Club Car Carryall 295 Maintenance And Service Manual
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Club Car Carryall 295 Maintenance And Service Manual

Club Car Carryall 295 Maintenance And Service Manual

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2013
Carryall 295/XRT 1550
Maintenance and Service
Manual
Carryall 295/295 SE, XRT 1550/1550 SE Gasoline, Diesel
and IntelliTach Vehicles
Manual Number 103997711
Edition Code 0613A00000

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  • Page 1 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Carryall 295/295 SE, XRT 1550/1550 SE Gasoline, Diesel and IntelliTach Vehicles Manual Number 103997711 Edition Code 0613A00000...
  • Page 3 If it appears that a service question is not answered in this manual, please contact your nearest authorized Club Car dealer or distributor for assistance. You may also write to us at: Club Car, LLC; P.O. Box 204658; Augusta, GA 30917-4658 USA, Attention: Technical Services.
  • Page 4 There are no warranties expressed or implied in this manual. See the limited warranty found in the vehicle owner’s manual or write to Club Car, LLC, P.O. Box 204658, Augusta, GA 30917-4658 USA, Attention: Warranty Department.

  • Page 5: Table Of Contents

    Side Cowl Panel (Fender) Installation ......................4-5 Front Fender Flare Removal........................4-6 Front Fender Flare Installation ........................4-6 Roll-Over Protective Structure (ROPS)......................4-6 ROPS Removal ............................4-7 ROPS Installation ............................4-8 Seat................................4-9 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page iii...
  • Page 6 Master Cylinder Installation ........................6-14 Bleeding the Hydraulic Brake System ......................6-15 Bleeding Brakes on a DOT 5 Fluid Filled System ..................6-15 Purging the Hydraulic System........................6-17 Park Brake System ............................6-18 Page iv 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 7 Trailing Arms and Lateral Links........................9-3 Lateral Link Removal ..........................9-3 Lateral Link Installation ..........................9-3 Trailing Arm Removal..........................9-5 Trailing Arm Installation..........................9-5 SECTION 10 – PERIODIC MAINTENANCE ...................... 10-1 Periodic Service Schedule..........................10-1 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page v...
  • Page 8 Voltage Regulator Installation ........................13-5 Warning Lights ............................13-6 Testing the Warning Lights ........................13-6 Warning Light Removal ..........................13-6 Warning Light Installation ......................... 13-6 Fuel Gauge/Hour Meter ..........................13-7 Page vi 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 9 Wire Harness Diode Removal........................13-18 Wire Harness Diode Installation.......................13-18 Battery ...............................13-18 General Information ..........................13-19 Testing the Battery ..........................13-19 Preventive Maintenance..........................13-19 Self-Discharge............................13-19 Water Level ............................13-20 Vibration Damage ...........................13-20 Mineral Content ............................13-20 Battery Removal .............................13-20 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page vii...
  • Page 10 Reverse Warning Buzzer Installation......................14-12 Reverse Warning Buzzer Limit Switch (If Equipped) ..................14-12 Testing the Reverse Warning Buzzer Limit Switch..................14-12 Reverse Warning Buzzer Limit Switch Removal..................14-12 Reverse Warning Buzzer Limit Switch Installation ..................14-12 Page viii 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 11 Fuel Lines ............................... 15-9 Fuel Filter..............................15-9 Fuel Pump .............................. 15-9 Carburetor............................... 15-9 Fuel Level Sending Unit ..........................15-12 Fuel Tank ...............................15-15 Carbon Canister .............................15-18 Fuel Shut-Off Valve..........................15-19 Engine Control Linkages ..........................15-20 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page ix...
  • Page 12 Front Differential ............................17-4 Front Differential Removal ........................17-4 Front Differential Installation ........................17-5 Front Driveshaft............................17-6 Front Driveshaft Removal......................... 17-6 Front Driveshaft Installation ........................17-6 Rear Axle ..............................17-7 Page x 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 13 Quick Connect Fittings (Auxiliary Hydraulic Circuit only) ................19-23 Quick Connect Removal..........................19-23 Quick Connect Installation........................19-23 Cylinders..............................19-24 Vehicle Mounted Cylinders ........................19-24 Auxiliary Cylinder (Optional) ........................19-25 Cylinder Disassembly ..........................19-27 Cylinder Assembly ..........................19-30 Cylinder Bushings (If Equipped).......................19-36 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page xi...
  • Page 14 Front Mount Removal ..........................19-39 Front Mount installation ...........................19-40 Hydraulic Pump Assembly...........................19-40 Fluid Level Inspection ..........................19-41 Fluid Change............................19-41 Pump Assembly .............................19-42 Reservoir ...............................19-44 Motor ..............................19-45 Pump..............................19-46 Priming the Pump ...........................19-46 SECTION i – INDEX Page xii 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 15: Section 1 - Safety

    A CAUTION, without the safety alert symbol, is intended for machine and property safety. It is used throughout this manual followed by specific instructions to prevent machine or property damage. Failure to follow these CAUTION messages could result in machine or property damage. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 1-1...

  • Page 16: Information

    Do not allow people to ride in any part of the vehicle that is not equipped with a seat and a seat belt. Do not allow a passenger to hold a child in his or her lap while the vehicle is moving. WARNING CONTINUED ON NEXT PAGE Page 1-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 17: Disabling The Vehicle

    Place the Forward/Reverse control in the NEUTRAL position. In addition, chock the wheels if servicing or repairing the vehicle. DISCONNECTING THE BATTERY – GASOLINE/DIESEL VEHICLES Disable the vehicle. See Disabling the Vehicle on page 1-3. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 1-3...

  • Page 18: Connecting The Battery - Gasoline/Diesel Vehicles

    Please contact your nearest dealer for information on how to properly recycle your batteries. Page 1-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 19 SAFETY General Warnings 1403 Figure 1-3 Dispose of Lead-acid Batteries Properly 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 1-5...

  • Page 20: International Safety Symbols On Batteries

    2. Read and follow operating instructions. 4. Keep away from children. 6. Explosive gas hazard. Refer to General Warnings for more information. 1642 Figure 1-4 International Safety Symbols on Batteries Page 1-6 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 21: Section 2 - Vehicle Specifications

    Side and rear body: Plastic ● ● ● ● Cargo bed: Powder-coated steel or aluminum ● ● ● ● Front body: Molded-in color ● ● ● ● TABLE CONTINUED ON NEXT PAGE 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 2-1...
  • Page 22 Maximum gross vehicle weight (fully loaded vehicle, including accessories) High capacity option: 3350 lb. (1519.1 kg) 3012 lb. (1366 kg) Standard seating capacity LIQUID CAPACITIES TABLE CONTINUED ON NEXT PAGE Page 2-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 23 Fuel tank: diesel grade no.2 with cetane rating of 45 or higher (24.6 L) (24.6 L) TIRE PRESSURE All-terrain tread and mud tires 20 to 22 psi (1.38 to 1.52 Bars) 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 2-3...

  • Page 24: 295 Homologated Specifications

    8.2 in. (20.8 cm) under differential Front wheel tread 48.2 in. (122.5 cm) Rear wheel tread 48.2 in. (122.5 cm) Forward speed 25 mph (40 km/h) TABLE CONTINUED ON NEXT PAGE Page 2-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 25 Fuel tank: diesel grade no.2 with cetane rating of 45 or higher 6.5 gallons (24.6 L) TIRE PRESSURE All-terrain tread and mud tires 20 to 22 psi (1.38 to 1.52 Bars) 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 2-5...

  • Page 26: Intellitach Specifications

    11.1 in. (28 cm) under floorboard Front wheel tread 48.25 in. (122.5 cm) Rear wheel tread 48.63 in. (123.5 cm) Weight (with all-terrain tires) 1800 lb. (815 kg) TABLE CONTINUED ON NEXT PAGE Page 2-6 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 27 6.5 gallons (24.6 L) Hydraulic fluid: ExxonMobil DTE15M (is compatible with Bobcat Hydraulic Fluid) 1.3 gallons (5.0 L) TIRE PRESSURE All-terrain tread and mud tires 20 to 22 psi (1.38 to 1.52 Bars) 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 2-7...

  • Page 29: Section 3 - General Information

    The terms front (1), left-hand (2), right-hand (3) and rear (4) are used in this manual to indicate the sides as they are seen from the operator’s seat. 1629 Figure 3-1 Vehicle Orientation 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 3-1...
  • Page 30 Reservoir (under hood) 8. Radiator and Coolant Reservoir (under hood) 9. Mirrors 10. Front Flasher Lamps 11. Rear Signal Lamps 2462 Figure 3-3 Vehicle Components – Homologated Vehicle for Europe Page 3-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 31: Model Identification - Domestic

    Differential Serial Number (Figure 3-8) SERIAL NUMBER PH0901-123456 BC54679 ASSEMBLED IN USA 1400 2474 Figure 3-4 Serial Number Decal with the Vehicle Build Figure 3-5 ROPS Serial Number Location Code 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 3-3...
  • Page 32 Model Identification – Domestic GENERAL INFORMATION Figure 3-6 Gasoline Engine Serial Number Location Figure 3-7 Diesel Engine Serial Number Location 2703 Figure 3-8 Differential Serial Number Location Page 3-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 33: Model Identification - Homologated

    Vehicle Serial Number (Figure 3-4) Year of Build (Figure 3-4) Vehicle Identification Number (VIN) (Figure 3-9) ROPS Serial Number (Figure 3-5) Engine Serial Number (Figure 3-7) Differential Serial Number (Figure 3-8) 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 3-5...

  • Page 34: Storage

    • Batteries in a low state of charge will freeze at low temperatures. 1. Fuel Shut-off Valve 2. Closed (OFF) 3. Open (ON) NOTE: When selecting valve position, ensure that it is fully opened or fully closed. Figure 3-10 Fuel Shut-off Valve Page 3-6 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 35: Preparing The Vehicle For Extended Storage

    2.1. Remove the plug from the fuel tank vent. 2.2. Connect the vent tube to the fuel tank vent. Connect battery and spark plug (Gas only) wires. See Connecting the Battery – Gasoline/Diesel Vehicle on page 1-4. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 3-7...

  • Page 36: Lifting The Vehicle

    Place vehicle on a level surface. Chock the front wheels. Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. If removing wheel, loosen the rear wheel lug nuts. Page 3-8 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 37: Lifting The Entire Vehicle

    – Ensure the wheels of the jack are able to roll freely without obstruction. Once vehicle is level, place jack stands under the rear axle tubes and lower onto stands. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 3-9...

  • Page 38: Using A Booster Battery (Jump Starting)

    (2). Then remove the cables from the booster battery. See following CAUTION. CAUTION • The alternator can be damaged if the following actions occur: – Engine is operated with battery cables disconnected. – Booster cables are connected wrong. Page 3-10 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 39 GENERAL INFORMATION Using A Booster Battery (Jump Starting) Figure 3-13 Jump Starting 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 3-11...

  • Page 41: Section 4 - Body And Trim

    (No. 00) steel wool. Battery acid, fertilizers, tars, asphalt, creosote, paint, or chewing gum should be removed immediately to prevent possible stains. SEAT CLEANING Clean seats regularly using the following guidelines: See following CAUTION. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 4-1...

  • Page 42: Front Body Repair

    Wipe clean with soft, clean cloth. Any dirt on cloth can mar surface. ABRASIONS AND HAZE Abrasions and haze can be greatly minimized by performing steps 5 through 7 above. Page 4-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 43: Large Scratches And Abrasions

    Gain access to the rear nut and washer by raising hood and reaching up inside rear of instrument panel. Snap the black plastic cap in place over the exposed hex bolt head. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 4-3...

  • Page 44: Front Fascia Removal

    Secure the hood to the hood hinge using the four Torx ® screws. Lower hood and latch securely. CENTER COWL PANEL REMOVAL Remove hood. See Hood Removal on page 4-4. Page 4-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 45: Center Cowl Panel Installation

    ROPS cowl support (if equipped) passes through the clearance hole in the side cowl panel. Rotate the side cowl panel down and over the ROPS cowl support (if equipped) until it is down and in place. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 4-5...

  • Page 46: Front Fender Flare Removal

    • Do not modify the ROPS or operate the vehicle with the ROPS removed. Doing so will void the certification and could result in property damage, personal injury, or death. WARNING CONTINUED ON NEXT PAGE Page 4-6 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 47: Rops Removal

    NOTE: It may facilitate removal to use a rubber mallet to disengage the rear-most tube of the side support first. Finally, disengage the front end of the tube by simultaniously twisting side to side and lifting. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 4-7...

  • Page 48: Rops Installation

    Position the top brace (23) to the top of the rear side supports (16) and secure with hex-head bolts (24) and flanged lock nuts (25). Page 4-8 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 49: Seat

    • Ensure that the seat hinges and latch are securely engaged before operating vehicle. Track-mounted driver seat 2.1. Sit in seat, grasp seat adjustment handle under seat bottom and slide seat to desired position. See preceding WARNING. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 4-9...

