................................................................................................................15-29

AirFilterOutletHoseInstallation..............................................................................................................15-29

Clutches.....................................................................................................................................................15-30

ClutchTroubleshooting...........................................................................................................................15-31

DriveBelt...............................................................................................................................................15-31

DriveClutch...........................................................................................................................................15-32

DrivenClutch.........................................................................................................................................15-38

ClutchCover..........................................................................................................................................15-41

SECTION16–DIESELENGINE,MUFFLER,FUELSYSTEM,ANDCLUTCHES...............................................16-1

DieselEngine..............................................................................................................................................16-1

EngineRemoval......................................................................................................................................16-1

EngineInstallation...................................................................................................................................16-3

ExhaustSystem..........................................................................................................................................16-5

MuferRemoval......................................................................................................................................16-5

IntermediatePipeRemoval......................................................................................................................16-5

ManifoldPipeRemoval............................................................................................................................16-6

ManifoldPipeInstallation.........................................................................................................................16-6

IntermediatePipeInstallation....................................................................................................................16-6

MuferInstallation....................................................................................................................................16-6

FuelSystem................................................................................................................................................16-8

FuelLines...............................................................................................................................................16-8

BleedingAirFromFuelSystem................................................................................................................16-9

FuelFilterReplacement...........................................................................................................................16-9

FuelPump.............................................................................................................................................16-12

FuelLevelSendingUnit..........................................................................................................................16-12

FuelTank...............................................................................................................................................16-15

EngineControlLinkages.............................................................................................................................16-18

AcceleratorCable...................................................................................................................................16-18

EngineRPMAdjustment.........................................................................................................................16-19

AirIntakeSystem.......................................................................................................................................16-22

AirFilterReplacement.............................................................................................................................16-22

Pagex2008-2012All-WheelDriveMaintenanceandServiceManual

AirCanisterRemoval..............................................................................................................................16-23

AirCanisterInstallation...........................................................................................................................16-23

AirFilterIntakeHoseRemoval................................................................................................................16-24

AirFilterIntakeHoseInstallation..............................................................................................................16-24

AirFilterOutletHoseRemoval................................................................................................................16-25

AirFilterOutletHoseInstallation..............................................................................................................16-25

Clutches.....................................................................................................................................................16-26

ClutchTroubleshooting...........................................................................................................................16-27

DriveBelt...............................................................................................................................................16-27

DriveClutch...........................................................................................................................................16-28

DrivenClutch.........................................................................................................................................16-34

ClutchCover..........................................................................................................................................16-37

SECTION17–DRIVETRAINCOMPONENTS..................................................................................................17-1

HalfShafts..................................................................................................................................................17-1

HalfShaftRemoval..................................................................................................................................17-1

HalfShaftInstallation...............................................................................................................................17-3

FrontDifferential..........................................................................................................................................17-4

FrontDifferentialRemoval........................................................................................................................17-4

FrontDifferentialInstallation.....................................................................................................................17-5

FrontDriveshaft...........................................................................................................................................17-6

FrontDriveshaftRemoval.........................................................................................................................17-6

FrontDriveshaftInstallation......................................................................................................................17-6

RearReceiverHitch.....................................................................................................................................17-7

RearReceiverHitchRemoval...................................................................................................................17-7

RearReceiverHitchInstallation................................................................................................................17-7

RearAxle–2008-2011Models.....................................................................................................................17-8

RearAxleRemoval..................................................................................................................................17-8

RearAxleInstallation...............................................................................................................................17-9

RearAxle–Starting2012ModelYear..........................................................................................................17-11

RearAxleRemoval.................................................................................................................................17-11

RearAxleInstallation..............................................................................................................................17-12

RearDriveshaft..........................................................................................................................................17-13

RearDriveshaftRemoval........................................................................................................................17-13

RearDriveshaftInstallation.....................................................................................................................17-13

Transmission..............................................................................................................................................17-13

TransmissionRemoval............................................................................................................................17-13

TransmissionInstallation.........................................................................................................................17-15

Forward/ReverseShifterCable................................................................................................................17-16

Forward/ReverseShifterHandle..............................................................................................................17-18

RearDifferentialandAxleShafts.................................................................................................................17-19

RearDifferentialandAxleShaftRemoval.................................................................................................17-19

RearDifferentialandAxleShaftInstallation..............................................................................................17-20

RearWheelBearings..............................................................................................................................17-20

SECTION18–RADIATORANDCOOLANTSYSTEM(DIESEL).......................................................................18-1

GeneralInformation.....................................................................................................................................18-1

EngineCoolantLevelCheck....................................................................................................................18-1

EngineCoolantChange...........................................................................................................................18-1

CoolantReservoir........................................................................................................................................18-3

CoolantReservoirRemoval......................................................................................................................18-3

