Download 2009 Carryall 295 and XRT 1550 with IntelliTach
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2009 Carryall 295 and XRT 1550 with IntelliTach Illustrated Parts List XRT 1550 and Carryall 295 with IntelliTach Diesel Vehicles Manual Number 103472619 Edition Code 0508F0310E USING THE ILLUSTRATED PARTS LIST ý WARNING • This manual is to be used only for identification and ordering of service parts. Be sure to read and use the maintenance and service manual before attempting any vehicle repairs. This manual covers all 2009 model year XRT1550 and Carryall 295 vehicles equipped with the IntelliTach accessory mounting system. The manual is divided into 14 sections. Sections 1 through 13 pertain to service parts for the vehicles, and Section 14 pertains to tools that are used on all Club Car products. Use the Table of Contents to find the sections and pages that contain the parts and assemblies you seek. The Table of Contents lists section numbers, and under them, the individual page titles and numbers to be found in that section. The index can be used to find specific parts and assemblies. The index is divided into numerical and alphabetical listings with the page numbers in italic text. There is a two-page spread for each individual page title in the Table of Contents. On the left-hand page is an illustration showing the parts in their relative positions; the parts are each tagged with an item number in a balloon. The right-hand page is the parts list page, and gives the page title at the top, then the item numbers (corresponding to the numbers on the illustration), part descriptions, and quantity of parts used. Note that a part description may be indented. This indention corresponds to a parts assembly level indicated by the numbers 1, 2, 3, and 4 at the top left corner of the parts description area of the parts list page. A part that is indented to level 2 is a component of the level 1 part (assembly) that it is listed under. A level 3 part is a component of the level 2 part that it is listed under, and a level 4 part is a component of the level 3 part preceding it. In each case, the part quantity given for a level 2, 3, or 4 part is the quantity used per next higher level assembly of which it is a component. A part that is not indented is a level 1 part. This means that the quantity given is the quantity used per the portion of the vehicle illustrated on that particular spread. HOW TO ORDER PARTS Replacement parts and accessories can be obtained from our network of authorized dealers and distributors. You can obtain the name and phone number of your closest authorized Club Car dealer or distributor by visiting our web site at www.clubcar.com and clicking on the “Distributor Search” link or by calling our toll-free Service Parts and Technical Assistance hotline at (800) 872-2246 or (706) 863-3000, extension 3887. P. O. Box 204658 Augusta, Georgia 30917-4658 USA Telephone 706-863-3000 Service Parts Fax 706-855-7413 www.clubcar.com NOTE: This illustrated parts list represents the most current information at the time of publication. Club Car, Inc. is continually working to further improve its vehicles and other products. These improvements may affect the parts used to service the vehicle. Any modification and/or significant change in specifications will be forwarded to all Club Car and Carryall distributors/dealers and will, when applicable, appear in future editions of this illustrated parts list. Club Car, Inc. reserves the right to change specifications and designs at any time without notice and without the obligation of making changes to units previously sold. Copyright © 2008 Club Car, Inc. Club Car is a registered trademark of Club Car, Inc. This manual effective August 1, 2008. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List CONTENTS SECTION 1 – HYDRAULIC ATTACHMENT SYSTEM AND ACCESSORIES Handbook ......................................................................................................................................................................................... 1-3 Attachment – Fork Pallet ............................................................................................................................................................. 1-5 Attachment – Bucket .................................................................................................................................................................... 1-7 Attachment – Snow Blade .......................................................................................................................................................... 1-9 Attachment – Broom .................................................................................................................................................................... 1-11 Attachment – Mower .................................................................................................................................................................... 1-13 Accessory Mounting Weldment ............................................................................................................................................... 1-15 Attachment Arm Kit ...................................................................................................................................................................... 1-17 Attachment Interface .................................................................................................................................................................... 1-19 Hydraulic Controls ......................................................................................................................................................................... 1-21 Accessory Hydraulic System – Standard ................................................................................................................................ 1-23 Accessory Hydraulics – Auxiliary .............................................................................................................................................. 1-25 Hydraulic Attachment Angle Kit ............................................................................................................................................... 1-27 Hydraulic Power Unit Components ......................................................................................................................................... 1-29 Hydraulic Power Unit with Auxillary Components ............................................................................................................ 1-31 Standard to Auxilliary Hydraulic Conversion Kit ................................................................................................................. 1-33 SECTION 2 – BODY AND TRIM Fascia and Fenders – Carryall Vehicles ................................................................................................................................... 2-3 Cowl Assemblies – Carryall Vehicles ....................................................................................................................................... 2-5 Cowl Assemblies – XRT Vehicles ............................................................................................................................................... 2-7 Cowl Assemblies – XRT Vehicles ............................................................................................................................................... 2-9 Front Body Components ............................................................................................................................................................. 2-11 Dash .................................................................................................................................................................................................... 2-13 Glove Box .......................................................................................................................................................................................... 2-15 Side Stringers ................................................................................................................................................................................... 2-17 Floor Mat ........................................................................................................................................................................................... 2-19 Floorboard ........................................................................................................................................................................................ 2-21 Bucket Seats – Gray ....................................................................................................................................................................... 2-23 Bucket Seats – Black ...................................................................................................................................................................... 2-25 Lower ROPS ...................................................................................................................................................................................... 2-27 Seat Belts and ROPS ...................................................................................................................................................................... 2-29 ROPS – Head Rests ......................................................................................................................................................................... 2-31 Latch Plate and Prop Rod ............................................................................................................................................................ 2-33 Tilt Bed, Hinge, and Latch ........................................................................................................................................................... 2-35 Electric Bed Lift ................................................................................................................................................................................ 2-37 Box Bed .............................................................................................................................................................................................. 2-39 Side Panels and Rear Fenders .................................................................................................................................................... 2-41 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 1 CONTENTS Cargo Box (Steel) ............................................................................................................................................................................. 2-43 SECTION 3 – WHEELS AND TIRES Wheels and Tires ............................................................................................................................................................................. 3-3 SECTION 4 – DECALS Safety Decals ..................................................................................................................................................................................... 4-3 Safety Decals, Continued ............................................................................................................................................................. 4-5 Badging Decals – Carryall Vehicles ........................................................................................................................................... 4-7 Badging Decals – XRT Vehicles .................................................................................................................................................. 4-9 Badging Decals – Intellitach ........................................................................................................................................................ 4-11 SECTION 5 – BRAKE SYSTEMS Front Brake Assembly .................................................................................................................................................................... 5-3 Rear Brake Assembly ...................................................................................................................................................................... 5-5 Master Cylinder with Remote Reservoir ................................................................................................................................. 5-7 Master Cylinder with Integral Reservoir ................................................................................................................................. 5-9 Hydraulic Brake Lines and Clips ................................................................................................................................................. 5-11 Brake Pedal Assembly ................................................................................................................................................................... 5-13 Park Brake System ........................................................................................................................................................................... 5-15 Park Brake Pedal Assembly .......................................................................................................................................................... 5-17 SECTION 6 – STEERING AND SUSPENSION Steering Column ............................................................................................................................................................................. 6-3 Steering Gear Assembly ............................................................................................................................................................... 6-5 Front Suspension – A-Arms ......................................................................................................................................................... 6-7 Cv Boot Repair Kits ......................................................................................................................................................................... 6-9 Shock Absorbers ............................................................................................................................................................................. 6-11 Rear Suspension – Standard ....................................................................................................................................................... 6-13 SECTION 7 – ELECTRICAL SYSTEM Wiring – Diesel Vehicle, Single Piece ....................................................................................................................................... 7-5 Wiring – Control Panel .................................................................................................................................................................. 7-9 Wiring – Seat Belt Reminder ....................................................................................................................................................... 7-11 Electrical Component Box, Diesel Vehicles ........................................................................................................................... 7-13 Electrical Components .................................................................................................................................................................. 7-15 Battery – Diesel Vehicles .............................................................................................................................................................. 7-17 Page 2 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List CONTENTS SECTION 8 – DIESEL ENGINE – CLOSED BREATHER Kubota D722 Diesel Engine Mounting ................................................................................................................................... 8-3 Crankcase .......................................................................................................................................................................................... 8-5 Oil Pan ................................................................................................................................................................................................ 8-7 Cylinder Head .................................................................................................................................................................................. 8-9 Gear Case ........................................................................................................................................................................................... 8-11 Head Cover ....................................................................................................................................................................................... 8-13 Dipstick and Guide ........................................................................................................................................................................ 8-15 Oil Pump ............................................................................................................................................................................................ 8-17 Main Bearing Case ......................................................................................................................................................................... 8-19 Camshaft and Idle Gear ................................................................................................................................................................ 8-21 Piston and Crankshaft ................................................................................................................................................................... 8-23 Flywheel ............................................................................................................................................................................................ 8-25 Shaft .................................................................................................................................................................................................... 8-27 Idle Apparatus ................................................................................................................................................................................. 8-29 Stop Solenoid .................................................................................................................................................................................. 8-31 60-Amp Alternator ......................................................................................................................................................................... 8-33 Injection Pump ................................................................................................................................................................................ 8-35 Speed Control Plate ....................................................................................................................................................................... 8-37 Nozzle Holders and Glow Plugs ................................................................................................................................................ 8-39 Governor Components ................................................................................................................................................................ 8-41 Starter ................................................................................................................................................................................................. 8-43 Valves and Rocker Arms ............................................................................................................................................................... 8-45 Diesel Inlet Manifold ..................................................................................................................................................................... 8-47 Exhaust Manifold ............................................................................................................................................................................ 8-49 Gasket Kits ......................................................................................................................................................................................... 8-51 Piston Kit ............................................................................................................................................................................................ 8-53 SECTION 9 – FUEL, INTAKE, & GOVERNOR SYSTEM Fuel System – Diesel ...................................................................................................................................................................... 9-3 Fuel Tank – Diesel Vehicles ......................................................................................................................................................... 9-5 Cables – Diesel Vehicle ................................................................................................................................................................. 9-7 Accelerator Pedal Assembly – Style B ..................................................................................................................................... 9-9 Intake Duct and Air Box Assembly – Diesel Vehicles ......................................................................................................... 9-11 SECTION 10 – EXHAUST SYSTEM Exhaust System ............................................................................................................................................................................... 10-3 Exhaust Pipes – Diesel Vehicles ................................................................................................................................................. 10-5 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 3 CONTENTS SECTION 11 – CLUTCHES Clutch Cover (Standard) ............................................................................................................................................................... 11-3 Clutch Cover (Sealed) .................................................................................................................................................................... 11-5 Drive Belt ............................................................................................................................................................................................ 11-7 Drive Clutch – Diesel Vehicles .................................................................................................................................................... 11-9 Driven Clutch .................................................................................................................................................................................... 11-11 SECTION 12 – DRIVETRAIN COMPONENTS Forward/Reverse Shifter Assembly .......................................................................................................................................... 12-3 Front Differential Mounting Plate ............................................................................................................................................. 12-5 Front Differential (Output Components) ............................................................................................................................... 12-7 Front Differential (Input Components) ................................................................................................................................... 12-9 Prop Shafts ........................................................................................................................................................................................ 12-11 Rear Differential ............................................................................................................................................................................... 12-13 Rear Differential, Continued ....................................................................................................................................................... 12-15 Transmission – Diesel Vehicles ................................................................................................................................................... 12-17 Transmission – Diesel Vehicles, Continued ........................................................................................................................... 12-19 Transmission – Diesel Vehicles, Shift Shaft and Bell Crank .............................................................................................. 12-21 SECTION 13 – RADIATOR AND COOLANT SYSTEM – DIESEL VEHICLES Radiator .............................................................................................................................................................................................. 13-3 Coolant Expansion Tank ............................................................................................................................................................... 13-5 Coolant Pipes and Hoses .............................................................................................................................................................. 13-7 Cooling System Clamps, Hoses, and Hardware ................................................................................................................... 13-9 Water Flange and Thermostat .................................................................................................................................................... 13-11 Water Pump ...................................................................................................................................................................................... 13-13 Block Coolant Pipe .......................................................................................................................................................................... 13-15 SECTION 14 – MAINTENANCE AND SERVICE TOOLS Maintenance and Service Tools ................................................................................................................................................. 14-3 Maintenance and Service Tools, Continued ......................................................................................................................... 14-5 Maintenance and Service Tools, Continued ......................................................................................................................... 14-7 Maintenance and Service Tools, Continued ......................................................................................................................... 14-9 Maintenance and Service Tools, Continued ......................................................................................................................... 14-11 SECTION i – INDEX Page 4 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List HYDRAULIC ATTACHMENT SYSTEM AND ACCESSORIES 1 G E D 1 G E D 2 3 000558-001 Page 1-2 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List HANDBOOK ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 N/A 103237501 103237701 Instl, Handbook, Club Car (includes items 2 and 3) ....................................................................... Handbook, Operator, Club Car ........................................................................................................ Weldment, Clip, Handbook ............................................................................................................... 1 1 1 1 G E D 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 1-3 1 G E D 4 3 2 4 2 000555-001 Page 1-4 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List ATTACHMENT – FORK PALLET ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 102930001 102927201 102927301 102927401 Attachment, Fork, Pallet (includes items 2 through 4) ................................................................. Fork Pallet ................................................................................................................................................ Bar, Fork Mount ..................................................................................................................................... Pin, Hair .................................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 1 2 Page 1-5 1 G E D 1 G E D 1 000555-002 Page 1-6 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List ATTACHMENT – BUCKET ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 102930101 Attachment, Bucket .................................................................................................................................. 1 1 G E D 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 1-7 1 G 13 E 3 13 D 14 3 3 9 3 3 2 14 2 14 5 2 6 10 7 7 11 12 8 8 12 4 Page 1-8 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 000555-003 ATTACHMENT – SNOW BLADE ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 102930201 102926601 102927401 102929601 102929801 103243001 103243101 103243201 103243501 103243601 103243701 103243801 103243901 103244001 Attachment, Blade, Snow (includes items 2 through 14) ............................................................ Bearing, Fiber, -12 ................................................................................................................................. Pin, Hair .................................................................................................................................................... Wldmnt, Mount, Angle ....................................................................................................................... Asm, Adjust, Manual ............................................................................................................................ Bolt, Carriage .......................................................................................................................................... Bolt, Carriage .......................................................................................................................................... Nut, Pretrq, Hex Lock ........................................................................................................................... Wldmnt, Head, Angle .......................................................................................................................... Wldmnt, Blade, Snow .......................................................................................................................... Edge, Cutting ......................................................................................................................................... Shoe, Skid ................................................................................................................................................ Pin, 5 In ..................................................................................................................................................... Pin, 3.9 In ................................................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 6 5 1 1 9 4 13 1 1 1 2 2 3 Page 1-9 1 G E D 1 G 9 E 3 9 D 10 3 3 8 3 3 2 10 2 10 7 2 5 6 4 000555-004 Page 1-10 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List ATTACHMENT – BROOM ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 102930301 102926601 102927401 102929501 102929601 102929701 102929801 103243501 103243901 103244001 Attachment, Broom, Push (includes items 2 through 10) ........................................................... Bearing, Fiber, -12 ................................................................................................................................. Pin, Hair .................................................................................................................................................... Broom, Whisker, 60 In ......................................................................................................................... Wldmnt, Mount, Angle ....................................................................................................................... Wldmnt, Mount, Whisker ................................................................................................................... Asm, Adjust, Manual ............................................................................................................................ Wldmnt, Head, Angle .......................................................................................................................... Pin, 5 In ..................................................................................................................................................... Pin, 3.9 In ................................................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 6 5 1 1 1 1 1 2 3 Page 1-11 1 G E D 1 G E D 000555-005 Page 1-12 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List ATTACHMENT – MOWER ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 N/A Attachment, Mower .................................................................................................................................. 1 1 G E D 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 1-13 1 G E D 5 4 3 8 2 7 8 6 5 4 000552-001 Page 1-14 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List ACCESSORY MOUNTING WELDMENT ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 N/A 102491501 102670701 102786101 102921601 102925201 103355401 96727003 Instl, Weldment, Mount (includes items 2 through 8) .................................................................. Washer Hard,m10 ................................................................................................................................. Nut Flg M10 X 1.5 Nylon .................................................................................................................... Ring, Rue, 3/4, Heavy ........................................................................................................................... Pin, Clevis, 3/4 X 4 ................................................................................................................................. Bolt, Flg, M10x1.5x55, Patch ............................................................................................................. Weldment, Front Mount .................................................................................................................... Bolt Flg, M10 X 1.5 X 30 ...................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 4 4 2 2 4 1 4 Page 1-15 1 G E D 1 G E D 2 3 4 2 3 1 000786-001 Page 1-16 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List ATTACHMENT ARM KIT ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 102923201 102786101 102921601 102923401 Kit, Arm, Attachment (includes items 2 through 4) ....................................................................... Ring, Rue, 3/4, Heavy ........................................................................................................................... Pin, Clevis, 3/4 X 4 ................................................................................................................................. Asm, Arm, Attachment ....................