Club Car Carryall 1500 2016 Maintenance And Service Manual

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2016

Carryall 1500/1700 and XRT 1550

Maintenance and Service

Manual

Carryall 1500/1700, XRT 1550/1550 SE Gasoline, Diesel and

IntelliTach Vehicles

Manual Number 105334710

Edition Code B

Table of Contents

Troubleshooting

Summary of Contents for Club Car Carryall 1500 2016

Page 1 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual Carryall 1500/1700, XRT 1550/1550 SE Gasoline, Diesel and IntelliTach Vehicles Manual Number 105334710 Edition Code B...
Page 3 To find your local authorized Club Car dealer, visit www.clubcardealer.com, call 1-800-ClubCar (258-2227), or scan this Quick Response (QR) code to be taken to the Club Car dealer locator. Refer to Figure 1. Download a QR code reader such as RedLaser or Barcode Scanner to your cell phone or tablet.
Page 4 CC PN 102498601 CC PN 102434701 NOTE: This manual represents the most current information at the time of publication. Club Car is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures. Any modification and/or significant change in specifications or procedures will be forwarded to all Club Car dealers and will, when applicable, appear in future editions of this manual.
Page 5: Table Of Contents
CONTENTS SECTION 1 — Safety............................1-1 Safety Details ..............................1-1 Personal Safety ............................1-1 Machine Safety............................1-1 Information..............................1-1 General Warnings............................1-2 Disabling the Vehicle..........................1-3 Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles ............1-3 Side-Post Battery: Connecting the Battery – Gasoline/Diesel Vehicles ............1-4 Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles ............
Page 6 Seat Adjustment ............................4-9 Seat Installation............................4-9 Seat Support Removal ..........................4-10 Seat Support Installation .......................... 4-10 Seat Belts ..............................4-10 Bench Seat Belt Removal......................... 4-10 Bench Seat Belt Installation........................4-11 Cargo Bed – Electric Lift..........................4-11 Testing the Bed Lift Motor..........................4-11 Bed Lift Motor Removal..........................4-11 Bed Lift Motor Installation .........................
Page 7 Bleeding the Hydraulic Brake System ......................6-18 Bleeding Brakes on a DOT 5 Fluid Filled System ..................6-18 Purging the Hydraulic System........................6-20 Park Brake System ............................6-21 Park Brake Caliper and Pad Replacement....................6-22 Park Brake Disc Replacement ........................6-22 Park Brake Cable Replacement........................
Page 8 SECTION 10 — Periodic Maintenance ......................10-1 Periodic Service Schedule..........................10-1 Periodic Service Schedule – IntelliTach ......................10-4 Periodic Lubrication Schedule ........................10-6 Periodic Lubrication Schedule – IntelliTach ....................10-8 Lubricating the Attachment Arm and Interface – IntelliTach ................10-9 Brake Fluid Reservoir ..........................10-10 Brake Fluid.............................10-10 Engine Oil ..............................10-10...
Page 9 Warning Light Removal ..........................13-6 Warning Light Installation ......................... 13-6 Fuel Gauge/Hour Meter ..........................13-7 Testing the Fuel Gauge/Hour Meter ......................13-7 Fuel Gauge/Hour Meter Removal ......................13-7 Fuel Gauge/Hour Meter Installation......................13-8 Key Switch ..............................13-8 Testing the Key Switch ..........................13-8 Key Switch Removal ..........................
Page 10 Vibration Damage ...........................13-20 Mineral Content ............................13-20 Battery Removal .............................13-20 Charging the Battery ..........................13-20 Battery Installation ..........................13-21 Battery Storage ............................13-21 Charging a Dead Battery.........................13-22 SECTION 14 — Electrical Components: Diesel Vehicles ..................14-1 Starter and Starter Solenoid ......................... 14-1 Relays ................................ 14-1 Testing the Relay .............................
Page 11 Testing the Reverse Warning Buzzer Limit Switch..................14-12 Reverse Warning Buzzer Limit Switch Removal..................14-12 Reverse Warning Buzzer Limit Switch Installation ..................14-13 Front Differential Limit Switch ........................14-13 Testing the Front Differential Limit Switch ....................14-13 Front Differential Limit Switch Removal ....................14-13 Front Differential Limit Switch Installation ....................14-14 Fuel Level Sending Unit ..........................14-14 Testing the Fuel Level Sending Unit ......................14-15 Fuel Level Sending Unit Removal ......................14-15...
Page 12 Carbon Canister .............................15-19 Fuel Shut-Off Valve..........................15-20 Engine Control Linkages ..........................15-21 General Information ..........................15-21 Ground Speed............................15-21 Accelerator Cable ...........................15-21 Choke Cable ............................15-22 Engine Governor Arm ..........................15-24 Engine RPM Adjustment .........................15-25 Air Intake System ............................15-27 Air Filter Replacement..........................15-27 Air Canister Removal ..........................15-28 Air Canister Installation ...........................15-28 Clutches..............................15-29 Clutch Troubleshooting ...........................15-29...
Page 13 Front Driveshaft Removal......................... 17-6 Front Driveshaft Installation ........................17-6 Transmission............................... 17-7 Transmission Removal..........................17-7 Transmission Installation .......................... 17-8 Forward/Reverse Shifter Cable........................17-10 Forward/Reverse Shifter Handle ......................17-12 Rear Driveshaft ............................17-13 Rear Driveshaft Removal ........................17-13 Rear Driveshaft Installation ........................17-13 Rear Axle ..............................17-14 Rear Axle Removal..........................17-14 Rear Axle Installation ..........................17-15 Rear Axle Tubes, Axle Shafts and Wheel Bearings ..................17-16 Rear Axle Tube and Axle Shaft Removal....................17-16...
Page 14 Cylinder Disassembly ..........................19-28 Cylinder Assembly ..........................19-32 Cylinder Bushings (If Equipped).......................19-37 Angle Frame Bushings..........................19-38 Snow Blade Angle Frame........................19-38 Whisk Broom Angle Frame........................19-40 Front Mount..............................19-41 Front Mount Removal ..........................19-41 Front Mount installation ...........................19-42 Hydraulic Pump Assembly...........................19-42 Fluid Level Inspection ..........................19-43 Fluid Change............................19-43 Pump Assembly .............................19-43 Reservoir ...............................19-46 Motor ..............................19-47...
Page 15: Section 1 - Safety
SECTION 1 — SAFETY SAFETY DETAILS Safety WARNING • This owner’s manual should be read completely before attempting to drive or service the vehicle. Failure to follow the instructions in this manual could result in property damage, severe personal injury, or death. PERSONAL SAFETY It is important to note that some vital statements throughout this manual and on the decals affixed to the vehicle are preceded by the words DANGER, WARNING, or CAUTION.
Page 16: General Warnings
General Warnings SAFETY GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated, repaired, or serviced. Other specific safety statements appear throughout this manual and on the vehicle. DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area.
Page 17: Disabling The Vehicle
SAFETY General Warnings WARNING • Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance, severe personal injury, or death. • Any modification or change to the vehicle that affects the electrical system, stability or handling of the vehicle, or increases maximum vehicle speed beyond factory specifications, could result in severe personal injury or death.
Page 18: Side-Post Battery: Connecting The Battery - Gasoline/Diesel Vehicles
General Warnings SAFETY 1. Remove negative battery cable. 2. Remove positive battery cable. Connect battery cables in reverse order. Figure 1-1 Side-Post Battery Cable Removal Figure 1-2 All-Wheel Drive Warning SIDE-POST BATTERY: CONNECTING THE BATTERY – GASOLINE/DIESEL VEHICLES Connect the battery cables, positive (+) cable first. Tighten battery terminals to 80 in-lb (9 N·m).
Page 19: Recycling Lead-Acid Batteries
SAFETY General Warnings (Viewed from driver side of vehicle) 1. Remove positive terminal cover. 2. Remove negative battery cable. 3. Remove positive battery cable. Connect battery cables in reverse order. Figure 1-3 Top-Post Battery- Battery Cable Removal-Gasoline Vehicles RECYCLING LEAD-ACID BATTERIES WARNING •...
Page 20: International Safety Symbols On Batteries
General Warnings SAFETY INTERNATIONAL SAFETY SYMBOLS ON BATTERIES Anyone using, repairing, or servicing the vehicle must understand and heed the safety symbols on the vehicle battery or batteries. 1. Shield eyes. 3. No smoking, no open flames, no sparks. 5. Battery acid hazard. 2.
Page 21: Section 2 - Vehicle Specifications
SECTION 2 — VEHICLE SPECIFICATIONS NOTE: Engine horsepower specifications are provided by the engine manufacturer. Actual horsepower in use may differ and is dependent on environmental conditions as well as maintenance condition of the engine. Vehicle Specifications 1500/1700 AND 1550/1550 SE SPECIFICATIONS FOUR FOUR SPECIFICATIONS...
Page 22 General Warnings VEHICLE SPECIFICATIONS FOUR FOUR SPECIFICATIONS PASSEN- PASSEN- PASSEN- PASSEN- GASO- GASO- POWER SOURCE DIESEL DIESEL LINE LINE Tires: All Terrain: 25 x 10.5 – 12 front and rear; tubeless, 4-ply rated load range ● ● ● ● Mud: 25 x 11 – 12 front and rear; tubeless, 4-ply rated load range DIMENSIONS/WEIGHT NOTE: Items marked with an asterisk (*) indicate approximate values.
Page 23 VEHICLE SPECIFICATIONS General Warnings FOUR FOUR SPECIFICATIONS PASSEN- PASSEN- PASSEN- PASSEN- GASO- GASO- POWER SOURCE DIESEL DIESEL LINE LINE 1 qt. and 1 qt.and Engine (Kawasaki) crankcase with filter: SAE 10W-30, API classification SJ 19 oz 19 oz (1.5 L) (1.5 L) Engine crankcase with filter: SAE 10W-30, API classification CF 3 qt (2.8 L)
Page 24: Intellitach Specifications
General Warnings VEHICLE SPECIFICATIONS INTELLITACH SPECIFICATIONS CARRYALL 1500 & SPECIFICATIONS XRT 1550 INTELLITACH POWER SOURCE DIESEL Engine: 4-cycle OHV, 719 cc, 20.0 Engine Horsepower (15.0 kW) rated @ 3600 RPM (per SAE J1995), ● three-cylinder, liquid-cooled, with pressure lubrication system Fuel system: Mechanical injection, fuel water separator, fuel filters, and electric fuel pump ●...
Page 25 VEHICLE SPECIFICATIONS General Warnings CARRYALL 1500 & SPECIFICATIONS XRT 1550 INTELLITACH Weight (with all-terrain tires) 1800 lb. (815 kg) 25 mph Forward speed (40 kph) Governed RPM 3825 Turning radius (per SAE J 695) 138 in. (350.5) Load bed height 32.5 in.
Page 26 General Warnings VEHICLE SPECIFICATIONS Pagination Page Page 2-6 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual...
Page 27: Section 3 - General Information
SECTION 3 — GENERAL INFORMATION DANGER General Information • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. Throughout this manual, important features unique to each model are highlighted. The manufacturer recommends the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s).
Page 28 General Warnings GENERAL INFORMATION 1. Hood 2. ROPS 3. Fuel Fill Cap 4. Cargo Bed 5. Bed Lift Latch – vehicles with manual (standard) bed lift only 6. Engine Compartment, Battery, Fuel Tank (under seat; for four-passenger model, engine compartment is under rear seat) 7. Seat 8. Brake Fluid Reservoir (under hood) 9. Radiator and Coolant Reservoir (under hood) –...
Page 29: Model Identification
GENERAL INFORMATION Model Identification MODEL IDENTIFICATION The serial number of each vehicle is printed on a bar code decal mounted either below the passenger side cup holder or above the accelerator or brake pedal (Example: PH0901-583947) (Figure 3-3). The two letters (1) at the beginning of the serial number indicate the vehicle model. The following four digits (2) indicate the model year and production week during which the vehicle was built.
Page 30 Model Identification GENERAL INFORMATION Figure 3-5 Gasoline Engine Serial Number Location Figure 3-6 Diesel Engine Serial Number Location 2703 Figure 3-7 Differential Serial Number Location Page 3-4 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual...
Page 31: Storage
GENERAL INFORMATION Storage STORAGE See General Warnings on page 1-2. DANGER • Do not attempt to drain fuel when the engine is hot or while it is running. • Clean up any spilled fuel before operating the vehicle. • Store fuel in an approved fuel container only. Store in a well-ventilated area away from sparks, open flames, heaters, or heat sources.
Page 32: Preparing The Vehicle For Extended Storage
Storage GENERAL INFORMATION CAUTION 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 3-8 Fuel Shut-off Valve PREPARING THE VEHICLE FOR EXTENDED STORAGE Unload the vehicle so that the tires are supporting only the weight of the vehicle. Store the vehicle in a cool, dry place.
Page 33: Returning The Stored Vehicle To Service
GENERAL INFORMATION Lifting The Vehicle Change engine oil. See Engine Oil and Filter Change on page 10-11. Disconnect battery and spark plug (Gas only) wires. See Disconnecting the Battery – Gasoline/Diesel Vehicle on page See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4..
Page 34: Lifting Only The Rear
Lifting The Vehicle GENERAL INFORMATION Lift front of vehicle and support on jack stands (Figure 3-9, Page 3-8). See WARNING “Lift only one end...” in General Warnings on page 1-2. 1890 Figure 3-9 Front Jack Stand Placement LIFTING ONLY THE REAR Place vehicle on a level surface.
Page 35: Lifting The Entire Vehicle
GENERAL INFORMATION Using A Booster Battery (Jump Starting) LIFTING THE ENTIRE VEHICLE WARNING • To place vehicle on four jack stands, lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use the lifting device to hold vehicle in the raised position.
Page 36 Using A Booster Battery (Jump Starting) GENERAL INFORMATION Access the engine compartment by raising the cargo bed. See WARNING “For vehicles with cargo beds...” in General Warnings on page 1-2. Locate the vehicle battery on the driver’s side of the vehicle under the cargo bed (Figure 3-11). Connect the end of the first cable (1) to the positive (+) terminal of the booster battery.
Page 37: Section 4 - Body And Trim
SECTION 4 — BODY AND TRIM DANGER Body and Trim • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. GENERAL INFORMATION The hood, center and side cowl panels are molded-in color, Geloy XTW plastic (except camo finishes and low-volume finishes, such as black, which remain painted but over the closest matching, molded-in color).
Page 38: Front Body Repair
Front Body Repair BODY AND TRIM Difficult Stains – Dampen a soft, white cloth with a solution of 10% household bleach (sodium hypochlorite) and 90% water. Rub gently to remove stain, then rinse with a water dampened cloth to remove bleach concentration. For More Difficult Stains –...
Page 39: Front Body Components
BODY AND TRIM Front Body Components FRONT BODY COMPONENTS See General Warnings, Section 1, Page 1-2. INSTRUMENT PANEL REMOVAL Make sure the key switch is OFF and the Forward/Reverse handle is in the NEUTRAL position. Remove the key. Chock the wheels. Disconnect battery.
Page 40: Front Fascia Removal
Front Body Components BODY AND TRIM Unchock wheels. FRONT FASCIA REMOVAL Remove both side cowl panels (fenders). See Side Cowl Panel (Fender) Removal on page 4-5. Remove the four Torx ® screws and the three hex head screws that secure the front fascia to the frame. Disconnect the lighting wire harness from each light at connectors.
Page 41: Side Cowl Panel (Fender) Removal
BODY AND TRIM Front Body Components Install four Tuflok plastic locking fasteners along the trailing edge of the center cowl panel to secure the panel to the instrument panel structural support. Replace, lower and secure hood. See Hood Installation on page 4-4. SIDE COWL PANEL (FENDER) REMOVAL Remove Roll-over Protective Structure (ROPS), if equipped.
Page 42: Front Fender Flare Installation
Roll-Over Protective Structure (ROPS) BODY AND TRIM FRONT FENDER FLARE INSTALLATION Position the front fender flare to the vehicle, and secure the flare to the upper frame support using the three hex-head screws. Tighten hardware to 55 in-lb (6.2 N·m). Secure the fender flare to the front floorboard using three hex-head screws.
Page 43: Rops Removal
BODY AND TRIM Roll-Over Protective Structure (ROPS) *Four Passenger Vehicles Only 2357 Figure 4-1 Roll-Over Protective Structure (ROPS) – Two and Four Passenger ROPS REMOVAL NOTE: Follow steps 1 through 3 for 2-passenger vehicles and steps 1 through 8 for 4-passenger vehicles. ROPS removal will be easier with the aid of an assistant and a rubber mallet.
Page 44: Rops Installation
Roll-Over Protective Structure (ROPS) BODY AND TRIM Remove the hex-head bolts (21) and flanged lock nuts (22) securing the rear support tubes (16) to the tube brackets (20) and to the forward side support tubes (4). Remove the tube brackets (20) and rear support tubes (16) from the vehicle. Remove the forward side supports (4).
Page 45: Seat
BODY AND TRIM Seat WARNING • Exceeding the maximum torque value could result in damage to the ROPS tubing and stripped threads on the hardware. • Ensure that the ROPS is properly installed before operating the vehicle. SEAT See General Warnings, Section 1, Page 1-2. SEAT REMOVAL Bucket seats 1.1.
Page 46: Seat Support Removal
Seat Belts BODY AND TRIM SEAT SUPPORT REMOVAL Remove the bolts (9), washers (10 and 11), and flanged locknuts (12) from the seat support (7) and engine cover plate (Figure 4-1, Page 4-7). Remove the seat support. SEAT SUPPORT INSTALLATION Install the seat support (7) (Figure 4-1, Page 4-7).
Page 47: Bench Seat Belt Installation
BODY AND TRIM Cargo Bed – Electric Lift 1446 1447 Figure 4-2 Coiled Seat Belt Assembly Figure 4-3 Center Seat Belt Fastener BENCH SEAT BELT INSTALLATION Install the center seat belt buckle assembly to the seat belt bracket with hardware previously removed except for the lock nut (Figure 4-3, Page 4-11).