CoolantReservoirInstallation...................................................................................................................18-4

Radiator......................................................................................................................................................18-4

RadiatorRemoval....................................................................................................................................18-4

RadiatorInstallation.................................................................................................................................18-5

CoolantPipeWeldment................................................................................................................................18-6

CoolantPipeWeldmentRemoval.............................................................................................................18-6

CoolantPipeWeldmentInstallation...........................................................................................................18-6

Fan.............................................................................................................................................................18-7

FanRemoval...........................................................................................................................................18-7

FanInstallation........................................................................................................................................18-7

2008-2012All-WheelDriveMaintenanceandServiceManualPagexi

SECTION19–HYDRAULICATTACHMENTSYSTEM......................................................................................19-1

ModelIdentication..................................................................................................................................19-1

RelievingHydraulicSystemPressure............................................................................................................19-1

ToRelieveHydraulicFluidPressure..........................................................................................................19-1

AttachmentInterface....................................................................................................................................19-2

Inspection...............................................................................................................................................19-2

RemovingandInstallingtheAttachmentArmMechanism...........................................................................19-3

Electrical.....................................................................................................................................................19-8

Joystick..................................................................................................................................................19-10

JoystickON/OFFSwitch.........................................................................................................................19-12

AttachmentArmFloatSwitch...................................................................................................................19-13

AuxiliaryHydraulicSwitch.......................................................................................................................19-15

Relays...................................................................................................................................................19-16

Solenoid.................................................................................................................................................19-18

CircuitBreaker.......................................................................................................................................19-18

ControlValves........................................................................................................................................19-19

Hoses........................................................................................................................................................19-21

HoseRouting.........................................................................................................................................19-21

HoseRemoval........................................................................................................................................19-22

HoseInstallation.....................................................................................................................................19-22

QuickConnectFittings(AuxiliaryHydraulicCircuitonly)................................................................................19-23

QuickConnectRemoval..........................................................................................................................19-23

QuickConnectInstallation.......................................................................................................................19-23

Cylinders....................................................................................................................................................19-24

VehicleMountedCylinders......................................................................................................................19-24

AuxiliaryCylinder(Optional)....................................................................................................................19-25

CylinderDisassembly.............................................................................................................................19-27

CylinderAssembly..................................................................................................................................19-30

CylinderBushings(IfEquipped)...............................................................................................................19-36

AngleFrameBushings................................................................................................................................19-37

SnowBladeAngleFrame........................................................................................................................19-37

WhiskBroomAngleFrame......................................................................................................................19-38

FrontMount................................................................................................................................................19-39

FrontMountRemoval.............................................................................................................................19-39

FrontMountinstallation...........................................................................................................................19-40

HydraulicPumpAssembly...........................................................................................................................19-40

FluidLevelInspection.............................................................................................................................19-41

FluidChange..........................................................................................................................................19-41

PumpAssembly.....................................................................................................................................19-42

Reservoir...............................................................................................................................................19-44

Motor.....................................................................................................................................................19-45

Pump.....................................................................................................................................................19-46

PrimingthePump...................................................................................................................................19-46

SECTIONi–INDEX

Pagexii2008-2012All-WheelDriveMaintenanceandServiceManual

SECTION1–SAFETY1

SAFETYDETAILS

WARNING

•Thisowner’smanualshouldbereadcompletelybeforeattemptingtodriveorservicethevehicle.

Failuretofollowtheinstructionsinthismanualcouldresultinpropertydamage,severepersonal

injury,ordeath.

PERSONALSAFETY

Itisimportanttonotethatsomevitalstatementsthroughoutthismanualandonthedecalsafxedtothevehicleare

precededbythewordsDANGER,WARNING,orCAUTION.Foryourprotection,werecommendthatyoutakespecial

noticeofthesesafetyprecautions.Safetyprecautionsareessentialandmustbefollowed.

Ifanyoftheoperationorwarningdecalsonthevehiclebecomedamaged,havebeenremoved,orcannotbeeasily

read,theyshouldbereplacedimmediatelytoavoidpossiblepropertydamage,personalinjury,ordeath.Contact

yourdealer.

DANGER

•ADANGERindicatesanimmediatehazardthatwillresultinseverepersonalinjuryordeath.The

colorassociatedwithDangerisRED.

WARNING

•AWARNINGindicatesanimmediatehazardthatcouldresultinseverepersonalinjuryordeath.

ThecolorassociatedwithWarningisORANGE.

CAUTION

•ACAUTIONwiththesafetyalertsymbolindicatesahazardorunsafepracticethatcouldresultin

minorpersonalinjury.ThecolorassociatedwithCautionisYELLOW.