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 2 1 Page 1-17 1 G E D 1 G E 8 16 D 14 15 11 6 4 10 1 2 15 13 9 12 7 5 000787-001 Page 1-18 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List ATTACHMENT INTERFACE ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 102923301 102786101 N/A 102617001 102789101 102789201 102789301 N/A 102790001 102790801 102790901 102791001 102791301 102926101 102921601 N/A Kit, Interface, Attachment (includes items 2 through 16) ........................................................... Ring, Rue, 3/4, Heavy ........................................................................................................................... Asm, Interface, Attachment (includes items 4 through 14) .................................................. Nut Flg, M8 X 1.25 Mech Def ...................................................................................................... Pin, Latch ........................................................................................................................................... Lever, Release .................................................................................................................................. Link, Chain 2080 ............................................................................................................................. Interface, W/a .................................................................................................................................. Brace, Cross ...................................................................................................................................... Bolt Flg, M8 X 1.25 X 20 ................................................................................................................ Nut, Flg, 3/8-16 Gr8 ....................................................................................................................... Screw, Shoulder Hex Skt .............................................................................................................. Spring, Ext, Interface ..................................................................................................................... Decal, Attachment Locking ........................................................................................................ Pin, Clevis, 3/4 X 4 ................................................................................................................................. Instruction, Kit, Attachment ............................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 1 2 2 1 2 1 1 2 1 1 1 1 2 1 Page 1-19 1 G E D 1 19 17 G 16 20 25 E 11 5 D 15 4 14 18 7 32 13 12 9 22 8 6 24 30 21 30 3 29 30 30 27 31 28 26 23 Page 1-20 000553-001 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List HYDRAULIC CONTROLS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 N/A 1011931 1014063 N/A 1016103 101932201 102442001 102854601 102854801 N/A 1012438 1017 102420201 102849801 102850501 102854401 102854501 102854901 102918501 1631 102936801 102937401 102937501 102937601 102967901 103215201 7173 7174 8717 8990 102928301 N/A Instl, Controls, Hydraulic (includes items 2 through 30) .............................................................. Washer, 1/4 Flat ..................................................................................................................................... Screw, 1/4-20 X 1.00 Hex Head ........................................................................................................ Screw, #6-32 X 1/2 Hex Washer-Head ........................................................................................... Screw, Pan Hd Tx, Taptite 6-32 ......................................................................................................... Locknut, #6-32 Nylon .......................................................................................................................... Pan, Center, Closeout .......................................................................................................................... Base, Control Box, Joystick ................................................................................................................ Console, Center, Insulator ................................................................................................................. Asm, Controls (includes items 11 through 20) ........................................................................... Locknut, #10-24 Nylon Insert ..................................................................................................... Nut, #10-24 Stainless-Steel Hex Machine .............................................................................. Relay, Mini ISO, SPDT .................................................................................................................... Decal, Controls, Bt .......................................................................................................................... Screw, Phillips Pn Hd ..................................................................................................................... Switch, Rocker, Svr, DPDT Momentary ................................................................................... Switch, Rocker, Svr, SPDT, lght ................................................................................................... Cover, Control Box, Joystick ........................................................................................................ Joystick, 4 Way, W/ Boot .............................................................................................................. Screw, #10-24 X 0.75 Phillips Pan-Head ................................................................................. Breaker, Circuit, 150-Amp .................................................................................................................. Wire Asm, #6, Red, Bt ........................................................................................................................... Wire Asm, #6, Red, Bt ........................................................................................................................... Wire Asm, #6, Black, Bt ........................................................................................................................ Rivet, Removable, Tuflok 1/4" .......................................................................................................... Switch, Rocker, Svr, On-off ................................................................................................................. Screw, 5/16-18 X 0.75 Hex-Head Cap ............................................................................................ Lockwasher, 5/16 Split ........................................................................................................................ Locknut, 1/4-28 Nylon Insert ............................................................................................................ Tie Wrap, 8" Nylon ................................................................................................................................ Switch, Sol Act Mtr St, 12vdc ................................................................................................................. Cover, Joystick ............................................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 2 4 4 4 1 1 1 1 4 2 2 1 2 1 1 1 1 4 1 1 1 1 4 1 1 1 2 8 1 1 Page 1-21 1 G E D 1 27 G 6 E 26 D 9 8 24 11 20 22 13 16 14 15 10 17 19 5 21 28 3 25 23 4 18 7 5 2 Page 1-22 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 000554-001 ACCESSORY HYDRAULIC SYSTEM – STANDARD ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 N/A 102491001 102617201 102618301 102618601 102784201 102785501 102786101 102787101 102787201 102787501 102787601 102784601 102784701 102784801 N/A N/A N/A 102787101 N/A 102787701 102787701 102859101 102921601 102921701 102923001 102923101 96741046 AM1245401 Instl, Hydraulic Sys, Std (includes items 2 through 29) ................................................................ Bolt Flanged Head, 3/8-16x1.0 with Loctite ................................................................................ Nut Flg M10 X 1.5 Mech Def ............................................................................................................. Bolt Flanged Head, M8 X 1.25 X 65 ................................................................................................ Lock Nut, Flg M8 X 1.25 Nylon ......................................................................................................... Tube, Hydraulic -6 JIC 180 End ........................................................................................................ Barrier, Heat, Powerunit ..................................................................................................................... Ring, Rue, 3/4, Heavy ........................................................................................................................... Mount, Fir Tree, Cable Tie .................................................................................................................. Mount, Saddle, Fir Tree ....................................................................................................................... Tie, Button Head ................................................................................................................................... Asm, Hoses, Hydraulic (includes items 13 through 21) .......................................................... Hose, -6jic Stf -6jic Stm Td ........................................................................................................... Hose, -6jic Stf -6jic Stf Tr ............................................................................................................... Hose, -6jic Stf -6jic Stf Ld ............................................................................................................. Hose, -6jic Stf -6jic Stf Lr ............................................................................................................... Mount, Cable Tie, 8mm Std Trq ................................................................................................. Mount, Hd, Cable Tie, 8mm Bolt ............................................................................................... Mount, Fir Tree, Cable Tie ............................................................................................................ Mount, Standoff, Dual Tie ........................................................................................................... Tie, Wide Strap ................................................................................................................................ Tie, Wide Strap ....................................................................................................................................... Bolt, M10 X 1.50 X 70 ........................................................................................................................... Pin, Clevis, 3/4 X 4 ................................................................................................................................. Weldment, Hydraulic Powerunit ..................................................................................................... Cylinder, Hydraulic, Lift ....................................................................................................................... Cylinder, Hydraulic, Tilt ....................................................................................................................... Washer, M10 Hard ................................................................................................................................ 5 Gal, Mobil Dte15m Hyd Fluid ....................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 2 1 2 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 2 1 Page 1-23 1 G E D 1 G E 37 34 36 7 32 26 27 D 33 10 35 9 29 31 12 6 23 16 25 14 19 15 18 17 11 19 22 5 24 38 3 30 28 4 21 8 5 2 Page 1-24 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 000554-002 ACCESSORY HYDRAULICS – AUXILIARY ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 N/A 102491001 102617201 102618301 102618601 102741601 102784201 102785501 102786101 102787101 102787201 102787501 102787602 102784601 102784701 102784801 N/A 102785001 102785101 N/A N/A 102787101 N/A 102787701 102787701 102794801 102794901 102859101 102921601 102921701 102922601 102922701 102923001 102923101 102923801 102973501 102973601 96741046 Instl, Hydraulic Sys, Aux (includes items 2 through 38) ............................................................... Bolt Flanged Head, 3/8-16x1.0 with Loctite ................................................................................ Nut Flg M10 X 1.5 Mech Def ............................................................................................................. Bolt Flanged Head, M8 X 1.25 X 65 ................................................................................................ Lock Nut, Flg M8 X 1.25 Nylon ......................................................................................................... Nut Flg M8 X 1.25 Gr 10 ...................................................................................................................... Tube, Hydraulic -6 JIC 180 End ........................................................................................................ Barrier, Heat, Powerunit ..................................................................................................................... Ring, Rue, 3/4, Heavy ........................................................................................................................... Mount, Fir Tree, Cable Tie .................................................................................................................. Mount, Saddle, Fir Tree ....................................................................................................................... Tie, Button Head ................................................................................................................................... Asm, Hoses, Hydraulic W/aux (includes items 14 through 24) ............................................ Hose, -6jic Stf -6jic Stm Td ........................................................................................................... Hose, -6jic Stf -6jic Stf Tr ............................................................................................................... Hose, -6jic Stf -6jic Stf Ld ............................................................................................................. Hose, -6jic Stf -6jic Stf Lr ............................................................................................................... Hose, -6jic Stf -6jic Stf A ............................................................................................................... Hose, -6jic Stf -8jic Stf B ................................................................................................................ Mount, Cable Tie, 8mm Std Trq ................................................................................................. Mount, Hd, Cable Tie, 8mm Bolt ............................................................................................... Mount, Fir Tree, Cable Tie ............................................................................................................ Mount, Standoff, Dual Tie ........................................................................................................... Tie, Wide Strap ................................................................................................................................ Tie, Wide Strap ....................................................................................................................................... Coupling, Female Quick -6jic ............................................................................................................ Coupling, Male Quick -6jic ................................................................................................................ Bolt, M10 X 1.50 X 70 ........................................................................................................................... Pin, Clevis, 3/4 X 4 ................................................................................................................................. Weldment, Hydraulic Powerunit ..................................................................................................... Bracket, Hydraulic, Auxiliary ............................................................................................................. Fhcs, M8x1.25x20 Lock Patch ........................................................................................................... Cylinder, Hydraulic, Lift ....................................................................................................................... Cylinder, Hydraulic, Tilt ....................................................................................................................... Nut, Lock, Hyd Tube, 3/4-16 ............................................................................................................. Cap, Quick Connect, Female ............................................................................................................. Cap, Quick Connect, Male ................................................................................................................. Washer, M10 Hard ................................................................................................................................ 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 2 1 2 2 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 2 2 1 1 2 1 1 1 1 1 2 Page 1-25 1 G E D 1 G E D 7 2 6 2 3 4 3 3 000556-001 Page 1-26 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List HYDRAULIC ATTACHMENT ANGLE KIT ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 102930501 102926301 102926401 102926501 102926601 102926701 102926801 Kit, Angle, Hyd, Attachment (includes items 2 through 7) ......................................................... Fitting, Elbow, 90, Hyd ........................................................................................................................ Asm, Hose, Ang, Hyd ........................................................................................................................... Cylinder, Attach, Ang, Hyd ................................................................................................................ Bearing, Fiber, -12 ................................................................................................................................. Coupler, Ff, Male, 1/2 ........................................................................................................................... Coupler, Ff, Fem, 1/2 ............................................................................................................................ 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 2 1 4 1 1 Page 1-27 1 G E D 1 4 5 7 2 G E 3 D 6 9 10 8 000788-001 Page 1-28 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List HYDRAULIC POWER UNIT COMPONENTS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 102784001 102928001 102928101 102928201 102928301 102928401 102928501 102928601 102928901 1308 Power Unit, DC Hydraulic Std (includes items 2 through 8) ....................................................... Clamp, Hose, Worm, Rsv, M-ser ....................................................................................................... Plug, Resv, Breather-filler ................................................................................................................... Motor, Dc, 12v, 4.5 In, I Trm ............................................................................................................... Switch, Sol Act Mtr St, 12vdc ............................................................................................................ Strap, Motor-solenoid Conn ............................................................................................................. Asm, Ctrlwire, 16awg, Hs, Ring ........................................................................................................ Asm, Valve, 4w/4w, Cartridge (includes items 9 and 10) ........................................................ Coil, 10vdc, #8, 2lead, Diode ...................................................................................................... Nut, 1/2-20 Hex ............................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 1 1 1 1 1 6 6 Page 1-29 1 G E D 1 4 5 7 2 G E 3 D 6 9 10 10 8 000788-002 Page 1-30 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List HYDRAULIC POWER UNIT WITH AUXILLARY COMPONENTS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 N/A 102928001 102928101 102928201 102928301 102928401 102928501 102928601 102928901 1308 102928701 Power Unit, DC Hydraulic with Auxillary (includes items 2 through 11) ............................... Clamp, Hose, Worm, Rsv, M-ser ....................................................................................................... Plug, Resv, Breather-filler ................................................................................................................... Motor, Dc, 12v, 4.5 In, I Trm ............................................................................................................... Switch, Sol Act Mtr St, 12vdc ............................................................................................................ Strap, Motor-solenoid Conn ............................................................................................................. Asm, Ctrlwire, 16awg, Hs, Ring ........................................................................................................ Asm, Valve, 4w/4w, Cartridge (includes items 9 and 10) ........................................................ Coil, 10vdc, #8, 2lead, Diode ...................................................................................................... Nut, 1/2-20 Hex ............................................................................................................................... Asm, Valve, 4w Section ....................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 1 1 1 1 1 6 6 1 Page 1-31 1 G E D 1 G E D 11 10 9 3 8 7 13 14 2 12 2 2 5 2 4 15 6 000557-001 Page 1-32 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List STANDARD TO AUXILLIARY HYDRAULIC CONVERSION KIT ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 102785401 102025401 102741601 102784003 102785001 102785101 102794801 102794901 102922601 102922701 N/A 102923801 102973501 102973601 103409001 Kit, Hydraulic, Aux (includes items 2 through 15) .......................................................................... Tie Wrap, Heavy Duty .......................................................................................................................... Nut Flg M8 X 1.25 Gr 10 ...................................................................................................................... Power Unit, DC Hydraulic, Auxillary ............................................................................................... Hose, -6jic Stf -6jic Stf A ...................................................................................................................... Hose, -6jic Stf -8jic Stf B ...................................................................................................................... Coupling, Female Quick -6jic ............................................................................................................ Coupling, Male Quick -6jic ................................................................................................................ Bracket, Hydraulic, Auxiliary ............................................................................................................. Fhcs, M8x1.25x20 Lock Patch ........................................................................................................... Instruction, Hyd, Aux ........................................................................................................................... Nut, Lock, Hyd Tube, 3/4-16 ............................................................................................................. Cap, Quick Connect, Female ............................................................................................................. Cap, Quick Connect, Male ................................................................................................................. Screw,1/4-20 X 3.5 Hex, Cap ............................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 8 2 1 1 1 1 1 1 2 1 2 1 1 3 Page 1-33 1 G E D 1 G E D BODY AND TRIM 2 G E D 2 G E D 17 11 9 3 3 6 17 9 11 3 3 4 15 5 16 2 5 2 3 8 18 16 12 7 10 14 2 3 5 13 000559-001 Page 2-2 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List FASCIA AND FENDERS – CARRYALL VEHICLES ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 N/A 1011578 102289001 102292356 102297230 102866901 102867001 102867602 102882401 102885001 102895101 102895401 102978801 102978901 103213201 103213501 103218107 808 Instl, Fascia & Fenders, Ca It (includes items 2 through 18) ........................................................ Washer, 5/16 Type B Flat .................................................................................................................... Screw, M8X1.25X30, Hex .................................................................................................................... Screw-1/4-20x56 Hwh Self Drill ....................................................................................................... Screw,m6,torx,interlock,thread ....................................................................................................... Fender, Front, Pass, AWD ................................................................................................................... Fender, Front, Drv, AWD ..................................................................................................................... Fascia, Dueal Round w/ Cut .............................................................................................................. Bracket, Latch, Draw ............................................................................................................................ Headlight, 4 In Round ......................................................................................................................... Latch, Draw, Hood ................................................................................................................................ Screw, D50x16, Torx PN Hd PT ......................................................................................................... Grill, Hex Cut, DS ................................................................................................................................... Grill, Hex, Cut, PS ................................................................................................................................... Harness, Bct/huv Restyle Headlight .............................................................................................. Harness, Headlight, Bct ...................................................................................................................... Screw, #8x2.00 AB Thd, Hex Hd ....................................................................................................... Washer, 3/8 Type B Flat ....................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 4 13 2 4 1 1 1 2 4 2 6 1 1 1 4 4 2 Page 2-3 2 G E D 2 G E D 11 22 33 44 6 5 16 27 38 7 18 29 40 17 28 39 2 9 20 31 42 4 15 26 37 8 3 13 24 35 19 30 41 14 25 36 10 21 32 43 000508-001 Page 2-4 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List COWL ASSEMBLIES – CARRYALL VEHICLES ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 N/A 102292701 102292801 102297230 102866510 102866610 102866710 102866810 102896401 102896501 102967901 N/A 102292701 102292801 102297230 102866514 102866614 102866714 102866814 102896401 102896501 102967901 N/A 102292701 102292801 102297230 102866518 102866618 102866718 102866818 102896401 102896501 102967901 N/A 102292701 102292801 102297230 102866518 102866618 102866718 102866818 102896401 102896501 102967901 Option, Color, CA, Dark Grn (includes items 2 through 11) ........................................................ Clip-body-trim ....................................................................................................................................... Pin, Bow Tie Locking - .072 ................................................................................................................ Screw,m6,torx,interlock,thread ....................................................................................................... Hood, Dark Green ................................................................................................................................. Panel, Cowl, Center, Dark Green ...................................................................................................... Panel, Cowl, Passenger-Side, Dark Green .................................................................................... Panel, Cowl, Driver-Side, Dark Green ............................................................................................. Weldment, Hinge, Hood .................................................................................................................... Prop, Hood .............................................................................................................................................. Rivet, Removable, Tuflok 1/4" .......................................................................................................... Option, Color, CA, Dark Gray (includes items 13 through 22) .................................................... Clip-body-trim ....................................................................................................................................... Pin, Bow Tie Locking - .072 ................................................................................................................ Screw,m6,torx,interlock,thread ....................................................................................................... Hood, Dark Gray .................................................................................................................................... Panel, Cowl, Center, Dark Gray ......................................................................................................... Panel, Cowl, Passenger-Side, Dark Gray ....................................................................................... Panel, Cowl, Driver-Side, Gray .......................................................................................................... Weldment, Hinge, Hood .................................................................................................................... Prop, Hood .............................................................................................................................................. Rivet, Removable, Tuflok 1/4" .......................................................................................................... Option, Color, CA, Real Tree Camo (includes items 24 through 33) ........................................ Clip-body-trim ....................................................................................................................................... Pin, Bow Tie Locking - .072 ................................................................................................................ Screw,m6,torx,interlock,thread ....................................................................................................... Hood, Real Tree Camo ........................................................................................................................ Panel, Cowl, Center, Real Tree Camo ............................................................................................. Panel, Cowl, Passenger-Side, Real Tree Camo ............................................................................ Panel, Cowl, Driver-Side, Real Tree Camo .................................................................................... Weldment, Hinge, Hood .................................................................................................................... Prop, Hood .............................................................................................................................................. Rivet, Removable, Tuflok 1/4" .......................................................................................................... Option, Color, CA, Dlx Real Tree Camo (includes items 35 through 44) ................................. Clip-body-trim ....................................................................................................................................... Pin, Bow Tie Locking - .072 ................................................................................................................ Screw,m6,torx,interlock,thread ....................................................................................................... Hood, Real Tree Camo ........................................................................................................................ Panel, Cowl, Center, Real Tree Camo ............................................................................................. Panel, Cowl, Passenger-Side, Real Tree Camo ............................................................................ Panel, Cowl, Driver-Side, Real Tree Camo .................................................................................... Weldment, Hinge, Hood .................................................................................................................... Prop, Hood .............................................................................................................................................. Rivet, Removable, Tuflok 1/4" .......................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 4 2 4 1 1 1 1 1 1 4 1 4 2 4 1 1 1 3 2 1 4 1 4 2 4 1 1 1 1 1 1 4 1 4 2 4 1 1 1 1 1 1 4 Page 2-5 2 G E D 2 G E D 10 5 4 6 1 8 7 3 2 9 000508-004 Page 2-6 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List COWL ASSEMBLIES – XRT VEHICLES ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 102292701 102292801 102297230 102866518 102866618 102866719 102866819 102896401 102896501 102967901 Clip-body-trim ............................................................................................................................................ Pin, Bow Tie Locking - .072 ..................................................................................................................... Screw,m6,torx,interlock,thread ............................................................................................................. Hood, Real Tree Camo .............................................................................................................................. Panel, Cowl, Center, Real Tree Camo ................................................................................................... Panel, Cowl, Ps, Moff ................................................................................................................................. Panel, Cowl, Drv, Moff ............................................................................................................................... Weldment, Hinge, Hood .......................................................................................................................... Prop, Hood ................................................................................................................................................... Rivet, Removable, Tuflok 1/4" ................................................................................................................ 