  • Page 50: Seat Installation

    Do not occupy the seat until the safety belt is repaired. BENCH SEAT BELT REMOVAL Remove the flange bolt and nut from the base of the coiled seat belt assembly (outside location) (Figure 4-2, Page 4-11). Page 4-10 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 51: Bench Seat Belt Installation

    Remove the nut, small washer and two large washers from the seat belt buckle assembly (center location) (Figure 4-3, Page 4-11). Remove the shoulder bolt, spring washer and seat belt buckle assembly. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 4-11...

  • Page 52: Seat Belt Installation - Homologated Models

    With the bed in the down position, working from under the vehicle, disconnect the two wires from the connectors at the electric bed lift motor. Remove the locknut, bolt, sleeve, spacers and washers from the rod end of the bed lift motor and bed frame. Page 4-12 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 53: Bed Lift Motor Installation

    Use a small hammer, and lightly tap the bolts through the hinges. Install a nylon locknut on each bolt, and tighten the hardware to 15 ft-lb (21 N·m). Install the electric actuator. See Bed Lift Motor Installation on page 4-13. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 4-13...

  • Page 54: Cargo Bed - Manual Lift

    Carefully remove the three Tuflok plastic fasteners securing the top of the fender to the rear frame. 2.1. Using a size P2 Phillips head screwdriver, back out the Tuflok screws at least 1/2 inch (1.25 cm). Page 4-14 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 55: Rear Fender Installation

    Install the two Phillips head screws and washers to secure the side of the fender to the frame. Repeat steps 1 through 5 to install the remaining fender if necessary. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 4-15...
  • Page 56 Rear Fender BODY AND TRIM 1884 Figure 4-5 Cargo Bed Page 4-16 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 57: Section 5 - Accelerator And Brake Pedal Assemblies

    Figure 5-1 Z-Shaped Cable End At Accelerator Pedal Figure 5-2 Accelerator Pedal Mounting Hardware Remove the pedal pivot bolt (1) and locknut (2) that secure the pedal assembly to the chassis (Figure 5-2, Page 5-1). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 5-1...

  • Page 58: Accelerator Pedal Installation

    Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. 2- 7/16 in. (± 1/8) 61 mm ( + 3) 2361 Figure 5-3 Accelerator Pedal Return Spring Length (To Face Of Nut As Shown) Page 5-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 59: Brake Pedal

    Perform all brake system inspections to ensure that the hydraulic brake system and the park brake system are adjusted and operating correctly before the vehicle is returned to service. See Brake System Inspection, Section 6, Page 6-1. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 5-3...

  • Page 60: Park Brake Pedal

    PARK BRAKE PEDAL ASSEMBLY INSTALLATION – CABLE ONLY SYSTEM If installing a used assembly, be sure to use a small, stiff brush to remove all dirt and debris from the ratchet teeth (Figure 5-5, Page 5-4). Page 5-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 61 Connect battery. See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. Adjust the brake cable equalizer. See Front Park Brake Cable Adjustment – Cable Only System on page 6-18. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 5-5...

  • Page 63: Section 6 - Hydraulic And Park Brake Systems

    If the pedal goes to the floor, inspect the hydraulic system for leaks and repair any worn or damaged components. After repair, bleed the hydraulic brake system. See Bleeding the Hydraulic Brake System on page 6-15. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 6-1...

  • Page 64: Master Cylinder Inspection

    15. Tee 8. Passenger Side Mounting 12. Driver Side Rear Brake 16. Passenger Side Rear Brake 4. T-Bracket Bracket With P-Clamp Caliper Caliper 2565 Figure 6-1 Hydraulic Disc Brake System Page 6-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 65: Brake Line Inspection

    • Use only approved replacement brake pads designed for your vehicle. • Use only DOT 5 brake fluid. • Do not pump brake pedal without fluid in the reservoir or master cylinder. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 6-3...

  • Page 66: Brake System Troubleshooting

    Cylinder and Reservoir on page 6-14. Replace the brake pads. See Brake Pads Over-aggressive braking Incorrect or distorted brake pads and Caliper on page 6-6. TABLE CONTINUED ON NEXT PAGE Page 6-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 67 See Park Brake Adjustment – At Rear Rear brakes drag Improper brake adjustment Calipers on page 6-18. Also See Park Brake Wheel Cables on page 6-19. TABLE CONTINUED ON NEXT PAGE 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 6-5...

  • Page 68: Brake Pads And Caliper

    If the caliper will be used again, plug the banjo bolt hole to prevent dirt and debris entering the caliper. Place a plastic bag over the hose fitting to prevent dirt and debris entering the hose. Page 6-6 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 69: Brake Pad And Caliper Installation

    NOTE: To help prevent noise, a silicone-based brake lubricant may be applied to the surfaces (on the back side of the brake pads) that contact the caliper. A thin film may also be applied to the slide-pins. Always follow lubricant manufacturer’s directions. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 6-7...
  • Page 70 System on page 6-15. Once purged, the spongy brake pedal should disappear. The residual fluid that seeped past the seal will still appear as a leak, however if the brakes are working correctly, further service/replacement is not necessary. Page 6-8 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 71: Brake Discs

    Burnish the new pads before initial vehicle operation. On a flat, open surface, accelerate the vehicle to moderate speed, then apply the brakes under modest, steady pressure. Repeat this procedure eight to twelve times. BRAKE DISCS See General Warnings on page 1-2. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 6-9...

  • Page 72: Disc Removal

    • To perform any of the following procedures, the hydraulic system must be opened. As a result, the brakes must be bled after the correct reinstallation of the brake components. Failure to bleed the WARNING CONTINUED ON NEXT PAGE Page 6-10 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 73: Front Brake Line Removal

    P-clamp on the frame and tighten the hardware to 85 in-lb (9.6 N·m). Install the two support brackets and tighten the hardware to 50 in-lb (5.6 N·m) (Figure 6-8, Page 6-12). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 6-11...

  • Page 74: Rear Brake Line Removal

    Remove the brake lines, banjo bolts and copper washers from each rear caliper assembly. See following NOTE. Page 6-12 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 75: Rear Brake Line Installation

    Fill the reservoir of the master cylinder and bleed the hydraulic system. See Bleeding the Hydraulic Brake System on page 6-15. Perform all of the brake system inspections. See Brake System Inspection on page 6-1. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 6-13...

  • Page 76: Master Cylinder And Reservoir

    Adjust the brake pedal stroke with the clevis and master cylinder push rod threaded connection. Tighten the jam nut to 14 ft-lb (19 N·m). See Brake Pedal Adjustment, Section 5, Page 5-3. Inspect the brake system. See Brake System Inspection on page 6-1. Page 6-14 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 77: Bleeding The Hydraulic Brake System

    NEVER mix DOT 3, DOT 4, or DOT 5.1 with DOT 5 as it IS NOT compatible. Place, but do not tighten, the cap on the master cylinder reservoir. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 6-15...
  • Page 78 Gently tap the caliper and the master cylinder with a plastic-tipped hammer and repeat the bleeding sequence. This will dislodge air bubbles that tend to accumulate, allowing for a more complete bleeding process. Page 6-16 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 79: Purging The Hydraulic System

    With the vacuum running, tighten the two top bleeder valves. Allow the handle on the brake bleeder tool to open, turning the vacuum system off. Repeat steps 1 through 4 for the two remaining wheels. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 6-17...

  • Page 80: Park Brake System

    NOTE: Adjust rear brake calipers and park brake before adjusting park brake cable. See Park Brake Adjustment – At Rear Calipers on page 6-18. Press on service brake pedal to ensure caliper pistons are set against rotor. Page 6-18 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 81: Park Brake Wheel Cables

    Remove the P-clamp and nylon wire tie securing the cable to the frame. Remove the C-clip securing the left rear cable sheath to the caliper bracket (Figure 6-11, Page 6-19). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 6-19...

  • Page 82: Front Park Brake Cable Removal - Cable Only System

    FRONT PARK BRAKE CABLE REMOVAL – CABLE ONLY SYSTEM Chock the rear wheels and release the park brake. Remove the spring (1) from the threaded adjustment rod (2) at the equalizer (Figure 6-14, Page 6-21). Page 6-20 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 83: Front Park Brake Cable Installation - Cable Only System

    Note the orientation of and remove the two nuts (1), cone washer (3) and cup washer (4) from the threaded adjustment rod (Figure 6-12, Page 6-19). Disconnect the rear park brake cables (6 and 8) from the equalizer (2) and remove the equalizer. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 6-21...

  • Page 84: Park Brake Equalizer Installation - Cable Only System

    Secure the spring (1) to the end of the threaded adjustment rod (2) and the chassis (Figure 6-14, Page 6-21). Adjust the brake cable equalizer. See Front Park Brake Cable Adjustment – Cable Only System on page 6-18. Page 6-22 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 85: Section 7 - Steering And Front Suspension

    6.4. Use a 1/2-inch drive air impact wrench to tighten the anvil screw (6) until the steering wheel releases from the steering shaft. 6.5. Remove the steering wheel from the steering column. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 7-1...

  • Page 86: Steering Wheel Installation

    Remove the three nuts from the steering column mount bolts. NOTE: Bolts are pressed into the steering column mount bracket. Remove the steering column, and pull the shaft up through the hole in the splash guard. Page 7-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 87: Steering Column Installation

    • Front impacts that bend tie rods and/or drag links can possibly damage internal steering gear components. See Rack and Pinion Inspection on page 7-4. The manufacturer recommends inspecting the rack and pinion and replacing if damaged. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 7-3...

  • Page 88: Rack And Pinion Inspection

    Apply a light coat of anti-seize lubricant to the splined portion of the pinion shaft to minimize corrosion. Position the rack and pinion base next to the mounting bracket, and install the four bolts. Tighten the hardware to 23 ft-lb (31 N·m) (Figure 7-6, Page 7-4). Page 7-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 89: Rack And Pinion Disassembly

    Remove the two outer ball joints from the drag links (Figure 7-7, Page 7-5). Remove both drag links (19) (Figure 7-8, Page 7-5). 2048 2049 Figure 7-7 Drag Link Ball Joint Figure 7-8 Drag Link 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 7-5...
  • Page 90 11. If the pinion ball bearing has been damaged, remove the C-type stop ring (16) (Figure 7-11, Page 7-6), and use a press to remove the bearing (Figure 7-13, Page 7-7). Page 7-6 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 91 13.3.Remove the ball joint from the rack. 14. Remove the rack (2) from the housing (1) (Figure 7-16, Page 7-8). 2055 2056 Figure 7-14 Secure Racks Figure 7-15 Remove Inner Ball Joints 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 7-7...
  • Page 92 Rack and Pinion STEERING AND FRONT SUSPENSION 2057 Figure 7-16 Steering Gear Assembly Page 7-8 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 93: Rack And Pinion Assembly

    Place a few drops of Loctite 222 on the threads of the screw (7) (Figure 7-18, Page 7-9). 10. Install the rack guide (5), pressure spring (6), and screw (7). Thread-in the screw until it bottoms out, and then unscrew it 1/4 turn (Figure 7-16, Page 7-8). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 7-9...

  • Page 94: Front Suspension

    • These vehicles historically have used a toe-in setting. At S/N 1309-347765, a change in front suspension components resulted in vehicles requiring toe-out unless the steering damper accessory is installed. All vehicles equipped with a steering damper must use a toe-in setting. Page 7-10 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 95 After the toe-in adjustment is complete, the steering wheel should be at the center of its travel. If not, remove and correct the position so it is as close to center as possible. See Steering Wheel Installation on page 7-2. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 7-11...
  • Page 96 See Steering Wheel Installation on page 7-2. Camber Measurement On a level, hard, and smooth surface roll the vehicle forward, then stop. Make sure the front wheels are pointed straight ahead. See following NOTE. Page 7-12 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 97 Check the measurement on the camber, and repeat steps 1 through 4 if necessary. Repeat steps 1 through 5 for the remaining front wheel. 2063 2062 Figure 7-26 Measure Camber Figure 7-27 Adjust Camber 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 7-13...

  • Page 98: Front Suspension Components

    Remove and discard the two hex-head bolts that secure the caliper assembly to the upright (Figure 7-29, Page 7-14). Rest the brake caliper on the A-arm. Ensure that there is no strain on the brake hose. See following WARNING. Page 7-14 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 99 15. Remove the upper ball joint from the upright (Figure 7-32, Page 7-15). See following NOTE and CAUTION. NOTE: It may be necessary to use a ball joint removal tool to separate the ball joint stud from the upright. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 7-15...

  • Page 100: Steering Upright Installation

    20. Align the front wheels. See Wheel Alignment on page 7-10. UPPER A-ARM REMOVAL Lift and support the front of vehicle and remove the wheels. See Lifting The Vehicle on page 3-8. Remove the brake line bracket from the A-arm. Page 7-16 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 101 Allow the Loctite to set up for at least 20 minutes before assembling the front suspension. See following NOTE. NOTE: The Loctite 641 will set in 20 minutes, thus allowing the vehicle to be driven, and will be completely cured in 24 hours. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 7-17...

