Club car Intellitach carryall 295 Manual

2013

Carryall295/XRT1550

MaintenanceandService

Manual

Carryall295/295SE,XRT1550/1550SEGasoline,Diesel

andIntelliTachVehicles

ManualNumber103997711

EditionCode0613A00000

FOREWORD

ClubCarvehiclesaredesignedandbuilttoprovidetheultimateinperformanceefciency;however,proper

maintenanceandrepairareessentialforachievingmaximumservicelifeandcontinuedsafeandreliableoperation.

Thismanualprovidesdetailedinformationforthemaintenanceandrepairof2013Carryall295,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.Youmayalsowritetousat:ClubCar,LLC;P .O.Box204658;Augusta,

GA30917-4658USA,Attention:TechnicalServices.

ClubCar,Carryall,andArmorFlex

areregisteredtrademarksofClubCar,LLC

ThismanualeffectiveJuly18,2012

2013Carryall295/XRT1550MaintenanceandServiceManualPagei

FOREWORD

WARNING

•ReadSafetyonpage1-1beforeattemptinganyserviceonthisvehicle.

•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.....................................................................................................1-6

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......................................................................................................................3-3

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

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

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

Storage.........................................................................................................................................................3-6

PreparingtheVehicleforExtendedStorage................................................................................................3-7

ReturningtheStoredVehicletoService......................................................................................................3-7

LiftingTheVehicle.........................................................................................................................................3-8

LiftingOnlyTheFront................................................................................................................................3-8

LiftingOnlyTheRear.................................................................................................................................3-8

LiftingTheEntireVehicle............................................................................................................................3-9

UsingABoosterBattery(JumpStarting).......................................................................................................3-10

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

GeneralInformation.......................................................................................................................................4-1

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

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

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

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

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

LargeScratchesandAbrasions..................................................................................................................4-3

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

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

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

2013Carryall295/XRT1550MaintenanceandServiceManualPageiii

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

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

SeatInstallation.......................................................................................................................................4-10

SeatSupportRemoval.............................................................................................................................4-10

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

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

BenchSeatBeltRemoval.........................................................................................................................4-10

BenchSeatBeltInstallation.......................................................................................................................4-11

SeatBeltRemoval–HomologatedModels.................................................................................................4-11

SeatBeltInstallation–HomologatedModels.............................................................................................4-12

CargoBed–ElectricLift...............................................................................................................................4-12

TestingtheBedLiftMotor.........................................................................................................................4-12

BedLiftMotorRemoval............................................................................................................................4-12

BedLiftMotorInstallation.........................................................................................................................4-13

CargoBedRemoval................................................................................................................................4-13

CargoBedInstallation..............................................................................................................................4-13

CargoBed–ManualLift...............................................................................................................................4-14

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

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

RearFender................................................................................................................................................4-14

RearFenderRemoval..............................................................................................................................4-14

RearFenderInstallation...........................................................................................................................4-15

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

AcceleratorPedal..........................................................................................................................................5-1

AcceleratorPedalRemoval........................................................................................................................5-1

AcceleratorPedalInstallation.....................................................................................................................5-2

BrakePedal..................................................................................................................................................5-3

BrakePedalRemoval................................................................................................................................5-3

BrakePedalInstallation.............................................................................................................................5-3

BrakePedalAdjustment.............................................................................................................................5-3

ParkBrakePedal...........................................................................................................................................5-4

ParkBrakePedalAssemblyRemoval–CableOnlySystem.........................................................................5-4

ParkBrakePedalAssemblyInstallation–CableOnlySystem......................................................................5-4

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.................................................................................................................................6-6

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

BrakePadandCaliperInstallation..............................................................................................................6-7

BrakeDiscs...................................................................................................................................................6-9

DiscRemoval..........................................................................................................................................6-10

DiscInstallation.......................................................................................................................................6-10

HydraulicLineReplacement.........................................................................................................................6-10

FrontBrakeLineRemoval.........................................................................................................................6-11

FrontBrakeLineInstallation......................................................................................................................6-11

RearBrakeLineRemoval........................................................................................................................6-12

RearBrakeLineInstallation......................................................................................................................6-13

MasterCylinderandReservoir.....................................................................................................................6-14

FillingtheHydraulicSystem.....................................................................................................................6-14

MasterCylinderRemoval.........................................................................................................................6-14

MasterCylinderInstallation......................................................................................................................6-14

BleedingtheHydraulicBrakeSystem...........................................................................................................6-15

BleedingBrakesonaDOT5FluidFilledSystem.......................................................................................6-15

PurgingtheHydraulicSystem...................................................................................................................6-17

ParkBrakeSystem......................................................................................................................................6-18

Pageiv2013Carryall295/XRT1550MaintenanceandServiceManual

ParkBrakeAdjustment–AtRearCalipers................................................................................................6-18

FrontParkBrakeCableAdjustment–CableOnlySystem..........................................................................6-18

ParkBrakeWheelCables........................................................................................................................6-19

FrontParkBrakeCableRemoval–CableOnlySystem.............................................................................6-20