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 4 2 4 1 1 1 1 1 1 4 Page 2-7 2 G E D 2 G E D 11 22 33 44 6 5 16 27 38 7 18 29 40 17 28 39 2 9 20 31 42 4 15 26 37 8 3 13 24 35 19 30 41 14 25 36 10 21 32 43 000508-001 Page 2-8 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List COWL ASSEMBLIES – XRT VEHICLES ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 N/A 102292701 102292801 102297230 102866510 102866610 102866710 102866810 102896401 102896501 102967901 N/A 102292701 102292801 102297230 102866515 102866615 102866715 102866815 102896401 102896501 102967901 N/A 102292701 102292801 102297230 102866518 102866618 102866718 102866818 102896401 102896501 102967901 N/A 102292701 102292801 102297230 102866518 102866618 102866718 102866818 102896401 102896501 102967901 Option, Color, XRT, Dark Green (includes items 2 through 11) ................................................. Clip-body-trim ....................................................................................................................................... Pin, Bow Tie Locking - .072 ................................................................................................................ Screw,m6,torx,interlock,thread ....................................................................................................... Hood, Dark Green ................................................................................................................................. Panel, Cowl, Center, Dark Green ...................................................................................................... Panel, Cowl, Passenger-Side, Dark Green .................................................................................... Panel, Cowl, Driver-Side, Dark Green ............................................................................................. Weldment, Hinge, Hood .................................................................................................................... Prop, Hood .............................................................................................................................................. Rivet, Removable, Tuflok 1/4" .......................................................................................................... Option, Color, XRT, Red (includes items 13 through 22) .............................................................. Clip-body-trim ....................................................................................................................................... Pin, Bow Tie Locking - .072 ................................................................................................................ Screw,m6,torx,interlock,thread ....................................................................................................... Hood, Red ................................................................................................................................................ Panel, Cowl, Center, Red ..................................................................................................................... Panel, Cowl, Passenger-Side, Red ................................................................................................... Panel, Cowl, Driver-Side, Red ........................................................................................................... Weldment, Hinge, Hood .................................................................................................................... Prop, Hood .............................................................................................................................................. Rivet, Removable, Tuflok 1/4" .......................................................................................................... Option, Color, XRT, Real Tree Camo (includes items 24 through 33) ....................................... Clip-body-trim ....................................................................................................................................... Pin, Bow Tie Locking - .072 ................................................................................................................ Screw,m6,torx,interlock,thread ....................................................................................................... Hood, Real Tree Camo ........................................................................................................................ Panel, Cowl, Center, Real Tree Camo ............................................................................................. Panel, Cowl, Passenger-Side, Real Tree Camo ............................................................................ Panel, Cowl, Driver-Side, Real Tree Camo .................................................................................... Weldment, Hinge, Hood .................................................................................................................... Prop, Hood .............................................................................................................................................. Rivet, Removable, Tuflok 1/4" .......................................................................................................... Option, Color, XRT, Dlx Real Tree Camo (includes items 35 through 44) ............................... Clip-body-trim ....................................................................................................................................... Pin, Bow Tie Locking - .072 ................................................................................................................ Screw,m6,torx,interlock,thread ....................................................................................................... Hood, Real Tree Camo ........................................................................................................................ Panel, Cowl, Center, Real Tree Camo ............................................................................................. Panel, Cowl, Passenger-Side, Real Tree Camo ............................................................................ Panel, Cowl, Driver-Side, Real Tree Camo .................................................................................... Weldment, Hinge, Hood .................................................................................................................... Prop, Hood .............................................................................................................................................. Rivet, Removable, Tuflok 1/4" .......................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 4 2 4 1 1 1 1 1 1 4 1 4 2 4 1 1 1 1 2 1 4 1 4 2 4 1 1 1 1 1 1 4 1 4 2 4 1 1 1 1 1 1 4 Page 2-9 2 G E D 2 G E D 12 16 16 13 10 8 3 11 9 16 8 14 10 8 16 16 9 6 7 8 4 9 15 5 2 2 000521-001 Page 2-10 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List FRONT BODY COMPONENTS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 N/A 1016967 102298401 102298720 102323501 102491301 102491302 102491501 102617201 102618301 102935501 102977201 102983201 102983601 103296001 96715552 Instl, Cowl Weldmnt/Splash Guard (includes items 2 through 16) .......................................... Blind Rivet, Push Type ......................................................................................................................... Nut,m8,all Metal Lock ......................................................................................................................... M8-1.25x20 Taptite .............................................................................................................................. Washer, Flat, 3/8, Blk Fin ..................................................................................................................... Bolt, M10x1.50x100 (Black) ............................................................................................................... Bolt, M10 X 1.50 X 110 Black ............................................................................................................. Washer Hard,m10 ................................................................................................................................. Nut Flg M10 X 1.5 Mech Def ............................................................................................................. Bolt Flanged Head, M8 X 1.25 X 65 ................................................................................................ Weldment, Dash, Front ....................................................................................................................... Bracket, Column, Steering ................................................................................................................. Weldment, Front, Base, ROPS, Right-Hand .................................................................................. Weldment, Front, Base, ROPS, Left-Hand ..................................................................................... Guard, Splash, Gas Injection ............................................................................................................. Bolt, M10 X 1.50 X 65 ........................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 4 2 2 2 3 1 12 10 2 1 1 1 1 1 8 Page 2-11 2 G E D 2 G E D 4 13 5 7 2 7 8 6 11 16 14 12 15 19 3 6 18 9 10 7 17 10 9 000519-001 Page 2-12 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List DASH ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 N/A 1016916 101804301 N/A N/A 102289001 102297230 102298580 102491501 102618601 102867101 102867301 102883401 103233001 103179901 103180001 103253801 103268001 8233 Instl, Dash (includes items 2 through 19) .......................................................................................... Screw, 1/4-20 X 1.50 Hex-Head Cap ............................................................................................... Screw, #8 X 0.500, Hex-Head Hi-Lo ................................................................................................ Cap, 1/4" Plastic Screw Head ............................................................................................................ Washer, 1/4 Id Scalloped Plast ......................................................................................................... Screw, M8X1.25X30, Hex .................................................................................................................... Screw,m6,torx,interlock,thread ....................................................................................................... M8-1.25 X 80 Sems ............................................................................................................................... Washer Hard,m10 ................................................................................................................................. Lock Nut, Flg M8 X 1.25 Nylon ......................................................................................................... Dash, Design A ...................................................................................................................................... Support, Structural .............................................................................................................................. Cup Holder, Utility ................................................................................................................................ Asm, Brush, Fnr (includes items 15 and 16) ................................................................................ Brush, Strip, FNR ............................................................................................................................. Holder, Brush, Strip, Fnr ............................................................................................................... Bracket, Hood Support ....................................................................................................................... Rod, Connection, Dash ....................................................................................................................... Locknut, 1/4-20 Nylon Insert ............................................................................................................ 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 2 1 1 6 5 1 2 2 1 1 2 2 2 2 1 1 1 Page 2-13 2 G E D 2 G E D 4 1 2 3 000789-001 Page 2-14 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List GLOVE BOX ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 102867202 103182701 103182702 103182801 Cover, Storage, Dash, Awd, Cci .............................................................................................................. Latch, Push Close ....................................................................................................................................... Latch, Push Close W/ Key ........................................................................................................................ Keeper, Latch, Push Close ....................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 1 Page 2-15 2 G E D 2 G E D 3 2 4 4 3 6 5 7 000527-001 Page 2-16 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List SIDE STRINGERS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 N/A 102185401 102950402 102950503 357 706 808 Instl, Stringer, Black (includes items 2 through 7) .......................................................................... Tape, 3M VHB 4950 .............................................................................................................................. Bolt, 3/8-16 X 3, Carriage Blk ............................................................................................................ Stringer, Side, 1349.25, Black ............................................................................................................ Washer, Lock, Hel Sp 3/8 Reg ........................................................................................................... Nut, Hex 3/8-16 ..................................................................................................................................... Washer, 3/8 Type B Flat ....................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 A/R 4 2 4 4 4 Page 2-17 2 G E D 2 G E D 3 2 1 000520-001 Page 2-18 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List FLOOR MAT ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 1015392 N/A 102895701 Rivet, 3/16 Pop ............................................................................................................................................ Screw, 1/4-20 X .75 Torx Pn Hd .............................................................................................................. Floor Mat ....................................................................................................................................................... 4 2 1 2 G E D 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 2-19 2 G 5 E D 6 6 4 8 2 3 7 000790-001 Page 2-20 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List FLOORBOARD ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 N/A 1011578 102618601 103319601 103319701 103400001 N/A N/A Instl, Floorboard (includes items 2 through 8) ................................................................................ Washer, 5/16 Type B Flat .................................................................................................................... Lock Nut, Flg M8 X 1.25 Nylon ......................................................................................................... Floorboard, Lower ................................................................................................................................ Floorboard, Upper ................................................................................................................................ 3/16 X 1.19 Alum Rivet, Blk ............................................................................................................... Bracket, Support, Floorboard ........................................................................................................... Bolt, M8 X 1.25 X 110 ........................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 1 1 6 1 1 Page 2-21 2 G E D 2 15 24 G 15 23 7 28 23 13 E 17 26 14 22 D 9 21 6 20 19 25 21 10 10 12 11 19 20 8 21 20 10 5 27 16 18 19 - 4 28 5 - 17 33 33 32 31 30 3 36 2 30 29 34 35 1 000524-001 Page 2-22 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List BUCKET SEATS – GRAY ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 101887601 102059001 102442001 102473701 1011652 102047001 102059401 102061101 102298130 102298401 102456001 102458901 102473501 102473601 102475901 103267001 451 N/A 1011652 1012830 1013734 102023703 102047001 102059401 102061101 102458901 103267001 451 102670601 102718101 102732401 102763701 102967901 103216401 332 96742515 Locknut, M6-1.00 Nylon Insert .............................................................................................................. Seat Holder Base ........................................................................................................................................ Pan, Center, Closeout ................................................................................................................................ Asm, Bucket Seat Adjustable (includes items 5 through 17) ..................................................... Hinge Plate ............................................................................................................................................. Rivet, 1/4 X .438 Blind ......................................................................................................................... Screw, 6m-1.00 X 10mm Hex Head ................................................................................................ Seat Holder Cup .................................................................................................................................... Bolt, Flange Head, M8 X 30.0 ............................................................................................................ Nut,m8,all Metal Lock ......................................................................................................................... Pan, Seat, Driver Asm .......................................................................................................................... Decal, Hot Surface Warning .............................................................................................................. Adjuster, Forward/Aft .......................................................................................................................... Adjuster, Slider ...................................................................................................................................... Washer, Bell ............................................................................................................................................. Seat, Bucket, Gray ................................................................................................................................. Lockwasher, 1/4 Helical Split ............................................................................................................ Assembly, Bucket Seat w/Spacers (includes items 19 through 28) ......................................... Hinge Plate ............................................................................................................................................. Screw, M8-125 X 22 Hex-Head ......................................................................................................... Lockwasher, 8mm Split ...................................................................................................................... Pan, Seat, Passenger ............................................................................................................................ Rivet, 1/4 X .438 Blind ......................................................................................................................... Screw, 6m-1.00 X 10mm Hex Head ................................................................................................ Seat Holder Cup .................................................................................................................................... Decal, Hot Surface Warning .............................................................................................................. Seat, Bucket, Gray ................................................................................................................................. Lockwasher, 1/4 Helical Split ............................................................................................................ Bracket, Seatbelt, Bolt-On ....................................................................................................................... Washer, Hard, M10, Zn-Ni/Blk ................................................................................................................ Bolt, M10 X 45, Zn-Ni (Black) .................................................................................................................. Cover, Center Console .............................................................................................................................. Rivet, Removable, Tuflok 1/4" ................................................................................................................ Nut, Flanged, M10 x 1.5, Black ............................................................................................................... Washer, 1/4 Type A Narrow Flat ............................................................................................................ Bolt, M6 X 1 X 45 ......................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 2 2 1 1 2 4 1 1 4 4 1 1 1 1 4 1 1 1 2 4 4 1 4 1 1 1 1 1 1 2 2 1 4 2 2 2 Page 2-23 2 G E D 2 21 30 G 21 29 13 34 29 19 E 23 32 20 28 D 15 27 12 26 25 31 27 16 16 18 17 25 26 14 27 16 11 26 33 22 24 25 - 10 34 11 23 - 8 8 7 6 5 3 36 2 5 4 9 35 1 000524-002 Page 2-24 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List BUCKET SEATS – BLACK ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 101887601 102059001 102442001 102670601 102718101 102732401 102763701 102967901 103216401 103218901 1011652 102047001 102059401 102061101 102298130 102298401 102456001 102458901 102473501 102473601 102475901 103267002 451 N/A 1011652 1012830 1013734 102023703 102047001 102059401 102061101 102458901 103267002 451 332 96742515 Locknut, M6-1.00 Nylon Insert .............................................................................................................. Seat Holder Base ........................................................................................................................................ Pan, Center, Closeout ................................................................................................................................ Bracket, Seatbelt, Bolt-On ....................................................................................................................... Washer, Hard, M10, Zn-Ni/Blk ................................................................................................................ Bolt, M10 X 45, Zn-Ni (Black) .................................................................................................................. Cover, Center Console .............................................................................................................................. Rivet, Removable, Tuflok 1/4" ................................................................................................................ Nut, Flanged, M10 x 1.5, Black ............................................................................................................... Asm, Bracket Seat, Adj, Blk (includes items 11 through 23) ....................................................... Hinge Plate ............................................................................................................................................. Rivet, 1/4 X .438 Blind ......................................................................................................................... Screw, 6m-1.00 X 10mm Hex Head ................................................................................................ Seat Holder Cup .................................................................................................................................... Bolt, Flange Head, M8 X 30.0 ............................................................................................................ Nut,m8,all Metal Lock ......................................................................................................................... Pan, Seat, Driver Asm .......................................................................................................................... Decal, Hot Surface Warning .............................................................................................................. Adjuster, Forward/Aft .......................................................................................................................... Adjuster, Slider ...................................................................................................................................... Washer, Bell ............................................................................................................................................. Seat, Bucket, Black ............................................................................................................................... Lockwasher, 1/4 Helical Split ............................................................................................................ Asm, Bracket Seat, Passenger, Blk (includes items 25 through 34) .......................................... Hinge Plate ............................................................................................................................................. Screw, M8-125 X 22 Hex-Head ......................................................................................................... Lockwasher, 8mm Split ...................................................................................................................... Pan, Seat, Passenger ............................................................................................................................ Rivet, 1/4 X .438 Blind ......................................................................................................................... Screw, 6m-1.00 X 10mm Hex Head ................................................................................................ Seat Holder Cup .................................................................................................................................... Decal, Hot Surface Warning .............................................................................................................. Seat, Bucket, Black ............................................................................................................................... Lockwasher, 1/4 Helical Split ............................................................................................................ Washer, 1/4 Type A Narrow Flat ............................................................................................................ Bolt, M6 X 1 X 45 ......................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 2 2 1 1 2 2 1 4 2 1 2 4 1 1 4 4 1 1 1 1 4 1 1 1 2 4 4 1 4 1 1 1 1 1 2 2 Page 2-25 2 G E D 2 G E D 8 7 9 8 10 9 10 6 2 5 1 3 4 000560-001 Page 2-26 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List LOWER ROPS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 N/A 102491301 102491501 102617201 102718101 103361701 N/A 102988701 103216401 103377501 Instl, Rops, Lower (includes items 2 through 6) .............................................................................. Bolt, M10x1.50x100 (Black) ............................................................................................................... Washer Hard,m10 ................................................................................................................................. Nut Flg M10 X 1.5 Mech Def ............................................................................................................. Washer, Hard, M10, Zn-Ni/Blk .......................................................................................................... Weldment,seat Support,hs,rops ..................................................................................................... Instl, Rear Brace, Head Rest (includes items 8 through 10) ......................................................... Bolt, Flanged, M10 X 1.5 X 65 .......................................................................................................... Nut, Flanged, M10 x 1.5, Black ......................................................................................................... Brkt, Spprt, Rear, Rops, Fin ................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 4 4 4 4 1 1 2 2 2 Page 2-27 2 G E D 2 G 9 E 9 9 12 D 9 11 10 10 9 11 11 9 3 2 4 7 5 6 000560-002 Page 2-28 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List SEAT BELTS AND ROPS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 N/A 102324401 102671201 103210801 103210802 103210901 N/A 103215901 102988701 103192101 103216401 103225801 Instl, Seat Belt, 3 Point (includes items 2 through 7) ..................................................................... Lock Nut, 7/16-20 Nylon Black ......................................................................................................... Screw,m12x1.75x30 Thd Form Blk ................................................................................................. Spacer, .69 Od X .5 Id X .60 ................................................................................................................ Spacer, .69 Od X .5 Id X .20 ................................................................................................................ Seat Belt, 3 Pt, Lock Tongue .............................................................................................................. Screw, 7/16-20 X 1.75 .......................................................................................................................... Kit, ROPS, Domestic (includes items 9 through 11) ....................................................................... Bolt, Flanged, M10 X 1.5 X 65 .......................................................................................................... Tube, Side Support Short, ROPS ..................................................................................................... Nut, Flanged, M10 x 1.5, Black ......................................................................................................... Asm, Top, ROPS ........................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 2 2 2 2 2 1 8 2 8 1 Page 2-29 2 G E D 2 G E D 4 2 2 4 7 6 6 7 8 5 3 1 2 - 4 000029-005 Page 2-30 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List ROPS – HEAD RESTS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 103274602 102490101 103274502 96741046 N/A 102988701 103216401 103283801 Kit, Head Restraint, Black (includes items 2 through 4) ............................................................... Bolt, M10 X 1.5 X 20 Loctite .............................................................................................................. Asm, Head Restraint, Black ................................................................................................................ Washer, M10 Hard ................................................................................................................................ Kit, Rear Brace, ROPS (includes items 6 through 8) ....................................................................... Bolt, Flanged, M10 X 1.5 X 65 .......................................................................................................... Nut, Flanged, M10 x 1.5, Black ......................................................................................................... Asm, Rear Brace ..................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 4 2 4 1 2 2 1 Page 2-31 2 G E D 2 G E D 5 10 7 6 12 11 8 10 4 1 2 9 11 11 3 000036-001 Page 2-32 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List LATCH PLATE AND PROP ROD ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 1015277 1016078 101835601 101958602 102301401 102323101 102418101 102426601 102493801 102618301 102618601 334 Latch Plate, Tilt Bed ................................................................................................................................... Latch Plate Shim ......................................................................................................................................... Locknut, 1/4-20 Hex Whiz ....................................................................................................................... Bolt, Carriage, 1/4-20 X 1.0 ..................................................................................................................... Rod, Prop ....................................................................................................................................................... Pin, Bow Tie Locking ................................................................................................................................. Track, Prop Rod ........................................................................................................................................... Bumper, Bed, Mtg, Front .......................................................................................................................... Bracket, Latch, Bed .................................................................................................................................... Bolt Flanged Head, M8 X 1.25 X 65 ...................................................................................................... Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. Washer, 3/8 Type A Flat ............................................................................................................................ 