  • Page 102: Upper A-Arm Installation

    Remove lower ball joint nut and separate lower ball joint from upright. Remove the bolt, washer, and flanged locknut from the lower A-arm and frame. Remove the A-arm from the frame and the bushings. Page 7-18 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 103: Lower A-Arm Installation

    NOTE: The urethane bushings fit tightly. It may be necessary to press them into place. Use the assembly bolts and large flat washers to draw the bushings together in the frame brackets. Slide the A-arm over the frame bushings, and locate the bolt alignment. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 7-19...

  • Page 104: Front Coil-Over Shock Absorber Removal

    Remove the bolt and flanged locknut from the top of the shock mount. Remove the shock absorber. Repeat steps for the remaining shock absorber. 1890 Figure 7-38 Jack Stand Placement 2073 2074 Figure 7-39 Front Shock Bottom Mount Figure 7-40 Front Shock Top Mount Page 7-20 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 105: Front Coil-Over Shock Absorber Installation

    Install the front tire and wheel. Finger-tighten the lug nuts. Raise the vehicle, and remove the jack stands. Tighten the lug nuts to 87 ft-lb (118 N·m). Repeat steps 1 through 6 for the remaining shock absorber. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 7-21...

  • Page 107: Section 8 - Wheels, Tires And Hubs

    • Inspect the brake hoses at all four wheels. The hoses should not come in contact with any component. • Check the park brake cables. The cables should not come in contact with the tires or wheels. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 8-1...

  • Page 108: Wheels

    Remove the tire and wheel assembly from the vehicle. See Wheel Removal on page 8-2. Remove the valve cap and valve core and allow air to escape from the tire. Use a tire machine to remove the tire from the wheel. Page 8-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 109: Tire Installation

    2.5. Use a rod or bar (8) slightly smaller than the inside diameter of the inner bearing race (7) and press the hub from the bearing. See following NOTE. NOTE: Bearings will be damaged when the hub is removed. Replace the bearings during reassembly. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 8-3...
  • Page 110 9/16 inch and block 3 height is 1-11/16 inch). 3.3. Make special bar (10), that fits inside cutouts of the bearing cavity opening (7), to rest on the outer race of the bearing. Press out bearing. Page 8-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 111: Front Hub Installation

    • Do not press against the lug bolts. Press only against the center of the hub. 2.2. Apply anti-seize compound to the hub shaft. 2.3. Position the upright (5) and bearing (7) onto the shaft of the hub as level as possible. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 8-5...

  • Page 112: Rear Hubs

    • Strain on the brake hose or the brake hose fittings can result in damage to the line or fittings and cause a leak in the hydraulic system, diminished brake performance, or brake failure. WARNING CONTINUED ON NEXT PAGE Page 8-6 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 113: Rear Hub Installation

    Inspect the brake pads for wear and replace if necessary. See Brake Disc and Pad Inspection on page 6-3. NOTE: If brake pads are replaced on one side, replace the opposite side also. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 8-7...
  • Page 114 13. Tighten the lug nuts to 85 ft-lb (115 N·m) using a crisscross pattern. 14. Connect battery and spark plug wire(s) (gasoline vehicles only). See Connecting the Battery – Gasoline/Diesel Vehicles on page 1-4. Page 8-8 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 115: Section 9 - Rear Suspension

    Remove the lock nut and bolt securing the rear shock absorber to the rear axle (Figure 9-1, Page 9-2). Discard lock nut. Remove the lock nut and bolt securing the rear shock absorber to the chassis. Discard lock nut. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 9-1...

  • Page 116: Rear Shock Installation

    If detached during removal, secure the brake hose and rubber grommet in the lower shock bracket. Install wheel and lower vehicle. See Wheel Installation on page 8-2. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline/Diesel Vehicles on page 1-4. Page 9-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 117: Trailing Arms And Lateral Links

    Tighten hardware at each end of link to 57 ft-lb (77 N·m). Install wheel and lower vehicle. See Wheel Installation on page 8-2. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline/Diesel Vehicles on page 1-4. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 9-3...
  • Page 118 Trailing Arms and Lateral Links REAR SUSPENSION 2495 Figure 9-2 Rear Suspension Components – 4 Link Page 9-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 119: Trailing Arm Removal

    Install wheel and lower vehicle. See Wheel Installation on page 8-2. Lower the cargo bed. See Body and Trim, Section 4, Page 4-1. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline/Diesel Vehicles on page 1-4. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 9-5...

  • Page 121: Section 10 - Periodic Maintenance

    See Draining Water from Fuel Filter on page 10-21. Check brake fluid; add if necessary. Check brake pedal for proper operation. See Brakes Performance Inspection in the vehicle owner’s manual. TABLE CONTINUED ON NEXT PAGE 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 10-1...
  • Page 122 Replace if necessary. Replace air filter element. See Air Filter Replacement on page 15-26. Engine air intake system Check clamps for tightness; check hose for cracks. TABLE CONTINUED ON NEXT PAGE Page 10-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 123 Replace. Dispose of used filters properly. Check safety decals. Replace if damaged or Safety decals illegible. Every 200 hours of operation by trained Inspect drive belt for cracks/damage. Replace Drive Belt technician only. if necessary. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 10-3...

  • Page 124: Periodic Service Schedule - Intellitach

    Check air pressure and adjust if necessary. Transmission and differentials Check lubricant levels. Add if necessary. Wash engine compartment and underside of General vehicle vehicle. Do not wash engine when hot. TABLE CONTINUED ON NEXT PAGE Page 10-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 125 • If any problems are found during scheduled inspection or service, do not operate vehicle until repairs are made. Failure to make necessary repairs could result in fire, property damage, severe personal injury, or death. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 10-5...

  • Page 126: Periodic Lubrication Schedule

    20 oz. (600 mL) Mobil 424, Exxon Hydraul whichever comes first Change transmission lubricant 560, or Esso Hydraul 56 lubricant (CC P/N AM1245401) 2080 Figure 10-1 Lubrication Points – Gasoline Vehicles Page 10-6 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 127 PERIODIC MAINTENANCE Periodic Lubrication Schedule Figure 10-2 Lubrication Points – Diesel Vehicles 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 10-7...

  • Page 128: Periodic Lubrication Schedule - Intellitach

    20 oz. (600 mL) Mobil 424, Exxon Hydraul whichever comes first Change transmission lubricant 560, or Esso Hydraul 56 lubricant (CC P/N AM1245401) Figure 10-3 Lubrication Points – Diesel Vehicles with Hydraulic Attachment Page 10-8 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 129: Lubricating The Attachment Arm And Interface - Intellitach

    2. Attachment Arm Pivot - vehicle side (both sides). 3. Attachment Arm Cylinder (both ends). 4. Attachment Arm Pivot - interface side (both sides). Figure 10-4 Lubricate Grease Zerks located on Cylinder and Attachment Arm Ends 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 10-9...

  • Page 130: Brake Fluid Reservoir

    Even though the low oil warning light on the instrument panel should illuminate if the oil level becomes low, the engine oil level should be checked daily. The vehicle should be on a level surface when the oil is checked. Do not overfill the engine with oil. Page 10-10 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 131: Oil Pressure - Gasoline Engine

    The engine oil and oil filter should be changed at the following intervals: • Kawasaki gasoline engine: after the first 10 hours of operation. • Kubota diesel engine: after the first 50 hours of operation. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 10-11...
  • Page 132 14.5 ft-lb (20 N·m) for gas vehicles or to 31 ft-lb (42 N·m) for diesel vehicles. Figure 10-9 Engine Oil Drain Plug and Pan – Gasoline Figure 10-10 Engine Oil Drain Plug and Oil Filter – Diesel Vehicles Vehicles Page 10-12 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 133 Install the new oil filter (gas: CC P/N 103887901) (diesel: CC P/N 102703301). See following NOTE. NOTE: Only use oil filters designed for this engine. Hand tighten 2/3 to 3/4 turn after the filter gasket contacts the mounting surface. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 10-13...

  • Page 134: Oil Viscosity

    Choose the viscosity according to the temperature as shown in the appropriate oil viscosity chart (Figure 10-16 or Figure 10-17). See following NOTE. NOTE: Use engine oil with API classification SJ for gasoline engines and CF for diesel engines. Page 10-14 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 135: Spark Plugs

    When the vehicle is on a level surface, use the level indicator hole (1) as a lubricant level indicator (Figure 10-18). Lubricant level should be even with the bottom of level indicator hole (1). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 10-15...

  • Page 136: Lubrication Change For Front Differential, Transmission And Rear Differential

    This is an established process and is not detrimental to gear service life. Dispose of used oil according to the environmental laws and regulations for your area. Page 10-16 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 137 (1) with specified oil type and volume. See Periodic Lubrication Schedule on page 10-6. Apply Loctite 567 to the threads of the fill plug (1) and tighten to 21 ft-lb (28 N·m). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 10-17...

  • Page 138: Hydraulic System - Intellitach Vehicle

    If hydraulic oil must be added, thoroughly clean the area around the fill cap. Remove the fill cap and add hydraulic fluid until it is between the Maximum Fluid Level and the Minimum Fluid Level lines. ENGINE COOLANT – DIESEL VEHICLES See General Warnings, Section 1, Page 1-2. Page 10-18 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 139: Engine Coolant Level Check

    • Diesel vehicles: Use only diesel fuel grade no. 2 with a cetane rating of 45 or higher. Replace the fuel cap. Ensure that the cap is tightened securely. Clean any spilled fuel from the cap or around the fuel cap area. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 10-19...

  • Page 140: Biodiesel Fuel (Diesel Vehicles Only)

    • Ensure that the fuel tank cap is securely tightened to prevent water from entering the fuel tank. • Drain all water from the fuel filter daily before operating vehicle. See Draining Water from Fuel Filter. Page 10-20 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 141: Draining Water From Fuel Filter

    To resupply the filter with fuel, turn the key switch to the ON position for 10 seconds. See following NOTE. NOTE: Dispose of water according to the environmental laws and regulations for your area. 2327 Figure 10-25 Fuel Filter with Water Separator 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 10-21...

  • Page 142: Battery

    Battery PERIODIC MAINTENANCE BATTERY For periodic battery maintenance, see Battery on page 13-18 (gasoline vehicles) or page 14-21 (diesel vehicles). Page 10-22 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 143: Section 11 - Troubleshooting And Electrical System: Gasoline Vehicles

    Diode 3 failed open 39 on page 11-20 Test Procedure 14 – Diode 5 on wire 131 and Diode 5 failed open 129 on page 11-21 TABLE CONTINUED ON NEXT PAGE 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 11-1...
  • Page 144 (CC P/N 103351201). Engine pre-ignites. Spark plug heat range is incorrect Spark Plugs on page 10-15 Unsuitable or contaminated fuel Fuel System on page 15-8 TABLE CONTINUED ON NEXT PAGE Page 11-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 145 See the Kawasaki FH680D engine manual Carburetor vent is clogged (CC P/N 103351201). See the Kawasaki FH680D engine manual Float needle valve not functioning properly (CC P/N 103351201). TABLE CONTINUED ON NEXT PAGE 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 11-3...
  • Page 146 Gearcase Lubrication on page 10-15 type of lubricant in transmission See the Engines and Drivetrain Components Internal gears are damaged or worn manual (CC P/N 102396501). TABLE CONTINUED ON NEXT PAGE Page 11-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 147 Test Procedure 36 – Bed Lift Switch on page Bed lift does not function Bed lift switch failed 11-37 Test Procedure 37 – Bed Lift Circuit Breaker Bed lift circuit breaker failed on page 11-37 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 11-5...

  • Page 148: Wiring Diagram

    WIRING DIAGRAM DIODE 3 DIODE 2 DIODE 1 FRONT DIFFERENT IAL LIMIT SWITCH WD1033057-7-L NOTE: AWD diagram shown; 2-wheel drive vehicle uses same harness Figure 11-1 Wiring Diagram – Front Page 11-6 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 149 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Wiring Diagram DIODE 4 DIODE 5 WD1033057-7-R NOTE: AWD diagram shown; 2-wheel drive vehicle uses same harness Figure 11-2 Wiring Diagram – Rear 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 11-7...