Page 48: Bed Lift Motor Installation
Cargo Bed – Electric Lift BODY AND TRIM BED LIFT MOTOR INSTALLATION NOTE: If replacing the actuator, adjust the length of dimension between the base rod hole and the rod end hole using the prior actuator as a guide. The rod end of the actuator can be turned clockwise to shorten and counterclockwise to lengthen the dimension.
Page 49: Cargo Bed - Manual Lift
BODY AND TRIM Cargo Bed – Manual Lift CARGO BED – MANUAL LIFT See General Warnings, Section 1, Page 1-2. CARGO BED REMOVAL NOTE: Cargo bed removal and installation will be easier with the aid of an assistant. Raise the bed and ensure that the prop rod is securely engaged. Hold the bed securely, and remove the cotter pin (3) and flat washer (4) from the top end of the prop rod where the prop rod is attached to the bed (Figure 4-4, Page 4-15).
Page 50: Rear Fender
Rear Fender BODY AND TRIM REAR FENDER See General Warnings, Section 1, Page 1-2. REAR FENDER REMOVAL Lift bed. 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). 2.2.
Page 51 BODY AND TRIM Rear Fender 1884 Figure 4-4 Cargo Bed 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual Page 4-15...
Page 52 Rear Fender BODY AND TRIM Pagination Page Page 4-16 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual...
Page 53: Section 5 - Accelerator And Brake Pedal Assemblies
SECTION 5 — ACCELERATOR AND BRAKE PEDAL ASSEMBLIES DANGER Accelerator and Brake Pedal Assemblies • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. ACCELERATOR PEDAL See General Warnings, Section 1, Page 1-2. ACCELERATOR PEDAL REMOVAL Disconnect battery and spark plug wire(s).
Page 54: Accelerator Pedal Installation
ACCELERATOR AND BRAKE PEDAL Accelerator Pedal ASSEMBLIES AWD only: Remove hardware (4) securing the front differential limit switch (5) to the pedal. Inspect the pedal bushings (6) for wear and replace if worn. ACCELERATOR PEDAL INSTALLATION Installation is reverse of removal procedure. Check return spring length and adjust if necessary (Figure 5-3, Page 5-2).
Page 55: Brake Pedal
ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Brake Pedal BRAKE PEDAL See General Warnings, Section 1, Page 1-2. BRAKE PEDAL REMOVAL Disable the vehicle. See Disabling the Vehicle on page 1-3. Disconnect battery. See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 56: Park Brake Pedal
ACCELERATOR AND BRAKE PEDAL Park Brake Pedal ASSEMBLIES 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.
Page 57 ACCELERATOR AND BRAKE PEDAL ASSEMBLIES Park Brake Pedal Connect the cable end to the park brake pedal and secure with bow tie locking pin (1). Connect battery. See Side-Post Battery: Connecting the Battery – Gasoline/Diesel Vehicles on page 1-4. See Top-Post Battery: Connecting the Battery- Gasoline/Diesel Vehicles on page 1-4. Adjust the park brake cable.
Page 58 ACCELERATOR AND BRAKE PEDAL Park Brake Pedal ASSEMBLIES Pagination Page Page 5-6 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual...
Page 59: Section 6 - Hydraulic Brake And Park Brake Systems
SECTION 6 — HYDRAULIC BRAKE AND PARK BRAKE SYSTEMS DANGER Hydraulic Brake and Park Brake Systems • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. CAUTION • Worn or damaged brake discs cannot be machined to refinish them. Replace as necessary. GENERAL INFORMATION The hydraulic service brake system consists of a master cylinder actuating dual piston front calipers and single piston rear calipers.
Page 60: Master Cylinder Inspection
HYDRAULIC BRAKE AND PARK BRAKE Brake System Inspection SYSTEMS MASTER CYLINDER INSPECTION • Inspect the exterior of the master cylinder. Replace any leaking components and bleed the hydraulic brake system. See Bleeding the Hydraulic Brake System on page 6-18. • Check the brake fluid level. See Brake Fluid Reservoir on page 10-10. •...
Page 61 HYDRAULIC BRAKE AND PARK BRAKE SYSTEMS Brake System Inspection 9. Passenger Side Front Brake 5. Driver Side Front Brake Caliper 1. Brake Fluid Reservoir 13. Grommet Caliper 2. Master Cylinder 6. Driver Side P-Clamp 10. Mid Brake Hydraulic Hose 14. P-Clamp 3.
Page 62: Brake Disc And Pad Inspection
HYDRAULIC BRAKE AND PARK BRAKE Brake System Inspection SYSTEMS BRAKE DISC AND PAD INSPECTION • Inspect each brake disc. They should not be warped or have excessive scores or heat checks. Each disc should be at least 0.150 inches (3.81 mm) at the thinnest point. •...
Page 63: Brake System Troubleshooting
HYDRAULIC BRAKE AND PARK BRAKE SYSTEMS Brake System Troubleshooting BRAKE SYSTEM TROUBLESHOOTING The procedures used in making the checks provided in the following troubleshooting guide can be found in the referenced sections of this maintenance and service manual. TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION...
Page 64 HYDRAULIC BRAKE AND PARK BRAKE Brake System Troubleshooting SYSTEMS TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Replace the brake pads. See Brake Pads Incorrect or distorted brake pads and Caliper on page 6-7. Replace hub, axle seal, or caliper, and replace Grease or brake fluid on the brake pads the brake pads.
Page 65: Brake Pads And Caliper
HYDRAULIC BRAKE AND PARK BRAKE SYSTEMS Brake Pads and Caliper TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Replace the caliper. See Brake Pads and Sticking caliper pistons Caliper on page 6-7. Replace the brake pads. See Brake Pads Bent or distorted brake pads and Caliper on page 6-7.
Page 66: Front Brake Pad Installation
HYDRAULIC BRAKE AND PARK BRAKE Brake Pads and Caliper SYSTEMS 2755 Figure 6-2 Front Brake Pad and Caliper FRONT BRAKE PAD INSTALLATION WARNING • If at any point in this procedure the hydraulic system is opened, the brakes must be bled after the correct reinstallation of the brake components.
Page 67: Front Caliper Removal
HYDRAULIC BRAKE AND PARK BRAKE SYSTEMS Brake Pads and Caliper FRONT CALIPER REMOVAL WARNING • If at any point in this procedure the hydraulic system is opened, the brakes must be bled after the correct reinstallation of the brake components. Failure to bleed the brakes could result in decreased braking performance due to air being trapped in the hydraulic system.
Page 68: Rear Brake Pad And Caliper Removal
HYDRAULIC BRAKE AND PARK BRAKE Brake Pads and Caliper SYSTEMS WARNING • To reduce the possibility of diminished brake performance or failure, never use petroleum-based lubricants on brake system components, and ensure lubricant does not contact friction surfaces of brake pads or rotors. Secure caliper assembly to steering upright with two, new socket-head bolts (5).
Page 69: Rear Brake Pad And Caliper Installation
HYDRAULIC BRAKE AND PARK BRAKE SYSTEMS Brake Pads and Caliper NOTE: Driver's side brake hose connection uses 2 hoses (6 and 9) and a double length banjo bolt (8). (Figure 6-4, Page 6-11). Place a clean, tray-type container below the caliper and brake hose assembly to catch brake fluid when the brake hose and caliper body are separated.
Page 70 HYDRAULIC BRAKE AND PARK BRAKE Brake Pads and Caliper SYSTEMS Caliper Only: Secure the brake hose (6) to the caliper with banjo bolt (5) and new copper washers (4) (Figure 6-3, Page 6-11). Tighten to 146 in-lb (16.5 N·m). See following CAUTION and NOTE. CAUTION •...
Page 71: Brake Discs
HYDRAULIC BRAKE AND PARK BRAKE SYSTEMS Brake Discs BRAKE DISCS See General Warnings on page 1-2. DISC REMOVAL WARNING • If at any point in this procedure the hydraulic system is opened, the brakes must be bled after the correct reinstallation of the brake components. Failure to bleed the brakes could result in decreased braking performance due to air being trapped in the hydraulic system.
Page 72: Brake Hose Replacement
HYDRAULIC BRAKE AND PARK BRAKE Brake Hose Replacement SYSTEMS BRAKE HOSE REPLACEMENT See General Warnings, Section 1, Page 1-2. WARNING • 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 brakes could result in decreased braking performance due to air being trapped in the hydraulic system.
Page 73: Mid Brake Hose Removal
HYDRAULIC BRAKE AND PARK BRAKE SYSTEMS Brake Hose Replacement 2754 2770 Figure 6-5 Front Brake Hose T-Bracket Figure 6-6 Front Brake Hose Snap Clip and P-clamp Connect front brake hose to each front caliper with banjo bolts and new copper washers. Tighten banjo bolts to 13 ft-lb (18 N·m).
Page 74: Mid Brake Hose Installation
HYDRAULIC BRAKE AND PARK BRAKE Brake Hose Replacement SYSTEMS Unsnap the brake hose clips along the driver side frame rail and remove hose from vehicle. MID BRAKE HOSE INSTALLATION Install new mid brake hose and position it along the driver side frame rail and up to the master cylinder. Carefully install the flared end of the brake hose into the master cylinder and tighten to 132 in-lb (15 N·m).
Page 75: Master Cylinder And Reservoir
HYDRAULIC BRAKE AND PARK BRAKE SYSTEMS Master Cylinder and Reservoir MASTER CYLINDER AND RESERVOIR See General Warnings, Section 1, Page 1-2. FILLING THE HYDRAULIC SYSTEM The brake fluid reservoir is accessible by opening the hood. Do not allow the brake fluid level to fall below the MIN line.
Page 76: Bleeding The Hydraulic Brake System
HYDRAULIC BRAKE AND PARK BRAKE Bleeding the Hydraulic Brake System SYSTEMS 2038 Figure 6-7 Master Cylinder Rod and Brake Pedal BLEEDING THE HYDRAULIC BRAKE SYSTEM See General Warnings, Section 1, Page 1-2. WARNING • Do not bleed the brakes in the same manner as a DOT 3 system. Failure to bleed the brakes as instructed in this manual will result in decreased braking performance due to air being trapped in the hydraulic system.
Page 77 HYDRAULIC BRAKE AND PARK BRAKE SYSTEMS Bleeding the Hydraulic Brake System Remove the cap from the master cylinder reservoir and top off the master cylinder with fresh DOT 5 silicone brake fluid. 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.
Page 78: Purging The Hydraulic System
HYDRAULIC BRAKE AND PARK BRAKE Bleeding the Hydraulic Brake System SYSTEMS repeat the bleeding sequence. This will dislodge air bubbles that tend to accumulate, allowing for a more complete bleeding process. 6.5. Ensure that no brake fluid gets on the brake rotors or pads. If fluid gets on the brake rotors, they should be cleaned with brake cleaner.
Page 79: Park Brake System
HYDRAULIC BRAKE AND PARK BRAKE SYSTEMS Park Brake System PARK BRAKE SYSTEM See General Warnings, Section 1, Page 1-2. NOTE: The park brake pads are not replaceable. Once pads are worn, the park brake caliper and pad assembly must be replaced as a unit. 2742a Figure 6-8 Park Brake Caliper, and Disc 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual...
Page 80: Park Brake Caliper And Pad Replacement
HYDRAULIC BRAKE AND PARK BRAKE Park Brake System SYSTEMS PARK BRAKE CALIPER AND PAD REPLACEMENT NOTE: A wave washer is to be used during the park brake disc/rotor installation to keep pressure against the rotor to eliminate noise. Chock the wheels, and release the park brake. Remove the seat bottom.
Page 81: Park Brake Adjustment
HYDRAULIC BRAKE AND PARK BRAKE SYSTEMS Park Brake System At pedal, install cable in bracket and secure with jam nuts (Figure 5-5, Page 5-4). Tighten jam nuts to 18 lb-ft (25 N·m). Place cable end over pin on pedal and secure with bow-tie clip. At transmission, install cable (11) in bracket (13) and finger-tighten jam nuts.
Page 82: Park Brake Switch
HYDRAULIC BRAKE AND PARK BRAKE Park Brake System SYSTEMS PARK BRAKE SWITCH Figure 6-9 Park Brake Switch Park Brake Switch Removal Disable the vehicle. Make sure the park brake is engaged. NOTE: When the park brake is engaged, there is more room to remove and install the park brake switch. Remove the screws (1), washers (2 and 3), and barrel nuts (4) (Figure 6-9).
Page 83: Section 7 - Steering And Front Suspension
SECTION 7 — STEERING AND FRONT SUSPENSION DANGER Steering and Front Suspension • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. STEERING WHEEL See General Warnings, Section 1, Page 1-2. STEERING WHEEL REMOVAL Disconnect battery.
Page 84: Steering Wheel Installation
Steering Column STEERING AND FRONT SUSPENSION 2478 2043 Figure 7-1 Steering Wheel Removal Figure 7-2 Steering Wheel Puller STEERING WHEEL INSTALLATION Install the steering wheel (3) on the hex portion of the steering shaft. Align the hex fitting of the wheel with the steering column shaft (Figure 7-1, Page 7-2).
Page 85 STEERING AND FRONT SUSPENSION Steering Column Loosen the bolt (1) on the top yoke (Figure 7-3). Remove the bolt (2) from the bottom yoke. 000070-006A Figure 7-3 Remove Steering Column from Rack and Pinion Remove the three locknuts (3) from the steering column mount bolts (Figure 7-4). NOTE: Bolts are pressed into the steering column mount bracket.
Page 86: Steering Column Installation
Steering Column STEERING AND FRONT SUSPENSION Remove the steering column assembly through the hole (4) in the splash guard (Figure 7-5). 2045B Figure 7-5 Hole in Splash Guard STEERING COLUMN INSTALLATION Install the steering column assembly through the column mounting bracket, frame opening, and down through the hole (1) in the splash guard (Figure 7-6).
Page 87 STEERING AND FRONT SUSPENSION Steering Column Install the bottom yoke (2) onto the rack and pinion shaft (3) (Figure 7-7). 000070-006C Figure 7-7 Bottom Yoke onto Rack and Pinion Install the bolt (4) on the bottom yoke. Tighten the bolt to 18 ft-lb (24 N·m) (Figure 7-8). Loosen the bolt (5) on the top yoke.
Page 88 Steering Column STEERING AND FRONT SUSPENSION 000070-006E Figure 7-9 Install Steering Column onto Mounting Bracket Tighten the bolt (5) on the top yoke to 15 ft-lb (20 N·m) (Figure 7-8, Page 7-5). Rotate the steering wheel to the point of least clearance (A) between the steering intermediate shaft and the accelerator pivot bolt (Figure 7-10).
Page 89: Rack And Pinion
STEERING AND FRONT SUSPENSION Rack and Pinion 10.3. Measure the clearance between the steering intermediate shaft and the accelerator pivot bolt. The clearance must be more than 0.060 in. Install the instrument panel. Lower and secure the hood. Install the steering wheel. Gasoline vehicles: Connect the spark plug.
Page 90: Rack And Pinion Installation
Rack and Pinion STEERING AND FRONT SUSPENSION 2046 2047 Figure 7-11 Drag Link Ball Joint Figure 7-12 Rack and Pinion Bolts Loosen the bolts on the steering universal joint that secure the steering column shaft and the rack and pinion shaft. Remove the rack and pinion spline bolt, and slide the universal joint up on the steering column shaft away from the rack and pinion splined shaft.
Page 91 STEERING AND FRONT SUSPENSION Rack and Pinion Remove both drag links (19) (Figure 7-14, Page 7-9). 2048 2049 Figure 7-13 Drag Link Ball Joint Figure 7-14 Drag Link Remove both bellows clamps (metal clamps or plastic wire ties) (Figure 7-15, Page 7-9). See following NOTE. NOTE: If the dust seal bellows are secured with a metal clamp, remove the clamp.
Page 92 Rack and Pinion STEERING AND FRONT SUSPENSION Remove the snap ring (4) (Figure 7-17, Page 7-10). 2051 2052 Figure 7-16 Remove Dust Seal Figure 7-17 Remove Pinion Snap Ring Install the universal joint on the pinion, and place a fork or a large open-end wrench under the universal joint (Figure 7-18, Page 7-10).
Page 93 STEERING AND FRONT SUSPENSION Rack and Pinion Remove the rack (2) from the housing (1) (Figure 7-22, Page 7-12). 2055 2056 Figure 7-20 Secure Racks Figure 7-21 Remove Inner Ball Joints 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual Page 7-11...
Page 94 Rack and Pinion STEERING AND FRONT SUSPENSION 2057 Figure 7-22 Steering Gear Assembly Page 7-12 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual...
Page 95: Rack And Pinion Assembly
STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION ASSEMBLY Apply a liberal amount of EP grease to the teeth of the rack (2), then slide the rack through the bushing (17) and housing (1) (Figure 7-22, Page 7-12). CAUTION •...
Page 96: Front Suspension
Front Suspension STEERING AND FRONT SUSPENSION 2060 2061 Figure 7-25 Adjust Rack and Pinion Resistance Figure 7-26 Install Inner Ball Joint Insert a 3/8-inch, 1/4-drive deep-well socket into the steering column end of the universal joint (2), and tighten the bolts (1) to 15 ft-lb (20.3 N·m) (Figure 7-25, Page 7-14).
Page 97 STEERING AND FRONT SUSPENSION Front Suspension Wheel alignment consists of adjusting the toe-in or toe-out and camber of the front wheels. See Toe-in Measurement – for vehicles equipped with steering damper accessory on page 7-15. See Toe-Out Measurement on page 7-15.
Page 98 Front Suspension STEERING AND FRONT SUSPENSION Mark each front tire at the center of the tread face that is facing the rear of the vehicle. The marks should be at the same height as the center of each hub. Measure the distance between the marks. Roll the vehicle forward one-half wheel revolution until the marks appear on the forward facing surfaces of the tires at the same height as the center of each hub.