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 2 A/R 4 4 1 1 1 2 2 3 5 1 Page 2-33 2 G E D 2 G E 4 9 14 12 13 11 8 7 6 15 10 15 5 D 2 20 19 17 1 2 16 3 18 000037-001 Page 2-34 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List TILT BED, HINGE, AND LATCH ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1012303 1015583 102065901 102171503 1010435 1014471 N/A N/A 1015391 1015399 1015400 101835601 102426901 403 7473 102614101 103538701 103538901 8754 8755 Bushing, Steel .............................................................................................................................................. Bushing, Urethane ..................................................................................................................................... Locknut, 3/8-16 Flanged Dimple .......................................................................................................... Tilt Bed Assembly (includes items 5 through 15) ........................................................................... Bolt, Carriage, 5/16-18 X 1.00 ........................................................................................................... Tape, Vinyl Foam 1/8" x 3/4" * .......................................................................................................... Plate, Floor Bed ..................................................................................................................................... Frame Assembly .................................................................................................................................... Extension, Spring Latch ...................................................................................................................... Screw, 5/16-18 X 0.88 Torx Truss-Head ......................................................................................... Grip, Tilt Latch Hand ............................................................................................................................ Locknut, 1/4-20 Hex Whiz ................................................................................................................. Ltch Weld Asm Tlt Bd .......................................................................................................................... Screw, 1/4-20 X 0.625 Hex-Head Cap ............................................................................................ Locknut, 5/16-18 Nylon Insert ......................................................................................................... Plate, Back ..................................................................................................................................................... Extr, Brkt, Hinge, Bed ................................................................................................................................ 3/8-16 X 3.5 Carr Blt Gr5 Zn .................................................................................................................... Locknut, 3/8-16 Hex .................................................................................................................................. Screw, 3/8-16 X 3.375 Hex Cap .............................................................................................................. 2 2 4 1 4 A/R 1 1 2 4 1 4 1 4 8 2 2 4 2 2 * Note: Item not shown. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 2-35 2 G E D 2 G 1 16 6 6 E D 7 6 10 9 8 15 15 4 6 15 6 16 3 5 2 14 14 16 15 5 13 2 8 11 12 17 000158-002 Page 2-36 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List ELECTRIC BED LIFT ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1010200 1016603 1017162 1017167 1017774 102066001 102426601 102465701 102614101 102618601 102629001 102882501 103227001 357 8754 8755 8990 Bolt, 3/8-16 X 4.25 Hex Head ................................................................................................................. Bushing Long .............................................................................................................................................. Actuator Assembly, Electric .................................................................................................................... Actuator Adapter ....................................................................................................................................... Body Spacer ................................................................................................................................................. Washer, 3/8 Type B Hard Flat ................................................................................................................. Bumper, Bed, Mtg, Front .......................................................................................................................... Weldment, Bracket, Actuator ................................................................................................................. Plate, Back ..................................................................................................................................................... Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. Tie Wrap, 8.00" With Mount .................................................................................................................... Switch, Rocker, Spring Return, Bed Lift .............................................................................................. Harness, AWD Bedlift ................................................................................................................................ Washer, Lock, Hel Sp 3/8 Reg ................................................................................................................. Locknut, 3/8-16 Hex .................................................................................................................................. Screw, 3/8-16 X 3.375 Hex Cap .............................................................................................................. Tie Wrap, 8" Nylon ..................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 1 1 8 8 2 1 1 2 2 1 1 2 9 6 5 Page 2-37 2 G E D 2 33 G 34 E D 40 31 37 30 32 4 5 6 8 29 35 41 11 36 2 43 10 2 3 38 24 7 8 17 10 26 27 16 9 14 10 12 13 42 39 15 21 22 28 42 19 18 25 20 23 Page 2-38 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 000532-001 BOX BED ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 N/A 1010435 1010934 1014321 1014387 1014415 1014537 1015399 N/A 101963401 102030101 102030201 1013317 1015246 N/A 7973 103191401 1010434 1011990 1015313 1015363 1015390 1015400 103191201 1032 103379401 N/A 1231 103191501 1010434 1011990 1015245 1015363 1015390 1015400 103191301 1032 103379401 N/A 1231 332 7049 8233 Install, Box Bed (includes items 2 through 43) ................................................................................ Bolt, Carriage, 5/16-18 X 1.00 ........................................................................................................... Screw, 5/16-18 X 1.00 Hex Cap ........................................................................................................ Screw, #10 Truss-Head Torx .............................................................................................................. Cap, Corner ............................................................................................................................................. Screw, 1/4-20 X 0.75 Torx Truss-Head ........................................................................................... Stud, Self-Clinching Flush Head ...................................................................................................... Screw, 5/16-18 X 0.88 Torx Truss-Head ......................................................................................... Box Bed Tailgate Angle ....................................................................................................................... Locknut, 5/16-18 Hex Flange ........................................................................................................... Panel, Front ............................................................................................................................................. Tailgate Asm (includes items 13 through 16) ............................................................................. Decal, Logo, Tailgate ..................................................................................................................... Plate, Tailgate Latch Wear ........................................................................................................... Tailgate Weldment ......................................................................................................................... Rivet, 3/16 X .400 Blind ................................................................................................................ Asm, Panel, Side, Left (includes items 18 through 28) ............................................................ Barrel - Plastic .................................................................................................................................. Washer, 3/8 Flat ............................................................................................................................... Latch, Tailgate, Left-Hand ............................................................................................................ Bushing, Snap-In ............................................................................................................................ Compression Spring Latch Tilt .................................................................................................. Grip, Tilt Latch Hand ...................................................................................................................... Weldment, Panel, Side, Left ........................................................................................................ Bushing, Nylon ................................................................................................................................ Rivet, 1/4 X 0.30, Blind .................................................................................................................. Asm, Tlgt, Mtg Brkt, Ca Lh ........................................................................................................... Pin, 1/8 X 1.00 Split Roll ............................................................................................................... Asm, Panel, Side, Right (includes items 30 through 40) ......................................................... Barrel - Plastic .................................................................................................................................. Washer, 3/8 Flat ............................................................................................................................... Latch, Tailgate, Right-Hand ........................................................................................................ Bushing, Snap-In ............................................................................................................................ Compression Spring Latch Tilt .................................................................................................. Grip, Tilt Latch Hand ...................................................................................................................... Weldment, Panel, Side, Right ..................................................................................................... Bushing, Nylon ................................................................................................................................ Rivet, 1/4 X 0.30, Blind .................................................................................................................. Asm, Tlgt, Mtg Brkt, Ca Rh ........................................................................................................... Pin, 1/8 X 1.00 Split Roll ............................................................................................................... Washer, 1/4 Type A Narrow Flat ...................................................................................................... Bushing, Nylon ...................................................................................................................................... Locknut, 1/4-20 Nylon Insert ............................................................................................................ 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 11 2 4 2 4 2 16 1 33 1 1 1 2 1 4 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 2 1 1 4 2 4 Page 2-39 2 G E D 2 G E D 9 16 26 5 15 25 9 8 19 29 16 26 31 2 3 13 23 4 14 24 3 7 6 17 12 22 13 23 18 28 27 10 20 30 10 20 30 000518-001 Page 2-40 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List SIDE PANELS AND REAR FENDERS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 N/A 1014306 102491701 102913801 102913901 102914001 102914101 102914102 103200501 8251 N/A 1014306 102491701 102913801 102913901 103200501 103289001 103289101 103289103 8251 N/A 1014306 102491701 102913801 102913901 103200501 103289002 103289102 103289104 8251 103331201 Instl, Panels, Fenders, Blk (includes items 2 through 10) ............................................................. Washer, 1/4" Type B Flat ..................................................................................................................... Well Nut 1/4-20 ..................................................................................................................................... Left Rear Fender (Black) ...................................................................................................................... Right Rear Fender (Black) .................................................................................................................. Panel, Front, Kick (Black) .................................................................................................................... Panel, Side, Molded, Driver (Black) ................................................................................................. Panel, Side, Molded, Passenger (Black) ......................................................................................... Screw, Tuflok, 10mm ........................................................................................................................... Screw, 1/4-20 X 1.0 Truss-Head Machine ..................................................................................... Instl, Panels, Fenders, Rthwd (includes items 12 through 20) ................................................... Washer, 1/4" Type B Flat ..................................................................................................................... Well Nut 1/4-20 ..................................................................................................................................... Left Rear Fender (Black) ...................................................................................................................... Right Rear Fender (Black) .................................................................................................................. Screw, Tuflok, 10mm ........................................................................................................................... Panel, Front, Kick (Realtree Camo) .................................................................................................. Panel, Side, Molded, Driver (Realtree Camo) .............................................................................. Panel, Side, Molded, Passenger (Realtree Camo) ...................................................................... Screw, 1/4-20 X 1.0 Truss-Head Machine ..................................................................................... Instl, Panels, Fenders, Moff (includes items 22 through 30) ....................................................... Washer, 1/4" Type B Flat ..................................................................................................................... Well Nut 1/4-20 ..................................................................................................................................... Left Rear Fender (Black) ...................................................................................................................... Right Rear Fender (Black) .................................................................................................................. Screw, Tuflok, 10mm ........................................................................................................................... Panel, Front, Kick, Moff ....................................................................................................................... Pnl, Side, Mld, Drv, Moff ..................................................................................................................... Pnl, Side, Mld, Pass, Moff .................................................................................................................... Screw, 1/4-20 X 1.0 Truss-Head Machine ..................................................................................... Closeout, Extrusion ................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 4 8 1 1 1 1 1 6 8 1 4 8 1 1 6 1 1 1 8 1 4 8 1 1 6 1 1 1 8 1 Page 2-41 2 G E D 2 G 2 5 E 25 D 27 12 10 26 11 23 19 18 6 9 8 21 22 14 13 24 4 5 7 16 17 26 20 7 26 3 15 000038-001 Page 2-42 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List CARGO BOX (STEEL) ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 N/A 1010435 1010436 1014306 1014415 1014537 1015399 101894304 101963401 102221301 102221401 102221501 102221701 102222001 102239901 102614401 1013366 1014415 N/A 102221801 102222101 102222201 102673201 8233 332 7473 8233 Instl, Steel Box, XRT (includes items 2 through 27) ........................................................................ Bolt, Carriage, 5/16-18 X 1.00 ........................................................................................................... Bumper, Rubber .................................................................................................................................... Washer, 1/4" Type B Flat ..................................................................................................................... Screw, 1/4-20 X 0.75 Torx Truss-Head ........................................................................................... Stud, Self-Clinching Flush Head ...................................................................................................... Screw, 5/16-18 X 0.88 Torx Truss-Head ......................................................................................... Box Bed Tailgate Angle ....................................................................................................................... Locknut, 5/16-18 Hex Flange ........................................................................................................... Front Panel Weldment ........................................................................................................................ Left Panel Weldment ........................................................................................................................... Right Panel Weldment ........................................................................................................................ Front Corner Cap .................................................................................................................................. Slam Latch ............................................................................................................................................... Washer, Rubber, 3/8 ............................................................................................................................. Assembly, Tailgate (includes items 17 through 24) ................................................................. Hair Pin Clip ...................................................................................................................................... Screw, 1/4-20 X 0.75 Torx Truss-Head ..................................................................................... Tailgate, Weldment ........................................................................................................................ Tether Assembly ............................................................................................................................. Spring Latch Left ............................................................................................................................ Spring Latch Right ......................................................................................................................... Decal, Club Car Tailgate ............................................................................................................... Locknut, 1/4-20 Nylon Insert ..................................................................................................... Washer, 1/4 Type A Narrow Flat ...................................................................................................... Locknut, 5/16-18 Nylon Insert ......................................................................................................... Locknut, 1/4-20 Nylon Insert ............................................................................................................ 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 13 4 4 8 4 18 1 4 1 1 1 2 2 4 1 4 4 1 2 1 1 1 4 4 31 4 Page 2-43 2 G E D 2 G E D WHEELS AND TIRES 3 G E D 3 G E D 5 VALVE STEM 4 RIM 3 TIRE 2 FOR DRIVERS OR PASSENGERS SIDE 1 13 VALVE STEM 12 RIM 11 10 9 VALVE STEM 8 RIM 7 TIRE TIRE FOR PASSENGERS SIDE ONLY 6 FOR DRIVERS SIDE ONLY 000506-001 Page 3-2 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List WHEELS AND TIRES ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 102736901 102943807 102943101 103234503 7310 102943808 102945701 103234503 7310 102943809 102945701 103234503 7310 Nut, Lug, 1/2-20 SAE J2283 .................................................................................................................... Black Tire Asm HDAT 10.5 In (includes items 3 through 5) ......................................................... Heavy Duty All Terrain Tire, 25" ....................................................................................................... Wheel, All trail, 10 Window, Black ................................................................................................... Valve Stem .............................................................................................................................................. Black Tire Asm Mud 11.0 In Left-Hand (includes items 7 through 9) ...................................... Mud Tire, 25" .......................................................................................................................................... Wheel, All trail, 10 Window, Black ................................................................................................... Valve Stem .............................................................................................................................................. Black Tire Asm Mud 11.0 In Right-Hand (includes items 11 through 13) .............................. Mud Tire, 25" .......................................................................................................................................... Wheel, All trail, 10 Window, Black ................................................................................................... Valve Stem .............................................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 16 4 1 1 1 2 1 1 1 2 1 1 1 Page 3-3 3 G E D 3 G E D DECALS 4 G E D 4 G 9 E 5 D 3 10 4 6 1 2 8 7 000561-002 Page 4-2 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List SAFETY DECALS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 1011553 101609401 102224001 102459301 102459401 102926101 102930801 102950601 102961201 103188601 Decal, Trailer Hitch ..................................................................................................................................... Decal, Crush Area Warning ..................................................................................................................... Decal, Rotating Parts Warning .............................................................................................................. Decal, Bed Crush Area Warning ............................................................................................................ Decal, Young Driver Warning ................................................................................................................ Decal, Attachment Locking .................................................................................................................... Decal, Loading, Intellitach ...................................................................................................................... Decal, Hydra Pump .................................................................................................................................... Decal, Warning, AWD ROPS .................................................................................................................... Decal, Warn, Rollover & Attach ............................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 1 1 1 1 1 1 1 1 Page 4-3 4 G E D 4 G E D 4 6 7 8 2 3 1 5 000561-001 Page 4-4 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List SAFETY DECALS, CONTINUED ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 102458901 102459001 102459101 102459201 102459501 102460201 103188701 103319901 Decal, Hot Surface Warning ................................................................................................................... Decal, Hot Manifold Warning ................................................................................................................ Decal, Frame Ground Warning .............................................................................................................. Decal, Diesel Explosion/Fire Warning ................................................................................................. Decal, Rotating Parts and Hot Exhaust Warning ............................................................................ Decal, Rotating Parts Warning .............................................................................................................. Decal, Operator Instructions, Intellitach ............................................................................................ Decal, Joystick, On Off .............................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 3 1 1 1 1 1 1 1 Page 4-5 4 G E D 4 G E D 3 7 2 4 6 8 000562-001 Page 4-6 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List BADGING DECALS – CARRYALL VEHICLES ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 N/A 103233614 103233714 103234201 N/A 103233617 103233717 103234201 Instl, Decal, Bed, Cait,dkgray (includes items 2 through 4) ......................................................... Decal, Badge, CA 295, Driver-Side, Dk Gray ................................................................................ Decal, Badge, CA 295, Passenger-Side, Dk Gray ........................................................................ Decal, Badge, 4x4 ................................................................................................................................. Instl, Decal, Ca It, Stl, Ntrl (includes items 6 through 8) ............................................................... Decal, Badge, CA 295, Driver-Side, Ntrl ........................................................................................ Decal, Badge, CA 295, Passenger-Side, Ntrl ................................................................................ Decal, Badge, 4x4 ................................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 2 1 1 1 2 Page 4-7 4 G E D 4 G E D 3 7 11 2 4 8 6 10 12 000562-002 Page 4-8 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List BADGING DECALS – XRT VEHICLES ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 N/A 103233410 103233510 103234201 N/A 103233415 103233515 103234201 N/A 103233417 103233517 103234201 Instl, Decal, Bed, Xrtit,dkgrn (includes items 2 through 4) .......................................................... Decal, Bed, XRT 1550, Dk Grn, Ds .................................................................................................... Decal, Bed, XRT 1550, Dk Grn, Ps .................................................................................................... Decal, Badge, 4x4 ................................................................................................................................. Instl, Decal, Bed, Xrt It, Red (includes items 6 through 8) ............................................................ Decal, Bed, XRT 1550, Red, Ds .......................................................................................................... Decal, Bed, XRT 1550, Red, Ps ........................................................................................................... Decal, Badge, 4x4 ................................................................................................................................. Instl, Decal, Bed, Xrt It,ntrl (includes items 10 through 12) ........................................................ Decal, Bed, Xrt1550, Ntrl, Ds ............................................................................................................. Decal, Bed, XRT 1550, Ntrl, Ps ........................................................................................................... Decal, Badge, 4x4 ................................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 2 1 1 1 2 1 1 1 2 Page 4-9 4 G E D 4 G E D 2 000562-003 Page 4-10 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List BADGING DECALS – INTELLITACH ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 N/A 102925601 Instl, Decal, Intellitach (includes item 2) ............................................................................................ Decal, Brand, IntelliTach ..................................................................................................................... 1 2 4 G E D 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 4-11 4 G E D BRAKE SYSTEMS 5 G E D 5 G E 4 D 1 6 2 3 4 5 000067-001 Page 5-2 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List FRONT BRAKE ASSEMBLY ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 102367601 102488001 102491601 102493301 102714001 103418801 Brake Caliper, Front, with Brake Pads .................................................................................................. Bolt, Banjo, M10x1x19 .............................................................................................................................. Washer, Copper, M10 Crush ................................................................................................................... Bolt Flange Head, 3/8-24x.750 with Loctite ..................................................................................... Service Kit, Brake Pad (4 Pads) ............................................................................................................... Pin, Slide, 7/16 ............................................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 2 2 4 4 1 2 Page 5-3 5 G E D 5 G 2 E 5 1 D 5 8 6 4 3 000068-001 Page 5-4 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List REAR BRAKE ASSEMBLY ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 102399201 102399202 102488001 102491601 102493301 102714001 103418701 103418801 Caliper, Brake, Hydro-Mechanical, LH ................................................................................................. Caliper, Brake, Hydro-Mechanical, RH ................................................................................................ Bolt, Banjo, M10x1x19 .............................................................................................................................. Washer, Copper, M10 Crush ................................................................................................................... Bolt Flange Head, 3/8-24x.750 with Loctite ..................................................................................... Service Kit, Brake Pad (4 Pads) ............................................................................................................... Spring, Brake Caliper Return .................................................................................................................. Pin, Slide, 7/16 ............................................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 2 4 4 1 1 2 Page 5-5 5 G E D 5 6 G 5 7 E 2 D 10 11 8 4 3 9 1 8 000069-002 Page 5-6 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List MASTER CYLINDER WITH REMOTE RESERVOIR ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 101082903 1014306 102176901 102402801 102402901 102051401 N/A 102618401 102618601 103218213 103293201 Clevis Pin, 5/16 X 1 ..................................................................................................................................... Washer, 1/4" Type B Flat .......................................................................................................................... Pin, Rue .......................................................................................................................................................... Cylinder, Master, Tandem ........................................................................................................................ Assembly, Reservoir, Remote (includes items 6 and 7) ................................................................ Filler Cap Asm ........................................................................................................................................ Reservoir, Brake Fluid, Without Cap ............................................................................................... Bolt Flanged Head, M8 X 1.25 X 35 ...................................................................................................... Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. Screw, #10x3.50 Ab Thd, Hex Hd .......................................................................................................... Hose, Reservoir, Brake Fluid ................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 1 1 1 1 2 2 1 2 Page 5-7 5 G E D 5 G E D 6 2 5 1 3 4 000792-001 Page 5-8 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List MASTER CYLINDER WITH INTEGRAL RESERVOIR ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 101082903 102176901 102298401 102618401 103376101 N/A Clevis Pin, 5/16 X 1 ..................................................................................................................................... Pin, Rue .......................................................................................................................................................... Nut,m8,all Metal Lock ............................................................................................................................... Bolt Flanged Head, M8 X 1.25 X 35 ...................................................................................................... Cylinder, Master, Integral Res ................................................................................................................. Filler Cap Asm Integral Res ..................