  • Page 150: Test Procedures

    • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area. Ventilate when charging or using in an enclosed space. Wear a full face shield and DANGER CONTINUED ON NEXT PAGE Page 11-8 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 151 (Figure 11-3, Page 11-10). Record the reading. 10. Return the electrolyte to the cell from which it was taken. Replace vent cap. 11. Repeat steps 4 through 10 on all cells. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 11-9...
  • Page 152 50 points. Open-circuit voltage, the battery voltage with no electrical load, should be at least 12.4 volts. Page 11-10 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 153 • If a fuse is blown, determine the cause of the failure and make necessary repairs before installing a new fuse. Use the appropriately rated fuse; if a fuse with a higher amp rating is used, damage to the vehicle electrical system may occur. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 11-11...
  • Page 154 The readings obtained in the previous steps should indicate continuity. If any of the readings are incorrect, clean and tighten wire connections. If the connections are good and the reading is incorrect, repair or replace the wire. Page 11-12 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 155 TEST PROCEDURE 5 – Key Switch (Starter Circuit) See General Warnings, Section 1, Page 1-2. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 11-13...
  • Page 156 – Check the 25-amp fuse at the fuse block. See Test Procedure 2 – Fuse on page 11-11. – Check the start relay. See Test Procedure 7 – Start Relay on page 11-15. Page 11-14 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 157 The multimeter should indicate continuity when the key is in the START position. 7.4. If the multimeter does not indicate continuity while the key is in the START position and the relay clicks, the contacts have failed. Replace the relay. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 11-15...
  • Page 158 Monitor the multimeter. The reading should indicate 0 volts with the key off. The reading should indicate approximately 12 VDC with the key on. If the reading is 12 VDC and the relay does not click when the engine starts, replace the relay. Page 11-16 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 159 – Check the neutral switch on the transmission housing. See Test Procedure 15 – Neutral Switch (Transmission) on page 11-23. – Check for continuity of the wire harness on wires w139, w135, and w47. See Wiring Diagram on page 11-6. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 11-17...
  • Page 160 The wire harness is equipped with several in-line diodes. The following table describes each diode’s function in the electrical system, the location in the wire harness, and the symptom(s) of a diode failure. Page 11-18 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 161 Harness Diode Removal on page 13-18. Reverse the multimeter probes and note the reading. The multimeter should indicate approximately 540 mV, however, a range of 400 to 700 mV is acceptable. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 11-19...
  • Page 162 Disconnect the bullet connector in the carburetor solenoid green wire (Figure 11-15, Page 11-20). Disconnect the 18-gauge purple wire (w42) from the oil light. Disconnect the 18-gauge blue wire (w25) from the fuel gauge/hour meter. Page 11-20 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 163 The reading should indicate an over limit (no continuity). If the diode conducts current (shows continuity) with the meter probes connected as described, the diode has failed and must be replaced. See Wire Harness Diode Removal on page 13-18. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 11-21...
  • Page 164 400 to 700 mV is acceptable. 10. If the readings obtained in the previous steps are incorrect, replace the diode. See Wire Harness Diode Removal on page 13-18. Page 11-22 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 165 Figure 11-19 Neutral Switch – Reverse Position Check for continuity on the switch contacts with the Forward/Reverse handle in the NEUTRAL position (Figure 11-18, Page 11-23). The multimeter should indicate continuity. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 11-23...
  • Page 166 The front differential limit switch is located under the hood where the accelerator pedal mounts to the chassis. 2363 Figure 11-20 Front Differential Switch Disable the vehicle. See Disabling the Vehicle on page 1-3. Page 11-24 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 167 If the resistance is high, or the multimeter indicates an over limit (no continuity), the coil has failed. See the Kawasaki FH680D engine manual (CC P/N 103351201). 2095 Figure 11-21 Charge Coil Test (At Voltage Regulator Multi-Pin Connector) 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 11-25...
  • Page 168 Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. Disconnect the six wire engine harness connector located near the starter (Figure 11-22, Page 11-27). Page 11-26 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 169 If the engine does not run, connect the black wire at the bullet connector located near the starter and proceed to Test Procedure 21 – Ignition Spark on page 11-26. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 11-27...
  • Page 170 Place the Forward/Reverse handle in the REVERSE position to activate the limit switch. The multimeter should indicate continuity when the limit switch lever is activated. If either reading is incorrect, replace the limit switch (Figure 11-24, Page 11-28). Page 11-28 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 171 (ground) (Figure 11-25, Page 11-30). The resistance should be approximately 30 ohms. 2.4. If the resistance reading is incorrect, replace the solenoid coil. See the Kawasaki FH680D engine manual (CC P/N 103351201). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 11-29...
  • Page 172 (w47) at the key switch, replace the low oil warning light. See Warning Light Removal on page 13-6. 11. If the problem is not corrected by performing the previous steps, test the oil pressure switch. See the Kawasaki FH680D engine manual (CC P/N 103351201). Page 11-30 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 173 Make sure the float is at the surface of the fuel in the tank. TABLE CONTINUED ON NEXT PAGE 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 11-31...
  • Page 174 Turn the key switch ON. The voltage reading should be the same as the battery voltage reading recorded earlier. If not, check the continuity of the blue and black wires (Figure 11-28, Page 11-33). Page 11-32 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 175 Test Procedure 2 – Fuse on page 11-11. Disable the vehicle. See Disabling the Vehicle on page 1-3. Remove the light switch from the instrument panel. See Light Switch Removal on page 13-11. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 11-33...
  • Page 176 Use a multimeter set to 20 volts DC and place the black (–) probe into the black wire terminal of the wire harness. Place the red (+) probe into the blue wire terminal. Pull the light switch to the ON position. If the multimeter indicates approximately 12 volts, replace the headlight bulb. Page 11-34 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 177 Check the continuity of the headlight jumper harness wires. If the readings are correct in all of the previous steps, replace the headlight bulb. 2101 Figure 11-32 Bed Lift Motor Wires 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 11-35...
  • Page 178 If the bed lift motor does not function and the readings obtained in the previous steps are correct, the bed lift motor has failed and must be replaced. See Bed Lift Motor Removal, Section 4, Page 4-12. Page 11-36 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 179 Place the red probe of the multimeter on the circuit breaker terminals. If the multimeter does not indicate continuity, replace the circuit breaker. See Bed Lift Circuit Breaker Installation on page 13-10. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 11-37...

  • Page 181: Section 12 - Troubleshooting And Electrical System: Diesel Vehicles

    (CC P/N 103840201). broken, or valve seized Improper valve timing Piston ring worn Cylinder compression leak Fuel cam shaft worn Seizure of crankshaft, camshaft, piston, or bearing TABLE CONTINUED ON NEXT PAGE 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-1...
  • Page 182 Clutches are not backshifting properly Clutches on page 16-24 Low cylinder compression See the Kubota D722 diesel engine manual Incorrect injection timing (CC P/N 103840201). Seized engine parts TABLE CONTINUED ON NEXT PAGE Page 12-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 183 Failed thermostat See the Kubota D722 diesel engine manual (CC P/N 103840201). Failed water pump Vehicle is overloaded Do not overload vehicle. See owner’s manual. TABLE CONTINUED ON NEXT PAGE 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-3...
  • Page 184 Gearcase Lubrication on page 10-15 type of lubricant in transmission See the Engines and Drivetrain Components Internal gears are damaged or worn manual (CCI P/N 102396501). TABLE CONTINUED ON NEXT PAGE Page 12-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 185 Test Procedure 37 – Bed Lift Switch on page Bed lift does not function Bed lift switch failed 12-42 Test Procedure 38 – Bed Lift Circuit Breaker Bed lift circuit breaker failed on page 12-43 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-5...

  • Page 186: Wiring Diagram

    TROUBLESHOOTING AND ELECTRICAL Wiring Diagram SYSTEM: DIESEL VEHICLES WIRING DIAGRAM FUEL GAUGE/ HOUR METER FRONT DIFFERENTIAL LIMIT S WITCH WD1032775E7-L Figure 12-1 Wiring Diagram for Diesel Utility Vehicles (Front) Page 12-6 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 187 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Wiring Diagram LIGHTING RELAY WD1032775E7-R Figure 12-2 Wiring Diagram for Diesel Utility Vehicles (Rear) 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-7...
  • Page 188 TROUBLESHOOTING AND ELECTRICAL Wiring Diagram SYSTEM: DIESEL VEHICLES WD1033181B3 Figure 12-3 Main Light Wiring Diagram – Carryall 295 Homologated Vehicle Page 12-8 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 189 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Wiring Diagram WD1033173B4 Figure 12-4 High Beam Wiring Diagram – Carryall 295 Homologated Vehicle 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-9...

  • Page 190: Test Procedures

    See General Warnings, Section 1, Page 1-2. DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working around a battery. DANGER CONTINUED ON NEXT PAGE Page 12-10 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 191 (Figure 12-5, Page 12-12). Record the reading. 10. Return the electrolyte to the cell from which it was taken. Replace vent cap. 11. Repeat steps 4 through 10 on all cells. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-11...
  • Page 192 50 points. Open-circuit voltage, the battery voltage with no electrical load, should be at least 12.4 volts. Page 12-12 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 193 • If a fuse is blown, determine the cause of the failure and make necessary repairs before installing a new fuse. Use the appropriately rated fuse; if a fuse with a higher amp rating is used, damage to the vehicle electrical system may occur. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-13...
  • Page 194 The readings obtained in the previous steps should indicate continuity. If any of the readings are incorrect, clean and tighten wire connections. If the connections are good and the reading is incorrect, repair or replace the wire. Page 12-14 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 195 START, the key switch has failed and should be replaced. See Key Switch Removal on page 14-7. REAR VIEW FRONT VIEW Continuity Diagram Key Position PRE- START HEAT 2108 Figure 12-10 Key Switch Terminals and Continuity Diagram Check the B and I terminals. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-15...
  • Page 196 5.2. If the multimeter indicates continuity between the B and A terminals with the key in any position other than PREHEAT, the key switch has failed and should be replaced. See Key Switch Removal on page 14-7. Page 12-16 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 197 – Check for continuity of the wire harness on wires 127, 128, 147, and 109. See Wiring Diagram on page 12-6. If none of the previous steps resolves the problem, the starter solenoid and/or starter motor has failed. See the Kubota D722 diesel engine manual (CC P/N 103840201). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-17...
  • Page 198 If the reading obtained in step 5 is not 12 VDC with the key in the START position, perform the following test procedures: – Check battery. See Test Procedure 1 – Battery on page 12-10. Page 12-18 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 199 4.3. Turn the key switch ON. The relay should click, the fan should run and the meter should indicate continuity. See following NOTE. If not, replace the relay. NOTE: The start and accessory relays may be removed temporarily to isolate the sound of the fan relay click. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-19...
  • Page 200 • Hot! Coolant system is pressurized. Do not remove thermostat switch while engine is hot. Disconnect the two-pin connector between the thermostat switch and the wire harness (Figure 12-17, Page 12-21). Test for failed switches in closed condition. Page 12-20 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 201 Discard the failed thermostat switch and install a new one. See Thermostat Switch Installation on page 14-19. 6.9. Turn off the stove. See following WARNING. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-21...
  • Page 202 Set a multimeter to measure 20 VDC. Place the multimeter probes into each terminal of the two-pin connector disconnected from the fan motor (wire harness side). Page 12-22 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 203 – Key switch. See Test Procedure 5 – Key Switch (ON Position) on page 12-16. – Connections and wire continuity for wires w112, w44, w52, w51, w107, w109, w114, w146, w125, w24, and w48. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-23...
  • Page 204 Differential solenoid coil flyback diode With key switch ON, the 30-amp fuse Closed (on w125) will blow repeatedly until the diode has been replaced. TABLE CONTINUED ON NEXT PAGE Page 12-24 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 205 Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Raise the hood. Disconnect the two-pin connector between the fan and the wire harness (Figure 12-19, Page 12-23). Set the multimeter to the diode test function. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-25...
  • Page 206 12-23, Page 12-27). Disconnect the bullet connector, on the gray wire (w140), between the fuel pump and the wire harness (Figure 12-24, Page 12-27). Set the multimeter to the diode test function. Page 12-26 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 207 400 to 700 mV is acceptable. If the readings obtained in the previous steps are incorrect, replace the diode. See Wire Harness Diode Removal on page 14-20. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-27...
  • Page 208 12-27, Page 12-29). The multimeter should indicate no continuity. If any of the continuity readings are incorrect, replace the neutral switch. See Neutral Switch Removal on page 14-2. 2091 Figure 12-25 Neutral Switch – Forward Position Page 12-28 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 209 The front differential limit switch is located under the hood where the accelerator pedal mounts to the chassis. Disable the vehicle. See Disabling the Vehicle on page 1-3. Check for proper wiring and tight connections at the front differential limit switch (Figure 12-28, Page 12-30). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-29...
  • Page 210 The resistance should be 24.7 to 27.3 ohms. If the resistance is not within the stated range, replace the large output cover sub-assembly. See the Engines and Drivetrain Components manual (CC P/N 102396501). Page 12-30 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 211 Ensure that the nuts securing the link to the alternator and the large post of the starter solenoid are connected correctly and are tight. If they are not, rewire or tighten as necessary. Set the multimeter to 20 VDC. Place the black (–) probe on the frame (ground). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-31...
  • Page 212 If the voltage reading is approximately 12 VDC with the key switch in the OFF position, check the key switch for proper wiring and function. See Test Procedure 5 – Key Switch (ON Position) on page 12-16. Page 12-32 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 213 – Key Switch. See Test Procedure 6 – Key Switch (Glow Plug Circuit) on page 12-16. – Wire continuity of wires w125, w24, w26, w47, and w137. See Test Procedure 18 – Wire Continuity on page 12-29. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-33...
  • Page 214 See Wiring Diagram on page 12-6. If the buzzer does not function when properly wired, replace the buzzer. See Reverse Warning Buzzer Removal on page 14-11. Page 12-34 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 215 – Battery. See Test Procedure 1 – Battery on page 12-10. – 30-amp fuse on w125. See Test Procedure 2 – Fuse on page 12-13. – Key switch. See Test Procedure 5 – Key Switch (ON Position) on page 12-16. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-35...
  • Page 216 If the voltage is not approximately 12 VDC, check the 10-amp fuse on orange/white wire (w115) located on the electrical component mounting plate. See Test Procedure 2 – Fuse on page 12-13. If the fuse is good, check the continuity of the wires connected to the accessory receptacle. Page 12-36 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 217 If the readings are correct according to the position of the float, but the reading on the fuel gauge/hour meter is incorrect, test the fuel gauge/hour meter. See Test Procedure 32 – Fuel Gauge on page 12-38. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-37...
  • Page 218 1. 20 VDC Setting 2. Orange 3. Black 4. White 5. Blue 1. 20 VDC Setting 2. Orange Figure 12-35 Fuel Gauge Voltage Test - Terminal 2 Figure 12-36 Fuel Gauge Voltage Test - Terminal 4 Page 12-38 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 219 See Test Procedure 2 – Fuse on page 12-13. If the wires and fuse show continuity and the readings are still incorrect, replace the switch. See Light Switch Removal on page 14-10. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-39...
  • Page 220 (+) probe onto the positive (+) battery terminal. If the multimeter reading is approximately 12 volts, the black wire has continuity. If the readings are correct in all of the previous steps, replace the headlight bulb. Page 12-40 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 221 If the bed lift motor does not function and the readings obtained in the previous steps are correct, the bed lift motor has failed and must be replaced. See Bed Lift Motor Removal, Section 4, Page 4-12. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-41...
  • Page 222 1. #14 Black w2 2. #14 Red w3 4. #14 Red w7 5. #14 Red w7 6. #14 Yellow w5 8. #14 Black w2 2104 Figure 12-42 Bed Lift Switch Terminals (Rear View) Page 12-42 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 223 Place the red probe of the multimeter on the circuit breaker terminals. If the multimeter does not indicate continuity, replace the circuit breaker. See Bed Lift Circuit Breaker Installation on page 14-9. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 12-43...