Page 99 STEERING AND FRONT SUSPENSION Front Suspension Measure distance (A) between the edge of the square and a top location on the inside bead of the wheel rim. Record that measurement. See following NOTE. NOTE: Do not measure against the wheel rim edge or tire sidewall. Both of these can have variations in their surfaces that will result in inaccurate dimensions.
Page 100: Front Suspension Components
Front Suspension Components STEERING AND FRONT SUSPENSION FRONT SUSPENSION COMPONENTS See General Warnings, Section 1, Page 1-2. NOTE: Camber adjustment bars are marked with a D for driver side and P for passenger side and must be installed correctly. STEERING UPRIGHT REMOVAL Disconnect battery and spark plug wire(s) (gasoline vehicles only).
Page 101 STEERING AND FRONT SUSPENSION Front Suspension Components WARNING • If at any point in this procedure the hydraulic system is opened, the brakes must be bled after the correct reinstallation of the brake components. Failure to bleed the brakes could result in decreased braking performance due to air being trapped in the hydraulic system.
Page 102: Steering Upright Installation
Front Suspension Components STEERING AND FRONT SUSPENSION CAUTION • Take care when separating the ball joint stud from the upright so as not to tear or puncture the rubber seal around the ball socket. If damaged, the ball joint with rubber boot must be replaced. Remove the upright assembly from the vehicle.
Page 103 STEERING AND FRONT SUSPENSION Front Suspension Components 3.1. Remove the bolt from the bottom mount of the shock absorber, and remove the shock absorber from the A-arm. See following NOTE. NOTE: It may be necessary to place a floor jack under the A-arm assembly and raise it slightly to relieve pressure from the bottom shock absorber bolt.
Page 104: Upper A-Arm Installation
Front Suspension Components STEERING AND FRONT SUSPENSION 2070 Figure 7-41 Ball Joint C-Clip UPPER A-ARM INSTALLATION Install a new ball joint if necessary. See Upper Ball Joint Installation on page 7-21. Install new A-arm frame bushings. See following NOTE. 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.
Page 105: Lower A-Arm Installation
STEERING AND FRONT SUSPENSION Front Suspension Components 2071 2072 Figure 7-42 Lower A-Arm Attachment Figure 7-43 A-Arm Frame Bushings Lower Ball Joint Removal Inspect the ball joint. Replace the ball joint if it is worn, loose, or if the rubber boot is damaged. 1.1.
Page 106: Front Coil-Over Shock Absorber Removal
Front Suspension Components STEERING AND FRONT SUSPENSION Install a new bolt, washer, and new flanged locknut. Tighten the hardware to 110 ft-lb (148 N·m), applying torque to the bolt side. Repeat steps 1 through 4 for the remaining side if necessary. Align the front wheels.
Page 107: Front Coil-Over Shock Absorber Installation
STEERING AND FRONT SUSPENSION Front Suspension Components FRONT COIL-OVER SHOCK ABSORBER INSTALLATION NOTE: The standard-duty front coil-over springs and shocks are painted black. Heavy-duty front coil-over springs and shocks have shock housings painted black and springs painted silver. When front shock absorbers are installed, ensure both shock absorbers have identical part numbers. Install the top of the shock mount on the vehicle frame with a bolt and flange-head locknut.
Page 108 Front Suspension Components STEERING AND FRONT SUSPENSION Pagination Page Page 7-26 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual...
Page 109: Section 8 - Wheels, Tires And Hubs
SECTION 8 — WHEELS, TIRES AND HUBS DANGER Wheels, Tires and Hubs • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. GENERAL INFORMATION These vehicles are equipped with either all-terrain or mud tires. The same size tire is used for the front and rear. See Vehicle Specifications on page 2-1.
Page 110: Wheels
Wheels WHEELS, TIRES AND HUBS NOTE: Small holes in the tire can be plugged with a standard automotive tubeless tire repair kit available at auto supply stores. Tires must be removed and installed from the valve stem side of the rim. WHEELS See General Warnings, Section 1, Page 1-2.
Page 111: Tire Installation
WHEELS, TIRES AND HUBS Front Hubs TIRE INSTALLATION Use a tire machine to install the new tire on the wheel. See following NOTE. NOTE: When installing mud tires, determine which side of the vehicle they will be used on. The arrow molded on the sidewall indicates designed rotation when vehicle is moving forward (Figure 8-1, Page 8-1).
Page 112 Front Hubs WHEELS, TIRES AND HUBS 1899 Figure 8-2 Position Steel Blocks and Upright on Press Press the bearing out of the upright. 3.1. Position the upright (5) with the two ball joint arms down on one steel block (1) and the drag link arm down on a second steel block (1) (Figure 8-3, Page 8-4).
Page 113: Front Hub Installation
WHEELS, TIRES AND HUBS Front Hubs FRONT HUB INSTALLATION WARNING • If at any point in this procedure the hydraulic system is opened, the brakes must be bled after the correct reinstallation of the brake components. Failure to bleed the brakes could result in decreased braking performance due to air being trapped in the hydraulic system.
Page 114: Rear Hubs
Rear Hubs WHEELS, TIRES AND HUBS 2.4. Use a rod or bar (8) larger than the inner race diameter of the bearing (7) and press the bearing onto the hub until it bottoms out against the shoulder of the hub shaft. The hub shaft should be approximately 3/32 inch (2.38 mm) below the bearing inner race surface (Figure 8-6, Page 8-6).
Page 115: Rear Hub Installation
WHEELS, TIRES AND HUBS Rear Hubs WARNING • 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. •...
Page 116 Rear Hubs WHEELS, TIRES AND HUBS Inspect the brake pads for wear and replace if necessary. NOTE: If brake pads are replaced on one side, replace the opposite side also. Install rear brake caliper onto axle tube. See following NOTE. NOTE: It may be necessary to loosen the park brake adjuster arm on the caliper.
Page 117: Section 9 - Rear Suspension
SECTION 9 — REAR SUSPENSION DANGER Rear Suspension • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. REAR COIL-OVER SHOCK ABSORBER See General Warnings, Section 1, Page 1-2. Standard models are equipped with rear shock absorbers and coil-over springs designed for standard-duty service. Heavy-duty rear shock absorbers and coil-over springs are available as an option for heavy-duty service.
Page 118: Rear Shock Installation
Rear Coil-Over Shock Absorber REAR SUSPENSION 1. Location of brake hose with rubber grommet 2494 Figure 9-1 Rear Shock Absorber Removal REAR SHOCK INSTALLATION Ensure that the adjustment position of the coil spring on the new shock absorber is the same as the previous shock absorber.
Page 119: Trailing Arms And Lateral Links
REAR SUSPENSION Trailing Arms and Lateral Links TRAILING ARMS AND LATERAL LINKS See General Warnings, Section 1, Page 1-2. LATERAL LINK REMOVAL Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4.
Page 120 Trailing Arms and Lateral Links REAR SUSPENSION 2495 Figure 9-2 Rear Suspension Components – 4 Link Page 9-4 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual...
Page 121: Section 10 - Periodic Maintenance
SECTION 10 — PERIODIC MAINTENANCE DANGER Periodic Maintenance • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. PERIODIC SERVICE SCHEDULE See General Warnings, Section 1, Page 1-2. WARNING • Service, repairs, and adjustments must be made per instructions in this maintenance and service manual.
Page 122 Periodic Service Schedule PERIODIC MAINTENANCE PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Check engine circulating air passage; visually inspect unshrouded area around engine Engine exhaust for grass and debris and clean if necessary. Diesel vehicles: Check for grass and debris around the radiator. Monthly service by owner or trained Check air pressure and adjust if necessary.
Page 123: Periodic Service Schedule
PERIODIC MAINTENANCE Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Check for leaks around gaskets, fill plugs, etc. Gasoline vehicles: Adjust valve clearance. See Kawasaki FH680D Service Manual. Gasoline vehicles: Inspect, clean, and gap spark plug; replace if necessary. See authorized dealer or trained technician for Engine service.
Page 124: Periodic Service Schedule - Intellitach
Periodic Service Schedule – IntelliTach PERIODIC MAINTENANCE PERIODIC SERVICE SCHEDULE – INTELLITACH See General Warnings, Section 1, Page 1-2. WARNING • Service, repairs, and adjustments must be made per instructions in the appropriate maintenance and service manual. NOTE: If the vehicle is constantly subjected to heavy use or severe operating conditions, these preventive maintenance procedures should be performed more often than recommended in the Periodic Service and Lubrication Schedules.
Page 125 PERIODIC MAINTENANCE Periodic Service Schedule – IntelliTach PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Battery Clean terminals and wash dirt from casing; check electrolyte level (on side-post battery only). Add distilled water if necessary. See page Battery on page 14-21. Front wheel alignment and toe-in Check and adjust if necessary.
Page 126: Periodic Lubrication Schedule
Periodic Lubrication Schedule PERIODIC MAINTENANCE PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Gasoline vehicle: Kawasaki engine- First change 10 hours Gasoline (Kawasaki engine) vehicles: 1 Diesel vehicle: First change qt. and 19 oz (1.5 L) with filter 50 hours Additional change Change engine oil and oil filter Diesel vehicles: 3 qt.
Page 127 PERIODIC MAINTENANCE Periodic Lubrication Schedule Figure 10-2 Lubrication Points – Diesel Vehicles 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual Page 10-7...
Page 128: Periodic Lubrication Schedule - Intellitach
Periodic Lubrication Schedule – IntelliTach PERIODIC MAINTENANCE PERIODIC LUBRICATION SCHEDULE – INTELLITACH PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Diesel vehicle: First change 50 hours – additional change Diesel vehicles: 3 qt. (2.8 L) with filter. See for both every 100 hours of Change engine oil and oil filter Oil Viscosity on page 10-14.
Page 129: Lubricating The Attachment Arm And Interface - Intellitach
Lubricating the Attachment Arm and PERIODIC MAINTENANCE Interface – IntelliTach LUBRICATING THE ATTACHMENT ARM AND INTERFACE – INTELLITACH Always use a good quality, lithium-based, multi-purpose grease. Apply lubricant until extra grease shows. Grease the 8 grease fittings every 50 hours of operation, 2 times a year (whichever occurs first) or whenever the attachment arm and interface are removed and reinstalled on the vehicle.
Page 130: Brake Fluid Reservoir
Brake Fluid Reservoir PERIODIC MAINTENANCE BRAKE FLUID RESERVOIR 1. Full Level 2. Safe Level 3. Low Level 2692 2693 Figure 10-5 Brake Fluid and Coolant Access (diesel only) Figure 10-6 Brake Fluid Reservoir Level The brake fluid reservoir (1) is located under the hood. Raise the hood to check the brake fluid level. During the brake fluid level inspection, also inspect the following: •...
Page 131: Engine Oil Level Check
PERIODIC MAINTENANCE Engine Oil NOTE: The normal oil pressure value stated in the Kawasaki engine manual is 35 to 45 psi at idle; however, the remote filter design causes oil pressure to be 18 psi, which is normal for this type of oil circulation design. ENGINE OIL LEVEL CHECK Remove the oil level dipstick from the oil filler tube and wipe oil from the dipstick (Figure 10-7 and Figure 10-8).
Page 132 Engine Oil PERIODIC MAINTENANCE Disconnect battery and spark plug (Gas only) wires. See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4. Remove the oil filler cap to allow the oil to drain properly. Position a pan designed for oil changes under the drain plug (Figure 10-9 or Figure 10-10).
Page 133 PERIODIC MAINTENANCE Engine Oil Figure 10-11 Replace Engine Oil Filter – Kawasaki Gasoline Vehicles Engine Oil Filter Change Drain the engine oil. See Engine Oil Draining on page 10-11. Place the oil drain pan under the engine oil filter (2) (Figure 10-10 or Figure 10-11). Remove the engine oil filter.
Page 134: Oil Viscosity
Engine Oil PERIODIC MAINTENANCE Hand tighten 2/3 to 3/4 turn after the filter gasket contacts the mounting surface. Figure 10-14 Add Engine Oil – Gasoline Vehicles Figure 10-15 Add Engine Oil – Diesel Vehicles Engine Oil Filling Add engine oil (Figure 10-14 or Figure 10-15). With filter change, the engine requires the following amounts: –...
Page 135: Spark Plugs
PERIODIC MAINTENANCE Spark Plugs NOTE: Use engine oil with API classification SJ for gasoline engines and CF for diesel engines. Gasoline Vehicles Only: Below 40°F (4°C), the use of SAE 30 may result in hard starting. Gasoline Vehicles Only: Above 80°F (27°C), the use of 10W-30 may cause increased oil consumption. Check oil level more frequently.
Page 136: Gearcase Lubrication
Gearcase Lubrication PERIODIC MAINTENANCE GEARCASE LUBRICATION LUBRICATION LEVEL CHECK FOR FRONT DIFFERENTIAL, TRANSMISSION AND REAR DIFFERENTIAL Front differential: 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). Figure 10-18 Front Differential Level Indicator, Fill and Drain Plug Transmission: When the vehicle is on a level surface, use the level indicator hole (1) as a lubricant level indicator (Figure 10-19).
Page 137 PERIODIC MAINTENANCE Gearcase Lubrication 1. Fill Plug 2. Drain Plug 1. Lubricant Level Indicator 2. Drain Plug 3. Fill Plug 2558 2480 Figure 10-19 Transmission Level Indicator, Fill and Drain Figure 10-20 Rear Differential Fill and Drain Plugs Plugs Front differential: Clean and install the drain plug (2) and washer before filling the front differential with new lubricant (Figure 10-18).
Page 138: Hydraulic System - Intellitach Vehicle
Hydraulic System – IntelliTach Vehicle PERIODIC MAINTENANCE HYDRAULIC SYSTEM – INTELLITACH VEHICLE WARNING • Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand.
Page 139: Engine Coolant - Diesel Vehicles
PERIODIC MAINTENANCE Engine Coolant – Diesel Vehicles ENGINE COOLANT – DIESEL VEHICLES See General Warnings, Section 1, Page 1-2. ENGINE COOLANT LEVEL CHECK The coolant reserve tank (2) is located under the hood on the passenger side (Figure 10-5, Page 10-10). Raise the hood to check the coolant level before every operation.
Page 140: Biodiesel Fuel (Diesel Vehicles Only)
Fueling Instructions PERIODIC MAINTENANCE Replace the fuel cap. Ensure that the cap is tightened securely. Clean any spilled fuel from the cap or around the fuel cap area. Figure 10-23 Fuel Tank – Gasoline Vehicles Figure 10-24 Fuel Tank – Diesel Vehicles BIODIESEL FUEL (DIESEL VEHICLES ONLY) Biodiesel has unique qualities that should be considered before it is used in the Kubota D722 diesel engine.
Page 141: Draining Water From Fuel Filter
PERIODIC MAINTENANCE Fueling Instructions If biodiesel is used, be sure to apply the following guidelines: • Ensure the fuel tank is as full as possible at all times to prevent moisture from collecting. • Ensure that the fuel tank cap is securely tightened to prevent water from entering the fuel tank. •...
Page 142: Battery
Battery PERIODIC MAINTENANCE 2327 Figure 10-25 Fuel Filter with Water Separator BATTERY For periodic battery maintenance, see Battery on page 13-18 (gasoline vehicles) or page 14-21 (diesel vehicles). Page 10-22 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual...
Page 143: Section 11 - Troubleshooting And Electrical System: Gasoline Vehicles
SECTION 11 — TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES DANGER Troubleshooting and Electrical System: Gasoline Vehicles • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. TROUBLESHOOTING GUIDE The following troubleshooting guide will be helpful in identifying operating difficulties should they occur. The guide includes the symptom, probable cause(s) and suggested checks.
Page 144 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: GASOLINE VEHICLES TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Spark plug is fouled or in poor condition Spark Plugs on page 10-15 See the Kawasaki FH680D engine manual Spark plug wire is damaged or loose (CC P/N 103351201).
Page 145 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO See the Kawasaki FH680D engine manual Exhaust valve is restricted with carbon deposit (CC P/N 103351201). Muffler or exhaust pipe restricted with carbon Exhaust System on page 15-6 or other substance Test Procedure 21 –...
Page 146 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: GASOLINE VEHICLES TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Test Procedure 6 – Starter Control Circuit on Starter control circuit is not operating page 11-15 Start relay failure Test Procedure 7 – Start Relay on page 11-16 Fuse is blown Test Procedure 2 –...
Page 147 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Section 15 — Gasoline Engine, Muffler, Fuel Engine mounting nuts or bolts are loose System, and Clutches Misaligned muffler mounting clamp Exhaust System on page 15-6 Damaged drive belt Clutches on page 15-29 Excessive vehicle vibration.
Page 148: Wiring Diagram
TROUBLESHOOTING AND ELECTRICAL Wiring Diagram SYSTEM: GASOLINE VEHICLES WIRING DIAGRAM WD1033057A7-L NOTE: AWD diagram shown; 2-wheel drive vehicle uses same harness Figure 11-1 Wiring Diagram – Front Page 11-6 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual...
Page 149 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Wiring Diagram WD1033057A7-R NOTE: AWD diagram shown; 2-wheel drive vehicle uses same harness Figure 11-2 Wiring Diagram – Rear 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual Page 11-7...
Page 150 TROUBLESHOOTING AND ELECTRICAL Wiring Diagram SYSTEM: GASOLINE VEHICLES 000662-005 1. Diodes Figure 11-3 Sonic Weld and Diode Locations (Approximate) – Gasoline Page 11-8 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual...
Page 151: Test Procedures
TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures TEST PROCEDURES Index of Test Procedures 1 – Battery 2 – Fuse 3 – Ground Cables 4 – Key Switch (ON Position) 5 – Key Switch (Starter Circuit) 6 – Starter Control Circuit 7 –...
Page 152 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES DANGER • 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 rubber gloves when working on or near batteries.