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 2 2 1 1 Page 5-9 5 G E D 5 G E 2 D 8 3 1 12 9 11 6 3 5 3 4 7 10 000015-003 Page 5-10 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List HYDRAULIC BRAKE LINES AND CLIPS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 101887601 102296140 102296716 102376603 N/A 102475801 102407801 102474301 102475701 102689001 103174301 8639 Locknut, M6-1.00 Nylon Insert .............................................................................................................. Bolt, Flanged Head, M6x1.0x40 ............................................................................................................ Screw, M6 X 16 Tt Hx Fl Hd ..................................................................................................................... Assy, Rotor, Brake, Front, Wt (includes items 5 and 6) .................................................................. Rotor, Brake, Front, Wt ........................................................................................................................ Stud, Wheel Lug .................................................................................................................................... Assembly, Brake Line, Rear ..................................................................................................................... Bracket, Tee, Brakeline .............................................................................................................................. Clip, Brake Line ............................................................................................................................................ Bracket, Line, Hydraulic ........................................................................................................................... Brakeline, Front, Assembly ..................................................................................................................... Tie Wrap, 11" Nylon ................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 2 1 8 2 1 4 1 1 6 2 1 1 Page 5-11 5 G E D 5 G E D 4 3 8 2 1 6 5 7 000088-001 Page 5-12 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List BRAKE PEDAL ASSEMBLY ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 102380601 102618101 102618301 102618601 N/A 102442901 102626201 103273101 Bracket, Pedal, Brake ................................................................................................................................. Nut M6x1 Mech Def Center .................................................................................................................... Bolt Flanged Head, M8 X 1.25 X 65 ...................................................................................................... Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. Asm, Pedal, Brake, Hung (includes items 6 and 7) ......................................................................... Bushing, Greaseless ............................................................................................................................. Weldment, Pedal, Brake, Hung ........................................................................................................ Bolt, Shoulder, M8 X 70, Hc .................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 2 2 1 2 1 1 Page 5-13 5 G E D 5 G E 9 D 3 13 13 8 14 7 12 5 4 2 6 11 10 000533-001 Page 5-14 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List PARK BRAKE SYSTEM ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 N/A 1010521 1011779 1013531 N/A 102052801 102618301 102618601 102712601 102763301 102763401 103189001 1035 8639 Instl, Brake, Park, AWD (includes items 2 through 14) .................................................................. Nut, 5/16-24 Hex ................................................................................................................................... E-Clip, 1/2 ................................................................................................................................................ Spring, Brake Return ............................................................................................................................ Equalizer Bracket .................................................................................................................................. Nut, 5/16-24 Hex Cone ....................................................................................................................... Bolt Flanged Head, M8 X 1.25 X 65 ................................................................................................ Lock Nut, Flg M8 X 1.25 Nylon ......................................................................................................... Cable, Crank, Bell, Front ..................................................................................................................... Cable, Noncoated, Pbrake, Left ....................................................................................................... Cable, Noncoated, Pbrake, Rght ..................................................................................................... Cable, Crank, Bell, Main ...................................................................................................................... Cotter Pin, 3/32 x 1 ............................................................................................................................... Tie Wrap, 11" Nylon ............................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 2 1 1 1 1 1 1 1 1 1 2 2 Page 5-15 5 G E D 5 10 7 G E D 8 6 10 5 9 11 12 4 15 13 14 1 2 000086-002 Page 5-16 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List PARK BRAKE PEDAL ASSEMBLY ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 102618301 102618601 102751501 102323501 102716001 102741501 102741601 102751301 N/A 103305001 103305101 1035 102892401 N/A 102896601 Bolt Flanged Head, M8 X 1.25 X 65 ...................................................................................................... Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. Asm, Sub, Bracket, Park Brake (includes items 4 through 12) .................................................... Washer, Flat, 3/8, Blk Fin ..................................................................................................................... Cable, Crank, Bell .................................................................................................................................. Bolt Flg, M8x1.25 X 35, Gr10.9 ......................................................................................................... Nut Flg M8 X 1.25 Gr 10 ...................................................................................................................... Asm, Bellcrank, Upper ......................................................................................................................... Asm, Bellcrank, Lower ......................................................................................................................... Brkt, Bellcrank, Prk Brk, Awd ............................................................................................................. Spacer, Pivot, Park Brk, Awd .............................................................................................................. Cotter Pin, 3/32 x 1 ............................................................................................................................... Asm, Pedal, Brake, Hard (includes items 14 and 15) ...................................................................... Pedal, Brake, Park .................................................................................................................................. Handle, Release, Park Brake .............................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 3 3 1 2 1 2 2 1 1 1 2 2 1 1 1 Page 5-17 5 G E D 5 G E D STEERING AND SUSPENSION 6 G E D 6 G E D 5 2 4 6 3 9 11 8 7 10 000070-002 Page 6-2 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List STEERING COLUMN ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 N/A 102290120 102298130 102363802 102367101 102618601 102989801 102298130 102571301 102616801 N/A Instl, Steering System (includes items 2 through 7) ...................................................................... Bolt, M10 X 20 Hex Washer Hd ........................................................................................................ Bolt, Flange Head, M8 X 30.0 ............................................................................................................ Steering Wheel, Viper, Hex Hub ...................................................................................................... Cap, Steering Wheel, Viper ................................................................................................................ Lock Nut, Flg M8 X 1.25 Nylon ......................................................................................................... Steering Column (includes items 8 through 11) ....................................................................... Bolt, Flange Head, M8 X 30.0 ..................................................................................................... Shroud, Steering Column ............................................................................................................ Bolt, M4 X .7 X 60 ............................................................................................................................ Handle, Steering, Tilt ..................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 1 1 3 1 1 1 1 1 Page 6-3 6 G E D 6 G E 2 18 3 4 11 6 7 8 13 15 16 9 10 5 14 12 D 21 17 22 1 19 20 000071-001 Page 6-4 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List STEERING GEAR ASSEMBLY ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1013042 102010102 1013035 1013042 1013044 1013051 1013052 101879401 101879701 101879801 101879901 101880201 N/A N/A N/A N/A N/A 8990 102022601 102022901 102687801 102816801 Nut, 12mm Hex ........................................................................................................................................... Steering Rack (includes items 3 through 18) ................................................................................... Bellows, Long ......................................................................................................................................... Nut, 12mm Hex ..................................................................................................................................... Rack Screw Locknut ............................................................................................................................. Snap Ring ................................................................................................................................................ Seal, Steering Pinion Dust ................................................................................................................. Bearing, Ball ............................................................................................................................................ Support Yoke ......................................................................................................................................... Rack Guide Pressure Spring .............................................................................................................. Ring, Stop, C-Type ................................................................................................................................ Inner Ball Joint Asm ............................................................................................................................. Pinion, Steering ..................................................................................................................................... Bearing, Lower Pinion ......................................................................................................................... Screw, Rack Guide ................................................................................................................................ Housing, Steering Gear ...................................................................................................................... Rack, Steering ........................................................................................................................................ Tie Wrap, 8" Nylon ................................................................................................................................ End, Tie Rod M12 X 1.25 .......................................................................................................................... Locknut, M12-1.25 Nylon ........................................................................................................................ Bolt, Flange Head, M10x 1.5 X 40 with Loctite ................................................................................ Link, Drag, Wt .............................................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 2 1 2 2 1 1 1 1 1 1 1 2 1 1 1 1 1 2 2 2 4 2 Page 6-5 6 G E D 6 4 G E 5 D 38 37 11 7 11 7 34 35 30 39 32 33 31 28 39 29 36 11 41 11 36 8 10 3 8 21 2 2 22 14 23 6 9 40 9 6 16 17 25 26 13 19 27 24 3 10 20 12 15 18 000534-001 Page 6-6 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List FRONT SUSPENSION – A-ARMS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 N/A 102022901 102274101 102408401 102437001 102490801 102616301 102617501 102617701 102617801 102620501 102791701 102022901 102464301 102874301 102361901 102722301 102874201 103277001 102791702 102022901 102464301 102874301 102361901 102722301 102874201 103277002 102792001 102361901 102722301 102927101 102792002 102361901 102722301 102927102 102874501 103256401 103256501 103256701 103296201 103345801 Suspension, AWD, Wide (includes items 2 through 40) ............................................................... Locknut, M12-1.25 Nylon .................................................................................................................. Center Cap, Rubber .............................................................................................................................. Bushing, A-Arm ..................................................................................................................................... Sleeve, Upper ......................................................................................................................................... Bolt, Flange Head, M12x 1.75x 30 with Loctite .......................................................................... Bolt, Flange Head, M12 X 1.75 X 70 ............................................................................................... Nut Flg, M22 X 1.5 Mech Def ............................................................................................................ Nut, Square, M12x 1.75 ...................................................................................................................... Washer Hard, M22 ................................................................................................................................ Nut Flg, M12x1.75, Nylon Gr 10 ....................................................................................................... Upright, Left-Hand (includes items 13 through 19) ................................................................. Locknut, M12-1.25 Nylon ............................................................................................................ Bearing ............................................................................................................................................... Asm, Adjuster, Slide (includes items 16 through 18) ......................................................... Joint, Ball ..................................................................................................................................... Ring, Retaining, Ext, 1-1/4" ................................................................................................... Slide, Adjuster ............................................................................................................................ Upright, Finished, Lh ..................................................................................................................... Upright, Right-Hand (includes items 21 through 27) .............................................................. Locknut, M12-1.25 Nylon ............................................................................................................ Bearing ............................................................................................................................................... Asm, Adjuster, Slide (includes items 24 through 26) ......................................................... Joint, Ball ..................................................................................................................................... Ring, Retaining, Ext, 1-1/4" ................................................................................................... Slide, Adjuster ............................................................................................................................ Upright, Finished, Rh .................................................................................................................... Asm, A-Arm, Upper, Left (includes items 29 through 31) ...................................................... Joint, Ball ........................................................................................................................................... Ring, Retaining, Ext, 1-1/4" ......................................................................................................... Arm, Upper, Wide, Machined, Lh .............................................................................................. Asm, A-arm, Upper, Right (includes items 33 through 35) .................................................... Joint, Ball ........................................................................................................................................... Ring, Retaining, Ext, 1-1/4" ......................................................................................................... Arm, Upper, Wide, Machined,rh ................................................................................................ A-Arm, Lower ......................................................................................................................................... Sleeve, Lower Arm ................................................................................................................................ Bushing, Lower Arm ............................................................................................................................ Bolt Flg, M12 X 1.75 X 200 10. .......................................................................................................... Half Shaft, Wide, Awd .......................................................................................................................... Ring, Hog, Half Shaft ................................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 2 8 4 4 4 2 4 2 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 4 2 2 2 Page 6-7 6 G E D 6 G E D 3 2 4 1 7 6 8 5 000791-001 Page 6-8 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List CV BOOT REPAIR KITS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 AM11807 N/A AM11808 N/A AM1241201 N/A AM1241301 N/A Boxed Outboard Boot Kit (includes item 2) ...................................................................................... Half Shaft Boot Instl. Instr. ................................................................................................................. Boxed Inboard Boot Kit (includes item 4) ......................................................................................... Half Shaft Boot Instl. Instr. ................................................................................................................. Kit, Outer Boot, Gen 2 (includes item 6) ............................................................................................ Instructions, Boot Replacement ...................................................................................................... Kit, Inner Boot, Gen 2 (includes item 8) ............................................................................................. Instructions, Boot Replacement ...................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 1 1 1 1 1 Page 6-9 6 G E D 6 G 3 E 3 D 4 7 7 8 8 4 4 2 3 3 2 3 5 4 6 3 4 000530-003 Page 6-10 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List SHOCK ABSORBERS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 N/A 102365601 102616301 102620501 102689101 102689102 102786301 102788701 Inst, Shock, Awd, Bt (includes items 2 through 8) .......................................................................... Shock, Coil Over Rear .......................................................................................................................... Bolt, Flange Head, M12 X 1.75 X 70 ............................................................................................... Nut Flg, M12x1.75, Nylon Gr 10 ....................................................................................................... Brkt, Line, Hyd, Shk Mnt, Drv ............................................................................................................ Brkt, Line, Hyd, Shk Mnt, Pass ........................................................................................................... Shock, Coil Over, 330 Lb/in ............................................................................................................... Bolt Flg, M12x1.75x100, Patch ......................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 6 6 1 1 2 2 Page 6-11 6 G E D 6 G E D 13 12 2 7 15 8 9 10 9 11 6 13 4 5 3 14 000031-002 Page 6-12 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List REAR SUSPENSION – STANDARD ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 N/A 1015597 102274101 102393501 102619801 102620401 102620501 N/A 102398901 102477001 103282301 102682901 102684501 102685601 102737101 Instl, Rear Suspension (includes items 2 through 15) ................................................................... Fitting, 1/4-28 Thread-Forming Grease ........................................................................................ Center Cap, Rubber .............................................................................................................................. Weldment, Receiver, Rear .................................................................................................................. Washer, Strip, Swingarm .................................................................................................................... Bolt Flanged Head, M12 X 1.75 X 50 .............................................................................................. Nut Flg, M12x1.75, Nylon Gr 10 ....................................................................................................... Sub Asm Swingarm (includes items 9 through 11) .................................................................. Bushing, Pivot, Urethane ............................................................................................................. Bushing, Teflon ................................................................................................................................ Swingarm, Rear, Awd .................................................................................................................... Pin, Swingarm, Weldment ................................................................................................................. Washer, M12 Hard Regular ................................................................................................................ Nut Flg M12 X 1.75 Cl10 ..................................................................................................................... Cotter, Rue Ring, 1/2" .......................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 2 1 2 8 2 2 2 2 1 2 10 8 2 Page 6-13 6 G E D 6 G E D ELECTRICAL SYSTEM 7 G E D 7 G DIESEL VEHICLE E D REVERSE BUZZER OPTIONAL 000662-002 Page 7-2 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 7 G E D 000662-002 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 7-3 7 G E D See previous two pages for illustration. Page 7-4 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List WIRING – DIESEL VEHICLE, SINGLE PIECE ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 102538501 103277501 103327201 Diode, General Purpose, 6.0a ................................................................................................................ Harness, Diesel AWD ................................................................................................................................. Asm, Switch, Limit, Awd .......................................................................................................................... A/R 1 1 7 G E D 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 7-5 7 G CONTROL PANEL HARNESS E D 000535-003 Page 7-6 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 7 G E D 000535-003 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 7-7 7 G E D See previous two pages for illustration. Page 7-8 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List WIRING – CONTROL PANEL ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 102786401 102936801 103245801 Wire Harness, Powerunit ......................................................................................................................... Breaker, Circuit, 150-Amp ....................................................................................................................... Wire Harness, Control Panel ................................................................................................................... 1 1 1 7 G E D 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 7-9 7 G E D 000535-005 Page 7-10 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List WIRING – SEAT BELT REMINDER ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 103213401 Harness, Seatbelt Light ............................................................................................................................ 1 7 G E D 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 7-11 7 G E D 7 10 11 1 8 3 5 9 12 4 8 13 2 6 000076-002 Page 7-12 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List ELECTRICAL COMPONENT BOX, DIESEL VEHICLES ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 1012295 N/A 1015741 102420201 **** 102420401 102420501 102447901 102448001 102492201 102492301 1108 332 Fuse, 10-Amp ............................................................................................................................................... Screw, 1/4-20 X .88 Hex Hd Cap ............................................................................................................ Fuse Block ..................................................................................................................................................... Relay, Mini ISO, SPDT ................................................................................................................................ Connector, Relay ........................................................................................................................................ Plate, Electrical ............................................................................................................................................ Cover, Electrical .......................................................................................................................................... Fastener, Push-in ........................................................................................................................................ Rivet, Drive ................................................................................................................................................... Fuse, 25-Amp ............................................................................................................................................... Fuse, 30-Amp ............................................................................................................................................... Locknut, 1/4-20 Dimpled ........................................................................................................................ Washer, 1/4 Type A Narrow Flat ............................................................................................................ 1 1 1 3 4 1 1 8 2 1 2 2 1 **** Special order item available upon request. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 7-13 7 G E D 7 G E D 13 5 2 3 4 11 9 10 12 8 15 7 14 6 000543-005 Page 7-14 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List ELECTRICAL COMPONENTS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 N/A N/A 1016630 101802601 101991101 102051601 102051701 102198001 102375401 102869401 102977501 103180101 103193401 103208801 103234401 Instl, Elec Sys, 2300 Restyle (includes items 2 through 15) ......................................................... Lockwasher, M4 ..................................................................................................................................... Light, Oil ................................................................................................................................................... Plug, Hole ................................................................................................................................................ Nut, M4-0.7 ............................................................................................................................................. Spacer, Keyswitch ................................................................................................................................. Nut, Key Switch ..................................................................................................................................... Receptacle, Accessory ......................................................................................................................... Light, Indicator, Coolant Temp ........................................................................................................ Switch, Rocker, Light ........................................................................................................................... Light, Indicator, Seat Belt ................................................................................................................... Cover, Hole, Switch, Rocker ............................................................................................................... Gauge, Fuel,hr,seatbelt Timer .......................................................................................................... Keyswitch, 12v, Diesel ......................................................................................................................... Keys (set of 2) ......................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 1 3 2 1 1 1 1 1 1 3 1 1 1 Page 7-15 7 G E D 7 G 3 5 E 1 D 6 4 2 7 8 10 11 9 000077-002 Page 7-16 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List BATTERY – DIESEL VEHICLES ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 1010934 1012328 1014375 101898001 102355301 102442201 102448401 102448501 102498201 1241 7473 Screw, 5/16-18 X 1.00 Hex Cap .............................................................................................................. Battery, 12-Volt ........................................................................................................................................... Screw, 3/8-16 X 0.50 Stainless Steel Hex-Head ............................................................................... Clamp, Battery ............................................................................................................................................. Lockwasher, 3/8 Stainless Stl ................................................................................................................. Asm, #6 Red Wire ....................................................................................................................................... Wire Asm, #6 Blk, Awd, 350 .................................................................................................................... Wire Asm, #6 Blk, Awd, 325 .................................................................................................................... Bolt, M10 X 1.25 X 25 Loctite ................................................................................................................. Washer, 5/16 Type A Flat ......................................................................................................................... Locknut, 5/16-18 Nylon Insert ............................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 2 1 2 1 1 1 1 1 1 Page 7-17 7 G E D 7 G E D DIESEL ENGINE – CLOSED BREATHER 8 G E D 8 G E D 12 28 20 9 24 17 30 4 19 22 30 23 19 30 8 18 27 1 7 11 29 30 16 15 6 14 10 25 3 29 4 16 30 26 21 5 13 2 4 000025-002 Page 8-2 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List KUBOTA D722 DIESEL ENGINE MOUNTING ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1012769 101833101 101833201 102298401 102370101 102370501 102370601 102382401 102410603 N/A 102414801 102462301 102462501 102465901 102490101 102490201 102490501 102494401 102498201 102618601 102621301 102621501 102670701 102934601 96701412 N/A 96704721 96718978 96741038 96741046 Screw, M6-1.00 X 25mm Hex Cap ........................................................................................................ Stud, M8-1.25 X 50 mm Two-Ended .................................................................................................... Stud, M8-1.25 X 60mm Two-Ended ..................................................................................................... Nut,m8,all Metal Lock ............................................................................................................................... Spacer, Engine, Diesel .............................................................................................................................. Isolator Ring and Bushing ....................................................................................................................... Washer, Snubbing, Ring N Bush ........................................................................................................... Bracket, FNR Trans Cable ......................................................................................................................... P-Clamp, Insulated .312 In ...................................................................................................................... Plate, Engine Mounting, Weld, Left-Hand ......................................................................................... Plate, Engine Mounting, Weld, Right-Hand ...................................................................................... Hose, Vent, Transmission ......................................................................................................................... Cover, CVT Inner, Diesel ........................................................................................................................... Shaft, CVT Adapter .................................................................................................................................... Bolt, M10 X 1.5 X 20 Loctite .................................................................................................................... Bolt, M8 X 1.25 X 25 Loctite .................................................................................................................... Bolt, M10 X 1.5 X 100 Loctite ................................................................................................................. Bracket, Transmission Mounting .......................................................................................................... Bolt, M10 X 1.25 X 25 Loctite ................................................................................................................. Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. Bolt, M8 X 1.25 X 40 with Loctite .......................................................................................................... Nut Flg, M6 X 1.0 Nylon ........................................................................................................................... Nut Flg M10 X 1.5 Nylon .......................................................................................................................... Engine, Kubota, D722, with Closed Breather, 60a .......................................................................... Washer, M12 Hard ...................................................................................................................................... Locknut, M12x1.75 Nylon Insert ........................................................................................................... Bolt, M12 X 1.75 X 90 ................................................................................................................................ Bolt, M8 X 1.25 X 80 ................................................................................................................................... Washer, M8 Hard ........................................................................................................................................ Washer, M10 Hard ...................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 3 1 1 7 1 4 4 1 1 1 1 1 1 1 4 7 1 2 8 1 3 3 1 1 4 4 4 1 10 12 Page 8-3 8 G E D 8 G 15 E 4 D 16 13 12 11 11 14 3 2 5 21 19 6 18 17 11 10 9 20 12 6 7 8 2 2 - 15 1 000039-001 Page 8-4 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List CRANKCASE ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 102600001 N/A N/A N/A N/A 102600701 102600801 102601001 N/A 102726201 102726301 102726401 N/A N/A N/A 102600301 102601401 102631601 N/A 102730801 N/A Engine Block (includes items 2 through 15) .................................................................................... Pin, Pipe, Dia 8 X 14 .............................................................................................................................. Pin, Straight, Dia 5 X 10 ...................................................................................................................... Pin, Pipe, Dia 7 X 14 .............................................................................................................................. Pin, Straight, Dia 8 X 16 ...................................................................................................................... Plug, 1/8" ................................................................................................................................................. Plug, 3/32" ............................................................................................................................................... Plug, 1/4" ................................................................................................................................................. Pin, Pipe, Dia 8 X 11 .............................................................................................................................. Cap, Sealing, Small ............................................................................................................................... Cap, Sealing, Med ................................................................................................................................. Cap, Sealing, Large ............................................................................................................................... Cover, Fuel Camshaft ........................................................................................................................... Plug, Expansion ..................................................................................................................................... Block, Engine .......................................................................................................................................... O Ring, 8 X 7 ................................................................................................................................................. Cock, Drain ................................................................................................................................................... Bolt, M6 X 1 X 20 ......................................................................................................................................... Plate, Engine Block .................................................................................................................................... Switch, Oil Pressure ................................................................................................................................... Gasket, Fuel Pump, D722 ........................................................................................................................ 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 2 1 2 3 5 1 2 3 5 2 1 1 1 1 1 2 1 1 1 Page 8-5 8 G E D 8 G E D 7 2 6 1 5 4 3 000040-001 Page 8-6 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List OIL PAN ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 N/A 102606901 102607001 102607201 102607301 102607401 102654601 Bolt, M6 X 1 X 14 ......................................................................................................................................... Bolt, M8 X 1.25 X 15 ................................................................................................................................... Oil Pan ............................................................................................................................................................ Plug, Drain, M12 X 14 ............................................................................................................................... Gasket, 20 X 13 ............................................................................................................................................ Filter, Oil, Pick Up ........................................................................................................................................ O Ring, 20 X 17 ............................................................................................................................................ 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 22 1 1 1 1 1 1 Page 8-7 8 G E D 8 G E D 10 11 2 12 7 3 13 6 4 5 9 1 9 - 13 8 000041-002 Page 8-8 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List CYLINDER HEAD ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 102600301 102652801 N/A 102654101 N/A N/A N/A 102798001 102600801 N/A N/A N/A N/A O Ring, 8 X 7 ................................................................................................................................................. Bolt, Cylinder Head .................................................................................................................................... Hook, Engine ............................................................................................................................................... Gasket, Cylinder Head .............................................................................................................................. Spring, Start ................................................................................................................................................. Bolt, Engine Hook ...................................................................................................................................... Stay, Cylinder Head ................................................................................................................................... Head, Cylinder, Complete (includes items 9 through 13) ............................................................ Plug, 3/32" ............................................................................................................................................... Guide, Exhaust Valve ........................................................................................................................... Guide, Inlet Valve .................................................................................................................................. Cap, Sealing, Head ............................................................................................................................... Cap, Sealing, Head, Top ...................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 14 2 1 1 2 1 1 1 3 3 1 2 Page 8-9 8 G E D 8 G E D 17 18 19 14 10 12 9 1 2 3 8 4 7 6 7 5 11 13 9 16 000042-002 Page 8-10 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List GEAR CASE ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 N/A N/A N/A N/A N/A N/A N/A 102602701 N/A N/A 102703301 N/A N/A 102729301 102798101 102601001 N/A N/A N/A O Ring, 18 X 13 ............................................................................................................................................ Spring, Valve ................................................................................................................................................ Ball, Valve ...................................................................................................................................................... Seat, Valve ..................................................................................................................................................... Joint, Pipe ..................................................................................................................................................... Washer, Plain, Special ............................................................................................................................... Bolt, M6 X 1 X 60 ......................................................................................................................................... Seal, Oil .......................................................................................................................................................... Bolt, D722, Front Case .............................................................................................................................. Bolt, D722 Intake Manfld Lower ........................................................................................................... Filter, Engine Oil, D722 ............................................................................................................................. Bolt, Gearcase, Top .................................................................................................................................... Bolt, Gearcase, Lower ............................................................................................................................... Gasket, Gearcase, D722 ........................................................................................................................... Case, Gear (includes items 16 through 19) ....................................................................................... Plug, 1/4" ................................................................................................................................................. Screw, Breather ..................................................................................................................................... Case, Gear ................................................................................................................................................ Stay, Spring ............................................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 3 1 1 1 1 1 2 1 9 1 1 2 1 1 1 2 2 1 1 Page 8-11 8 G E D 8 G E D 9 12 8 7 11 13 4 2 1 10 6 5 000181-001 Page 8-12 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List HEAD COVER ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 102644001 102644101 102798401 N/A 102798501 N/A N/A N/A N/A N/A 102798701 N/A N/A O Ring, 30 X 36 ............................................................................................................................................ Plug, Oil Filler ............................................................................................................................................... Assembly, Cylinder Head Cover (includes items 4 through 10) ................................................ Pipe, Water Return, D722 ................................................................................................................... Gasket, Cylinder Head Cover ............................................................................................................ Shield, Breather ..................................................................................................................................... Valve, Breather ....................................................................................................................................... Cover, Breather ...................................................................................................................................... Screw, Breather ..................................................................................................................................... Cover, Cylinder Head ........................................................................................................................... Bolt, Cylinder Head Cover ....................................................................................................................... Tube, Breather ............................................................................................................................................. Clamp, Breather Tube ............................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 1 1 1 1 1 4 1 4 1 2 Page 8-13 8 G E D 8 G E D 1 2 000044-002 Page 8-14 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List DIPSTICK AND GUIDE ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 102606701 102727701 Gauge, Oil ..................................................................................................................................................... Guide, Oil Gauge ........................................................................................................................................ 1 1 8 G E D 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 8-15 8 G E D 5 4 3 2 1 6 000045-001 Page 8-16 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List OIL PUMP ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 N/A N/A N/A 102606501 N/A 102727901 Nut, Flange, D722 Oil Pump ................................................................................................................... Gear, Oil Pump Drive ................................................................................................................................. Key, Feather, 8x4 ......................................................................................................................................... Assy, Pump, Oil ........................................................................................................................................... Gasket, Oil Pump ........................................................................................................................................ Bolt, Oil Pump ............................................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 1 1 3 Page 8-17 8 G E D 8 G E D 10 12 11 3 2 1 4 5 5 5 6 7 9 8 8 000046-001 Page 8-18 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List MAIN BEARING CASE ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 N/A N/A N/A N/A N/A 102609101 102609301 N/A 102609601 N/A N/A 102608501 Gasket, Bearing Case ................................................................................................................................ Gasket, Cover ............................................................................................................................................... Bolt, M6 X 1 X 20 ......................................................................................................................................... Bolt, M6 X 1 X 22 ......................................................................................................................................... Bolt, Bearing Case, Top ............................................................................................................................. Assy Case, Main Brg, First ........................................................................................................................ Assy Case, Main Brg, Sec .......................................................................................................................... Bolt, Bearing Case, Bottom ..................................................................................................................... Assy Case, Main Brg, Third ...................................................................................................................... Assy, Cover, Bearing Case (includes items 11 and 12) .................................................................. Cover, Bearing Case ............................................................................................................................. Seal, Oil ..................................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 8 8 6 1 1 2 1 1 1 1 Page 8-19 8 G E D 8 G E D 6 5 2 3 4 8 16 9 7 15 1 14 11 10 13 12 000047-002 Page 8-20 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List CAMSHAFT AND IDLE GEAR ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 N/A N/A N/A N/A N/A N/A N/A 102605401 102605501 102605801 102605601 N/A N/A N/A N/A N/A Bolt, D722, Cam End ................................................................................................................................. Gear, Idle (includes items 3 and 4) ....................................................................................................... Bushing, D722 Idle Gear ..................................................................................................................... Gear, Idle .................................................................................................................................................. Shaft, Idle Gear ............................................................................................................................................ Bolt, M6 X 1 X 14 ......................................................................................................................................... Ring, Snap ..................................................................................................................................................... Push Rod ....................................................................................................................................................... Tappet ............................................................................................................................................................ Assy Camshaft, Long (includes items 11 through 15) .................................................................. Key, Feather, Long Camshaft ............................................................................................................ Gear, Cam ................................................................................................................................................ Stopper, Camshaft ................................................................................................................................ Camshaft ................................................................................................................................................. Ball, Check ............................................................................................................................................... Collar, Idle Gear ........................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 2 1 1 1 1 3 1 6 6 1 1 1 1 1 1 1 Page 8-21 8 G E D 8 G E D 2 3 11 36 37 24 26 35 25 34 9 4 12 13 14 10 6 7 8 5 15 16 17 1 18 19 20 30 31 32 33 21 22 23 27 28 29 000048-002 Page 8-22 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List PISTON AND CRANKSHAFT ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 N/A 102607601 102607602 102607801 102607901 102630701 N/A N/A 102732201 N/A 102608101 102608801 N/A N/A 102608804 N/A N/A 102609001 N/A N/A 102609801 N/A N/A 102610001 N/A N/A 102630001 N/A N/A N/A N/A N/A N/A 102630901 102631001 102728101 102728102 Key, Feather, Short Camshaft ................................................................................................................. Assy Piston Ring, D722 Std ..................................................................................................................... Assy Piston Ring, D722 +.025 ................................................................................................................ Assy, Connecting Rod (includes items 5 through 10) ................................................................... Bolt, Connecting Rod .......................................................................................................................... Metal, Crank, Rod, D722, Std ............................................................................................................ Metal, Crank, Rod, D722, .020 .......................................................................................................... Metal, Crank, Rod, D722, .040 .......................................................................................................... Bushing, Piston Pin, D722 .................................................................................................................. Rod, Connecting ................................................................................................................................... Sleeve, Crankshaft ..................................................................................................................................... Metal,crank, O Side, Std ........................................................................................................................... Metal,crank, O Side, +.020 ...................................................................................................................... Metal,crank, O Side, +.040 ...................................................................................................................... Metal,crank, I Side, Std ............................................................................................................................. Metal,crank, I Side, +.020 ........................................................................................................................ Metal,crank, I Side, +.040 ........................................................................................................................ Metal, Crank, Main, Rear Std .................................................................................................................. Metal, Crank, Main, Rear -.020 ............................................................................................................... Metal, Crank, Main, Rear -.040 ............................................................................................................... Metal, Crank, Main, Mid Std ................................................................................................................... Metal, Crank, Main, Mid +.020 ............................................................................................................... Metal, Crank, Main, Mid +.040 ............................................................................................................... Crankshaft (includes items 25 and 26) ............................................................................................... Ball, Crankshaft ...................................................................................................................................... Crankshaft ............................................................................................................................................... Metal, Crank, D722, Frnt, Std ................................................................................................................. Metal, Crank, 722, Frnt, -.020 ................................................................................................................. Metal, Crank, 722, Frnt, -.040 ................................................................................................................. Gear, Crank ................................................................................................................................................... Slinger, Oil ..................................................................................................................................................... O Ring, 23 X 26 ............................................................................................................................................ Collar, Crankshaft ....................................................................................................................................... Circlip, Piston Pin ........................................................................................................................................ Pin, Piston ..................................................................................................................................................... Piston, D722, Std ........................................................................................................................................ Piston, D722, +0.25 .................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 3 3 3 6 3 3 3 3 1 1 2 2 2 2 2 2 1 1 1 4 2 2 1 3 1 1 1 1 1 1 1 1 6 3 3 3 Page 8-23 8 G E D 8 G E D 5 1 6 4 3 2 000049-001 Page 8-24 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List FLYWHEEL ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 N/A 102647801 N/A N/A N/A 102728301 Plate, Rear End ............................................................................................................................................ Flywheel (includes items 3 and 4) ........................................................................................................ Gear, Ring, D722 .................................................................................................................................... Flywheel ................................................................................................................................................... Bolt, Flange Head, M10 X 1.5 X 25 ....................................................................................................... Bolt, End Plate ............................................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 1 5 10 Page 8-25 8 G E D 8 G E D 14 1 3 2 13 12 11 10 9 8 7 4 6 5 000050-001 Page 8-26 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List SHAFT ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 N/A N/A 102604801 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A Bolt, D722, Cam End ................................................................................................................................. Circlip, External ........................................................................................................................................... Stopper, Fuel, C/shaft ............................................................................................................................... Assy, Fuel Camshaft (includes items 5 through 13) ....................................................................... Gear, Injection Pump ........................................................................................................................... Ball, Injection Pump ............................................................................................................................. Sleeve, Governor ................................................................................................................................... Ball, Governor ........................................................................................................................................ Case, Governor Ball .............................................................................................................................. Circlip ........................................................................................................................................................ Bearing, Ball ............................................................................................................................................ Key, Feather, Short Camshaft ........................................................................................................... Camshaft, Fuel, Short .......................................................................................................................... Bearing, Ball ................................................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 2 1 1 1 1 8 1 32 1 1 1 1 1 1 Page 8-27 8 G E D 8 G 7 E 11 5 6 D 11 2 8 10 9 12 1 13 3 4 000051-002 Page 8-28 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List IDLE APPARATUS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 102635301 102635701 102637001 102637101 102728601 N/A N/A 102635901 N/A N/A N/A 102728901 102799501 Gasket, 6 X 10 .............................................................................................................................................. Cap, Bolt Assy .............................................................................................................................................. Nut, Lock, Special ....................................................................................................................................... Nut, Special .................................................................................................................................................. Assy, Idle Apparatus (includes items 6 through 11) ...................................................................... Nut, M8, D722 Idle App, Specl ......................................................................................................... Nut, M8, D722 Idle App ...................................................................................................................... Assy, Bolt, Adjusting (includes items 9 and 10) ......................................................................... Spring, Idle Apparatus .................................................................................................................. Stud, Idle Adjustment ................................................................................................................... Gasket, Idle Apparatus, Rear ............................................................................................................. Gasket, Idle Apparatus, Front ................................................................................................................ Bolt, Idle Adjusting .................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 1 1 1 1 1 1 1 2 1 1 Page 8-29 8 G E D 8 G E D 2 4 5 3 1 6 000182-001 Page 8-30 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List STOP SOLENOID ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 102640601 N/A 102799601 102799701 102799801 N/A Washer, Spring, M6, D722 ....................................................................................................................... Bolt, Solenoid, Stop, D722 ...................................................................................................................... Solenoid, Stop ............................................................................................................................................. Stay, Stop Solenoid ................................................................................................................................... O-Ring, Stop Solenoid .............................................................................................................................. Bolt, Stop Solenoid .................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 2 2 1 1 1 2 Page 8-31 8 G E D 8 G E D 4 8 13 2 9 3 14 5 11 7 12 1 11 15 6 10 000057-003 Page 8-32 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 60-AMP ALTERNATOR ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 102630601 102631601 102647701 N/A 102730201 N/A N/A N/A 102732501 102800701 102801001 102934701 102934801 102934901 103239901 Pulley, Fan Drive ......................................................................................................................................... Bolt, M6 X 1 X 20 ......................................................................................................................................... Nut, M8, Plate .............................................................................................................................................. Pulley, Water Pump ................................................................................................................................... Collar, Alternator Assy, D722 .................................................................................................................. Bolt, Alt, D722, Adjuster ........................................................................................................................... Bolt, Alt, D722, Drive Pulley .................................................................................................................... Bolt, D722, Drive Pulley ........................................................................................................................... Washer, Spring, D722, Starter ................................................................................................................ Bolt, Alternator, Lower ............................................................................................................................. Washer, Alternator, Upper ...................................................................................................................... Alternator, 60 Amp .................................................................................................................................... Brkt, Alt, D722, 60 Amp ............................................................................................................................ Belt, Acc Drive, D722, 60 Amp ............................................................................................................... Guard, Acc Belt ............................................................................................................................................ 