  • Page 225: Section 13 - Electrical Components: Gasoline Vehicles

    See Test Procedure 7 – Start Relay on page 11-15. See also Test Procedure 8 – Carburetor Heater Relay on page 11-16. 2126 2127 Figure 13-1 Relays Figure 13-2 Neutral Switch 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 13-1...

  • Page 226: Relay Removal

    Install the neutral switch to the transmission housing. Tighten the hardware to 20.5 ft-lb (27.8 N·m). Connect the two-pin connector between the neutral switch and the wire harness. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. Page 13-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 227: Carburetor Solenoid

    Connect the two-pin connector to the carburetor solenoid (Figure 13-3, Page 13-3). Install the engine front cover. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 13-3...

  • Page 228: Carburetor Heater

    Connect the green wire to the heater (Figure 13-4, Page 13-4). Install the engine top cover. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. Page 13-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 229: Voltage Regulator

    With the Forward/Reverse handle in NEUTRAL, start the engine and check the regulator for proper functioning as described in the voltage regulator test procedure. See Test Procedure 20 – Voltage Regulator on page 11-26. 2130 Figure 13-5 Voltage Regulator 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 13-5...

  • Page 230: Warning Lights

    Reconnect the wires from the wire harness to the warning light. Lower and secure the hood. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. Page 13-6 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 231: Fuel Gauge/Hour Meter

    Remove the mounting clip (3) that secures the gauge/meter. Alternate pulling the lower and upper tabs away from the gauge housing to remove clip. Pull gauge/meter from the instrument panel. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 13-7...

  • Page 232: Fuel Gauge/Hour Meter Installation

    From under the hood, connect the multi-pin connector to the key switch. Lower and secure the hood. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. Page 13-8 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 233: 12-Volt Accessory Receptacle

    Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. BED LIFT SWITCH TESTING THE BED LIFT SWITCH See Test Procedure 36 – Bed Lift Switch on page 11-37. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 13-9...

  • Page 234: Bed Lift Switch Removal

    Pull the circuit breaker out of the in-line fuse holder to remove. BED LIFT CIRCUIT BREAKER INSTALLATION Install the circuit breaker in the reverse order of removal. LIGHT SWITCH See General Warnings, Section 1, Page 1-2. Page 13-10 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 235: Testing The Light Switch

    Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. Remove the electrical component cover (located near the battery) and remove the fuse from the fuse block. FUSE INSTALLATION Install the fuse. See following WARNING. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 13-11...

  • Page 236: Reverse Warning Buzzer (If Equipped)

    Remove the plastic rivets securing the reverse warning buzzer and remove the reverse warning buzzer (Figure 13-7, Page 13-12). 2098 Figure 13-7 Reverse Warning Buzzer and Limit Switch REVERSE WARNING BUZZER INSTALLATION Install the reverse warning buzzer and secure it with two plastic rivets. Page 13-12 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 237: Reverse Warning Buzzer Limit Switch (If Equipped)

    Adjustment Slot (Properly Adjusted) REVERSE WARNING BUZZER LIMIT SWITCH INSTALLATION Install the reverse warning buzzer limit switch in the reverse order of removal. Place the Forward/Reverse handle in the REVERSE position. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 13-13...

  • Page 238: Front Differential Limit Switch

    Locate front differential limit switch above accelerator pedal. Disconnect wire leads of switch (1) from wire harness (Figure 13-10, Page 13-15). Remove the nuts (2) and screws (3) that secure the switch (1) and remove the switch. Page 13-14 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 239: Front Differential Limit Switch Installation

    See General Warnings, Section 1, Page 1-2. Thoroughly test the fuel level sending unit before replacing the unit. TESTING THE FUEL LEVEL SENDING UNIT See Test Procedure 30 – Fuel Level Sending Unit on page 11-31. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 13-15...

  • Page 240: Fuel Level Sending Unit Removal

    Refer to the engine manual for additional testing, removal, disassembly, and installation procedures. See the Kawasaki FH680D engine manual (CC P/N 103351201). HEADLIGHTS See General Warnings, Section 1, Page 1-2. Page 13-16 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 241: Testing The Headlight Bulb And Socket

    Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. WIRE HARNESS DIODES See General Warnings, Section 1, Page 1-2. The wire harness is equipped with several in-line diodes. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 13-17...

  • Page 242: Testing The Wire Harness Diodes

    For added protection, cover top of the battery when servicing the vehicle. • Battery – Poison! Contains acid! Causes severe burns! Avoid contact with skin, eyes, or clothing. DANGER CONTINUED ON NEXT PAGE Page 13-18 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 243: General Information

    Hot weather also has an effect on a battery’s self-discharge rate. The higher the temperature, the quicker a battery will discharge. Therefore, the battery should be checked more often in hotter climates. When storing the battery, keep it in a cool place. See Battery Storage on page 13-21. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 13-19...

  • Page 244: Water Level

    45° angle when lifting, carrying or installing battery. The battery acid could cause severe personal injury when accidentally coming in contact with the skin or eyes and could damage clothing. Page 13-20 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 245: Charging The Battery

    Check the state of charge periodically. A battery that is discharged and left in a cold environment can freeze and crack. If the specific gravity drops below 1.220, the battery should be recharged. See following WARNING. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 13-21...

  • Page 246: Charging A Dead Battery

    The charge coil is not designed to charge a dead battery. If the vehicle battery has become discharged, it must be charged with a properly rated automotive type charger. See following WARNING. WARNING • Do not jump-start a dead battery with another battery and jumper cables. Page 13-22 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 247: Section 14 - Electrical Components: Diesel Vehicles

    See Test Procedure 8 – Start Relay on page 12-18. See also Test Procedure 9 – Fan Relay on page 12-19. 2134 2135 Figure 14-1 Relays Figure 14-2 Neutral Switch 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 14-1...

  • Page 248: Relay Removal

    Install the neutral switch to the transmission housing. Tighten to 20.5 ft-lb (27.8 N·m). Connect the two-pin connector between the neutral switch and the wire harness. Connect battery. See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. Page 14-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 249: Fuel Solenoid

    Secure the wire lead bracket to the engine with two bolts and tighten firmly. Connect the three-pin connector from the fuel solenoid to the wire harness (Figure 14-3, Page 14-3). Connect battery. See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 14-3...

  • Page 250: 60-Amp Fusible Link

    Attach the other end of the fusible link wire assembly (1) to the alternator and secure with nut (3) (Figure 14-5, Page 14-4). Tighten the nut to 84 in-lb (9.5 N·m) and move the terminal cover (2) over the connection. Page 14-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 251: Warning Lights

    14-6, Page 14-6). Reconnect the wires from the wire harness to the warning light. Lower and secure the hood. Connect battery. See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 14-5...

  • Page 252: Fuel Gauge/Hour Meter

    The hour meter displays the number of hours of use in increments of 0.1 (one tenth) hour, but does not record additional time unless the key switch is in the ON position and the engine is on. When recording, the hourglass icon blinks. Page 14-6 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 253: Fuel Gauge/Hour Meter Removal

    14-6). Pull the key switch, with spacer (8), from the back side of the instrument panel. KEY SWITCH INSTALLATION Place spacer on key switch and reverse the removal procedure to install switch in the instrument panel. Tighten the key switch nut firmly. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 14-7...

  • Page 254: 12-Volt Accessory Receptacle

    From under the hood, connect the the wires to the accessory receptacle. Lower and secure the hood. Connect battery. See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. Page 14-8 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 255: Bed Lift Switch

    14-6, Page 14-6). Pull the circuit breaker out of the in-line fuse holder to remove. BED LIFT CIRCUIT BREAKER INSTALLATION Install the circuit breaker in the reverse order of removal. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 14-9...

  • Page 256: Light Switch

    FUSE REMOVAL Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Remove the electrical component cover (located near the battery). Remove the fuse from the fuse block. Page 14-10 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 257: Fuse Installation

    Raise the hood. Remove the plastic rivets securing the reverse warning buzzer and remove the reverse warning buzzer (Figure 14-7, Page 14-11). 2098 Figure 14-7 Reverse Warning Buzzer and Limit Switch 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 14-11...

  • Page 258: Reverse Warning Buzzer Installation

    Figure 14-9 Reverse Warning Buzzer Limit Switch Adjustment Slot (Properly Adjusted) REVERSE WARNING BUZZER LIMIT SWITCH INSTALLATION Install the reverse warning buzzer limit switch in the reverse order of removal. Page 14-12 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 259: Front Differential Limit Switch

    Locate front differential limit switch above accelerator pedal. Disconnect wire leads of switch (1) from wire harness (Figure 14-10, Page 14-14). Remove the nuts (2) and screws (3) that secure the switch (1) and remove the switch. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 14-13...

  • Page 260: Front Differential Limit Switch Installation

    See General Warnings, Section 1, Page 1-2. Thoroughly test the fuel level sending unit before replacing the unit. TESTING THE FUEL LEVEL SENDING UNIT See Test Procedure 31 – Fuel Level Sending Unit on page 12-37. Page 14-14 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 261: Fuel Level Sending Unit Removal

    Loosen and remove the belt tension adjustment bolt at the top of the alternator (Figure 14-13, Page 14-16). Loosen and remove the alternator mounting bolt at the bottom of the alternator (Figure 14-14, Page 14-16). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 14-15...

  • Page 262: Alternator And V-Belt Installation

    Connect the 12-gauge blue fusible link to the alternator (Figure 14-12, Page 14-15). Tighten the nut to 84 in-lb (9.5 N·m). Connect the 18-gauge purple wire to the alternator (Figure 14-11, Page 14-15). Connect battery. See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. Page 14-16 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 263: Oil Pressure Sensor

    Figure 14-15 Headlight Bulb HEADLIGHT BULB INSTALLATION NOTE: When handling halogen bulbs, do not touch the glass portion of bulb. Oil from finger tips can cause premature failure of the bulb. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 14-17...

  • Page 264: Thermostat Switch

    • Hot! Coolant system is pressurized. Do not remove thermostat switch while engine is hot. Loosen the radiator cap to relieve pressure. Unscrew the thermostat switch from the engine block. See preceding WARNING. 2147 Figure 14-16 Thermostat Switch Page 14-18 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 265: Thermostat Switch Installation

    (Figure 14-17, Page 14-20). See following NOTE. NOTE: To aid reassembly, note the orientation of the electric fan assembly on the fan shroud, particularly the wire lead of the motor. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 14-19...

  • Page 266: Fan Installation

    Note the polarity of the diode, as indicated by the silver stripe on one end of the diode, and mark the wire on the side of the silver stripe. Cut the wires attached to each side of the diode and discard the diode. Page 14-20 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 267: Wire Harness Diode Installation

    8-1/4 inches W x 6-1/2 inches D x 7-1/4 inches H (21.0 cm W x 16.5 cm D x 18.4 cm H). It is important to use the proper size to ensure that the battery clamp will fit correctly. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 14-21...