FrontParkBrakeCableInstallation–CableOnlySystem...........................................................................6-21

ParkBrakeEqualizerRemoval–CableOnlySystem.................................................................................6-21

ParkBrakeEqualizerInstallation–CableOnlySystem..............................................................................6-22

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

SteeringUprightRemoval........................................................................................................................7-14

SteeringUprightInstallation......................................................................................................................7-16

UpperA-ArmRemoval.............................................................................................................................7-16

UpperA-ArmInstallation..........................................................................................................................7-18

LowerA-ArmRemoval.............................................................................................................................7-18

LowerA-ArmInstallation..........................................................................................................................7-19

FrontCoil-OverShockAbsorberRemoval.................................................................................................7-20

FrontCoil-OverShockAbsorberInstallation..............................................................................................7-21

SECTION8–WHEELS,TIRESANDHUBS.......................................................................................................8-1

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

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

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

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

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

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

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

FrontHubs....................................................................................................................................................8-3

FrontHubRemoval....................................................................................................................................8-3

FrontHubInstallation.................................................................................................................................8-5

RearHubs.....................................................................................................................................................8-6

RearHubRemoval....................................................................................................................................8-6

RearHubInstallation.................................................................................................................................8-7

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

RearCoil-OverShockAbsorber......................................................................................................................9-1

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

RearShockInstallation..............................................................................................................................9-2

TrailingArmsandLateralLinks.......................................................................................................................9-3

LateralLinkRemoval.................................................................................................................................9-3

LateralLinkInstallation..............................................................................................................................9-3

TrailingArmRemoval.................................................................................................................................9-5

TrailingArmInstallation..............................................................................................................................9-5

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

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

2013Carryall295/XRT1550MaintenanceandServiceManualPagev

PeriodicServiceSchedule–IntelliTach.........................................................................................................10-4

PeriodicLubricationSchedule......................................................................................................................10-6

PeriodicLubricationSchedule–IntelliTach....................................................................................................10-8

LubricatingtheAttachmentArmandInterface–IntelliT ach.............................................................................10-9

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

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

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

OilPressure–GasolineEngine...............................................................................................................10-11

EngineOilLevelCheck...........................................................................................................................10-11

EngineOilandFilterChange...................................................................................................................10-11

OilViscosity...........................................................................................................................................10-14

SparkPlugs................................................................................................................................................10-15

SparkPlugCleaningAndInspection........................................................................................................10-15

SparkPlugGapInspection......................................................................................................................10-15

GearcaseLubrication..................................................................................................................................10-15

LubricationLevelCheckforFrontDifferential,TransmissionandRearDifferential.......................................10-15

LubricationChangeforFrontDifferential,TransmissionandRearDifferential.............................................10-16

HydraulicSystem–IntelliTachVehicle.........................................................................................................10-18

EngineCoolant–DieselVehicles................................................................................................................10-18

EngineCoolantLevelCheck...................................................................................................................10-19

FuelingInstructions.....................................................................................................................................10-19

BiodieselFuel(DieselVehiclesOnly).......................................................................................................10-20

DrainingWaterfromFuelFilter................................................................................................................10-21

Battery.......................................................................................................................................................10-22

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

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

WiringDiagram.............................................................................................................................................11-6

TestProcedures...........................................................................................................................................11-8

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

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

WiringDiagram............................................................................................................................................12-6

TestProcedures.........................................................................................................................................12-10

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

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

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

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

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

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

Pagevi2013Carryall295/XRT1550MaintenanceandServiceManual

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............................................................................................................................................13-9

TestingtheBedLiftSwitch.......................................................................................................................13-9

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

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

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

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

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

BedLiftCircuitBreakerInstallation..........................................................................................................13-10

LightSwitch................................................................................................................................................13-10

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

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

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

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

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

FuseRemoval........................................................................................................................................13-11

FuseInstallation.....................................................................................................................................13-11

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

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

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

ReverseWarningBuzzerInstallation........................................................................................................13-12

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

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

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

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

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

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

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

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

FuelLevelSendingUnit..............................................................................................................................13-15

TestingtheFuelLevelSendingUnit.........................................................................................................13-15

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

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

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

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

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

OilPressureSensor....................................................................................................................................13-16

Headlights..................................................................................................................................................13-16

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

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

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

WireHarnessDiodes..................................................................................................................................13-17

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

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

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

Battery.......................................................................................................................................................13-18

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

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

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

Self-Discharge........................................................................................................................................13-19

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

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

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

BatteryRemoval.....................................................................................................................................13-20

2013Carryall295/XRT1550MaintenanceandServiceManualPagevii

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

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

BatteryStorage......................................................................................................................................13-21

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

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

Pageviii2013Carryall295/XRT1550MaintenanceandServiceManual

FrontDifferentialLimitSwitch......................................................................................................................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

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...............................................................................................................................................15-9

FuelFilter................................................................................................................................................15-9

FuelPump..............................................................................................................................................15-9

Carburetor...............................................................................................................................................15-9

FuelLevelSendingUnit..........................................................................................................................15-12

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

CarbonCanister.....................................................................................................................................15-18