MACHINESAFETY

CAUTION

•ACAUTIONwithoutthesafetyalertsymbolindicatesapotentiallyhazardoussituationthatcould

resultinpropertydamage.

ACAUTION,withoutthesafetyalertsymbol,isintendedformachineandpropertysafety.Itisusedthroughoutthis

manualfollowedbyspecicinstructionstopreventmachineorpropertydamage.FailuretofollowtheseCAUTION

messagescouldresultinmachineorpropertydamage.

2008-2012All-WheelDriveMaintenanceandServiceManualPage1-1

1GeneralWarningsSAFETY

INFORMATION

NOTE:Instructionsthatclarifysteps,procedures,orotherinformationinthismanual.

GENERALWARNINGS

Thefollowingsafetystatementsmustbeheededwheneverthevehicleisbeingoperated,repaired,orserviced.Other

specicsafetystatementsappearthroughoutthismanualandonthevehicle.

DANGER

•Battery–Explosivegases!Donotsmoke.Keepsparksandamesawayfromthevehicleandservice

area.Ventilatewhenchargingoroperatingvehicleinanenclosedarea.Wearafullfaceshieldand

rubbergloveswhenworkingonornearbatteries.

•Gasoline/Diesel–Flammable!Explosive!Donotsmoke.Keepsparksandamesawayfromthe

vehicleandservicearea.Serviceonlyinawell-ventilatedarea.

•Donotoperateengineinanenclosedareawithoutproperventilation.Theengineproducescarbon

monoxide,whichisanodorless,deadlypoisonthatcanquicklyaccumulateinanenclosedcab.Do

notruntheengineinaparkedvehiclewithoutpropercabventilation.Movetofreshairifyoufeel

nausea,headache,dizziness,drowsinessorweakness.

•Thevehiclewillnotprovideprotectionfromlightning,yingobjects,orotherstorm-relatedhazards.

Ifcaughtinastormwhiledrivingthisvehicle,exitthevehicleandseekshelterinaccordancewith

applicablesafetyguidelinesforyourlocation.

•Donotweldtoawheelorrimuntilthetireiscompletelyremoved.Inatedtirescangenerateagas

mixturewiththeairthatcanbeignitedbyhightemperaturesfromweldingproceduresperformedon

thewheelorrim.Removingtheairorlooseningthetireontherim(breakingthebead)willNOT

eliminatethehazard.Thisconditioncanexistwhethertiresareinatedordeated.ThetireMUST

becompletelyremovedfromthewheelorrimpriortoweldingthewheelorrim.Failuretocomply

willresultindeathorseriousinjury.

WARNING

•Followtheproceduresexactlyasstatedinthismanual,andheedallDANGER,WARNING,and

CAUTIONstatementsinthismanualaswellasthoseonthevehicle.

•Thisvehicleisnotintendedtobeusedwhereriskoffallingobjectsexist.Ifyourvehiclewillbeusedin

suchanenvironment,contactyourlocaldealer.

•Donotleavechildrenunattendedonvehicle.

•Childrenrequiringachildsafetyseatmustnotrideonthevehicle.Complywithstateandlocallaws

pertainingtochildsafety.

•Thedriverandpassengermustberestrainedatalltimeswiththeseatbeltsprovidedtohelpprevent

injuryintheeventofsuddenbraking,collision,orroll-over.

•Nomorethanonepersonperbucketseatatonetime.Nomorethantwopersonsperbenchseatat

onetime.Donotallowpeopletorideinanypartofthevehiclethatisnotequippedwithaseatanda

seatbelt.Donotallowapassengertoholdachildinhisorherlapwhilethevehicleismoving.

WARNINGCONTINUEDONNEXTPAGE

Page1-22008-2012All-WheelDriveMaintenanceandServiceManual

SAFETYGeneralWarnings1

WARNING

•Priortoleavingthevehicleunattendedorservicingthevehicle,placeattachmentontheground,set

theparkbrake,placetheForward/ReversehandleintheNEUTRALposition,turnthekeyswitchtothe

OFFposition,andremovethekey.Chockthewheelswhenservicingthevehicle.

•Improperuseofthevehicleorfailuretoproperlymaintainitcouldresultindecreasedvehicle

performance,severepersonalinjury,ordeath.

•Anymodicationorchangetothevehiclethataffectsthestabilityorhandlingofthevehicle,or

increasesmaximumvehiclespeedbeyondfactoryspecications,couldresultinseverepersonal

injuryordeath.

•Checkthevehicleforproperlocationofallvehiclesafetyandoperationdecalsandmakesuretheyare

inplaceandareeasytoread.