  • Page 268: Testing The Battery

    For the longest battery life, distilled water should be used in the battery. However, if tap water is going to be used, contact your local water department to be sure mineral contents are below the levels listed in the following table. See following NOTE. Page 14-22 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 269: Battery Removal

    • Do not disconnect the charger DC leads from the battery when the charger is on. The resulting arcing between the DC leads and battery post could cause an explosion. WARNING CONTINUED ON NEXT PAGE 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 14-23...

  • Page 270: Battery Installation

    The charge coil is not designed to charge a dead battery. If the vehicle battery has become discharged, it must be charged with a properly rated automotive type charger. See following WARNING. Page 14-24 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 271 ELECTRICAL COMPONENTS: DIESEL VEHICLES Battery WARNING • Do not jump-start a dead battery with another battery and jumper cables. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 14-25...

  • Page 273: Section 15 - Gasoline Engine, Muffler, Fuel System, And Clutches

    • Gasoline! Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. 10. Remove the choke cable. See Choke Cable Removal on page 15-21. 11. Remove the engine air inlet hose (4). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 15-1...
  • Page 274 GASOLINE ENGINE, MUFFLER, FUEL Gasoline Engine SYSTEM, AND CLUTCHES 2573 Figure 15-1 Engine Removal and Installation Components Page 15-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 275: Engine Installation

    (10) (Figure 15-1, Page 15-2). Secure the engine oil inlet and outlet hoses to the engine ports with new clamps. See Oil Filter Hose Installation on page 15-5. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 15-3...
  • Page 276 • Gasoline! Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. 19. Open the fuel valve on the fuel tank. 20. Install the engine top cover (1) and tighten the four bolts to 35 in-lb (4 N·m). Page 15-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 277: Oil Filter Hoses

    NOTE: Make sure the outlet port on the engine is connected to the inlet port on the oil filter and the outlet port of the oil filter is connected to the inlet port on the engine. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 15-5...

  • Page 278: Exhaust System

    Figure 15-4 Muffler Bracket and Inlet Pipe INTERMEDIATE PIPE REMOVAL Loosen the muffler spring suspension bracket bolts. Remove the springs from the intermediate pipe and muffler inlet. See following WARNING and NOTE. Page 15-6 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 279: Intermediate Pipe Installation

    See following DANGER. DANGER • The engine produces carbon monoxide, which is an odorless, deadly poison. Do not operate the engine in an enclosed area without proper ventilation. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 15-7...

  • Page 280: Fuel System

    ** A 3/16 inch -to- 1/4 inch flared vent hose connected the fuel tank to the carbon canister. During 2012 model year, a running change to a 1/4 inch tank vent nipple eliminated the need for the flared end. 2695 Figure 15-5 Fuel and Evaporative Emission System Page 15-8 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 281: Fuel Lines

    • Fuel pump. See the Kawasaki FH680D engine manual (CC P/N 103351201). • Fuel lines (from fuel tank to filter to pump to carburetor). See Fuel Lines on page 15-9. • Exhaust system (for restrictions). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 15-9...
  • Page 282 3300-6600 FT. 6600 FT. AND HIGHER NUMBER 0-3300 FT. (0-1000 M) MODEL/REVISION (1000-2000 M) (2000 M AND HIGHER) 47007 AS09, BS09 102/102 99/99 96/96 47038 TABLE CONTINUED ON NEXT PAGE Page 15-10 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 283 3300-6600 FT. 6600 FT. AND HIGHER NUMBER 0-3300 FT. (0-1000 M) MODEL/REVISION (1000-2000 M) (2000 M AND HIGHER) CS09 47050 Left: 102 99/99 96/96 Right: 104 DS09 to current 40755 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 15-11...

  • Page 284: Fuel Level Sending Unit

    Remove the hex-head plastic thread screw (10) securing the black ground wire (6) to the fuel level sending unit and remove the black ground wire. Retain the hardware. Remove the four remaining hex-head plastic thread screws from the fuel level sending unit flange (5). Retain the hardware. Page 15-12 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 285 NOTE: The fuel level sending unit mounts to the fuel tank only one way. If the unit does not fit on the fuel tank correctly, adjust the unit until it is properly aligned with the fuel tank. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 15-13...
  • Page 286 Tighten the hardware to 17 in-lb (1.9 N·m) and secure the rubber boot (8) to the center post. Install the passenger seat. See Seat Installation, Section 4, Page 4-10. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. Page 15-14 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 287: Fuel Tank

    11. Use a siphon with a built-in suction device to siphon all fuel from the tank and into an approved container. See following DANGER and WARNING. DANGER • Gasoline! Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 15-15...
  • Page 288 Install the seat frame on the vehicle frame. Secure the seat side plates with bolts, flat washers, and flanged locknuts. Tighten the nut to 37 ft-lb (50 N·m). 10. Install the top portion of the ROPS. See ROPS Installation, Section 4, Page 4-8. Page 15-16 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 289 17.1.Check all clamps at the carburetor, fuel filters, fuel pump, and fuel tank for leaks. 17.2.Inspect each fuel line to ensure that the lines are not cracked, cut, or worn. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 15-17...

  • Page 290: Carbon Canister

    Align canister mounting tabs with slots in mounting bracket and push/pull the canister into bracket (Figure 15-12, Page 15-18). Force it in until fully seated. Attach hoses to appropriate locations on carbon canister and secure with hose clamps. Lower cargo bed. Page 15-18 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 291: Fuel Shut-Off Valve

    (OFF) position during vehicle storage, towing or trailering, and maintenance and service (Figure 15-13, Page 15-19). 1. Fuel Shut-off Valve 2. Closed (OFF) 3. Open (ON) NOTE: When selecting valve position, ensure that it is fully opened or fully closed. Figure 15-13 Fuel Shut-off Valve 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 15-19...

  • Page 292: Engine Control Linkages

    Remove the accelerator cable from the plastic retaining clips under the passenger side of the frame and pull the cable at the dashboard away from the engine compartment. See following NOTE. Page 15-20 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 293: Choke Cable

    NOTE: Tie a heavy nylon cord to the cable end before removing the cable. When removing the cable, allow the cord to travel from the engine compartment up through the instrument panel hole. Use the cord to route the cable during installation. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 15-21...
  • Page 294 11. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. 12. Install the center seat plate (bucket seat vehicles only). 13. Install seat(s). 14. Lower and secure the hood. Page 15-22 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 295: Engine Governor Arm

    Figure 15-18 Governor Arm Engine Governor Arm Removal and Installation Refer to the engine manual for additional testing, removal, disassembly, and installation procedures. See the Kawasaki FH680D engine manual (CC P/N 103351201). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 15-23...

  • Page 296: Engine Rpm Adjustment

    NOTE: With engine at operating temperature and idling at specified RPM, it is normal to have a small gap between the throttle lever (5) and carburetor idle stop screw (1) (Figure 15-20, Page 15-25). Page 15-24 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 297 Adjust the high-speed RPM screw (3) until the tachometer displays 3825 ±25 RPM (Figure 15-21, Page 15-25). See following NOTE. NOTE: Turn the screw counterclockwise to raise the RPM and clockwise to lower the RPM. Release the accelerator pedal. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 15-25...

  • Page 298: Air Intake System

    Remove the air filter cartridge (1). See following NOTE. NOTE: The filter cartridge is specifically designed for this engine. It fits into the canister only one way. Use only direct replacement part (CC P/N 102498601). Page 15-26 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 299: Air Canister Removal

    Install a new air filter cartridge. See Air Filter Installation on page 15-27. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 15-27...

  • Page 300: Clutches

    If cleaning both clutches does not solve the problem, disassemble and thoroughly clean all parts in the drive and driven clutches. Check the drive clutch rollers and weights for wear. See Drive Clutch Cleaning and Inspection on page 15-30. Page 15-28 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 301: Drive Belt

    • Be very careful with the clutches. A clutch that has been dropped will not be properly balanced. If either clutch is dropped, assume that it is damaged and replace it. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 15-29...
  • Page 302 Use a 1/2-inch drive ratchet to disengage the moveable sheave (12) and spider (5), which will come off as an assembly, from the fixed sheave (15) (Figure 15-28, Page 15-32). Page 15-30 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 303 GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches 2500 Figure 15-27 Using the Drive Clutch Service Tool (Three-Weight) 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 15-31...
  • Page 304 13. Locknut, #10-24 Spacer, Clutch, 1.44x1.125x0.23 Button, Torque Primary 14. Screw, Shoulder, Hex Socket, 0.25x2.5 Spider 10. Shim, 1.63x1.33 15. Fixed Sheave 2501 Figure 15-28 Drive Clutch Components (Three-Weight) (19 MPH) Page 15-32 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 305: Driven Clutch

    • Be very careful with the clutches. A clutch that has been dropped will not be properly balanced. If either clutch is dropped, assume that it is damaged and replace it. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 15-33...
  • Page 306 Place the driven clutch onto the Spring compression base (CC P/N 102603501) (1) (Figure 15-29, Page 15-34). Place the Spring compression collar (CC P/N 102605201) (2) onto the driven clutch. Page 15-34 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 307 Place the spring compression collar onto the cup (Figure 15-29, Page 15-34). Tighten the spring compression nut just enough to enable the snap ring to be installed. Use snap ring pliers to install the snap ring. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 15-35...

  • Page 308: Clutch Cover

    Align the mounting holes in the clutch cover with the transmission and engine bolt holes. Loosely install one bolt and washer in each transmission and engine mounting hole. Finger-tighten the bolts and washers. Page 15-36 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 309 Install the clutch outer cover. See Clutch Outer Cover Installation on page 15-36. 10. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. 2176 Figure 15-31 Clutch Inner Cover 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 15-37...

  • Page 311: Section 16 - Diesel Engine, Muffler, Fuel System, And Clutches

    • Diesel fuel! Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 16-1...
  • Page 312 18. Disconnect the two black ground wires (13) from the engine block. 19. Disconnect the air filter outlet hose from the intake manifold. 20. Loosen the hardware that secures the muffler. See Muffler Removal on page 16-5. Page 16-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 313: Engine Installation

    Install the clutch inner cover. See Clutch Inner Cover Installation on page 16-33. Install the clutches. See Drive Clutch Installation on page 16-29. Also see Driven Clutch Installation on page 16-31. Install the drive belt. See Drive Belt Installation on page 16-25. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 16-3...
  • Page 314 30. Adjust the engine RPM setting if required. See Engine RPM Adjustment on page 16-19. 31. Install both seats. 32. Test-drive the vehicle to ensure all systems are functional and adjusted correctly. Page 16-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 315: Exhaust System

    NOTE: Shift the end of the muffler inlet and intermediate pipe from side to side to relax and disconnect the springs. Remove the springs from the intermediate pipe and manifold pipe and remove the pipe. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 16-5...

  • Page 316: Manifold Pipe Removal

    NOTE: Replace springs that show signs of brittleness, broken coils, or loss of tension. Loosely secure the muffler and spring suspension bracket to the chassis with two bolts and large flat washers (Figure 16-7, Page 16-7). Page 16-6 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 317 See following DANGER. DANGER • The engine produces carbon monoxide, which is an odorless, deadly poison. Do not operate the engine in an enclosed area without proper ventilation. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 16-7...

  • Page 318: Fuel System

    The fuel lines must be properly routed and all hose clamps must be tight (Figure 16-8, Page 16-8). The fuel lines should be kept clean. See following NOTE and WARNING. NOTE: Use only 5/16-inch and 3/16-inch hoses with SAE J30R7 rating to replace the fuel lines. Page 16-8 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 319: Bleeding Air From Fuel System

    (Figure 16-9). Lift the passenger-side seat. Position a pan under the fuel filter. Locate the valve (1) at the bottom of the filter and attach a drain hose to the spout. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 16-9...
  • Page 320 Install new fuel filter (diesel: CC P/N 103761801) on the manifold. Tighten the filter by hand a fraction of a turn until filter hits positive stop. Do not use a band wrench or channel lock pliers. Page 16-10 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 321 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System Verify the water separator drain valve is closed, bleed air from the system and check for leaks. See Bleeding Air From Fuel System on page 16-9. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 16-11...

  • Page 322: Fuel Pump

    Immediately place the fuel level sending unit in a pan to catch fuel. See following DANGER and NOTE. DANGER • Clean up any spilled fuel before operating the vehicle. NOTE: The rheostat arm and float should be positioned toward the passenger’s side surface of the fuel tank. Page 16-12 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 323 (5). Ensure the replacement gasket is rubber and that the mounting holes in the gasket are aligned properly with the mounting holes on the fuel tank. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 16-13...
  • Page 324 Carefully thread each hex-head screw by hand, with the ring terminal on the black ground wire (6) under the screw head closest to the engine (Figure 16-10, Page 16-13). See following CAUTION. Page 16-14 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 325: Fuel Tank

    • Use only diesel grade no. 2 fuel with a cetane rating of 45 or higher for diesel engines. Fuel Tank Removal Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Remove seat(s) and, if equipped, the center seat plate. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 16-15...
  • Page 326 11. Remove the nut from the fuel tank strap below the passenger seat area. 12. Lift the strap end and remove the opposite end from the slotted bracket. Page 16-16 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 327 12. Install the center seat plate. 13. Add the appropriate fuel to the fuel tank. 14. Connect battery. See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. 15. Install both seats. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 16-17...