Page 153 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures 1.250 1.280 1. Level Indicator 2. Cap 3. Plates Electrolyte level at least 1/2 inch (13 MM) above plates or to level indicator. View at eye level. Figure 11-4 Hydrometer Test Figure 11-5 Battery Electrolyte Level (Side-Post Battery Only) Hydrometer Calibration Most hydrometers are calibrated to read correctly at 80 °F (27 °C).
Page 154 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES NOTE: A fully charged battery that is in good condition should have a specific gravity of at least 1.225 in all cells and the difference in the specific gravity of any two cells should be less than 50 points. Open-circuit voltage, the battery voltage with no electrical load, should be at least 12.4 volts.
Page 155 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures WARNING • 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.
Page 156 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES 2082 2083 Figure 11-7 Frame Ground Figure 11-8 Engine Ground to Frame TEST PROCEDURE 4 – Key Switch (ON Position) See General Warnings, Section 1, Page 1-2. Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 157 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures TEST PROCEDURE 5 – Key Switch (Starter Circuit) See General Warnings, Section 1, Page 1-2. Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4.
Page 158 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES 2084 Figure 11-10 Solenoid Coil Wire (w127) Removed If the readings differ from those described in step 5, perform the following test procedures: – Check the battery. See Test Procedure 1 – Battery on page 11-9. –...
Page 159 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures NOTE: The carburetor heater and accessory relays (if equipped with accessory relay) may be removed to isolate the sound of the start relay click. If the reading is 12 VDC and the relay does not click when the key switch is turned to the START position, replace the relay.
Page 160 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES Set the multimeter to 20 VDC. Place the probes to measure the voltage between the 18-gauge purple relay wire (w135) terminal and the frame ground (Figure 11-13, Page 11-18). Monitor the multimeter. The reading should indicate 0 volts with the key off. The reading should indicate approximately 12 VDC with the key on.
Page 161 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures TEST PROCEDURE 9 – Wire Harness Diodes See General Warnings, Section 1, Page 1-2. A diode is designed to conduct current in one direction only. Depending on the application, diodes are used in the vehicle to control electrical system logic, or to help protect relay and switch contacts from excessive arcing.
Page 162 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES DIODE TROUBLESHOOTING GUIDE IN-LINE WIRE FAILURE DIODE LOCATION FUNCTION SYMPTOM/COMMENT CONDITION (WIRES) Will contribute to the premature failure Open of the limit switch (switch is only used Front differential coil flyback diode in AWD vehicle).
Page 163 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures TEST PROCEDURE 10 – Diode 1 on wire 32 and 35 See General Warnings, Section 1, Page 1-2. Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4.
Page 164 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES 2089 Figure 11-16 Carburetor Solenoid Bullet Connector TEST PROCEDURE 12 – Diode 3 on wire 45 and 39 See General Warnings, Section 1, Page 1-2. Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 165 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures Raise the hood and disconnect the multi-pin connector from the key switch. Disconnect the bullet connector in the carburetor solenoid green wire (Figure 11-16, Page 11-22). Set the multimeter to the diode test function. Connect the black (–) probe of the multimeter to the frame (ground).
Page 166 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURE 15 – Neutral Switch (Transmission) See General Warnings, Section 1, Page 1-2. The neutral switch is located on the transmission housing. Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 167 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures 2092 2094 Figure 11-19 Neutral Switch – Neutral Position Figure 11-20 Neutral Switch – Reverse Position Check for continuity on the switch contacts with the Forward/Reverse handle in the NEUTRAL position (Figure 11-19, Page 11-25).
Page 168 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES 2363 Figure 11-21 Front Differential Switch 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 11-21, Page 11-26). Move the accelerator pedal and listen for an audible click from the switch.
Page 169 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures TEST PROCEDURE 19 – Charge Coil See General Warnings, Section 1, Page 1-2. Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4. Disconnect the 3-pin connector from the voltage regulator.
Page 170 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES If the reading is less than 14.0 volts and not rising, check the charge coil. See Test Procedure 19 – Charge Coil on page 11-27. Also check for a loose connection at the voltage regulator 3-pin connector and check the continuity of each wire in the voltage regulator 3-pin connector.
Page 171 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures TEST PROCEDURE 21 – Ignition Spark See General Warnings, Section 1, Page 1-2. NOTE: Keep the battery connected during this test procedure. Disable the vehicle. See Disabling the Vehicle on page 1-3. Remove the spark plug wire from one of the spark plugs.
Page 172 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES 2096 2097 Figure 11-23 Engine Harness Connector Figure 11-24 Engine Kill Wire TEST PROCEDURE 23 – Grounded Kill Wire See General Warnings, Section 1, Page 1-2. NOTE: Keep the battery connected during this test procedure. Disable the vehicle.
Page 173 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures TEST PROCEDURE 24 – Key Switch (Engine Kill Circuit) See General Warnings, Section 1, Page 1-2. Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4.
Page 174 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURE 26 – Reverse Warning Buzzer (If Equipped) See General Warnings, Section 1, Page 1-2. Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4.
Page 175 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures 2089 Figure 11-26 Carburetor Solenoid Bullet Connector TEST PROCEDURE 28 – Low Oil Warning Light Circuit See General Warnings, Section 1, Page 1-2. If the low oil warning light stays on, test the oil pressure switch. See the Kawasaki FH680D engine manual (CC P/N 103351201).
Page 176 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURE 29 – 12-Volt Accessory Receptacle See General Warnings, Section 1, Page 1-2. NOTE: Keep the battery connected during this test procedure. Disable the vehicle. See Disabling the Vehicle on page 1-3. Set the multimeter to 20 VDC.
Page 177 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures may be used as a guideline to determine if the fuel level sending unit is operating correctly. Make sure the float is at the surface of the fuel in the tank. FLOAT POSITION RESISTANCE READING FUEL GAUGE READINGS Lower position (tank empty)
Page 178 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES Set a multimeter to 20 volts DC and place the red (+) probe on the positive (+) post of the battery. Place the black (–) probe on the negative (–) post of the battery. Record the voltage reading. Set a multimeter to 20 volts DC and place the red (+) probe on the (2) terminal of the fuel gauge/hour meter where the blue wire (w25) is connected.
Page 179 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures TEST PROCEDURE 33 – Light Switch See General Warnings, Section 1, Page 1-2. NOTE: The headlight circuit is protected by the 20-amp fuse. Check the fuse before this procedure is performed. See Test Procedure 2 –...
Page 180 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 11-32 Voltage Measurement at Headlight Socket If there is no voltage reading at the wire harness, check the continuity of the 16-gauge blue wires (w01 and w03) from the headlight to the light switch.
Page 181 TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES Test Procedures 2102 2103 Figure 11-34 Bed Lift Motor Voltage Reading with Switch Figure 11-35 Bed Lift Motor Voltage Reading with Switch in UP position in DOWN position TEST PROCEDURE 35 – Bed Lift Motor NOTE: Keep the battery connected during this test procedure.
Page 182 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: GASOLINE VEHICLES TEST PROCEDURE 36 – Bed Lift Switch Remove the bed lift switch. See Bed Lift Switch Removal on page 13-10. Check continuity between the terminals (Figure 11-36, Page 11-40) of the switch and compare the readings with the Bed Lift Switch Continuity Table.
Page 183: Section 12 - Troubleshooting And Electrical System: Diesel Vehicles
SECTION 12 — TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES DANGER Troubleshooting and Electrical System: Diesel Vehicles • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. TROUBLESHOOTING GUIDE The following troubleshooting guide will be helpful in identifying operating difficulties should they occur. The guide includes the symptom, probable cause(s) and suggested checks.
Page 184 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: DIESEL VEHICLES TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Fuel tank is empty Fuel System on page 16-8 Fuel with low cetane number Use specified fuel. See owner’s manual. Use specified fuel and engine oil. See owner’s Excessively high viscosity fuel or engine oil manual.
Page 185 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Battery is discharged Test Procedure 1 – Battery on page 12-10 Test Procedure 4 – Key Switch (Starter Circuit) Key switch failed on page 12-15 Test Procedure 7 –...
Page 186 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: DIESEL VEHICLES TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Oil level is low Add engine oil. See owner’s manual. See the Kubota D722 diesel engine manual Oil level sensor failure Low oil warning light stays on. (CC P/N 103840201).
Page 187 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO See the Kubota D722 diesel engine manual Fuel mixed into engine lubricant oil. Worn injection pump plunger (CC P/N 103840201). Failed head gasket See the Kubota D722 diesel engine manual Water mixed into engine lubricant oil.
Page 188 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: DIESEL VEHICLES TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Drive belt is worn, cracked, glazed, or frayed Drive Belt Removal on page 16-25 Drive Clutch Cleaning and Inspection on page Torque converter does not shift smoothly. Drive clutch malfunction 16-26 Driven clutch malfunction...
Page 189: Wiring Diagram
TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Wiring Diagram WIRING DIAGRAM WD1032775E7-L Figure 12-1 Wiring Diagram for Diesel Utility Vehicles (Front) 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual Page 12-7...
Page 190 TROUBLESHOOTING AND ELECTRICAL Wiring Diagram SYSTEM: DIESEL VEHICLES WD1032775E7-R Figure 12-2 Wiring Diagram for Diesel Utility Vehicles (Rear) Page 12-8 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual...
Page 191 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Wiring Diagram 000662-004 1. Diodes Figure 12-3 Sonic Weld and Diode Locations (Approximate) – Diesel 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual Page 12-9...
Page 192: Test Procedures
TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES TEST PROCEDURES Index of Test Procedures 1 – Battery 2 – Fuse 3 – Ground Cables 4 – Key Switch (Starter Circuit) 5 – Key Switch (ON Position) 6 – Key Switch (Glow Plug Circuit) 7 –...
Page 193 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures DANGER • 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 rubber gloves when working on or near batteries.
Page 194 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES 1.250 1.280 1. Level Indicator 2. Cap 3. Plates Electrolyte level at least 1/2 inch (13 MM) above plates or to level indicator. View at eye level. Figure 12-4 Hydrometer Test Figure 12-5 Battery Electrolyte Level (Side-Post Battery Only) Hydrometer Calibration Most hydrometers are calibrated to read correctly at 80 °F (27 °C).
Page 195 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures NOTE: A fully charged battery that is in good condition should have a specific gravity of at least 1.225 in all cells and the difference in the specific gravity of any two cells should be less than 50 points. Open-circuit voltage, the battery voltage with no electrical load, should be at least 12.4 volts.
Page 196 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES WARNING • 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.
Page 197 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures 2106 2107 Figure 12-7 Frame Ground Figure 12-8 Engine Ground (Under Starter) TEST PROCEDURE 4 – Key Switch (Starter Circuit) See General Warnings, Section 1, Page 1-2. Disconnect battery. See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 198 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES REAR VIEW FRONT VIEW Continuity Diagram Key Position PRE- START HEAT 2108 Figure 12-9 Key Switch Terminals and Continuity Diagram Check the B and I terminals. 6.1. Use alligator clips to connect the multimeter probes between the B and I terminals. With the key in the START position, the multimeter should indicate continuity (Figure 12-9, Page 12-16).
Page 199 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures TEST PROCEDURE 6 – Key Switch (Glow Plug Circuit) See General Warnings, Section 1, Page 1-2. Disconnect battery. See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4. Ensure that the key switch connector is connected correctly and is tight.
Page 200 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES TEST PROCEDURE 7 – Starter Control Circuit See General Warnings, Section 1, Page 1-2. Disable the vehicle. See Disabling the Vehicle on page 1-3. Disconnect the 16-gauge green wire (w127) from the starter solenoid coil to prevent the vehicle from unintentionally starting (Figure 12-10, Page 12-18).
Page 201 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures 2111 2112 Figure 12-12 Start Relay Coil Circuit Test Figure 12-13 Start Relay Contact Test TEST PROCEDURE 8 – Start Relay See General Warnings, Section 1, Page 1-2. Disable the vehicle. See Disabling the Vehicle on page 1-3. Disconnect the 16-gauge green wire (w127) from the starter solenoid coil to prevent the vehicle from unintentionally starting (Figure 12-10, Page 12-18).
Page 202 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES 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 203 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures NOTE: The start and accessory relays may be removed temporarily to isolate the sound of the fan relay click. 2113 2114 Figure 12-14 Check Power To Fan Relay Figure 12-15 Fan Relay Contact Test If the fan runs constantly, even with the key switch OFF, remove the relay.
Page 204 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES WARNING • 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 12-16, Page 12-22). Test for failed switches in closed condition.
Page 205 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures WARNING • Hot! Do not touch hot surfaces or boiling water. Contact with hot surfaces or boiling water will result in severe burns. Allow hot surfaces to cool adequately before touching them. 6.8.
Page 206 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES Voltage to Fan Motor Disable the vehicle. See Disabling the Vehicle on page 1-3. Raise the hood. Disconnect the two-pin connector from the fan motor (Figure 12-18, Page 12-24). Disconnect the two-pin connector from the thermostat switch (Figure 12-19, Page 12-24). Place a jumper wire between the frame and the 18-gauge yellow/black wire at the two-pin connector disconnected from the thermostat switch.
Page 207 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures TEST PROCEDURE 12 – Wire Harness Diodes See General Warnings, Section 1, Page 1-2. A diode is designed to conduct current in one direction only. Depending on the application, diodes are used in the vehicle to control electrical system logic, or to help protect relay and switch contacts from excessive arcing.
Page 208 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES DIODE TROUBLESHOOTING GUIDE IN-LINE WIRE FAILURE DIODE LOCATION FUNCTION SYMPTOM/COMMENT CONDITION (WIRES) Will contribute to the premature failure Open of the differential limit switch contacts. Diode 1 w32 and w35 Differential solenoid coil flyback diode With key switch ON, the 30-amp fuse Closed (on w125) will blow repeatedly until the...
Page 209 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures TEST PROCEDURE 14 – Diode 2 on wire 40 See General Warnings, Section 1, Page 1-2. Disconnect battery. See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4. Raise the hood.
Page 210 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES Disconnect the three-pin connector (w122, w135, w108) between the fuel solenoid and the wire harness (Figure 12-22, Page 12-28). Disconnect the bullet connector, on the gray wire (w140), between the fuel pump and the wire harness (Figure 12-23, Page 12-28).
Page 211 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures If the readings obtained in the previous steps are incorrect, replace the diode. See Wire Harness Diode Removal on page 14-20. 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual Page 12-29...
Page 212 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES TEST PROCEDURE 17 – Neutral Switch (Transmission) See General Warnings, Section 1, Page 1-2. The neutral switch is located on the transmission housing. Disconnect battery. See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 213 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures 2092 2094 Figure 12-25 Neutral Switch – Neutral Position Figure 12-26 Neutral Switch – Reverse Position TEST PROCEDURE 18 – Wire Continuity See General Warnings, Section 1, Page 1-2. Disconnect battery. See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 214 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES 2363 Figure 12-27 Front Differential Switch Move the accelerator pedal and listen for an audible click from the switch. If there is no click, check the limit switch for proper alignment and switch arm movement. Place the red (+) probe of the multimeter on one terminal and the black (–) probe on the other terminal of the switch.
Page 215 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures TEST PROCEDURE 21 – Alternator See General Warnings, Section 1, Page 1-2. NOTE: Keep the battery connected during this test procedure. Disable the vehicle. See Disabling the Vehicle on page 1-3. Ensure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Check engine RPM setting to ensure it is adjusted correctly.
Page 216 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES Place the red (+) probe on the fusible link ring terminal atttached to the alternator stud. The reading should indicate approximately 12 VDC (or full battery voltage). If the multimeter did not indicate voltage, check the following: –...
Page 217 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures 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. If the voltage reading obtained in step 8 is correct, check the filament of the warning light.
Page 218 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES – Wire continuity of wires w125, w24, w26, w47, and w137. See Test Procedure 18 – Wire Continuity on page 12-31. TEST PROCEDURE 25 – Reverse Warning Buzzer Limit Switch (If Equipped) See General Warnings, Section 1, Page 1-2.
Page 219 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures TEST PROCEDURE 27 – Fuel Solenoid Pull Coil Circuit See General Warnings, Section 1, Page 1-2. NOTE: Keep the battery connected during this test procedure. Disable the vehicle. See Disabling the Vehicle on page 1-3. Disconnect the three-pin connector between the fuel solenoid and the wire harness (Figure 12-22, Page 12-28).
Page 220 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES – Wire continuity of wires w122, w121, w37, w48, w24, w125, w126, and w201. See Test Procedure 18 – Wire Continuity on page 12-31. TEST PROCEDURE 29 – Low Oil Warning Light Circuit See General Warnings, Section 1, Page 1-2.
Page 221 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures TEST PROCEDURE 31 – Fuel Level Sending Unit See General Warnings, Section 1, Page 1-2. WARNING • To avoid the possibility of fire or explosion, make sure the fuel tank cap is securely in place while performing this test procedure.
Page 222 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES – Black ground wires at the fuel level sending unit (w106) and at the fuel gauge/hour meter (w22). See Fuel Gauge/Hour Meter Removal on page 14-7. 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.
Page 223 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures TEST PROCEDURE 32 – Fuel Gauge See General Warnings, Section 1, Page 1-2. NOTE: Keep the battery connected during this test procedure. 1. Black(Jumper Wire From 6) 2. Blue 4. Orange 6. Black 7. White Figure 12-33 Fuel Gauge/Hour Meter Disable the vehicle.
Page 224 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES WAVETEK WAVETEK 1000 1000 2000 2000 200k 200k 200nA 200nA 1000 --- FUSED 750V 1000 --- FUSED 750V 1. 20 VDC Setting 2. Orange 3. Black 4. White 5. Blue 1. 20 VDC Setting 2. Orange Figure 12-34 Fuel Gauge Voltage Test - Terminal 2 Figure 12-35 Fuel Gauge Voltage Test - Terminal 4 TEST PROCEDURE 33 –...