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 1 1 1 1 1 4 1 1 2 1 1 1 1 Page 8-33 8 G E D 8 G 9 E 10 D 8 1 11 2 3 2 4 5 6 7 000053-002 Page 8-34 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List INJECTION PUMP ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 N/A 102640601 N/A 102640901 102641001 N/A N/A 102800101 N/A N/A N/A Bolt, Hex-Head, M5 X 0.75 X ................................................................................................................... Washer, Spring, M6, D722 ....................................................................................................................... Nut, Special .................................................................................................................................................. Shim, Injection Pump, 0.20 mm ............................................................................................................ Shim, Injection Pump, 0.25 mm ............................................................................................................ Shim, Injection Pump, 0.30 mm ............................................................................................................ Stud, M5 X 25 ............................................................................................................................................... Assembly, Fuel Injection Pump (includes items 9 through 11) ................................................. Screw, Hollow, D722, Inj Pump ........................................................................................................ Joint, Eye .................................................................................................................................................. Pump, Injection ..................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 2 4 2 A/R A/R A/R 2 1 1 1 1 Page 8-35 8 G E D 8 G 6 E 15 14 D 7 13 8 12 5 9 10 16 17 1 18 11 19 4 2 3 000054-002 Page 8-36 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List SPEED CONTROL PLATE ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 102634501 N/A 102635301 N/A 102800401 N/A N/A N/A 102634001 102634101 N/A N/A N/A N/A N/A N/A N/A N/A N/A Gasket, Control Plate ................................................................................................................................ Bolt, M6 X 1 X 30 ......................................................................................................................................... Gasket, 6 X 10 .............................................................................................................................................. Bolt, D722 Intake Manfld Lower ........................................................................................................... Assembly, Speed Plate (includes items 6 through 19) ................................................................. Lever, Engine Stop ................................................................................................................................ Nut, Speed Control .............................................................................................................................. Lever, Speed Control ........................................................................................................................... O Ring, 19 X 16 ...................................................................................................................................... Plate, Speed Control ............................................................................................................................ O Ring, 9 X 7 ........................................................................................................................................... Collar, Lever ............................................................................................................................................ Spring, Return ........................................................................................................................................ Cap, Speed Cntrl Plate Rtrn ............................................................................................................... Pin, Spring, Speed Plate ..................................................................................................................... Nut, Speed Control .............................................................................................................................. Bolt, Speed Control .............................................................................................................................. Lever, Governor ..................................................................................................................................... Shaft, Governor Lever ......................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 Page 8-37 8 G E D 8 G E 4 D 3 5 6 7 8 9 1 10 17 19 16 11 18 14 12 13 15 2 000055-001 Page 8-38 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List NOZZLE HOLDERS AND GLOW PLUGS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 102605701 102635301 102642401 102642501 102642601 N/A N/A 102643001 102643101 102643201 N/A 102643401 N/A N/A 102643701 102729701 102641501 102642701 102643601 Assy Pipe, D722 Fuel Over Flow ............................................................................................................ Gasket, 6 X 10 .............................................................................................................................................. Cord, Glow Plug .......................................................................................................................................... Nut, Flange,m4 ............................................................................................................................................ Glow Plug ..................................................................................................................................................... Screw, Washer ............................................................................................................................................. Clamp, Pipe, Top ......................................................................................................................................... Pipe, Injection, Left .................................................................................................................................... Pipe, Injection, Right ................................................................................................................................. Pipe, Injection, Middle ............................................................................................................................. Clamp, Pipe, Bottom ................................................................................................................................. Assy Pipe, Over Flow (includes items 13 and 14) ........................................................................... Clip, Pipe, Return .................................................................................................................................. Hose, Overflow ...................................................................................................................................... Screw, Air Bleeder ...................................................................................................................................... Kit, Holder, Nozzle (includes items 17 through 19) ....................................................................... Assembly, Nozzle Holder ................................................................................................................... Seal, Heat ................................................................................................................................................. Gasket, Nozzle ....................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 3 3 2 2 1 1 1 2 1 2 1 1 3 3 3 3 Page 8-39 8 G E D 8 G E D 1 3 10 11 12 9 2 8 5 4 7 6 000056-002 Page 8-40 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List GOVERNOR COMPONENTS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 102635101 N/A 102800201 N/A N/A N/A N/A N/A N/A N/A N/A N/A Spring, Governor ........................................................................................................................................ Bolt, M5 X 0.75 X 25 .................................................................................................................................. Spring, Start ................................................................................................................................................. Assembly, Governor Fork (includes items 5 through 9) ............................................................... Holder, Fork Lever ................................................................................................................................ Bolt, M5 X 0.75 X 11 ............................................................................................................................ Washer, Spring, M5 .............................................................................................................................. Lever, Fork, Middle, D722 CB ............................................................................................................ Assembly, Governor Fork Level, Lower, D722 CB (includes items 10 through 12) ........ Pin, Spring ......................................................................................................................................... Shaft, Fork Lever ............................................................................................................................. Lever, Fork, End, D722 CB ............................................................................................................ 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 1 1 1 1 1 1 1 1 1 1 Page 8-41 8 G E D 8 G E D 2 5 3 4 5 1 3 000058-001 Page 8-42 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List STARTER ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 102645501 102647701 102648401 102648501 102732501 Nut, D722, Starter ...................................................................................................................................... Nut, M8, Plate .............................................................................................................................................. Bolt, M8 X 1.25 X 28 ................................................................................................................................... Motor, Starter .............................................................................................................................................. Washer, Spring, D722, Starter ................................................................................................................ 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 2 2 2 1 4 Page 8-43 8 G E D 8 G E 10 9 D 12 19 5 11 7 6 14 8 18 2 13 15 4 3 1 16 17 000062-002 Page 8-44 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List VALVES AND ROCKER ARMS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 102653101 102653201 102653301 102653601 102653701 N/A 102801201 Bolt, M6 X 1 X 8 ........................................................................................................................................... Washer, D722, Plain, Rocker ................................................................................................................... Washer, Rocker Arm .................................................................................................................................. Pin, Spring, D722, Rocker ........................................................................................................................ Assy Rocker Arm (includes items 6 through 8) ............................................................................... Nut, M6 ..................................................................................................................................................... Screw-Adjusting .................................................................................................................................... Arm, Rocker ............................................................................................................................................ Shaft, Rocker Arm ...................................................................................................................................... Spring, Rocker Arm ................................................................................................................................... Collet, Valve Spring, Set ........................................................................................................................... Cap, Valve, D722 ......................................................................................................................................... Spring, Valve ................................................................................................................................................ Retainer, Spring .......................................................................................................................................... Seal, Valve Stem .......................................................................................................................................... Valve, Exhaust .............................................................................................................................................. Valve, Inlet .................................................................................................................................................... Bracket, Rocker Arm, D722 Closed-Breather .................................................................................... Bolt, Rocker Arm ......................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 2 2 2 1 6 6 6 1 1 2 6 6 6 6 6 3 3 3 3 Page 8-45 8 G E D 8 G E D 3 1 5 6 4 2 000063-002 Page 8-46 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List DIESEL INLET MANIFOLD ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 N/A N/A N/A 102646001 N/A N/A Bolt, M6 X 1 X 45 ......................................................................................................................................... Bolt, D722 Intake Manfld Lower ........................................................................................................... Assembly, Intake Manifold (includes items 4 through 6) ............................................................ Gasket, Intake Manifold ..................................................................................................................... Pipe, Breather ......................................................................................................................................... Manifold, Intake .................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 3 2 1 1 1 1 Page 8-47 8 G E D 8 G E D 3 2 7 1 6 5 4 7 000064-001 Page 8-48 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List EXHAUST MANIFOLD ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 N/A N/A 102646601 N/A N/A 102731501 102731601 Cover, Heat Proof ....................................................................................................................................... Stud, M6 X 26 ............................................................................................................................................... Gasket, Ex-manifold .................................................................................................................................. Nut, Flange, M6, Ubs ................................................................................................................................. Bolt, Flange Head, M6 X 1 X 16 ............................................................................................................. Manifold, Exhaust, D722 .......................................................................................................................... Bolt, D722, Exhst Manfld Cover ............................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 3 1 3 3 1 2 Page 8-49 8 G E D 8 G 11 E 12 9 D 4 2 1 10 5 6 3 7 13 8 20 26 27 25 22 21 15 14 24 19 23 17 18 16 000065-001 Page 8-50 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List GASKET KITS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 102731801 102422301 102600301 102633401 102635301 102644001 102644501 102646001 102646601 102653301 102654101 102654701 102798501 102731901 N/A N/A N/A N/A N/A 102632701 102634001 N/A 102634501 102654601 N/A 102729301 N/A Kit, Gasket Upper, D722 (includes items 2 through 13) ............................................................... Gasket, Exhaust Diesel ........................................................................................................................ O Ring, 8 X 7 ........................................................................................................................................... Gasket, Thermostat .............................................................................................................................. Gasket, 6 X 10 ......................................................................................................................................... O Ring, 30 X 36 ...................................................................................................................................... Gasket, Head Cover .............................................................................................................................. Gasket, Intake Manifold ..................................................................................................................... Gasket, Ex-manifold ............................................................................................................................. Seal, Valve Stem .................................................................................................................................... Gasket, Cylinder Head ......................................................................................................................... Gasket, Water Flange .......................................................................................................................... Gasket, Cylinder Head Cover ............................................................................................................ Kit, Gasket Lower, D722 (includes items 15 through 27) ............................................................. O Ring, 18 X 13 ...................................................................................................................................... Gasket, Oil Pump .................................................................................................................................. Gasket, Bearing Case ........................................................................................................................... Gasket, Cover ......................................................................................................................................... O Ring, 23 X 26 ...................................................................................................................................... Gasket, Water Pump, D722 ............................................................................................................... O Ring, 19 X 16 ...................................................................................................................................... O Ring, 9 X 7 ........................................................................................................................................... Gasket, Control Plate ........................................................................................................................... O Ring, 20 X 17 ...................................................................................................................................... Gasket, Idle Apparatus, Rear ............................................................................................................. Gasket, Gearcase, D722 ...................................................................................................................... Gasket, Fuel Pump, D722 ................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 1 3 1 1 1 1 6 1 1 1 1 3 1 1 1 1 1 1 1 1 1 2 1 1 Page 8-51 8 G E D 8 G E D 2 1 5 3 4 3 6 000066-001 Page 8-52 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List PISTON KIT ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 102732001 102607601 102630901 102631001 102728101 102732201 Kit, Piston Rebuild, D722 (includes items 2 through 6) ................................................................ Assy Piston Ring, D722 Std ................................................................................................................ Circlip, Piston Pin .................................................................................................................................. Pin, Piston ................................................................................................................................................ Piston, D722, Std ................................................................................................................................... Bushing, Piston Pin, D722 .................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 2 1 1 1 Page 8-53 8 G E D 8 G E D FUEL, INTAKE, & GOVERNOR SYSTEM 9 G E D 9 G E D 15 10 11 9 20 3 19 7 9 1 17 13 8 22 4 5 21 18 16 23 9 4 9 6 12 14 000081-003 Page 9-2 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List FUEL SYSTEM – DIESEL ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 102410801 N/A 101313402 1013746 101587703 101824401 102289001 102410602 102411203 102426301 102430001 102430101 102430201 102430301 102430401 102434601 102434701 102434801 102466201 102618601 102670801 102710301 96705587 Pump, Diesel Fuel Electric ....................................................................................................................... Asm, Fuel System, Kubota (includes items 3 through 23) ........................................................... Clamp, Green Hose .............................................................................................................................. Clamp, 0.301 ID Hose .......................................................................................................................... Hose, Fuel, Vent, 22" Long ................................................................................................................. Vent Barb ................................................................................................................................................. Screw, M8X1.25X30, Hex .................................................................................................................... P-Clamp, Insulated 1.75 In ................................................................................................................. Clamp, Hose, Ctb 14mm .................................................................................................................... Strap, Tank, Fuel .................................................................................................................................... Hose, Tank To Prefilter Diesel ........................................................................................................... Hose, Fuel Prefilter To Pump ............................................................................................................. Hose, Fuel Pump To Filter .................................................................................................................. Hose, Fuel Filter To Eng ...................................................................................................................... Hose, Fuel Return ................................................................................................................................. Filter Assy, Fuel ...................................................................................................................................... Filter, Fuel ................................................................................................................................................ Adapter, 90, 5/16 Tube ....................................................................................................................... Bezel, Fuel Fill ......................................................................................................................................... Lock Nut, Flg M8 X 1.25 Nylon ......................................................................................................... Screw, M6 X 1 X 25 Thd Form ........................................................................................................... Plate, Fuel/Oil System ......................................................................................................................... Bolt, M8 X 1.25 X 30 ............................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 2 1 1 5 1 6 1 1 1 1 1 1 1 1 2 1 3 1 1 2 Page 9-3 9 G E D 9 G E 16 D 6 15 2 7 8 3 11 5 12 4 13 10 9 14 000082-005 Page 9-4 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List FUEL TANK – DIESEL VEHICLES ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 102952101 1013461 1013462 1015139 1015143 1016 N/A N/A 102406701 102406801 102478501 102494701 102522001 N/A 183 8797 Asm, Tank, Fuel, Diesel, 4x4 (includes items 2 through 16) ........................................................ Screw, #10-16 Hex-Head Hi-Lo ........................................................................................................ Sending Unit, Fuel Level * ................................................................................................................. Insulation Grommet ............................................................................................................................ Vent, Fuel Tank ...................................................................................................................................... Washer, #10 Split Lock ........................................................................................................................ Wire Asm, Blk, 170mm ........................................................................................................................ Wire Asm, Org, 170mm ....................................................................................................................... Bushing, Line, Return .......................................................................................................................... Elbow, 90 Barbed .................................................................................................................................. Pickup Tube, Fuel .................................................................................................................................. Cap, Fuel (Diesel) .................................................................................................................................. Gasket, Rubber ...................................................................................................................................... Tank, Fuel, Diesel, 4x4 ......................................................................................................................... Washer, #10 Type A Flat ...................................................................................................................... Nut, #10-32 Brass Hex ......................................................................................................................... 1 5 1 1 1 1 1 1 2 1 1 1 1 1 1 1 * Note: Must replace fuel sending unit gasket when servicing this component. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 9-5 9 G E D 9 G 3 5 1 E D 6 4 5 1 2 000536-002 Page 9-6 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List CABLES – DIESEL VEHICLE ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 1011084 102475701 102495801 102498801 102615801 8990 Nut, 1/4-28 Hex Jam ................................................................................................................................. Clip, Brake Line ............................................................................................................................................ Cable, Transmission Shift ........................................................................................................................ Cable, Accelerator, Diesel ........................................................................................................................ Joint, Ball, .346 Dia ..................................................................................................................................... Tie Wrap, 8" Nylon ..................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 2 3 1 1 2 1 Page 9-7 9 G E D 9 G E D 2 6 2 7 18 18 5 11 19 12 9 16 3 17 8 4 10 15 4 19 13 14 000026-001 Page 9-8 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List ACCELERATOR PEDAL ASSEMBLY – STYLE B ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 102489901 102296401 N/A 102442901 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 102618101 103273101 96706825 102618301 102618601 Asm, Pedal, Accelerator (includes items 2 through 17) ................................................................ Nut-m6x1.0 Flng All Mtl Lock ........................................................................................................... Pullrod, Spring, Compression ........................................................................................................... Bushing, Greaseless ............................................................................................................................. Spring, Comp, Pedal, Pullrod ............................................................................................................ Washer, Retaining Spring, 7mm ...................................................................................................... Guide, Cable, Accelerator .................................................................................................................. Weldment, Bracket, Pedal .................................................................................................................. Weldment, Lever, Motion, Lost ........................................................................................................ Spring, Torsion ....................................................................................................................................... Spring, Stop, Pedal ............................................................................................................................... Bolt, Stop, Pedal .................................................................................................................................... Pad, Grip Tape, Accelerator ............................................................................................................... Weldment, Pedal, Accelerator .......................................................................................................... Nut M6x1 Mech Def Center .............................................................................................................. Bolt, Shoulder, M8 X 70, Hc ............................................................................................................... Bolt, M6 X 1 X 70 ................................................................................................................................... Bolt Flanged Head, M8 X 1.25 X 65 ...................................................................................................... Lock Nut, Flg M8 X 1.25 Nylon .............................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 3 1 4 1 2 1 1 1 1 1 1 1 1 1 1 2 2 2 Page 9-9 9 G E D 9 G E 1 D 3 11 4 12 9 10 13 5 5 6 8 7 4 2 000090-002 Page 9-10 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List INTAKE DUCT AND AIR BOX ASSEMBLY – DIESEL VEHICLES ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 102379001 102395601 102411209 102411210 102541465 102621201 102621501 N/A 102810701 102498601 102725501 102725601 N/A Hose, Intake, D722 ..................................................................................................................................... Hose, Intake, Primary ................................................................................................................................ Clamp, Hose, Ctb 55mm .......................................................................................................................... Clamp, Hose, Ctb 64mm .......................................................................................................................... Bolt, M 6 X 1.0 X 65 Hex, Flange, Head, Black ................................................................................... Bolt Flanged Head, M8 X1.25x 16 with Loctite ............................................................................... Nut Flg, M6 X 1.0 Nylon ........................................................................................................................... Weldment, Support, Air Cleaner .......................................................................................................... Filter, Air, Canister, W/labe (includes items 10 through 13) ....................................................... Element, Filter, Air, 5 In ....................................................................................................................... Valve, Evacuator, Filter Air ................................................................................................................. Cap, Latch Lock, Filter, Air .................................................................................................................. Body, Canister, Filter, Air ..................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 3 2 2 2 1 1 1 1 1 1 Page 9-11 9 G E D 9 G E D EXHAUST SYSTEM 10 G E D 10 G 5 E D 10 8 7 9 6 4 4 11 2 3 000538-001 Page 10-2 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List EXHAUST SYSTEM ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 N/A 101887601 102298720 102409501 102621201 102786201 102812801 102409501 N/A N/A 102930901 Instl, Exhaust, AWD (includes items 2 through 11) ........................................................................ Locknut, M6-1.00 Nylon Insert ........................................................................................................ M8-1.25x20 Taptite .............................................................................................................................. Spring, Exhaust ...................................................................................................................................... Bolt Flanged Head, M8 X1.25x 16 with Loctite .......................................................................... Pipe, Exhaust, Int, Offset .................................................................................................................... Asm, Muffler, AWD Homologation (includes items 8 through 10) ..................................... Spring, Exhaust ............................................................................................................................... Muffler ................................................................................................................................................ Bracket, Muffler ............................................................................................................................... Shield, Exhaust, Clearance ................................................................................................................ 