FuelShut-OffValve.................................................................................................................................15-19

EngineControlLinkages.............................................................................................................................15-20

2013Carryall295/XRT1550MaintenanceandServiceManualPageix

GeneralInformation................................................................................................................................15-20

GroundSpeed........................................................................................................................................15-20

AcceleratorCable...................................................................................................................................15-20

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

EngineGovernorArm.............................................................................................................................15-23

EngineRPMAdjustment.........................................................................................................................15-24

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

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

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

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

Clutches.....................................................................................................................................................15-28

ClutchTroubleshooting...........................................................................................................................15-28

DriveBelt...............................................................................................................................................15-29

DriveClutch...........................................................................................................................................15-29

DrivenClutch.........................................................................................................................................15-33

ClutchCover..........................................................................................................................................15-36

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

GeneralInformation................................................................................................................................16-18

GroundSpeed........................................................................................................................................16-18

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

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

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

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

AirCanisterRemoval..............................................................................................................................16-22

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

Clutches.....................................................................................................................................................16-24

ClutchTroubleshooting...........................................................................................................................16-24

DriveBelt...............................................................................................................................................16-24

DriveClutch...........................................................................................................................................16-25

DrivenClutch.........................................................................................................................................16-29

ClutchCover..........................................................................................................................................16-32

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

RearAxle....................................................................................................................................................17-7

Pagex2013Carryall295/XRT1550MaintenanceandServiceManual

RearAxleRemoval..................................................................................................................................17-7

RearAxleInstallation...............................................................................................................................17-8

RearDriveshaft...........................................................................................................................................17-9

RearDriveshaftRemoval.........................................................................................................................17-9

RearDriveshaftInstallation.....................................................................................................................17-10

Transmission..............................................................................................................................................17-10

TransmissionRemoval............................................................................................................................17-10

TransmissionInstallation.........................................................................................................................17-11

Forward/ReverseShifterCable................................................................................................................17-12

Forward/ReverseShifterHandle..............................................................................................................17-14

RearAxleTubes,AxleShaftsandWheelBearings.......................................................................................17-15

RearAxleTubeandAxleShaftRemoval..................................................................................................17-15

RearAxleTubeandAxleShaftInstallation...............................................................................................17-16

RearWheelBearingRemoval.................................................................................................................17-16

RearWheelBearingInstallation...............................................................................................................17-17

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

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

2013Carryall295/XRT1550MaintenanceandServiceManualPagexi

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

Pagexii2013Carryall295/XRT1550MaintenanceandServiceManual

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.

2013Carryall295/XRT1550MaintenanceandServiceManualPage1-1

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

Page1-22013Carryall295/XRT1550MaintenanceandServiceManual

SAFETYGeneralWarnings1

WARNING

•Priortoleavingthevehicleunattendedorservicingthevehicle,placeattachmentontheground,set

theparkbrake,placetheForward/ReversehandleintheNEUTRALposition,turnthekeyswitchtothe

OFFposition,andremovethekey.Chockthewheelswhenservicingthevehicle.

•Improperuseofthevehicleorfailuretoproperlymaintainitcouldresultindecreasedvehicle

performance,severepersonalinjury,ordeath.

•Anymodicationorchangetothevehiclethataffectstheelectricalsystem,stabilityorhandling

ofthevehicle,orincreasesmaximumvehiclespeedbeyondfactoryspecications,couldresultin

severepersonalinjuryordeath.

•Checkthevehicleforproperlocationofallvehiclesafetyandoperationdecalsandmakesuretheyare

inplaceandareeasytoread.

•Forvehicleswithcargobeds,removeallcargo(includingaccessories)beforeraisingthebedor

servicingthevehicle.Ifthevehicleisequippedwithaproprod,ensurethatitissecurelyengaged

whilebedisraised.Donotclosebeduntilallpersonsareclearofcargobedarea.Keephandsclearof

allcrushareas.Donotdropcargobed;lowergentlyandkeepentirebodyclear.Failuretoheedthis

warningcouldresultinseverepersonalinjuryordeath.

•Onlytrainedtechniciansshouldserviceorrepairthevehicle.Anyonedoingevensimplerepairsor

serviceshouldhaveknowledgeandexperienceinelectricalandmechanicalrepair.Theappropriate

instructionsmustbeusedwhenperformingmaintenance,service,oraccessoryinstallation.

•Toavoidunintentionallystartingthevehicle,disconnectbatteryandsparkplug(Gasonly)wires.See

DisconnectingtheBattery–Gasoline/DieselVehiclesonpage1-3.

•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.

2013Carryall295/XRT1550MaintenanceandServiceManualPage1-3

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

contactyournearestdealerforinformationonhowtoproperlyrecycleyourbatteries.

Page1-42013Carryall295/XRT1550MaintenanceandServiceManual

SAFETYGeneralWarnings1

1403

Figure1-3DisposeofLead-acidBatteriesProperly

2013Carryall295/XRT1550MaintenanceandServiceManualPage1-5

1GeneralWarningsSAFETY

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

Page1-62013Carryall295/XRT1550MaintenanceandServiceManual

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