•Forvehicleswithcargobeds,removeallcargobeforeraisingthebedorservicingthevehicle.Ifthe

vehicleisequippedwithaproprod,ensurethatitissecurelyengagedwhilebedisraised.Donot

closebeduntilallpersonsareclearofcargobedarea.Keephandsclearofallcrushareas.Donot

dropcargobed;lowergentlyandkeepentirebodyclear.Failuretoheedthiswarningcouldresultin

severepersonalinjuryordeath.

•Onlytrainedtechniciansshouldserviceorrepairthevehicle.Anyonedoingevensimplerepairsor

serviceshouldhaveknowledgeandexperienceinelectricalandmechanicalrepair.Theappropriate

instructionsmustbeusedwhenperformingmaintenance,service,oraccessoryinstallation.

•Toavoidunintentionallystartingthevehicle,disconnectbatteryandsparkplug(Gasonly)wires.See

DisconnectingtheBattery–Gasoline/DieselVehicleonpage1-3.

•Frameground–Donotallowtoolsorothermetalobjectstocontactframewhendisconnectingbattery

cablesorotherelectricalwiring.Donotallowapositivewiretotouchthevehicleframe,engine,or

anyothermetalcomponent.

•Wearsafetyglassesorapprovedeyeprotectionwhenservicingthevehicle.Wearafullfaceshieldand

rubbergloveswhenworkingonornearbatteries.

•Donotwearlooseclothingorjewelrysuchasrings,watches,chains,etc.,whenservicingthevehicle.

•Useinsulatedtoolswhenworkingnearbatteriesorelectricalconnections.Useextremecautionto

avoidshortingofcomponentsorwiring.

•Whenservicingthevehiclewithpartofthevehicleonjackstands,donotoperatetheenginewiththe

Forward/ReversehandleineithertheFORWARDorREVERSEposition.Theall-wheeldrivesystemwill

engageanywheel(s),frontorrear,withtraction(Figure1-2,Page1-4).

DISABLINGTHEVEHICLE

1.Settheparkbrake.

2.TurnthekeyswitchOFFandremovethekey.

3.PlacetheForward/ReversecontrolintheNEUTRALposition.

4.Inaddition,chockthewheelsifservicingorrepairingthevehicle.

DISCONNECTINGTHEBATTERY–GASOLINE/DIESELVEHICLES

1.Disablethevehicle.SeeDisablingtheVehicleonpage1-3.

2008-2012All-WheelDriveMaintenanceandServiceManualPage1-3

1GeneralWarningsSAFETY

2.Disconnectthebatterycables,negative(–)cablerst,asshown(Figure1-1).

3.GasolineVehiclesOnly:Disconnectthesparkplugwire(s)fromthesparkplug(s).

NEG

PO S

(–)

(+)

1.Removenegativebatterycable.

2.Removepositivebatterycable.

Connectbatterycablesinreverseorder.

188

Figure1-1BatteryCableRemoval

189

Figure1-2All-WheelDriveWarning

CONNECTINGTHEBATTERY–GASOLINE/DIESELVEHICLES

1.Connectthebatterycables,positive(+)cablerst.

2.Tightenbatteryterminalsto80in-lb(9N·m).

3.CoatterminalswithBatteryT erminalProtectorSpray(CCP/N1014305)tominimizecorrosion.

4.GasolineVehiclesOnly:Connectthesparkplugwire(s)tothesparkplug(s).

RECYCLINGLEAD-ACIDBATTERIES

WARNING

•Lead-acidbatteriescontainlead(Pb),othermetals,acidsandothercompounds.Ifimproperlyhandled,

theycancontaminatebothwaterandsoil,causingenvironmentaldamageandpersonalinjury.

Lead-acidbatteriesareidentiedbythesymbolshownbelowandshouldbeproperlyrecycled(Figure1-3).They

cannotbedisposedasmunicipalwasteandmustbecollectedseparately.Responsibilityforenvironmentalprotection

mustbeshared,notonlybythemanufacturersofthebatteries,butbypeoplewhousethebatteriesaswell.Please

contactyournearestClubCardealerordistributorforinformationonhowtoproperlyrecycleyourbatteries.

Page1-42008-2012All-WheelDriveMaintenanceandServiceManual

SAFETYGeneralWarnings1

1403

Figure1-3DisposeofLead-acidBatteriesProperly

INTERNATIONALSAFETYSYMBOLSONBATTERIES

Anyoneusing,repairing,orservicingthevehiclemustunderstandandheedthesafetysymbolsonthevehiclebattery

orbatteries.

123456

1.Shieldeyes.3.Nosmoking,noopenames,nosparks.5.Batteryacidhazard.

2.Readandfollowoperatinginstructions.4.Keepawayfromchildren.6.Explosivegashazard.

RefertoGeneralWarningsformoreinformation.

1642

Figure1-4InternationalSafetySymbolsonBatteries

2008-2012All-WheelDriveMaintenanceandServiceManualPage1-5

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