Page 225 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures Press the upper and lower retaining tabs and push the light switch out of the instrument panel. Use a multimeter set to 20 volts DC and place alligator clips on the multimeter probes. Connect the red (+) probe to the light switch terminal where the blue wire (w03) is connected (Figure 12-36, Page 12-43).
Page 226 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES 7.1. Set the multimeter to 20 VDC. 7.2. Place the black (–) probe of multimeter into the black wire (w13) terminal of the wire harness and use an alligator clip to attach the red (+) probe onto the positive (+) battery terminal. If the multimeter reading is approximately 12 volts, the black wire has continuity.
Page 227 TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES Test Procedures – A reading of approximately 0 VDC indicates a failed bed lift switch, failed bed lift circuit breaker, a poor connection in the bed lift wire harness, or a broken wire. 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.
Page 228 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: DIESEL VEHICLES BED LIFT SWITCH CONTINUITY Between Terminals Cont. when pushed DOWN Cont. when Cont. when pushed DOWN pushed UP Cont. when pushed UP Cont. when pushed DOWN Cont. when Cont. when pushed DOWN pushed UP Cont.
Page 229: Section 13 - Electrical Components: Gasoline Vehicles
SECTION 13 — ELECTRICAL COMPONENTS: GASOLINE VEHICLES DANGER Electrical Components: Gasoline Vehicles • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. STARTER AND STARTER SOLENOID See General Warnings, Section 1, Page 1-2. Refer to the engine manual for testing, removal, disassembly, and installation procedures.
Page 230: Relay Removal
ELECTRICAL COMPONENTS: GASOLINE Neutral Switch VEHICLES RELAY REMOVAL Disable the vehicle. See Disabling the Vehicle on page 1-3. Remove the electrical component cover. Remove the relay from the multi-pin connector. RELAY INSTALLATION Insert the relay into the multi-pin connector. See following NOTE. NOTE: The relay contacts are keyed to ensure that the relay can only be installed in the correct orientation.
Page 231: Testing The Carburetor Solenoid
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Carburetor Heater TESTING THE CARBURETOR SOLENOID See Test Procedure 27 – Carburetor Solenoid Circuit on page 11-32. CARBURETOR SOLENOID REMOVAL Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4.
Page 232: Carburetor Heater Removal
ELECTRICAL COMPONENTS: GASOLINE Carburetor Heater VEHICLES CARBURETOR HEATER REMOVAL Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4. Remove the top cover from the engine. Disconnect the green wire from the carburetor heater (1) (Figure 13-4, Page 13-4).
Page 233: Voltage Regulator
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Voltage Regulator VOLTAGE REGULATOR See General Warnings, Section 1, Page 1-2. TESTING THE VOLTAGE REGULATOR See Test Procedure 20 – Voltage Regulator on page 11-27. VOLTAGE REGULATOR REMOVAL Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 234: Warning Lights
ELECTRICAL COMPONENTS: GASOLINE Warning Lights VEHICLES WARNING LIGHTS See General Warnings, Section 1, Page 1-2. TESTING THE WARNING LIGHTS See Test Procedure 28 – Low Oil Warning Light Circuit on page 11-33. WARNING LIGHT REMOVAL Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 235: Fuel Gauge/Hour Meter
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Fuel Gauge/Hour Meter 2131 Figure 13-6 Instrument Panel Electrical Components FUEL GAUGE/HOUR METER See General Warnings, Section 1, Page 1-2. TESTING THE FUEL GAUGE/HOUR METER See Test Procedure 31 – Fuel Gauge on page 11-35. Also see Test Procedure 32 – Hour Meter on page 11-36. With the key switch in the OFF position, the fuel gauge field is blank;...
Page 236: Fuel Gauge/Hour Meter Installation
ELECTRICAL COMPONENTS: GASOLINE Key Switch VEHICLES 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. FUEL GAUGE/HOUR METER INSTALLATION Install a new fuel gauge/hour meter (2) into the hole in the instrument panel until the flange seats against the instrument panel (Figure 13-6, Page 13-7).
Page 237: 12-Volt Accessory Receptacle
ELECTRICAL COMPONENTS: GASOLINE VEHICLES 12-Volt Accessory Receptacle 12-VOLT ACCESSORY RECEPTACLE See General Warnings, Section 1, Page 1-2. TESTING THE 12-VOLT ACCESSORY RECEPTACLE See Test Procedure 29 – 12-Volt Accessory Receptacle on page 11-34. 12-VOLT ACCESSORY RECEPTACLE REMOVAL Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 238: Bed Lift Switch
ELECTRICAL COMPONENTS: GASOLINE Bed Lift Switch VEHICLES BED LIFT SWITCH TESTING THE BED LIFT SWITCH See Test Procedure 36 – Bed Lift Switch on page 11-40. BED LIFT SWITCH REMOVAL Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 239: Light Switch
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Light Switch LIGHT SWITCH See General Warnings, Section 1, Page 1-2. TESTING THE LIGHT SWITCH See Test Procedure 33 – Light Switch on page 11-37. LIGHT SWITCH REMOVAL Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 240: Fuse Installation
ELECTRICAL COMPONENTS: GASOLINE Reverse Warning Buzzer (If Equipped) VEHICLES FUSE INSTALLATION Install the fuse. See following WARNING. WARNING • 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.
Page 241: Reverse Warning Buzzer Installation
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Reverse Warning Buzzer Limit Switch (If Equipped) REVERSE WARNING BUZZER INSTALLATION Install the reverse warning buzzer and secure it with two plastic rivets. Connect the black wire from the wire harness to the negative (–) terminal on the buzzer. Connect the red/white wire from the wire harness to the positive (+) terminal on the buzzer.
Page 242: Reverse Warning Buzzer Limit Switch Installation
ELECTRICAL COMPONENTS: GASOLINE Front Differential Limit Switch VEHICLES 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. Tighten the limit switch mounting screws so that they are snug, but the limit switch can still be rotated in the adjustment slot (Figure 13-8, Page 13-13).
Page 243: Front Differential Limit Switch Installation
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Fuel Level Sending Unit 2496 Figure 13-10 Front Differential Limit Switch Removal FRONT DIFFERENTIAL LIMIT SWITCH INSTALLATION Install the front differential limit switch (1) in the reverse order of removal and tighten the nuts (2) to 4 in-lb (0.5 N·m) (Figure 13-10, Page 13-15).
Page 244: Testing The Fuel Level Sending Unit
ELECTRICAL COMPONENTS: GASOLINE Ignition Coil and Charge Coil VEHICLES TESTING THE FUEL LEVEL SENDING UNIT See Test Procedure 30 – Fuel Level Sending Unit on page 11-34. FUEL LEVEL SENDING UNIT REMOVAL See Fuel Level Sending Unit Removal on page 15-12. FUEL LEVEL SENDING UNIT INSTALLATION See Fuel Level Sending Unit Installation on page 15-13.
Page 245: Testing The Headlight Bulb And Socket
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Wire Harness Diodes TESTING THE HEADLIGHT BULB AND SOCKET See Test Procedure 34 – Voltage at Headlight Socket on page 11-37. See also Test Procedure 33 – Light Switch on page 11-37. HEADLIGHT BULB REMOVAL Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 246: Testing The Wire Harness Diodes
ELECTRICAL COMPONENTS: GASOLINE Battery VEHICLES The wire harness is equipped with several in-line diodes. TESTING THE WIRE HARNESS DIODES See Test Procedure 9 – Wire Harness Diodes on page 11-19. WIRE HARNESS DIODE REMOVAL Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 247: General Information
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Battery DANGER – External: Flush with water. Call a physician immediately. – Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable oil. Call a physician immediately. – Eyes: Flush with water for 15 minutes. Call a physician immediately. GENERAL INFORMATION See preceding DANGER statement.
Page 248: Vibration Damage
ELECTRICAL COMPONENTS: GASOLINE Battery VEHICLES VIBRATION DAMAGE The battery hold-down clamp should always be tight enough to keep the battery from bouncing. Battery life may be severely shortened if the clamp is too loose. Excessive vibration shortens the life of the battery. It may also cause acid to leak from the vent caps and corrosion to build up on surrounding metal parts.
Page 249: Battery Installation
ELECTRICAL COMPONENTS: GASOLINE VEHICLES Battery Attach the charger, positive (+) cable to the positive (+) battery post and negative (–) cable to the negative (–) battery post. The battery may be charged with a slow charge (3 to 10 amps) or a fast charge (20 to 30 amps). Charge until the specific gravity reaches 1.250.
Page 250: Charging A Dead Battery
ELECTRICAL COMPONENTS: GASOLINE Battery VEHICLES CHARGING A DEAD BATTERY See General Warnings on page 1-2. 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 •...
Page 251: Section 14 - Electrical Components: Diesel Vehicles
SECTION 14 — ELECTRICAL COMPONENTS: DIESEL VEHICLES DANGER Electrical Components: Diesel Vehicles • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. STARTER AND STARTER SOLENOID See General Warnings, Section 1, Page 1-2. Refer to the engine manual for testing, removal, disassembly, and installation procedures.
Page 252: Relay Installation
ELECTRICAL COMPONENTS: DIESEL Neutral Switch VEHICLES Remove the electrical component cover. Remove the relay from the multi-pin connector. RELAY INSTALLATION Insert the relay into the multi-pin connector. See following NOTE. NOTE: The relay contacts are keyed to ensure that the relay can only be installed in the correct orientation. If the relay is not easy to insert, rotate the relay until the correct contact orientation is obtained.
Page 253: Fuel Solenoid
ELECTRICAL COMPONENTS: DIESEL VEHICLES Fuel Solenoid FUEL SOLENOID See General Warnings, Section 1, Page 1-2. The fuel solenoid is mounted to the passenger-side of the engine block at the front of the injector pump. TESTING THE FUEL SOLENOID See Test Procedure 27 – Fuel Solenoid Pull Coil Circuit on page 12-37. See also Test Procedure 28 – Fuel Solenoid Hold Coil Circuit on page 12-37.
Page 254: 60-Amp Fusible Link
ELECTRICAL COMPONENTS: DIESEL 60-Amp Fusible Link VEHICLES 60-AMP FUSIBLE LINK See General Warnings, Section 1, Page 1-2. TESTING THE 60-AMP FUSIBLE LINK See Test Procedure 22 – 60-Amp Fusible Link on page 12-33. The fusible link is a short length of special, high temperature insulated wire and should not be confused with standard wire.
Page 255: Warning Lights
ELECTRICAL COMPONENTS: DIESEL VEHICLES Warning Lights Connect battery. See Side-Post Battery: Connecting the Battery – Gasoline/Diesel Vehicles on page 1-4. See Top-Post Battery: Connecting the Battery- Gasoline/Diesel Vehicles on page 1-4. WARNING LIGHTS See General Warnings, Section 1, Page 1-2. TESTING THE WARNING LIGHTS See Test Procedure 23 –...
Page 256: Fuel Gauge/Hour Meter
ELECTRICAL COMPONENTS: DIESEL Fuel Gauge/Hour Meter VEHICLES 2131 Figure 14-6 Instrument Panel Electrical Components FUEL GAUGE/HOUR METER See General Warnings, Section 1, Page 1-2. TESTING THE FUEL GAUGE/HOUR METER See Test Procedure 32 – Fuel Gauge on page 12-41. Also see Test Procedure 33 – Hour Meter on page 12-42. With the key switch in the OFF position, the fuel gauge field is blank;...
Page 257: Fuel Gauge/Hour Meter Removal
ELECTRICAL COMPONENTS: DIESEL VEHICLES Key Switch FUEL GAUGE/HOUR METER REMOVAL Disconnect battery. See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4. Raise the hood. Disconnect the wires from the fuel gauge/hour meter (2) (Figure 14-6, Page 14-6). Remove the mounting clip (3) that secures the gauge/meter.
Page 258: 12-Volt Accessory Receptacle
ELECTRICAL COMPONENTS: DIESEL 12-Volt Accessory Receptacle VEHICLES Connect battery. See Side-Post Battery: Connecting the Battery – Gasoline/Diesel Vehicles on page 1-4. See Top-Post Battery: Connecting the Battery- Gasoline/Diesel Vehicles on page 1-4. 12-VOLT ACCESSORY RECEPTACLE See General Warnings, Section 1, Page 1-2. TESTING THE 12-VOLT ACCESSORY RECEPTACLE See Test Procedure 30 –...
Page 259: Bed Lift Switch
ELECTRICAL COMPONENTS: DIESEL VEHICLES Bed Lift Switch BED LIFT SWITCH TESTING THE BED LIFT SWITCH See Test Procedure 37 – Bed Lift Switch on page 12-45. BED LIFT SWITCH REMOVAL Disconnect battery. See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 260: Light Switch
ELECTRICAL COMPONENTS: DIESEL Light Switch VEHICLES LIGHT SWITCH See General Warnings, Section 1, Page 1-2. TESTING THE LIGHT SWITCH See Test Procedure 34 – Light Switch on page 12-42. LIGHT SWITCH REMOVAL Disconnect battery. See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 261: Fuse Installation
ELECTRICAL COMPONENTS: DIESEL VEHICLES Reverse Warning Buzzer (If Equipped) FUSE INSTALLATION Install the fuse. See following WARNING. WARNING • 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.
Page 262: Reverse Warning Buzzer Installation
ELECTRICAL COMPONENTS: DIESEL Reverse Warning Buzzer Limit Switch (If Equipped) VEHICLES REVERSE WARNING BUZZER INSTALLATION Install the reverse warning buzzer and secure it with two plastic rivets. Connect the black wire from the wire harness to the negative (–) terminal on the buzzer. Connect the red/white wire from the wire harness to the positive (+) terminal on the buzzer.
Page 263: Reverse Warning Buzzer Limit Switch Installation
ELECTRICAL COMPONENTS: DIESEL VEHICLES Front Differential Limit Switch 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. Tighten the limit switch mounting screws so that they are snug, but the limit switch can still be rotated in the adjustment slot (Figure 14-8, Page 14-12).
Page 264: Front Differential Limit Switch Installation
ELECTRICAL COMPONENTS: DIESEL Fuel Level Sending Unit VEHICLES 2496 Figure 14-10 Front Differential Limit Switch Removal FRONT DIFFERENTIAL LIMIT SWITCH INSTALLATION Install the front differential limit switch (1) in the reverse order of removal and tighten the nuts (2) to 4 in-lb (0.5 N·m) (Figure 14-10, Page 14-14).
Page 265: Testing The Fuel Level Sending Unit
ELECTRICAL COMPONENTS: DIESEL VEHICLES Alternator TESTING THE FUEL LEVEL SENDING UNIT See Test Procedure 31 – Fuel Level Sending Unit on page 12-39. FUEL LEVEL SENDING UNIT REMOVAL See Fuel Level Sending Unit Removal on page 16-11. FUEL LEVEL SENDING UNIT INSTALLATION See Fuel Level Sending Unit Installation on page 16-12.
Page 266: Alternator And V-Belt Installation
ELECTRICAL COMPONENTS: DIESEL Alternator VEHICLES Remove the belt shield and the alternator from the engine compartment. If necessary, remove the V-belt. 2145 2146 Figure 14-13 Belt Tension Adjustment Bolt Figure 14-14 Alternator Mounting Bolt ALTERNATOR AND V-BELT INSTALLATION Place the alternator and belt shield on the engine and insert the alternator mounting bolt through the shield and alternator and into the engine block (Figure 14-14, Page 14-16).
Page 267: Oil Pressure Sensor
ELECTRICAL COMPONENTS: DIESEL VEHICLES Oil Pressure Sensor OIL PRESSURE SENSOR See General Warnings, Section 1, Page 1-2. Refer to the engine manual for testing, removal, disassembly, and installation procedures. See the Kubota D722 diesel engine manual (CC P/N 103840201). HEADLIGHTS See General Warnings, Section 1, Page 1-2.
Page 268: Thermostat Switch
ELECTRICAL COMPONENTS: DIESEL Thermostat Switch VEHICLES Attach the connector harness to the halogen bulb. The retaining tab should lock onto the halogen bulb (Figure 14-15, Page 14-17). From the front of vehicle, reach under the cowl and insert the bulb assembly into the headlight lens. Turn the bulb assembly counterclockwise one-quarter turn.
Page 269: Thermostat Switch Installation
ELECTRICAL COMPONENTS: DIESEL VEHICLES THERMOSTAT SWITCH INSTALLATION Apply Loctite 567 Liquid Thread Sealer to the threads of the thermostat switch. See following CAUTION. CAUTION • Do not use any thread-sealing tape on the threads of the thermostat switch. The housing of the thermostat switch must make a good connection to the engine block.
Page 270: Fan Installation
ELECTRICAL COMPONENTS: DIESEL Wire Harness Diodes VEHICLES 2148 Figure 14-17 Fan and Shroud FAN INSTALLATION Correctly position the electric fan assembly on the fan shroud and secure with four lock-patch bolts. Tighten the hardware to 48 in-lb (5 N·m). See preceding NOTE. Connect the two-pin connector from the fan motor to the wire harness (Figure 14-17, Page 14-20).
Page 271: Wire Harness Diode Installation
ELECTRICAL COMPONENTS: DIESEL VEHICLES Battery WIRE HARNESS DIODE INSTALLATION Slide a piece of heatshrink tubing over one of the wire ends where the diode will be attached. Use in-line wire splicing connectors to install the new diode. Make sure to observe polarity and place the end of the diode with the silver stripe on the wire that was marked when the diode was removed.
Page 272: Testing The Battery
ELECTRICAL COMPONENTS: DIESEL Battery VEHICLES TESTING THE BATTERY See Test Procedure 1 – Battery on page 12-10. PREVENTIVE MAINTENANCE To keep the battery in good operating condition, remove corrosion immediately. Post connections should be clean and tight. Frayed or worn wires should be replaced. After all cables have been connected and properly tightened to 20 ft-lb (27.1 N·m), coat terminals with Battery Terminal Protector Spray (CC P/N 1014305) to prevent future corrosion.