  • Page 328: Engine Control Linkages

    See General Warnings, Section 1, Page 1-2. WARNING • To avoid unintentionally starting a diesel vehicle, disconnect the battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Page 16-18 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 329: Engine Rpm Adjustment

    Inspect the accelerator pedal and cable. See Section 5 – Accelerator and Brake Pedal Assemblies. Check idle and high-speed RPM. See Idle RPM Adjustment on page 16-20. See High-Speed RPM Adjustment on page 16-21. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 16-19...
  • Page 330 Figure 16-18 Diesel Probe Fuel Line Clamp On Engine Figure 16-19 Diesel Probe Battery Cable Clamp Secure the fuel line probe clamp to the clean area of the fuel injector line (Figure 16-18, Page 16-20). Page 16-20 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 331 Turn the key switch to start and allow the engine to idle. Press the accelerator pedal all the way to the floor. Measure the RPM. Repeat steps 5 and 6 until the high-speed RPM is correct. NOTE: The high-speed RPM for this diesel engine is 3825 RPM ±25. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 16-21...

  • Page 332: Air Intake System

    Place the canister cap, marked TOP, on the top center of the canister (Figure 16-22, Page 16-22). Secure the canister cap with both tab locks. Figure 16-22 Air Filter Cartridge AIR CANISTER REMOVAL Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Page 16-22 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 333: Air Canister Installation

    Secure the top (outlet) hose to the canister port. Install a new air filter cartridge. See Air Filter Installation on page 16-22. Connect battery. See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 16-23...

  • Page 334: Clutches

    If cleaning both clutches does not solve the problem, disassemble and thoroughly clean all parts in the drive clutch. See Drive Clutch Cleaning and Inspection on page 16-26. Check the drive clutch rollers and weights for wear. DRIVE BELT See General Warnings, Section 1, Page 1-2. Page 16-24 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 335: Drive Clutch

    Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. Remove the top air filter hose (outlet) from the air filter canister. Remove the clutch outer cover. See Clutch Outer Cover Removal on page 16-32. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 16-25...
  • Page 336 Use a 1/2-inch drive ratchet to disengage the moveable sheave (12) and spider (5), which will come off as an assembly, from the fixed sheave (15) (Figure 16-28, Page 16-28). Page 16-26 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 337 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches 2500 Figure 16-27 Using the Drive Clutch Service Tool (Three-Weight) 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 16-27...
  • Page 338 Washer, Flat 13. Locknut, #10-24 Spacer, Clutch, 1.44x1.125x0.15 Button, Torque Primary 14. Screw, Shoulder, Hex Socket, 0.25x2.5 Spider 10. Shim, 1.63x1.33 15. Fixed Sheave 2501 Figure 16-28 Drive Clutch Components (Three-Weight) Page 16-28 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 339: Driven Clutch

    • Be very careful with the clutches. A clutch that has been dropped will not be properly balanced. If either clutch is dropped, assume that it is damaged and replace it. Driven Clutch Removal Disconnect battery. See Disconnecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-3. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 16-29...
  • Page 340 Remove the moveable sheave (4) from the fixed sheave (5). See following NOTE. NOTE: Both the moveable and fixed sheaves have spacers (6). Be sure to retain the spacers for reassembly of the driven clutch. Page 16-30 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 341 Install the drive belt as instructed. See Drive Belt Installation on page 16-25. Install the clutch outer cover and tighten the screws to 72 in-lb (8 N·m). Install the top air filter hose on the filter canister. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 16-31...

  • Page 342: Clutch Cover

    Ensure the studs remain on the engine block when the nuts are removed. Remove the clutch inner cover. Remove the inner cover spacer between the inner cover and the engine block (Figure 16-32, Page 16-33). Page 16-32 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 343 Install the drive belt. See Drive Belt Installation on page 16-25. 10. Install the outer cover. See Clutch Outer Cover Installation on page 16-32. 11. Connect battery. See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 16-33...

  • Page 345: Section 17 - Drivetrain Components

    Remove both spindle nuts and large washers (Figure 17-1, Page 17-1). Remove the upper shock absorber bolt and locknut. Remove the lower shock absorber bolts and flanged locknuts. Remove the shock absorber and coil-over spring. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 17-1...
  • Page 346 The hub end of the half shaft has a round compression ring and groove. The compression ring mates with a groove inside the differential (Figure 17-5, Page 17-3). 14. Repeat steps for the remaining half shaft. Page 17-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 347: Half Shaft Installation

    Secure the caliper and discs to the upright and wheel hub disc with new lock-patch bolts. Tighten the hardware to 36 ft-lb (49 N·m) (Figure 17-2, Page 17-2). See following CAUTION. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 17-3...

  • Page 348: Front Differential

    Remove the roll pin securing the differential pinion shaft to the front driveshaft (Figure 17-7, Page 17-5). See following NOTE. NOTE: Use a 1/4-inch roll pin punch to drive out the roll pin. Remove the vent tube from the differential housing (Figure 17-8, Page 17-5). Page 17-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 349: Front Differential Installation

    NOTE: It is not necessary to remove the differential from its mounting plate to repair or service the unit. 2199 2200 Figure 17-9 Differential Clutch Connector Figure 17-10 Front Differential Plate Bolts FRONT DIFFERENTIAL INSTALLATION See General Warnings, Section 1, Page 1-2. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 17-5...

  • Page 350: Front Driveshaft

    Apply a light coat of anti-seize compound to the differential pinion shaft and splined shaft of transmission. Slide the front driveshaft through the oval-shaped frame shield and onto the splined shaft of the transmission. Page 17-6 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 351: Rear Axle

    11. Support the rear driveshaft and slide the rear axle out of the driveshaft universal joint and out the rear of the vehicle. See preceding NOTE. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 17-7...

  • Page 352: Rear Axle Installation

    Install both rear brake calipers to axle (Figure 17-11, Page 17-8). Tighten new bolts to 36 ft-lb (49 N·m). Anchor the hydraulic brake hose to rear axle at all original locations (Figure 17-11, Page 17-8). See following CAUTION. Tighten P-clamp bolt to 84 in-lb (9.5 N·m). Page 17-8 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 353: Rear Driveshaft

    Slide the driveshaft forward on the transmission to release the driveshaft from the differential pinion shaft. Then slide the driveshaft toward the rear and off the transmission shaft. 2197 Figure 17-12 Roll Pin in Driveshaft and Pinion Shaft 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 17-9...

  • Page 354: Rear Driveshaft Installation

    Tighten the base bracket hardware to 39 ft-lb (53 N·m). If the transmission is not replaced, leave the base brackets attached to help stabilize the transmission during repair. Page 17-10 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 355: Transmission Installation

    12. Install the drive belt. See Drive Belt Installation on page 15-29 (gasoline vehicles). 13. Install the clutch outer cover. See Clutch Outer Cover Installation on page 15-36 (gasoline vehicles). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 17-11...

  • Page 356: Forward/Reverse Shifter Cable

    Disconnect cable end from transmission shifter arm by removing clip (Figure 17-16, Page 17-13) Loosen the flanged nuts from the cable bracket that is below and forward of the transmission shifter arm (Figure 17-16, Page 17-13). See following NOTE. Page 17-12 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 357 Verify that the transmission shifter arm is in the NEUTRAL position. Loosen the flanged nuts from the cable bracket that is below and forward of the transmission shifter arm (Figure 17-16, Page 17-13). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 17-13...

  • Page 358: Forward/Reverse Shifter Handle

    Remove the socket-head pivot shoulder bolt (3), two large flat washers (4), bushing (5), and nylon locknut (6) from the shifter handle and frame bracket (Figure 17-17, Page 17-14). Remove the shifter handle (2). Remove cable pin (7) and locknut (8) from the shifter handle (2). Page 17-14 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 359: Rear Axle Tubes, Axle Shafts And Wheel Bearings

    Separate each axle tube (8) from the differential and carefully pull tube straight away until it clears the splined end of the axle shaft (3). Avoiding damage caused by dragging splines across lip of seal in differential, carefully pull axle shaft from differential. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 17-15...

  • Page 360: Rear Axle Tube And Axle Shaft Installation

    Removal on page 17-15. Remove the retaining ring (2) that is in front of the bearing (3). Drive bearing (3) from axle tube (1) by applying force to the outer race. Page 17-16 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 361: Rear Wheel Bearing Installation

    Using an appropriate sized bearing driver that fits the outer race, drive in new bearing (3) until fully seated. Install retaining ring (2). Clean axle shaft and carefully install axle tube (1) to avoid damaging new seals. See Rear Axle Tube and Axle Shaft Installation on page 17-16. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 17-17...

  • Page 363: Section 18 - Radiator And Coolant System (Diesel)

    NOTE: Removing the block plug allows air to escape during the fill process without forming an air lock to coolant flow. Check the hoses and clamps for looseness or damage. Replace if necessary. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 18-1...
  • Page 364 16. If necessary, remove reservoir cap and fill to the FULL mark. Replace cap. See preceding WARNING. 17. Lower and secure the hood. 2216 2217 Figure 18-1 Engine Block Coolant Drain Valve Figure 18-2 Engine Block Coolant Plug Page 18-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 365: Coolant Reservoir

    Lift up rear of reservoir to clear mounting tab of chassis and pull reservoir forward and up to remove. 1. Clamps 2. Mounting Points 3. 5/8” Hose Clamp 2218 Figure 18-3 Reservoir Hoses And Mounting Points 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 18-3...

  • Page 366: Coolant Reservoir Installation

    Disconnect the two-pin connector between the fan motor and the wire harness (Figure 18-4, Page 18-5). Remove the flanged locknuts and flanged bolts securing the two radiator support brackets to the chassis and remove brackets. Page 18-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 367: Radiator Installation

    Connect battery. See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. Start and run the engine until it reaches operating temperature and check for leaks. 10. Stop the engine and allow the engine and coolant to cool. See following WARNING. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 18-5...

  • Page 368: Coolant Pipe Weldment

    Connect battery. See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. Start and run the engine until it reaches operating temperature and check for leaks. Stop the engine and allow the engine and coolant to cool. See following WARNING. Page 18-6 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 369: Fan

    If necessary, remove reservoir cap and fill to the FULL mark. Replace cap. See preceding WARNING. 10. Lower and secure the hood. See General Warnings, Section 1, Page 1-2. FAN REMOVAL See Fan Removal on page 14-19. FAN INSTALLATION See Fan Installation on page 14-20. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 18-7...

  • Page 371: Section 19 - Hydraulic Attachment System

    Use the following procedure to relieve hydraulic pressure in the system. TO RELIEVE HYDRAULIC FLUID PRESSURE Remove attachment if installed. See Attachment Interface on page 19-2. Lower attachment interface, fully extending the lift and tilt cylinders. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-1...

  • Page 372: Attachment Interface

    Inspect the linkages and pins for excessive wear or damage (Figure 19-3, Page 19-3). Replace any parts that are damaged, bent or missing. Keep all fasteners tight. Page 19-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 373: Removing And Installing The Attachment Arm Mechanism

    NOTE: When removing the cylinders from the attachment arm or the interface, the cylinders may need to be retracted slightly. Do not have hands in the area of the cylinders when extending or retracting the cylinders. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-3...
  • Page 374 14. Lower the attachment arm to the ground. 15. To store, install pins (1) into the attachment arm holes (both sides) and secure with the retaining pins (2) (Figure 19-11, Page 19-5). Page 19-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 375 Raise the attachment arms and align the holes in the attachment arms to the vehicle mounting holes (Figure 19-13, Page 19-6). Install the pins (2) and retaining rings (1) (both sides). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-5...
  • Page 376 NOTE: When aligning the cylinders to the attachment arm and interface during installation, the cylinders may need to be retracted slightly to relieve the hydraulic pressure. Do not have hands in the area of the cylinders when extending or retracting the cylinders. Page 19-6 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 377 13. Raise the attachment interface and align it with the cylinder. Install the pin (2) and the retaining ring (1) (Figure 19-17, Page 19-7). 2225 Figure 19-17 Raise Interface, Install Pin and Retainer Ring 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-7...

  • Page 378: Electrical

    Electrical HYDRAULIC ATTACHMENT SYSTEM ELECTRICAL Diode 2 Diode 3 WD1027864C-L Figure 19-18 Wiring Diagram for Hydraulic Attachment System Vehicles (Front) Page 19-8 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 379 HYDRAULIC ATTACHMENT SYSTEM Electrical Diode 4 WD1027864C-R Figure 19-19 Wiring Diagram for Hydraulic Attachment System Vehicles (Rear) 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-9...