Page 273: Battery Removal
ELECTRICAL COMPONENTS: DIESEL VEHICLES Battery IMPURITY ALLOWABLE CONTENT (PARTS PER MILLION) Suspended matter Trace Total solids 100.0 Calcium and magnesium oxides 40.0 Iron Ammonia Organic matter 50.0 Nitrates 10.0 Nitrites Chloride BATTERY REMOVAL See General Warnings on page 1-2. Disconnect battery. See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 274: Battery Installation
ELECTRICAL COMPONENTS: DIESEL Battery VEHICLES WARNING • If the battery case feels hot (approximately 125 °F (52 °C) or more), emits gases, or fluid boils from vents, stop charging immediately. Failure to stop charging battery when any of these conditions are present could result in an explosion, personal injury and/or damage to the battery.
Page 275 ELECTRICAL COMPONENTS: DIESEL VEHICLES Battery WARNING • Do not jump-start a dead battery with another battery and jumper cables. 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual Page 14-25...
Page 276 ELECTRICAL COMPONENTS: DIESEL Battery VEHICLES Pagination Page Page 14-26 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual...
Page 277: Section 15 - Gasoline Engine, Muffler, Fuel System, And Clutches
SECTION 15 — GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES DANGER Gasoline Engine, Muffler, Fuel System, and Clutches • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. GASOLINE ENGINE See General Warnings, Section 1, Page 1-2. This section contains information on removing and installing the Kawasaki gasoline engine.
Page 278 GASOLINE ENGINE, MUFFLER, FUEL Gasoline Engine SYSTEM, AND CLUTCHES 2573 Figure 15-1 Engine Removal and Installation Components Page 15-2 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual...
Page 279: Engine Installation
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Gasoline Engine Remove the accelerator cable. See Accelerator Cable Removal on page 15-21. Remove the muffler. See Muffler Removal on page 15-6. Remove the intermediate exhaust pipe. See Intermediate Pipe Removal on page 15-7. Remove the clutch outer cover.
Page 280 GASOLINE ENGINE, MUFFLER, FUEL Gasoline Engine SYSTEM, AND CLUTCHES 2151 Figure 15-2 Secure Oil Adapter to Engine Loosely install new flange-head bolts (8) up through engine plate and into engine mounting base. See following NOTE. NOTE: Engine mounting bolts will be tightened after the engine and transmission are aligned, the clutch inner cover is installed, and the cover bolts are tightened to maintain the alignment.
Page 281: Oil Filter Hoses
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Gasoline Engine Install the engine top cover (1) and tighten the four bolts to 35 in-lb (4 N·m). Install the seat frame and lower rear ROPS (Roll Over Protection Structure) bars. See Seat Support Installation on page 4-10 and ROPS Installation on page 4-8.
Page 282: Exhaust System
GASOLINE ENGINE, MUFFLER, FUEL Exhaust System SYSTEM, AND CLUTCHES 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. Use new clamps when the hoses are replaced.
Page 283: Intermediate Pipe Removal
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Exhaust System 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. WARNING • Always wear eye protection when springs are removed or installed. NOTE: Shift the end of the muffler inlet and intermediate pipe from side to side to relax and disconnect the springs.
Page 284: Fuel System
GASOLINE ENGINE, MUFFLER, FUEL Fuel System SYSTEM, AND CLUTCHES DANGER • The engine produces carbon monoxide, which is an odorless, deadly poison. Do not operate the engine in an enclosed area without proper ventilation. FUEL SYSTEM REF. FUEL LINE DIAMETER ROUTING Ø...
Page 285: Fuel Lines
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System REF. FUEL LINE DIAMETER ROUTING Ø 5/16 in. (8 mm) Vent Tube (Canister (7) to Atmosphere) ** 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.
Page 286: Fuel Filter
GASOLINE ENGINE, MUFFLER, FUEL Fuel System SYSTEM, AND CLUTCHES WARNING • Make sure fuel lines are the correct length and are properly routed. Failure to heed this warning could result in damage to the fuel lines and fire. FUEL FILTER See General Warnings, Section 1, Page 1-2.
Page 287 GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System Carburetor Grounding WARNING • The carburetor is equipped with an electric heater and must be grounded to the engine in order to prevent the risk of a spark. Always have a ground wire properly installed. The carburetor is equipped with an electric heater and must be grounded to the engine in order to prevent the risk of a spark.
Page 288: Fuel Level Sending Unit
GASOLINE ENGINE, MUFFLER, FUEL Fuel System SYSTEM, AND CLUTCHES Main Jet Elevation/Size Chart JET SIZE KAWASAKI FH680 CARBURETOR ENGINE 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...
Page 289 GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System 2153 Figure 15-7 Fuel Level Sending Unit Removal 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).
Page 290 GASOLINE ENGINE, MUFFLER, FUEL Fuel System SYSTEM, AND CLUTCHES WARNING • Do not use electrically powered tools to remove or install the fuel level sending unit. Failure to heed this warning could result in a fire or explosion. Place a new rubber gasket on the fuel tank with the notch (2) centered between the flange identification mounting holes (1).
Page 291 GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System 2154 2156 Figure 15-8 Fuel Level Sending Unit Alignment Figure 15-9 Fuel Level Sending Unit Position 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 15-7, Page 15-13).
Page 292: Fuel Tank
GASOLINE ENGINE, MUFFLER, FUEL Fuel System SYSTEM, AND CLUTCHES FUEL TANK See General Warnings, Section 1, Page 1-2. WARNING • If the fuel tank is damaged, replace it. Do not attempt to repair it. See the following tank removal and disposal procedure. Fuel Tank Removal Disconnect battery and spark plug wire(s).
Page 293 GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System WARNING • Never attempt to siphon fuel with a hose that does not have a built-in suction device. • Never attempt to siphon fuel with your mouth. Disconnect the black wire and orange wire from the fuel level sensor on the tank. Do not remove the lower nut from the center stud of the sensor.
Page 294 GASOLINE ENGINE, MUFFLER, FUEL Fuel System SYSTEM, AND CLUTCHES 2157 Figure 15-11 Fuel Level Sensor Install the center seat plate. Add the appropriate fuel to the fuel tank. Ensure the fuel shut-off valve on top of the fuel tank is in the open (ON) position (Figure 15-13, Page 15-20). Connect battery and spark plug wire(s).
Page 295: Carbon Canister
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System CARBON CANISTER See General Warnings, Section 1, Page 1-2. 2563 Figure 15-12 Carbon Canister, Hoses and Routing WARNING • If the carbon canister is damaged, replace it. Do not attempt to repair it. See the following canister removal procedure.
Page 296: Fuel Shut-Off Valve
GASOLINE ENGINE, MUFFLER, FUEL Fuel System SYSTEM, AND CLUTCHES FUEL SHUT-OFF VALVE See General Warnings, Section 1, Page 1-2. The fuel shut-off valve is located on top of the fuel tank. The fuel shut-off valve should always be turned to the closed (OFF) position during vehicle storage, towing or trailering, and maintenance and service (Figure 15-13, Page 15-20).
Page 297: Engine Control Linkages
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Engine Control Linkages ENGINE CONTROL LINKAGES GENERAL INFORMATION For proper vehicle operation, it is important the accelerator cable, governor, idle RPM and high-speed RPM adjustments are done correctly and in the proper sequence. See following CAUTION. CAUTION •...
Page 298: Choke Cable
GASOLINE ENGINE, MUFFLER, FUEL Engine Control Linkages SYSTEM, AND CLUTCHES 2362 2160 Figure 15-14 Accelerator Cable at Pedal (Z-Shaped Cable Figure 15-15 Accelerator Cable at Engine End and Anchor) Accelerator Cable Installation NOTE: When the accelerator cable is replaced, the high-speed RPM must be adjusted. See High-Speed RPM Adjustment on page 15-26.
Page 299 GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Engine Control Linkages 2162 2163 Figure 15-16 Choke Cable on Engine Figure 15-17 Choke Cable Through Front Cover Choke Cable Installation Secure a new choke cable to the nylon cord outside of the instrument panel. At the engine compartment, pull the nylon cord until the choke cable reaches the engine.
Page 300: Engine Governor Arm
GASOLINE ENGINE, MUFFLER, FUEL Engine Control Linkages SYSTEM, AND CLUTCHES ENGINE GOVERNOR ARM See General Warnings, Section 1, Page 1-2. Engine Governor Arm Adjustment Loosen nut (1) on governor arm (2) (Figure 15-18, Page 15-24). Force governor arm (2) forward until it stops. Hold in this position. Insert small allen wrench into shaft (3) and rotate shaft counterclockwise (CCW) until it stops.
Page 301: Engine Rpm Adjustment
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Engine Control Linkages ENGINE RPM ADJUSTMENT Vehicle Creep New vehicles or vehicles with a new drive belt or clutches may crawl forward with the shifter in FORWARD and the engine idling. This is considered normal until the drive belt is “broken-in” (approximately 15 hours of use). Other possible symptoms include difficulty or inability to shift into or out of gear and engine stalling.
Page 302 GASOLINE ENGINE, MUFFLER, FUEL Engine Control Linkages SYSTEM, AND CLUTCHES Throttle lever (5) against carburetor idle stop screw (1) with no gap (A). 2505 2506 Figure 15-20 Carburetor Idle Stop Screw Figure 15-21 Push Governor Arm Clockwise High-Speed RPM Adjustment DANGER •...
Page 303: Air Intake System
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Air Intake System AIR INTAKE SYSTEM See General Warnings, Section 1, Page 1-2. The air filter intake hose fits between the driver-side frame and the inlet port on the air filter canister. The frame serves as a duct to carry air from a location at the top of the front of the vehicle.
Page 304: Air Canister Removal
GASOLINE ENGINE, MUFFLER, FUEL Air Intake System SYSTEM, AND CLUTCHES Air Filter Installation Push the new filter cartridge onto the nozzle inside the canister. Position the canister cap so the TOP mark is at the top center of the canister (Figure 15-22, Page 15-27). Use both tab locks on the sides of the cap to secure the canister cap.
Page 305: Clutches
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches CLUTCHES The following service tools are required to disassemble the clutches properly and are available from a service parts representative (Figure 15-24, Page 15-29) and (Figure 15-25, Page 15-29): 1. Spring compression nut (CC P/N 102606101) 2. Spring compression collar (CC P/N 102605201) 3.
Page 306: Drive Belt
GASOLINE ENGINE, MUFFLER, FUEL Clutches SYSTEM, AND CLUTCHES DRIVE BELT See General Warnings, Section 1, Page 1-2. The drive belt should be inspected periodically for wear and glazing. If it is excessively worn, frayed, or glazed, replace the belt. 2171 Figure 15-26 Drive Belt Removal Drive Belt Removal Disconnect battery and spark plug wire(s).
Page 307 GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches Drive Clutch Removal Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4. Remove the top air filter hose (outlet) from the air filter canister.
Page 308 GASOLINE ENGINE, MUFFLER, FUEL Clutches SYSTEM, AND CLUTCHES 2500 Figure 15-27 Using the Drive Clutch Service Tool (Three-Weight) Page 15-32 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual...
Page 309 GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches Screw, Hex Flange Head, 1/4–20x1.25 Roller Weight Cover Plate Pin, 0.375x1.375 12. Moveable Sheave Spring, Compression, 2.0 OD Black/Or Washer, Flat 13. Locknut, #10-24 Spacer, Clutch, 1.44x1.125x0.23 Button, Torque Primary 14. Screw, Shoulder, Hex Socket, 0.25x2.5 Spider 10.
Page 310: Driven Clutch
GASOLINE ENGINE, MUFFLER, FUEL Clutches SYSTEM, AND CLUTCHES Drive Clutch Component Inspection – Three-Weight Design Inspect the rollers (6) and pins (7) (Figure 15-28, Page 15-33). Ensure they rotate freely without roughness or loose play. If they do not, the entire drive clutch must be replaced. The rollers and pins can not be replaced. Inspect the weights (11).
Page 311 GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches Remove the top air filter hose from the filter canister. Remove the clutch outer cover. See Clutch Outer Cover Removal on page 15-37. Remove the drive belt as instructed. See Drive Belt Removal on page 15-30. Remove the bolt and washer from the center of the clutch and discard bolt.
Page 312 GASOLINE ENGINE, MUFFLER, FUEL Clutches SYSTEM, AND CLUTCHES Use snap-ring pliers to remove the snap ring (1) (Figure 15-30, Page 15-36). Slowly remove the spring compression nut. The collar will then rise and release tension on the spring (3). Remove the cup (2) and spring (3). Remove the moveable sheave (4) from the fixed sheave (5).
Page 313: Clutch Cover
GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches Driven Clutch Installation Install the driven clutch assembly on the transmission splined shaft. Install the mounting washer and new retaining bolt. Tighten retaining bolt to 39 ft-lb (53 N·m). Install the drive belt as instructed. See Drive Belt Installation on page 15-30. Install the clutch outer cover and tighten the screws to 72 in-lb (8 N·m).
Page 314 GASOLINE ENGINE, MUFFLER, FUEL Clutches SYSTEM, AND CLUTCHES Clutch Inner Cover Installation 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 315: Section 16 - Diesel Engine, Muffler, Fuel System, And Clutches
SECTION 16 — DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES DANGER Diesel Engine, Muffler, Fuel System, and Clutches • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. DIESEL ENGINE See General Warnings, Section 1, Page 1-2. NOTE: During the 2015 Model Year, the Kubota E4B-series diesel engine superseded the E3B-series diesel engine.
Page 316 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Diesel Engine AND CLUTCHES DANGER • The diesel fuel tank does not have a fuel line valve. When the fuel line is removed from the engine, fuel can siphon fuel from the tank if the fuel line rests below the fuel level in the fuel tank. Securely cap or plug the fuel line immediately after it is removed from the fuel injector to prevent fuel leakage.
Page 317: Engine Installation
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Diesel Engine 2179 2180 Figure 16-3 Driver Side Diesel Engine Mount Figure 16-4 Passenger Side Diesel Engine Mount Remove the hardware securing manifold pipe to exhaust manifold and slide exhaust system as far to the rear as possible.
Page 318 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Diesel Engine AND CLUTCHES Using new gasket, slide exhaust system forward and secure the manifold pipe to the exhaust manifold. See Manifold Pipe Installation on page 16-6. Tighten the hardware that secures the muffler. See Muffler Installation on page 16-6. Attach the air filter outlet hose to the intake manifold.
Page 319: Exhaust System
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Exhaust System EXHAUST SYSTEM MUFFLER REMOVAL Disconnect battery. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4. Loosen the muffler spring suspension bracket bolts. Remove the two springs that secure the muffler inlet to the intermediate pipe (Figure 16-5, Page 16-5). See following NOTE.
Page 320: Manifold Pipe Removal
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Exhaust System AND CLUTCHES Remove the springs from the intermediate pipe and manifold pipe and remove the pipe. MANIFOLD PIPE REMOVAL Remove the three bolts and flange-head locknuts (Figure 16-6, Page 16-6). Separate the manifold pipe from the engine exhaust manifold. 2181 Figure 16-6 Diesel Manifold Pipe Flange MANIFOLD PIPE INSTALLATION...
Page 321 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Exhaust System Loosely secure the muffler and spring suspension bracket to the chassis with two bolts and large flat washers (Figure 16-7, Page 16-7). Secure the muffler inlet to the intermediate pipe with new springs. See following WARNING and NOTE. WARNING •...
Page 322: Fuel System
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Fuel System AND CLUTCHES FUEL SYSTEM LENGTH FUEL LINE DIAMETER ROUTING Ø SOLID COLOR CLEAR 5/16 in. (8 mm) Fuel tank to water separator 23.0 in. (58.4 cm) 5/16 in. (8 mm) Water separator to fuel pump 13.0 in.
Page 323: Fuel Lines
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System FUEL LINES See General Warnings, Section 1, Page 1-2. 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 324 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Fuel System AND CLUTCHES Draining Water from Fuel Filter Water should be drained from the fuel filter daily. The fuel filter is mounted to the chassis under the passenger-side seat (Figure 16-9). Lift the passenger-side seat. Position a pan under the fuel filter.
Page 325: Fuel Pump
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System WARNING • Clean up spilled fuel. Keep sparks and flames away from the vehicle and service area. Failure to heed this warning could result in an explosion or fire, resulting in severe personal injury or death. Fuel Filter Installation See General Warnings, Section 1, Page 1-2.
Page 326 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Fuel System AND CLUTCHES Remove the four remaining hex-head plastic thread screws from the fuel level sending unit flange (5). Retain the hardware. Carefully remove the sending unit and gasket (3). Feed the rheostat arm and float (4) through the fuel tank hole. Immediately place the fuel level sending unit in a pan to catch fuel.
Page 327 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System NOTE: The distance between the flange identification mounting holes (1) is larger than the distance between any of the other mounting holes in the sending unit flange (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.
Page 328: Fuel Tank
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Fuel System AND CLUTCHES 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 16-12). See following CAUTION. CAUTION •...
Page 329 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System CAUTION • Use only diesel grade no. 2 fuel with a cetane rating of 45 or higher for diesel engines. Fuel Tank Removal Disconnect battery. See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3.
Page 330 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Fuel System AND CLUTCHES Figure 16-13 Diesel Fuel Tank Disconnect the black wire and orange wire from the fuel level sensor on the tank. Do not remove the lower nut on the center stud of the sensor. Remove the nut from the fuel tank strap below the passenger seat area.
Page 331 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Fuel System 2157 Figure 16-14 Fuel Level Sensor Slide the rubber boot over the stud. Install the passenger-side bed latch bracket on the frame with a bolt and flanged nylon locknut. Tighten the hardware to 20 ft-lb (27 N·m).
Page 332: Engine Control Linkages
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Engine Control Linkages AND CLUTCHES ENGINE CONTROL LINKAGES GENERAL INFORMATION For proper vehicle operation, it is important the accelerator cable, idle RPM and high-speed RPM adjustments are done correctly and in the proper sequence. See following CAUTION. CAUTION •...
Page 333: Engine Rpm Adjustment
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Engine Control Linkages 2362 Figure 16-15 Accelerator Cable At Pedal (Z-Shaped Cable End and Anchor) Accelerator Cable Installation Installation is reverse of removal procedure. Connect battery. See Side-Post Battery: Connecting the Battery – Gasoline/Diesel Vehicles on page 1-4. See Top-Post Battery: Connecting the Battery- Gasoline/Diesel Vehicles on page 1-4.
Page 334 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Engine Control Linkages AND CLUTCHES 2185 2186 Figure 16-16 Tachometer For Engine RPM Figure 16-17 Clean Metal Fuel Line 2187 2188 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 335: Air Intake System
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Air Intake System 2189 3077 Figure 16-20 Idle Throttle Adjustment Screw Figure 16-21 High-Speed Throttle Adjustment Screw High-Speed RPM Adjustment Clean paint, grease, and dirt from any one of the three fuel injector lines (Figure 16-17, Page 16-20). See following NOTE.
Page 336: Air Canister Removal
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Air Intake System AND CLUTCHES CAUTION • Do not drill into the driver-side frame because it is part of the air intake system. Failure to heed this caution could damage the engine by allowing excessive contamination or water to enter the air intake system.
Page 337: Air Canister Installation
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Air Intake System 2041 Figure 16-23 Air Filter Canister AIR CANISTER INSTALLATION Position the canister next to the frame bracket with the tab lock released and oriented toward the passenger side. Install two bolts on the canister base bracket and vehicle frame bracket. Tighten the bolts to 21 ft-lb (28.5 N·m). Secure the bottom (inlet) hose to the canister port.
Page 338: Clutches
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Clutches AND CLUTCHES CLUTCHES The following service tools are required to disassemble the clutches properly and are available from a service parts representative (Figure 16-24, Page 16-24) and (Figure 16-25, Page 16-24): 1. Spring compression nut (CC P/N 102606101) 2. Spring compression collar (CC P/N 102605201) 3.
Page 339: Drive Belt
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches DRIVE BELT See General Warnings, Section 1, Page 1-2. The drive belt should be inspected periodically for wear and glazing. If it is excessively worn, frayed, or glazed, replace the belt. 2171 Figure 16-26 Drive Belt Removal Drive Belt Removal Disconnect battery.
Page 340 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Clutches AND CLUTCHES Drive Clutch Removal Disconnect battery. See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4. Remove the top air filter hose (outlet) from the air filter canister. Remove the clutch outer cover.
Page 341 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches 2500 Figure 16-27 Using the Drive Clutch Service Tool (Three-Weight) 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual Page 16-27...
Page 342 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Clutches AND CLUTCHES Screw, Hex Flange Head, 1/4–20x1.25 Roller Weight Cover Plate Pin, 0.375x1.375 12. Moveable Sheave Spring, Compression, 2.0 OD Black/Or 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.
Page 343: Driven Clutch
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches Drive Clutch Component Inspection – Three-Weight Design Inspect the rollers (6) and pins (7) (Figure 16-28, Page 16-28). Ensure they rotate freely without roughness or loose play. If they do not, the entire drive clutch must be replaced. The rollers and pins can not be replaced. Inspect the weights (11).
Page 344 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Clutches AND CLUTCHES Driven Clutch Removal Disconnect battery. See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4. Remove the top air filter hose from the filter canister. Remove the clutch outer cover.
Page 345 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches NOTE: Both the moveable and fixed sheaves have spacers (6). Be sure to retain the spacers for reassembly of the driven clutch. "X" "X" 2175 Figure 16-30 Driven Clutch Assembly Driven Clutch Assembly Place the fixed sheave (5) onto the spring compression base and note the location of the “X”...
Page 346: Clutch Cover
DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Clutches AND CLUTCHES Install the mounting washer and new retaining bolt. Tighten retaining bolt to 39 ft-lb (53 N·m). 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.
Page 347 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES Clutches 2191 2192 Figure 16-31 Diesel Inner Cover Assembly Figure 16-32 Diesel Inner Cover Spacer Clutch Inner Cover Installation Position the inner cover spacer on the engine block using the stud bolts for alignment (Figure 16-32, Page 16-33). Align the mounting holes in the inner cover with the transmission and engine bolt holes (Figure 16-31, Page 16-33).
Page 348 DIESEL ENGINE, MUFFLER, FUEL SYSTEM, Clutches AND CLUTCHES Pagination Page Page 16-34 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual...
Page 349: Section 17 - Drivetrain Components
SECTION 17 — DRIVETRAIN COMPONENTS DANGER Drivetrain Components • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. This section contains information on removing and installing the front differential, transmission, and rear differential. Refer to the appropriate manual for complete instructions on disassembly, repair, rebuilding, and reassembly.
Page 350: Half Shaft Installation
Half Shafts DRIVETRAIN COMPONENTS 1895 2193 Figure 17-1 Axle Spindle Nut And Washer Figure 17-2 Camber Adjustment Bar Separate the half shaft hub from the differential and remove the half shaft (Figure 17-3, Page 17-2). See following NOTE. NOTE: Use a 5/16-inch wide flat blade screwdriver to separate the half shaft hub and differential. The hub end of the half shaft has a round compression ring and groove.
Page 351: Front Differential
DRIVETRAIN COMPONENTS Front Differential 2196 Figure 17-5 Apply Anti-Seize to Splined Ends Install the half shaft into the front differential. Advance the half shaft until the compression ring seats into the groove inside the differential housing. Lift the wheel hub and upper A-frame. Slide the half shaft spindle into the wheel hub and insert the camber adjustment bar into the lower A-frame slot.
Page 352 Front Differential DRIVETRAIN COMPONENTS Loosen the axle spindle nuts (Figure 17-1, Page 17-2). Lift and support the front of vehicle and remove the wheel(s). See Lifting The Vehicle on page 3-7. Remove both half shafts. See Half Shaft Removal on page 17-1. Remove the lock nut and bolt securing the front driveshaft to the differential pinion shaft (Figure 17-9, Page 17-7).
Page 353: Front Differential Installation
DRIVETRAIN COMPONENTS Front Differential 2199 2200 Figure 17-7 Differential Clutch Connector Figure 17-8 Front Differential Plate Bolts FRONT DIFFERENTIAL INSTALLATION See General Warnings, Section 1, Page 1-2. NOTE: If the differential was removed or replaced from the differential plate, use new flange-head bolts and tighten the hardware to 30 ft-lb (41 N·m).
Page 354: Front Driveshaft
Front Driveshaft DRIVETRAIN COMPONENTS FRONT DRIVESHAFT FRONT DRIVESHAFT REMOVAL See General Warnings, Section 1, Page 1-2. Push the vehicle to a position that enables easy access to the roll pin securing the front driveshaft to the differential pinion shaft. Chock the rear wheels. Disconnect battery and spark plug wire(s) (gasoline vehicles only).
Page 355: Transmission
DRIVETRAIN COMPONENTS Transmission 2835 Figure 17-9 Driveshaft Hardware TRANSMISSION TRANSMISSION REMOVAL See General Warnings, Section 1, Page 1-2. Disconnect battery and spark plug wire(s) (gasoline vehicles only). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4. Remove the outer clutch cover.
Page 356: Transmission Installation
Transmission DRIVETRAIN COMPONENTS Detach the rear driveshaft. See Rear Driveshaft Removal on page 17-13. Detach the front driveshaft. See Front Driveshaft Removal on page 17-6. Remove the clutch inner cover. See Clutch Inner Cover Removal on page 15-37 (gasoline vehicles). See Clutch Inner Cover Removal on page 16-32 (diesel vehicles).
Page 357 DRIVETRAIN COMPONENTS Transmission Secure the clutch inner cover to the engine and transmission with bolts and washers. Finger-tighten the hardware. Gasoline vehicles: See Clutch Inner Cover Installation on page 15-38. Diesel vehicles: See Clutch Inner Cover Installation on page 15-38. See following NOTE. NOTE: Hole tolerances in the inner cover are very close in diameter to bolt sizes.
Page 358: Forward/Reverse Shifter Cable
Transmission DRIVETRAIN COMPONENTS FORWARD/REVERSE SHIFTER CABLE See General Warnings, Section 1, Page 1-2. Forward/Reverse Shifter Cable Removal NOTE: Before the Forward/Reverse cable is removed, note the cable routing and the wire tie positions and the positions of other devices securing the cable to the vehicle. When installed, the cable must be routed and secured as it was originally.
Page 359 DRIVETRAIN COMPONENTS Transmission 2567 Figure 17-13 Forward/Reverse Cable Connections At Shifter Handle and Transmission Forward/Reverse Shifter Cable Installation Secure a new cable to the transmission end of the nylon cord at the dash frame. Pull and route the cable from the dash frame to the transmission.
Page 360: Forward/Reverse Shifter Handle
Transmission DRIVETRAIN COMPONENTS Advance the front flanged nut, closest to the transmission shifter arm, up against the front side of the cable bracket. Advance the rear flanged nut, farthest away from the transmission shifter arm, down next to the back side of the cable bracket and tighten the front nut to 25 ft-lb (34 N·m).
Page 361: Rear Driveshaft
DRIVETRAIN COMPONENTS Rear Driveshaft NOTE: If the previously removed shoulder bolt and nylon locknut are used for installation, add Loctite 262 to the bolt threads and tighten the used hardware to 50 in-lb (6 N·m). Install cable pin (7) and locknut (8) on shifter handle (2). Tighten locknut (8) to 19 ft-lb (25 N·m). Attach cable end to Forward/Reverse shifter handle (Figure 17-13, Page 17-11).
Page 362: Rear Axle
Rear Axle DRIVETRAIN COMPONENTS REAR AXLE REAR AXLE REMOVAL Disconnect battery and spark plug wire(s) (gasoline vehicles only). See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4. Loosen the lug nuts on both rear wheels.
Page 363: Rear Axle Installation
DRIVETRAIN COMPONENTS Rear Axle 2502 Figure 17-15 Rear Brake Caliper and Hose Removal – 4 Link REAR AXLE INSTALLATION NOTE: These procedures are best performed with the help of an assistant. Place rear axle on floor jack, with differential resting on jack pad, and roll axle under rear suspension. Support the long axle tube and raise axle up to trailing arms and lateral links.
Page 364: Rear Axle Tubes, Axle Shafts And Wheel Bearings
Rear Axle Tubes, Axle Shafts and Wheel Bearings DRIVETRAIN COMPONENTS Ensure differential has appropriate type and volume of oil. See Gearcase Lubrication on page 10-16. Gasoline vehicles: Connect the spark plug wires. Connect battery. See Side-Post Battery: Connecting the Battery – Gasoline/Diesel Vehicles on page 1-4. See Top-Post Battery: Connecting the Battery- Gasoline/Diesel Vehicles on page 1-4.
Page 365: Rear Axle Tube And Axle Shaft Installation
DRIVETRAIN COMPONENTS Rear Axle Tubes, Axle Shafts and Wheel Bearings 2566 2214 Figure 17-16 Axle Shaft and Brake Rotor Figure 17-17 Axle Shaft Retaining Ring and Washer REAR AXLE TUBE AND AXLE SHAFT INSTALLATION Clean and lubricate the seals in the differential with appropriate oil. See Periodic Lubrication Schedule on page 10-6.
Page 366: Rear Wheel Bearing Installation
Rear Axle Tubes, Axle Shafts and Wheel Bearings DRIVETRAIN COMPONENTS 2215 Figure 17-18 Rear Wheel Bearing REAR WHEEL BEARING INSTALLATION Clean inside axle tube (1) where new bearing will sit and lightly lubricate the bore with anti-seize compound (Figure 17-18, Page 17-18). Using an appropriate sized bearing driver that fits the outer race, drive in new bearing (3) until fully seated.
Page 367: Section 18 - Radiator And Coolant System (Diesel)
SECTION 18 — RADIATOR AND COOLANT SYSTEM (DIESEL) DANGER Radiator and Coolant System (Diesel) • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. GENERAL INFORMATION See General Warnings, Section 1, Page 1-2. The diesel vehicle is equipped with a cooling system that includes a radiator, an electric radiator fan, a reservoir, and a circulating system.
Page 368 General Information RADIATOR AND COOLANT SYSTEM (DIESEL) NOTE: Use a mixture of 45% water and 55% propylene glycol with anti-corrosion additives. Apply Loctite 567 Liquid Thread Sealer to the threads of the block coolant plug. Install the plug and tighten to 144 in-lb (16 N·m).
Page 369: Coolant Reservoir
RADIATOR AND COOLANT SYSTEM (DIESEL) Coolant Reservoir COOLANT RESERVOIR See General Warnings, Section 1, Page 1-2. COOLANT RESERVOIR REMOVAL Disconnect battery. See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4. Raise the hood and remove the reservoir cap.
Page 370: Coolant Reservoir Installation
Radiator RADIATOR AND COOLANT SYSTEM (DIESEL) COOLANT RESERVOIR INSTALLATION Install reservoir, aligning holes in mounting tabs with holes in chassis, and secure with bolts. Tighten the hardware to 132 in-lb (15 N·m). Attach 5/8 inch hose to the bottom of reservoir and secure with clamp. Attach the two hoses to top of reservoir and secure with clamps.
Page 371: Radiator Installation
RADIATOR AND COOLANT SYSTEM (DIESEL) Radiator 1. Radiator Support Bracket 2. Flanged Bolts 3. Flanged Nut 4. Two-Pin Connector 2219 Figure 18-4 Radiator Bracket Attachment Push the splash guard toward the dash and carefully lift the radiator straight up to remove from vehicle. See following CAUTION.
Page 372: Coolant Pipe Weldment
Coolant Pipe Weldment RADIATOR AND COOLANT SYSTEM (DIESEL) WARNING • Coolant reservoir and radiator are pressurized. Remove caps slowly to relieve pressure. • Hot! Coolant system is pressurized. Do not remove radiator cap while engine is hot. If necessary, remove reservoir cap and fill to the FULL mark. Replace cap. See preceding WARNING. Lower and secure the hood.
Page 373: Fan
RADIATOR AND COOLANT SYSTEM (DIESEL) Stop the engine and allow the engine and coolant to cool. See following WARNING. WARNING • Coolant reservoir and radiator are pressurized. Remove caps slowly to relieve pressure. • Hot! Coolant system is pressurized. Do not remove radiator cap while engine is hot. If necessary, remove reservoir cap and fill to the FULL mark.
Page 374 RADIATOR AND COOLANT SYSTEM (DIESEL) Pagination Page Page 18-8 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual...
Page 375: Section 19 - Hydraulic Attachment System
SECTION 19 — HYDRAULIC ATTACHMENT SYSTEM DANGER Hydraulic Attachment System • See General Warnings, Section 1, Page 1-2. WARNING • See General Warnings, Section 1, Page 1-2. • Always wear eye protection and protective clothing when working on and around hydraulic systems. •...
Page 376: Attachment Interface
Attachment Interface HYDRAULIC ATTACHMENT SYSTEM 4.3. For the auxiliary circuit, if equipped, turn the key switch to the OFF position and press the auxiliary hydraulic switch to the right and then to left several times to relieve pressure. Once pressure is relieved from the circuit(s) to be serviced, make sure the key switch is in the OFF position and set the joystick ON/OFF switch to OFF.
Page 377: Removing And Installing The Attachment Arm Mechanism
HYDRAULIC ATTACHMENT SYSTEM Attachment Interface 2222 2223 Figure 19-3 Hand Lever Linkages and Pins Figure 19-4 Inspect Mount Mount NOTE: The following picture may not show your exact attachment but mounting frame inspections are the same. Inspect the pin mounts (1), mounting flange (2) and all welds for wear, damage and cracks (Figure 19-4, Page 19-3).
Page 378 Attachment Interface HYDRAULIC ATTACHMENT SYSTEM Lower the attachment arm to the ground and tilt the attachment interface forward (Figure 19-5, Page 19-3). Stop the engine, put the Forward/Reverse Handle in NEUTRAL, engage the park brake, unfasten your seat belt, and exit the vehicle. Remove the retaining ring (1) and pin (2) from the attachment interface cylinder rod end, and keep the retaining ring and pin for later use in this procedure (Figure 19-6, Page 19-3).
Page 379 HYDRAULIC ATTACHMENT SYSTEM Attachment Interface 2227 2228 Figure 19-9 Secure Attachment and Interface Cylinders Figure 19-10 Remove Attachment Arm Retaining Pins 2229 2230 Figure 19-11 Attachment Arm Pins and Retaining Rings Figure 19-12 Align the Vehicle to Attachment Arms Attachment Arm Installation Align the vehicle with the attachment arms (Figure 19-12, Page 19-5).
Page 380 Attachment Interface HYDRAULIC ATTACHMENT SYSTEM WARNING • Do not have hands in the area of the cylinders when extending or retracting the cylinders. Remove the two retaining rings (4 and 7) and pins (3 and 6) that secure the two cylinders (1 and 5) to the mount (2) (Figure 19-14, Page 19-6).
Page 381 HYDRAULIC ATTACHMENT SYSTEM Attachment Interface 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 382: 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 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual...
Page 383 HYDRAULIC ATTACHMENT SYSTEM Electrical Diode 4 WD1027864C-R Figure 19-19 Wiring Diagram for Hydraulic Attachment System Vehicles (Rear) 2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual Page 19-9...
Page 384: Joystick
Electrical HYDRAULIC ATTACHMENT SYSTEM JOYSTICK See General Warnings, Section 1, Page 1-2. Bottom View (Wire Harness Removed For Clarity) B. AUX SWITCH: 8 - Pin Connector (6 Wires) ON-OFF Switch A. FLOAT SWITCH: 8 - Pin Connector (4 Wires) Removed For Clarity 1.
Page 385 HYDRAULIC ATTACHMENT SYSTEM Electrical Check each switch, between the wired terminals, for no continuity with the joystick at “rest” and continuity with the joystick acting on the switch. If a switch does not work as stated in step 2, replace switch. If a switch does work as stated in step 2 and the joystick still does not work, check the following items: –...