  • Page 380: Joystick

    Access the underside of joystick but do not completely remove joystick or disconnect the wiring. See Joystick Removal on page 19-11. Check each switch, between the wired terminals, for no continuity with the joystick at “rest” and continuity with the joystick acting on the switch. Page 19-10 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 381 Cut the wire tie securing joystick harness to chassis (Figure 19-22, Page 19-11). Remove four screws securing control box cover/joystick assembly and pull assembly out enough to access the underside of joystick (Figure 19-21, Page 19-11). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-11...

  • Page 382: Joystick On/Off Switch

    – Ccontinuity of the 14-gauge red wire (w52) from the fuse to the Accessory Relay – Continuity of the 18-gauge red wire (w40) from the fuse to the ON/OFF switch. Page 19-12 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 383: Attachment Arm Float Switch

    Check the following location for no continuity with switch at “rest” and continuity with switch in the ON position (Figure 19-24, Page 19-13): – between terminal 2 (white wire w75) and terminal 3 (brown wire w20) 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-13...
  • Page 384 Install control box cover/joystick assembly and secure with the four screws. Secure joystick harness to chassis with new wire tie (Figure 19-22, Page 19-11). Connect battery. See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. Page 19-14 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 385: Auxiliary Hydraulic Switch

    Remove four screws securing control box cover/joystick assembly and pull assembly out enough to access the switch. See Joystick Removal on page 19-11. Ensure the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-15...

  • Page 386: Relays

    Remove four screws securing control box cover/joystick assembly and pull assembly out enough to access the relays. See Joystick Removal on page 19-11. Ensure the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Page 19-16 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 387 Connect battery. See Connecting the Battery – Gasoline/Diesel Vehicles, Section 1, Page 1-4. Install the electrical component cover and driver seat. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-17...

  • Page 388: Solenoid

    If there is no continuity, press the reset button and check again for continuity. If there is still no continuity, replace the breaker. Circuit Breaker Removal Empty and raise cargo bed. Page 19-18 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 389: Control Valves

    If the valve does not shift, check and repair (if necessary) the following items: – The valve “hot” wire and ground wire (Figure 19-19, Page 19-9). – The switch controlling the valve. See Electrical on page 19-8. – The supplied voltage. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-19...
  • Page 390 Three-Way 2-Position and Four-Way 2-Position Valves 2249 Figure 19-33 Three-Way 2-Position and Four-Way 2-Position Valve and Coil Troubleshoot and repair these valves as follows (Figure 19-33, Page 19-20): Page 19-20 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 391: Hoses

    At Tilt Up and Tilt Down Cylinder: 3. Pink 4. No Color At Pump: 5. Blue 6. Green 7. Pink 8. No Color 2250 Figure 19-34 Lift And Tilt Circuit Hoses 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-21...

  • Page 392: Hose Removal

    1.1. Make sure to match factory color marking to correct fitting (Figure 19-34, Page 19-21). 1.2. Secure with wire ties at all factory established locations. 1.3. Tighten hose fittings to 22 ft-lb (30 N·m). Page 19-22 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 393: Quick Connect Fittings (Auxiliary Hydraulic Circuit Only)

    Reverse the removal procedure to install quick connect fittings. Tighten jam nuts to 30 ft-lb (41 N·m). Match hose to fitting and connect hoses (Figure 19-35, Page 19-22). Tighten fittings to 22 ft-lb (30 N·m). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-23...

  • Page 394: Cylinders

    Mark hoses to ease reassembly and disconnect hoses from cylinders. Cover hoses and fittings to keep out debris. Remove retaining pin(s) and pivot pin(s) securing cylinder to chassis and remove cylinder (Figure 19-37, Page 19-24). Page 19-24 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 395: Auxiliary Cylinder (Optional)

    NOTE: Mark hoses for correct installation if factory markings are not found. Remove retaining pin (1) and pivot pin (2) from rod end of hydraulic cylinder (Figure 19-39, Page 19-25). 2254 2255 Figure 19-38 Hoses Figure 19-39 Remove Rod End Pins 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-25...
  • Page 396 Reverse the removal procedure to install the auxiliary hydraulic cylinder in the attachment. Install the retaining pin (1) as shown (Figure 19-39, Page 19-25). See following NOTE. NOTE: If installed incorrectly, this retaining pin will restrict attachment travel. Page 19-26 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 397: Cylinder Disassembly

    5. O-ring 9. Head 2. Nut 6. O-ring 10. Oil Seal 3. Seal 7. Back-up Ring 11. Dust Seal 8. O-ring 4. Piston 12. Rod 2258 Figure 19-42 Cylinder Exploded View 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-27...
  • Page 398 Pull the piston (1) off the rod. If the cylinder has a cushion sleeve (2), pull it off the rod. Pull the head (3) off the rod (Figure 19-46, Page 19-29). Page 19-28 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 399 Figure 19-47 Remove Seal Figure 19-48 Remove O-ring and Back-up Washer 12. Remove the wiper seal (Figure 19-49, Page 19-30). 13. Remove the oil seal from the head (Figure 19-50, Page 19-30). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-29...

  • Page 400: Cylinder Assembly

    • Wear safety glasses to prevent eye injury when any of the following conditions exist: – Fluids are under pressure. – Flying debris or loose material is present. WARNING CONTINUED ON NEXT PAGE Page 19-30 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 401 Use the ring compressor to compress the seal to the correct size (Figure 19-56, Page 19-32). NOTE: Leave the piston in the ring compressor for three minutes. 2269 2270 Figure 19-53 Install Piston O-ring Figure 19-54 Stretch Piston Seal 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-31...
  • Page 402 Figure 19-58 Install Oil Seal in Head Install the wiper seal with the lip toward the outside of the head (Figure 19-59, Page 19-33). Install the back-up washer on the head (Figure 19-60, Page 19-33). Page 19-32 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 403 15.1.For cylinders with a cushioned piston, install the piston on the rod with the tapered end first (toward the head) (Figure 19-65, Page 19-34). 15.2.For all other cylinders, install the cushion sleeve (if so equipped) and piston on the rod (Figure 19-66, Page 19-34). 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-33...
  • Page 404 17. Remove the rod from the vise. 18. Install the cylinder case in the vise. 19. Put oil on the seal surface of the cylinder case (Figure 19-68, Page 19-35). Page 19-34 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 405 23. Use the adjustable gland nut wrench to tighten the head until the head is flush with the case (Figure 19-72, Page 19-35). 2285 2286 Figure 19-69 Lubricate Piston Seal Figure 19-70 Install Rod Assembly 2287 2288 Figure 19-71 Lubricate Head Seals Figure 19-72 Tighten Head Against Case 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-35...

  • Page 406: Cylinder Bushings (If Equipped)

    Remove the two bushing(s) (1) (Figure 19-75, Page 19-37) from the rod end of the hydraulic cylinder. Apply LOCTITE 271 (Red) to the bushings (2) before installing them into the cylinder (Figure 19-76, Page 19-37). Page 19-36 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 407: Angle Frame Bushings

    Remove bushings (1) (Figure 19-77, Page 19-38) from both sides of angle frame. Apply LOCTITE 271 (Red) to the bushings before installing them into the frame. Install bushings (2) (Figure 19-78, Page 19-38) on both sides of the angle frame. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-37...

  • Page 408: Whisk Broom Angle Frame

    Figure 19-80 Apply LOCTITE and Install Four Pivot Bushings WHISK BROOM ANGLE FRAME Removal and Installation 2297 2298 Figure 19-81 Remove Whisk Broom Pivot Bushings Figure 19-82 Apply LOCTITE and Install Pivot Bushings Page 19-38 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 409: Front Mount

    • Wear safety glasses to prevent eye injury when any of the following conditions exist: – Fluids are under pressure. – Flying debris or loose material is present. – Engine is running. – Tools are being used. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-39...

  • Page 410: Front Mount Installation

    • Wear safety glasses to prevent eye injury when any of the following conditions exist: – Fluids are under pressure. – Flying debris or loose material is present. WARNING CONTINUED ON NEXT PAGE Page 19-40 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 411: Fluid Level Inspection

    If foreign fluid is present within power unit that must be drained before operation, follow steps above except add the following procedures: For step 6, also slowly loosen and disconnect hoses at pump. For step 10, purge hoses of fluid with compressed air. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-41...

  • Page 412: Pump Assembly

    Loosen two bolts, located under pump assembly, securing pump assembly to cradle (Figure 19-90, Page 19-43). Remove three bolts securing cradle to chassis (Figure 19-85, Page 19-42) and (Figure 19-86, Page 19-42). 2301 2302 Figure 19-85 Front Cradle Bolt Figure 19-86 Rear Cradle Bolts Page 19-42 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 413 12. Lift pump and cradle up and, while guiding the hoses/wiring around heat shield, place on top of chassis. See following WARNING and CAUTION. WARNING • To avoid risk of injury, use proper lifting techniques or, if available, a hoist to lift the pump assembly from the chassis. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-43...

  • Page 414: Reservoir

    Figure 19-91 Loosen Band Clamp Figure 19-92 Suction Tube Filter Reservoir Installation Drain remaining fluid and wipe or flush reservoir clean. Clean or replace suction tube filter (Figure 19-92, Page 19-44). Page 19-44 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...

  • Page 415: Motor

    Attach solenoid to motor and connect wires. See Solenoid Installation on page 19-18. Assemble pump assembly to cradle and place unit in chassis. See Pump Assembly Installation on page 19-44. 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page 19-45...

  • Page 416: Pump

    Cycle pump and cylinders, refilling reservoir as necessary, until the trapped air is forced into the reservoir and the cylinders function properly. Once primed, check fluid level again and add as necessary. Page 19-46 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 417 Monarch Hydraulics, Inc. Instructions for Installing Modular Pump on Existing Unit IMPORTANT: (See Figure #1) IMPORTANT: (See Figure #2) See Figure #3) IMPORTANT: Do not over tighten! Figure 1 Figure 2 Figure 3 Install (4) Screws Through Pump And Into Base. Drive Shaft Torque (4) Screws To 140-160 Inch Lbs.
  • Page 418 NOTES...
  • Page 419 (gasoline vehicles) 4 link ............. 17-8 installation ............13-10 removal removal ............13-10 4 link ............. 17-7 testing .............11-37 bed, cargo installation ..........4-13–4-14 removal ............4-13–4-14 belt, drive ball joint, lower 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page i-1...
  • Page 420 (gasoline vehicles) ......13-16 adjustment ............17-13 coil, ignition (gasoline vehicles)......13-16 installation ............17-13 column, steering removal ............17-12 installation ............7-3 camber removal .............. 7-2 adjustment ............7-13 Page i-2 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 421 (diesel vehicles) assembly testing ............12-19 three-weight design........15-33 fender, front cleaning............15-30 installation ............4-6 disassembly removal .............. 4-6 three-weight design........15-30 fender, rear inspection ............15-30 installation ............4-15 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page i-3...
  • Page 422 ............14-3 installation ........... 13-17 fuel system (diesel vehicles)........16-8 removal ............13-17 fuel system (gasoline vehicles) ......15-8 switch fuel tank (diesel vehicles) installation ............13-11 disposal ............16-17 removal ............13-11 Page i-4 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 423 ............13-8–13-9 starter circuit testing .........11-13 kill circuit, engine (gasoline vehicles) oil filter testing .............11-28 hose installation (gasoline vehicles)....15-5 kill wire, engine (gasoline vehicles) hose removal (gasoline vehicles)......15-5 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page i-5...
  • Page 424 ............19-44 reverse buzzer (diesel vehicles) quick connect fitting installation ............14-12 installation ............19-23 limit switch removal ............19-23 installation ........... 14-12 removal ............14-12 testing ............12-34 Page i-6 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 425 ............9-5 vehicle..............2-1 removal ............9-5 start relay (diesel vehicles) switch, auxiliary testing ............12-18 installation ............19-16 start relay (gasoline vehicles) removal ............19-15 testing .............11-15 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page i-7...
  • Page 426 38 bed lift circuit breaker ........12-43 testing ............12-20 4 key switch (starter circuit)......12-15 throttle 5 key switch (on position)......... 12-16 see accelerator, pedal.......... 5-1 6 key switch (glow plug circuit) ......12-16 Page i-8 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 427 ............14-20 wire harness diode (gasoline vehicles) installation ............13-18 removal ............13-18 wiring diagram (diesel vehicles) ......12-6 wiring diagram (gasoline vehicles) ......11-6 wiring diagram (hydraulic attachment) ....19-8 2013 Carryall 295/XRT 1550 Maintenance and Service Manual Page i-9...
  • Page 428 NOTES...
  • Page 429 5. If you are reviewing a Kit Instruction, were all indicated parts included in your kit? Yes / No Your Comments and Suggestions: Please send a copy of this page to: Thank You! E-mail: Tech_Pubs@clubcar.com Club Car’s Technical Publications Department 2013 Carryall 295/XRT 1550 Maintenance and Service Manual...
  • Page 430 NOTES...

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