Page 386: Joystick On/Off Switch
Electrical HYDRAULIC ATTACHMENT SYSTEM Disconnect battery. See Side-Post Battery: Disconnecting the Battery – Gasoline/Diesel Vehicles on page 1-3. See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4. 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).
Page 387: Attachment Arm Float Switch
HYDRAULIC ATTACHMENT SYSTEM Electrical If switch does work as stated in previous step and the joystick still does not have power, check the following items: – Fuse. – Continuity of the 14-gauge red wire (w06) from the “hot” side of the circuit breaker to the fuse. –...
Page 388 Electrical HYDRAULIC ATTACHMENT SYSTEM Testing the Float Switch NOTE: The control circuit is protected by a 20-amp fuse. Check the fuse before this procedure is performed. See Test Procedure 2 – Fuse on page 12-13. Remove the float switch. See Float Switch Removal on page 19-14. Check the following location for no continuity with switch at “rest”...
Page 389: Auxiliary Hydraulic Switch
HYDRAULIC ATTACHMENT SYSTEM Electrical AUXILIARY HYDRAULIC SWITCH See General Warnings, Section 1, Page 1-2. A. Extend Position B. Retract Position C. Alignment Notches Terminals: 1. #18 Gray w1 2. #18 Red/White w82 3. #18 Gray w57 4. #18 Green w22 5. #18 Orange w12 6. #18 Yellow w23 2241 Figure 19-25 Auxiliary Hydraulic Switch Test (Rear View) Testing the Auxiliary Switch...
Page 390: Relays
Electrical HYDRAULIC ATTACHMENT SYSTEM Ensure the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Unplug harness from switch (Figure 19-22, Page 19-11). Note orientation of alignment notches (Figure 19-25, Page 19-15). Squeeze tabs at each end of switch and push switch out the top of the control box cover. Auxiliary Switch Installation Orient alignment notches and insert switch into control box cover until fully seated (Figure 19-25, Page 19-15).
Page 391 HYDRAULIC ATTACHMENT SYSTEM Electrical 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. Locate and pull or pry the relay out of the multi-pin connector to remove (Figure 19-22, Page 19-11).
Page 392: Solenoid
Electrical HYDRAULIC ATTACHMENT SYSTEM Connect battery. See Side-Post Battery: Connecting the Battery – Gasoline/Diesel Vehicles on page 1-4. See Top-Post Battery: Connecting the Battery- Gasoline/Diesel Vehicles on page 1-4. Install the electrical component cover and driver seat. SOLENOID 1. Light Green (w34) – Positive [+] Terminal of Coil 2.
Page 393: Circuit Breaker
HYDRAULIC ATTACHMENT SYSTEM Electrical CIRCUIT BREAKER Testing the Circuit Breaker Check for continuity between each post. 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 394: Control Valves
Electrical HYDRAULIC ATTACHMENT SYSTEM CONTROL VALVES Two-Way 2-Position Normally Closed Valves 1. Two-Way 2-Position Control Valves 2. Three-Way 2-Position Control Valves 3. Four-Way 2-Position Control Valves 2247 2248 Figure 19-31 Control Valve Identification Figure 19-32 Two-Way 2-Position Valve and Coil These valves allow for free flow in one direction (from the bottom port to the side ports) at all times and controlled flow in the opposite direction until the solenoid coil is energized (Figure 19-32, Page 19-20).
Page 395 HYDRAULIC ATTACHMENT SYSTEM Electrical NOTE: The cartridge itself cannot be disassembled in the field as the proper tolerances cannot be duplicated. If the dirt cannot be removed the cartridge will have to be replaced. If the valve does not return to the neutral or unshifted position, check for either dirt in the valve cartridge or a bent stem.
Page 396: Hoses
Hoses HYDRAULIC ATTACHMENT SYSTEM – If it cannot be heard, remove the cartridge from the valve body and blow compressed air through all parts to dislodge dirt. Clean all parts in solvent, blow dry, and lubricate. If the valve does not return to the neutral or unshifted position, check for dirt in the valve cartridge and repair as described above.
Page 397: Hose Removal
HYDRAULIC ATTACHMENT SYSTEM Hoses 1. Red Hose At Pump 2. White Hose At Pump 3. White Hose At Quick Connect Fittings 4. Red Hose At Quick Connect Fittings 2251 Figure 19-35 Auxiliary Circuit Hoses HOSE REMOVAL Relieve pressure in hydraulic system. See Relieving Hydraulic System Pressure on page 19-1. Set the joystick ON/OFF switch to OFF, remove driver seat and disable vehicle.
Page 398: Quick Connect Fittings (Auxiliary Hydraulic Circuit Only)
Quick Connect Fittings (Auxiliary Hydraulic Circuit only) HYDRAULIC ATTACHMENT SYSTEM QUICK CONNECT FITTINGS (AUXILIARY HYDRAULIC CIRCUIT ONLY) 2252 Figure 19-36 Quick Connect Fitting Removal QUICK CONNECT REMOVAL Relieve pressure in hydraulic system. See Relieving Hydraulic System Pressure on page 19-1. Set the joystick ON/OFF switch to OFF, remove driver seat and disable vehicle.
Page 399: Cylinders
HYDRAULIC ATTACHMENT SYSTEM Cylinders CYLINDERS 1. Pivot Pin 2. Retaining Pin 3. Cylinder (Lift and Lower) 4. Cylinder (Tilt Up and Tilt Down) 5. Green 6. Blue 7. Pink 8. No Color 9. Wire Ties 2253 Figure 19-37 Cylinders and Hoses VEHICLE MOUNTED CYLINDERS Vehicle Mounted Cylinder Removal Relieve pressure in hydraulic system.
Page 400: Auxiliary Cylinder (Optional)
Cylinders HYDRAULIC ATTACHMENT SYSTEM Vehicle Mounted Cylinder Installation If installing a used cylinder, clean inside the attachment ends first. Otherwise, orient cylinder, align attachment ends and secure with pivot pin(s) and retaining pin(s). Match and connect hoses to fittings (Figure 19-37, Page 19-25). Tighten fittings to 22 ft-lb (30 N·m). Lubricate attachment ends.
Page 401 HYDRAULIC ATTACHMENT SYSTEM Cylinders 2254 2255 Figure 19-38 Hoses Figure 19-39 Remove Rod End Pins Remove retaining pin (1) from the base end of the hydraulic cylinder (Figure 19-40, Page 19-27). Remove pivot pin (2) (Figure 19-41, Page 19-27) from the base end of the hydraulic cylinder and remove cylinder. 2256 2257 Figure 19-40 Remove Retaining Pin...
Page 402: Cylinder Disassembly
Cylinders HYDRAULIC ATTACHMENT SYSTEM CYLINDER DISASSEMBLY Parts Identification NOTE: The drawing may not show your hydraulic cylinder exactly as it appears, but the internal assembly is the same. 1. Case 5. O-ring 9. Head 2. Nut 6. O-ring 10. Oil Seal 3.
Page 403 HYDRAULIC ATTACHMENT SYSTEM Cylinders WARNING • 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 CAUTION •...
Page 404 Cylinders HYDRAULIC ATTACHMENT SYSTEM 2259 2260 Figure 19-43 Loosen the Head Figure 19-44 Remove Rod Assembly 2261 2262 Figure 19-45 Remove Nut from Piston Figure 19-46 Pull Components from Rod If the head has a seal, remove the seal from the head (Figure 19-47, Page 19-30). Remove the O-ring and back-up washer from the head (Figure 19-48, Page 19-30).
Page 405 HYDRAULIC ATTACHMENT SYSTEM Cylinders Remove the wiper seal (Figure 19-49, Page 19-31). Remove the oil seal from the head (Figure 19-50, Page 19-31). 2265 2266 Figure 19-49 Remove Wiper Seal Figure 19-50 Remove Oil Seal Remove the piston seal from the piston (Figure 19-51, Page 19-31). Remove the O-ring from the piston (Figure 19-52, Page 19-31).
Page 406: Cylinder Assembly
Cylinders HYDRAULIC ATTACHMENT SYSTEM CYLINDER ASSEMBLY WARNING • 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. Install the O-ring on the piston (Figure 19-53, Page 19-32).
Page 407 HYDRAULIC ATTACHMENT SYSTEM Cylinders 2271 2272 Figure 19-55 Install Piston Seal Figure 19-56 Compress Piston Seal Install the oil seal on the rod seal tool (Figure 19-57, Page 19-33). NOTE: The O-ring side of the oil seal goes toward the inside of the cylinder. Install the oil seal in the head (Figure 19-58, Page 19-33).
Page 408 Cylinders HYDRAULIC ATTACHMENT SYSTEM 2275 2276 Figure 19-59 Install Wiper Seal Figure 19-60 Install Back-up Washer Install the O-ring next to the back-up ring as shown (Figure 19-61, Page 19-34). If a seal was removed from the head, use the following procedure to install a new seal. Install the guide with a pilot and an adapter, if they are required, on the head (Figure 19-62, Page 19-34).
Page 409 HYDRAULIC ATTACHMENT SYSTEM Cylinders 2279 2280 Figure 19-63 Compress Seal Figure 19-64 Install Head on Rod 2281 2282 Figure 19-65 Install Cushioned Piston (If Equipped) Figure 19-66 Install Cushion Sleeve (If Equipped) and Piston Install and tighten nut to 150 to 185 ft-lb (203 to 251 N·m) torque (Figure 19-67, Page 19-36). Remove the rod from the vise.
Page 410 Cylinders HYDRAULIC ATTACHMENT SYSTEM 2283 2284 Figure 19-67 Install and Tighten Piston Nut Figure 19-68 Lubricate Seal Put oil on the Teflon seal on the piston (Figure 19-69, Page 19-36). Install the rod assembly in the cylinder case (Figure 19-70, Page 19-36). Put oil on the seals and threads on the head (Figure 19-71, Page 19-37).
Page 411: Cylinder Bushings (If Equipped)
HYDRAULIC ATTACHMENT SYSTEM Cylinders 2287 2288 Figure 19-71 Lubricate Head Seals Figure 19-72 Tighten Head Against Case CYLINDER BUSHINGS (IF EQUIPPED) Removal and Installation WARNING • Wear safety glasses to prevent eye injury when any of the following conditions exist: –...
Page 412: Angle Frame Bushings
Angle Frame Bushings HYDRAULIC ATTACHMENT SYSTEM Remove the two bushing(s) (1) (Figure 19-75, Page 19-38) 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 19-38). 2291 2292 Figure 19-75 Remove Bushings from Rod End...
Page 413 HYDRAULIC ATTACHMENT SYSTEM Angle Frame Bushings 2293 2294 Figure 19-77 Remove Snow Blade Angle Pivot Bushings Figure 19-78 Apply LOCTITE and Install Angle Pivot Bushings Remove the four bushings (1) (Figure 19-79, Page 19-39) from both ends of the angle frame. Apply LOCTITE 271 (Red) to the bushings before installing them into the angle frame (Figure 19-80, Page 19-39).
Page 414: Whisk Broom Angle Frame
Angle Frame Bushings HYDRAULIC ATTACHMENT SYSTEM 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 Remove the two bushings (1) (Figure 19-81, Page 19-40) from both sides of the angle frame. Apply LOCTITE 271 (Red) to the bushing before installing them into the angle frame.
Page 415: Front Mount
HYDRAULIC ATTACHMENT SYSTEM Front Mount FRONT MOUNT FRONT MOUNT REMOVAL Front Mount Not Shown For Clarity 2299 2300 Figure 19-83 Front Fascia Bolts Figure 19-84 Front Mount Hardware WARNING • Wear safety glasses to prevent eye injury when any of the following conditions exist: –...
Page 416: Front Mount Installation
Hydraulic Pump Assembly HYDRAULIC ATTACHMENT SYSTEM Remove attachment if installed. See Attachment Interface on page 19-2. Remove attachment arm and interface assembly. See Attachment Arm Removal on page 19-3. Relieve pressure in hydraulic system. See Relieving Hydraulic System Pressure on page 19-1. Set the joystick ON/OFF switch to OFF, remove driver seat and disable vehicle.
Page 417: Fluid Level Inspection
HYDRAULIC ATTACHMENT SYSTEM Hydraulic Pump Assembly FLUID LEVEL INSPECTION See Hydraulic System – IntelliTach Vehicle, Section 10, Page 10-18. FLUID CHANGE If replacing the hydraulic fluid with fresh fluid, follow steps below. Remove attachment if installed. See Attachment Interface on page 19-2. Relieve pressure in hydraulic system.
Page 418 Hydraulic Pump Assembly HYDRAULIC ATTACHMENT SYSTEM NOTE: Mark hoses for correct installation if factory markings are not found. Contain and dispose of any leaking oil in an environmentally safe manner. Pump Assembly Removal Empty and remove cargo bed. See Cargo Bed Removal, Section 4, Page 4-12. Relieve pressure.
Page 419 HYDRAULIC ATTACHMENT SYSTEM Hydraulic Pump Assembly 2303 2304 Figure 19-87 Park Brake Cable Bolt Figure 19-88 Cover Edge of Heat Shield Remove bolt securing the passenger side park brake cable to the chassis, at the air filter, and move cable forward (Figure 19-87, Page 19-45).
Page 420: Reservoir
Hydraulic Pump Assembly HYDRAULIC ATTACHMENT SYSTEM Remove two bolts securing pump assembly to cradle and remove cradle (Figure 19-90, Page 19-45). Disconnect wires at motor solenoid. See Solenoid Removal on page 19-18. Disconnect wire harness from control valve leads. Place drain pan under pump to catch fluid. Slowly loosen and disconnect hoses at pump. Cover all hose ends and fittings to keep out debris.
Page 421: Motor
HYDRAULIC ATTACHMENT SYSTEM Hydraulic Pump Assembly Lubricate o-ring with new fluid and install reservoir, being careful not to pinch or deform the o-ring. Tighten clamp to 57 in-lb (6.3 N·m). Install pump assembly. See Pump Assembly Installation on page 19-46. MOTOR Motor Removal 2309...
Page 422: Pump
Hydraulic Pump Assembly HYDRAULIC ATTACHMENT SYSTEM 2311 2312 Figure 19-95 Align Slot In Armature Figure 19-96 Driveshaft PUMP Pump Removal See Pump Assembly Removal on page 19-44. Pump Installation See Instructions for Installing Modular Pump on Existing Unit following page 19-48. PRIMING THE PUMP Fill reservoir to the Maximum Fluid Level line.
Page 423: Index
Index Index 12-volt accessory receptacle (diesel vehicles) installation ............7-23 testing ............. 12-38 Index removal ............. 7-23 12-volt accessory receptacle (gasoline vehicles) ball joint, upper testing ..............11-34 installation ............7-21 removal ............. 7-21 battery (diesel vehicles) ........14-21 charging ..........14-23–14-24 hydrometer test ..........12-11 a-arm, lower installation ............
Page 424 INDEX belt, drive see drive belt ......... 15-30, 16-25 cable, accelerator belt, seat see accelerator, cable........15-21 see seat belt ............4-10 cable, forward/reverse body, front components ............4-3 adjustment ............17-11 removal ............... 4-4 installation ............17-11 repair..............4-2 removal ............17-10 box bed camber adjustment ............
Page 425 INDEX installation ............15-37 three-weight design........16-26 removal ............15-37 inspection ............16-26 clutch, drive three-weight design........16-29 see drive clutch ........15-31, 16-26 installation ............16-29 clutch, driven removal ............16-26 see driven clutch ........15-34, 16-30 troubleshooting ..........16-24 coil, charge (gasoline vehicles) ......
Page 426 INDEX testing ..............11-34 fuel pump (diesel vehicles) fan motor (diesel vehicles) installation ............16-12 installation ............14-20 fuel pump (gasoline vehicles) ....... 15-10 removal ............14-19 fuel shut-off valve (gasoline vehicles) ....15-20 testing ............. 12-23 fuel solenoid (diesel vehicles) fan relay (diesel vehicles) hold coil circuit testing........
Page 427 INDEX headlight (diesel vehicles) testing ............. 19-10 bulb installation ............ 14-17 removal ............14-17 switch installation ............ 14-10 key switch (diesel vehicles) removal ............14-10 glow plug circuit testing........12-17 testing ............12-42 installation ..........14-7–14-8 voltage testing..........12-43 on position testing ..........12-16 headlight (gasoline vehicles) removal .............14-7–14-8 bulb...
Page 428 INDEX removal ............. 15-6 pump, fuel, mechanical (diesel vehicles) installation ............16-11 removal ............16-11 pump, hydraulic installation ............19-48 neutral switch (diesel vehicles) removal ............19-48 installation ............14-2 removal ............. 14-2 testing ............. 12-30 neutral switch (gasoline vehicles) installation ............13-2 quick connect fitting removal .............
Page 429 INDEX installation ............14-2 rear removal ............. 14-1 installation ............9-2 relay, start (gasoline vehicles) removal ............9-1 installation ............13-2 solenoid, fuel (diesel vehicles) removal ............. 13-2 installation ............14-3 reservoir, coolant removal ............. 14-3 see coolant reservoir .......... 18-3 solenoid, hydraulic attachment reservoir, hydraulic fluid installation ............
Page 430 INDEX installation ............7-20 22 fusible link ........... 12-33 removal ............7-18 23 temperature warning light circuit ....12-34 toe-in adjustment..........7-16 24 glow plug circuit........... 12-35 toe-in measurement..........7-15 25 reverse buzzer limit switch ......12-36 toe-out adjustment..........7-15 26 reverse buzzer ..........
Page 431 INDEX 7 start relay............11-16 installation ............17-18 8 carburetor heater relay........11-17 removal ............17-17 9 wire harness diodes........11-19 wheel, steering test procedures (hydraulic attachment vehicles) installation ............7-2 accessory relay ..........19-17 removal ............... 7-1 auxiliary switch..........19-15 wire continuity (diesel vehicles) circuit breaker ..........
Page 432 NOTES...
Page 433 NOTES...
Page 434 NOTES...

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Club Car Carryall 1500 2016 Maintenance And Service Manual

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