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 2 4 2 1 1 4 1 1 1 Page 10-3 10 G E D 10 G E D 6 5 1 4 3 2 000538-003 Page 10-4 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List EXHAUST PIPES – DIESEL VEHICLES ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 102298401 102409301 102422301 102621301 102628101 102731601 Nut,m8,all Metal Lock ............................................................................................................................... Pipe, Exhaust Diesel Main ....................................................................................................................... Gasket, Exhaust Diesel ............................................................................................................................. Bolt, M8 X 1.25 X 40 with Loctite .......................................................................................................... Shield, Diesel Exhaust .............................................................................................................................. Bolt, D722, Exhst Manfld Cover ............................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 3 1 1 3 1 1 Page 10-5 10 G E D 10 G E D CLUTCHES 11 G E D 11 G E D 1 2 4 3 000008-002 Page 11-2 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List CLUTCH COVER (STANDARD) ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 102296716 102411210 N/A 103320601 Screw, M6 X 16 Tt Hx Fl Hd ..................................................................................................................... Clamp, Hose, Ctb 64mm .......................................................................................................................... Cover, Cvt, Open ......................................................................................................................................... Hose, Outlet, Cvt ........................................................................................................................................ 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 7 1 1 1 Page 11-3 11 G E D 11 G E D 8 3 10 9 2 4 4 11 6 7 4 5 2 1 Page 11-4 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 11 000008-001 CLUTCH COVER (SEALED) ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 102616003 101856102 102296716 102411210 102414501 102481001 102481201 102481301 102616101 102628001 103320601 Kit, Sealed CVT Cover (includes items 2 through 11) .................................................................... Screw, 1/4-15 X 1.50 Hi-lo Hex ......................................................................................................... Screw, M6 X 16 Tt Hx Fl Hd ................................................................................................................ Clamp, Hose, Ctb 64mm .................................................................................................................... Cover, CVT Outer .................................................................................................................................. Hose, Inlet, Cover, CVT ........................................................................................................................ Bracket, Inlet, Cover, CVT ................................................................................................................... Gasket, Cover, CVT ............................................................................................................................... Cap, Inlet, Cover, CVT .......................................................................................................................... Filter, Inlet, Cover, CVT ........................................................................................................................ Hose, Outlet, Cvt ................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 3 7 3 1 1 1 1 1 1 1 Page 11-5 11 G E D 11 G E 1 D 000084-001 Page 11-6 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List DRIVE BELT ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 102374901 Belt, Drive ...................................................................................................................................................... 1 11 G E D 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 11-7 11 G 11 6 E D 12 4 10 5 14 18 22 19 23 13 15 8 16 7 9 17 20 1 21 4 - 23 2 3 000007-004 Page 11-8 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List DRIVE CLUTCH – DIESEL VEHICLES ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 102385601 102616501 103185501 102690501 102690701 102690801 102691401 N/A 102691701 102691801 N/A N/A N/A 102690201 102690301 102690401 102690501 102690701 N/A 102839401 N/A 103185801 103185901 Washer, Stepped ........................................................................................................................................ Bolt, M10 X 1.5 X 160 ................................................................................................................................ Clutch, 4x4, Diesel, W/cover (includes items 4 through 23) ....................................................... Screw, Shlder Hex, .312 X 1.75 ......................................................................................................... Nut, Lock Hex, 1/14-20, Flexlc .......................................................................................................... Sub Assy, Wt Clutch, Diesel ............................................................................................................... Spring, Compression, Primary ......................................................................................................... Washer, Lock, H-Spring, 1/4 .............................................................................................................. Screw, Cap, Hex Hd, 1/4 X 1.25 ........................................................................................................ Shim, 1.63 X 1.33 ................................................................................................................................... Subassembly, Drive Clutch ............................................................................................................... Subassembly, Moveable, Drive Clutch .......................................................................................... Subassembly, Spider Utility, Diesel (includes items 14 through 20) .................................. Pin, Spring Slotted,1.25 X 1.0 ..................................................................................................... Pin, Dowel, .375 X 1.50 ................................................................................................................. Roller, Torque, Diesel ..................................................................................................................... Screw, Shlder Hex, .312 X 1.75 ................................................................................................... Nut, Lock Hex, 1/14-20, Flexlc .................................................................................................... Spider, Drive Clutch ....................................................................................................................... Sub Assy, Roller Weight ................................................................................................................ Cover, Drive Clutch .............................................................................................................................. Cover, Clutch, 4x4 ................................................................................................................................. Gasket, Cover, Clutch, 4x4 ................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 2 2 2 1 4 4 A/R 1 1 1 2 2 4 2 2 1 2 1 1 1 Page 11-9 11 G E D 11 G E 9 D 10 8 3 2 4 6 7 5 2 - 8 1 Page 11-10 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 000003-001 DRIVEN CLUTCH ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 102369901 102695401 N/A 102695601 102695701 102695801 102695901 N/A 102385701 102490501 CVT, Secondary (includes items 2 through 8) .................................................................................. Washer, Thrust, 1.53 X 1.92 ............................................................................................................... Sheave, Driven Clutch ......................................................................................................................... Retainer, Spring, Inner ........................................................................................................................ Spring, Compression, Secondary .................................................................................................... Retainer, Spring, Outer ....................................................................................................................... Ring, Retaining, External .................................................................................................................... Driven Clutch Base Sheave ............................................................................................................... Washer, Stepped ........................................................................................................................................ Bolt, M10 X 1.5 X 100 Loctite ................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 1 1 1 1 1 1 1 Page 11-11 11 G E D 11 G E D DRIVETRAIN COMPONENTS 12 G E D 12 G 4 E 6 D 12 3 11 9 10 7 9 8 2 8 5 2 000030-003 Page 12-2 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List FORWARD/REVERSE SHIFTER ASSEMBLY ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 N/A 102298401 102375901 102376001 N/A 102615701 102616701 102618301 102684501 102684601 103187501 8717 8990 Instl, Fnr, Shifter, Dom (includes items 2 through 13) ................................................................... Nut,m8,all Metal Lock ......................................................................................................................... Bushing, Fnr ........................................................................................................................................... Knob, Fnr ................................................................................................................................................ Weldment, FNR Shifter Bracket ....................................................................................................... Stud, Ball, .346 Dia ................................................................................................................................ Locknut, M10x1.5 Nylon Insert ........................................................................................................ Bolt Flanged Head, M8 X 1.25 X 65 ................................................................................................ Washer, M12 Hard Regular ................................................................................................................ Shoulder Bolt,m12 X 20 M10 Thd ................................................................................................... Weldment, FNR Shifter ....................................................................................................................... Locknut, 1/4-28 Nylon Insert ............................................................................................................ Tie Wrap, 8" Nylon ................................................................................................................................ 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 3 1 1 1 1 1 3 2 1 1 1 2 Page 12-3 12 G E D 12 G E D 2 1 6 5 3 4 000012-003 Page 12-4 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List FRONT DIFFERENTIAL MOUNTING PLATE ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 102381701 102462401 102491001 102491101 102711601 103244701 Spacer Block, Diff ....................................................................................................................................... Hose, Vent, Front Diff ................................................................................................................................ Bolt Flanged Head, 3/8-16x1.0 with Loctite ..................................................................................... Bolt Flanged Head, 3/8-16x1.500 with Loctite ................................................................................ Bolt, Flange Head, M10 X 1.5 X 25 ....................................................................................................... Asm, Mount, Diff Plate ............................................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 2 2 4 1 Page 12-5 12 G E D 12 2 G 8 E 6 7 9 3 10 11 12 13 4 5 D 33 34 32 35 26 28 29 27 31 30 20 21 22 23 24 25 35 17 15 18 16 14 19 40 38 36 39 37 000010-001 Page 12-6 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List FRONT DIFFERENTIAL (OUTPUT COMPONENTS) ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 102371801 102438201 N/A 102439101 102439201 N/A N/A N/A N/A N/A N/A N/A N/A 102438301 N/A 102439501 N/A N/A N/A 102438401 102439601 102439801 102439901 N/A N/A 102438501 102438601 N/A N/A N/A N/A 102438701 102438801 102438901 102439301 102440101 N/A N/A 102440301 N/A Differential, Front * (includes items 2 through 40) ........................................................................ Kit, Assy, Output Cover Plate (includes items 3 through 13) ................................................ Set Screw, #10-24 UNC-3A with Patch .................................................................................... Thrust Button ................................................................................................................................... Thrust Plate ...................................................................................................................................... Mate-N-Lock Pin ............................................................................................................................. Mate-N-Lock Housing ................................................................................................................... Oil Seal ............................................................................................................................................... Grommet ........................................................................................................................................... Plate, Output Cover ....................................................................................................................... O-Ring ................................................................................................................................................ Coil, Pocket Insert ........................................................................................................................... Coil with Press-Fit Bobbin ........................................................................................................... Kit, Assy, Race Output Hub (includes items 15 through 19) ................................................. Pin, Dowel ......................................................................................................................................... Bearing, Needle .............................................................................................................................. Race/Output Hub, Male ............................................................................................................... Bushing, PermiGlide ...................................................................................................................... Race/Output Hub, Female .......................................................................................................... Kit, Assy, Clutch (includes items 21 through 23) ....................................................................... Clutch Hsg/Ring Gear, Machined ............................................................................................. Kit, Roller (contains 14 rollers) ................................................................................................... Kit, Assy, Roll Cage (includes items 24 and 25) .................................................................... Kit, H-Clip Spring (contains 14 clips) ................................................................................. Roll Cage, Plastic ....................................................................................................................... Kit, Bolt (contains 7 bolts) .................................................................................................................. Kit, Minor Repair (includes items 28 through 31) ..................................................................... Oil Seal ............................................................................................................................................... O-Ring ................................................................................................................................................ O-Ring ................................................................................................................................................ Oil Seal, Triple-Lipped .................................................................................................................. Retaining, Ring Internal ...................................................................................................................... Plate, Armature ..................................................................................................................................... Shim, Armature, Plate ......................................................................................................................... Bearing, Ball ............................................................................................................................................ Kit, Assy, Drain Plug (includes items 37 and 38) ........................................................................ Plug, Oil Drain .................................................................................................................................. Washer, Nylon, 0.625 x 0.382 x 0.06 ......................................................................................... Plug, Oil Fill ............................................................................................................................................. Bushing, Self-Lubricating, 80 x 85 x 20 ......................................................................................... 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 12 1 1 1 1 1 * Note: This assembly also contains components listed on the following two pages. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 12-7 12 G E D 12 G E D 4 1 2 3 5 6 7 000010-002 Page 12-8 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List FRONT DIFFERENTIAL (INPUT COMPONENTS) ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 102440201 102440601 N/A N/A 102440401 102440501 N/A Kit, Assy, Input Cover Plate (includes items 2 through 4) ............................................................ Cover, Input, Machined ...................................................................................................................... O-Ring ....................................................................................................................................................... Oil Seal, Triple-Lipped ......................................................................................................................... Shaft, Pinion, Machined ........................................................................................................................... Bearing, Ball ................................................................................................................................................. Bushing, Plain 16 Id X 15 Wide .............................................................................................................. 1 1 1 1 1 1 1 Note: This page contains a list of components internal to the front differential. See the previous pages for other front differential components. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 12-9 12 G E D 12 G E D 4 2 3 000091-001 Page 12-10 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List PROP SHAFTS ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 N/A 102371701 102372101 95293643 Inst, Prop Shafts, Awd (includes items 2 through 4) ..................................................................... Prop Shaft, Front ................................................................................................................................... Prop Shaft, Rear ..................................................................................................................................... Pin, Spring, 5/16 X 1-1/2 Hd .............................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 2 Page 12-11 12 G E D 12 G 18 E 8 19 2 D 9 7 10 3 12 16 6 17 11 5 4 15 13 14 8 18 9 7 3 10 19 2 Page 12-12 000004-001 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List REAR DIFFERENTIAL ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 102831501 102276001 102376602 102449101 102463501 102463601 102672101 102672201 102672301 102672401 N/A 102693301 102693401 102693501 102694201 102694301 102694401 102694701 102694801 Axle, Rear, Guard Mounts (Complete Assembly) (includes items 2 through 19) ................ Locking Cap, Nut .................................................................................................................................. Assy, Rotor, Brake, Rear ....................................................................................................................... Gearcase, Lower, Machined .............................................................................................................. Axle, Right-hand ................................................................................................................................... Axle, Left-Hand ...................................................................................................................................... Washer,counterbored 51 X 30 ......................................................................................................... Washer, Bellevle, 1.063 X .043 .......................................................................................................... Washer, Belleville, 49 X 4 .................................................................................................................... Nut, Hex, M20 X 1.5 , Modified ........................................................................................................ Screw, M10 X 25 .................................................................................................................................... Screw,hex Flange, M8 X 35 ................................................................................................................ Plug,3/8-16, Hex Flange ..................................................................................................................... Washer, .625 X .382 X .60 ................................................................................................................... Plug, Square Skt, 1/12-14, Ptf ........................................................................................................... Bellows, Vent, Upper Housing ......................................................................................................... Clamp, Hose, Dw-9.5 ........................................................................................................................... Screw, Hex Fl, M12 X 1.75 X 30 ......................................................................................................... Pin, Cotter, 5/32 X 1.25 ........................................................................................................................ 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 2 1 1 1 2 12 2 2 8 9 1 1 1 1 1 12 2 Page 12-13 12 G E D 12 G 8 E 10 11 9 D 27 30 29 24 1 3 28 2 25 15 27 13 26 16 12 15 17 18 22 14 21 20 23 19 4 5 7 6 000004-002 Page 12-14 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List REAR DIFFERENTIAL, CONTINUED ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 102765301 N/A 102694001 102765401 N/A 102463801 102464301 102765501 N/A 102463801 102464301 102765801 102464201 102464401 102464501 N/A N/A N/A 102463901 102464001 102464101 102693601 102694502 102961501 102464201 102464401 102464501 102961301 102961401 102961601 Asm, Gearcase, Upper (includes items 2 and 3) .............................................................................. Gearcase, Upper, Machined .............................................................................................................. Vent, Top, Upper Housing ................................................................................................................. Asm, Axle Tube, RH (includes items 5 through 7) .......................................................................... Weldment, Axle Tube Rh ................................................................................................................... Ring, Retaining, Internal ..................................................................................................................... Bearing ..................................................................................................................................................... Asm, Axle Tube, LH (includes items 9 through 11) ........................................................................ Weldment, Axle Tube Lh .................................................................................................................... Ring, Retaining, Internal ..................................................................................................................... Bearing ..................................................................................................................................................... Kit, Rear Axle Gear Repair (includes items 13 through 17) ......................................................... Bearing, Ball ............................................................................................................................................ Seal, Dual-Lip 25x 62x 7tc .................................................................................................................. Seal, Dual-Lip 30x 62x 8tc .................................................................................................................. Gear, Ring, 33-Tooth ............................................................................................................................ Asm, Pinion W/ Bearings (includes items 18 through 23) ..................................................... Pinion, I0t Machined ..................................................................................................................... Ring, Retaining, External ............................................................................................................. Bearing, Ball ...................................................................................................................................... Bearing, Needle, Drawn Shell .................................................................................................... Washer, 2.625 X 2.367 X .06 ........................................................................................................ Shim, 1.50 X 1.189 X .008 ............................................................................................................. Asm, Differential & Carrier (includes items 25 through 30) ........................................................ Bearing, Ball ............................................................................................................................................ Seal, Dual-Lip 25x 62x 7tc .................................................................................................................. Seal, Dual-Lip 30x 62x 8tc .................................................................................................................. Housing, Differential, Mach .............................................................................................................. Pin, Dowel, 4 X 35 ................................................................................................................................. Asm, Locker, Nongrease/Spacers .................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 Page 12-15 12 G E D 12 G 24 E 27 22 28 26 D 25 23 29 9 4 6 8 5 3 7 10 17 18 14 21 19 13 20 12 11 15 21 2 16 000016-006 Page 12-16 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List TRANSMISSION – DIESEL VEHICLES ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 102943201 102693301 102697801 102764201 102694201 N/A N/A N/A N/A 102699401 102765201 102696201 N/A N/A 102696801 102696901 102697101 N/A N/A N/A 102699701 103250301 102693501 102694201 102696101 N/A 102699401 102721501 103250401 Transmission, Diesel, Parallel Shaft (includes items 2 through 22) .......................................... Screw,hex Flange, M8 X 35 ................................................................................................................ Fork, Transmission ................................................................................................................................ Asm, Gear Case, Rear (includes items 5 through 10) ............................................................... Plug, Square Skt, 1/12-14, Ptf ..................................................................................................... Oil, Deflector .................................................................................................................................... Gearcase, Rear ................................................................................................................................. Vent, Trans ........................................................................................................................................ Screw, Tapping # 10-24 X .375 ................................................................................................... Seal, Triple, 25 X 35 X 7.8 ............................................................................................................. Kit, Reverse Gear Repair (includes items 12 through 21) ....................................................... Ring, Retaining, Basic External .................................................................................................. Washer, Thrust, 1.007 X .062 ....................................................................................................... Washer, 26.231 X 39.167 X 1.57 ................................................................................................. Bearing, Ball ...................................................................................................................................... Bearing, Ball ...................................................................................................................................... Bearing, Needle .............................................................................................................................. Sprocket, 19-Tooth ......................................................................................................................... Sprocket, 51-Tooth ......................................................................................................................... Chain, .375p, .75 Wide, 60ptch .................................................................................................. Ring, Retaining, E-Ring ................................................................................................................. Asm, Case, Gear, Front (includes items 23 through 29) .......................................................... Washer, .625 X .382 X .60 ............................................................................................................. Plug, Square Skt, 1/12-14, Ptf ..................................................................................................... Pin, Dowel, 6 X 20 ........................................................................................................................... Gearcase, Front ............................................................................................................................... Seal, Triple, 25 X 35 X 7.8 ............................................................................................................. Seal, Dual-Lip ................................................................................................................................... Plug, 3/4-16 ...................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 11 1 1 1 1 1 1 1 2 1 2 1 1 1 1 2 1 1 1 2 1 1 1 2 1 1 1 1 Page 12-17 12 G E D 12 G 11 E 13 D 2 14 12 15 1 8 7 6 4 5 3 10 9 000016-008 Page 12-18 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List TRANSMISSION – DIESEL VEHICLES, CONTINUED ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 102697501 102698701 102764901 102696201 N/A 102696801 102696901 102697101 N/A N/A 102765101 N/A N/A N/A N/A Dog, Engagement ...................................................................................................................................... Shaft, Intermediate ................................................................................................................................... Kit, Forward Gear Repair (includes items 4 through 10) .............................................................. Ring, Retaining, Basic External ......................................................................................................... Washer, Thrust, 1.007 X .062 ............................................................................................................. Bearing, Ball ............................................................................................................................................ Bearing, Ball ............................................................................................................................................ Bearing, Needle ..................................................................................................................................... Gear, Helical 58-Tooth ......................................................................................................................... Gear, Helical 34-Tooth ......................................................................................................................... Kit, Neutral Switch Repair (includes items 12 through 15) ......................................................... Spring, .484 X .340 X 1.076 ................................................................................................................ Guide, Detent Bullet ............................................................................................................................ Bullet, Detent ......................................................................................................................................... Switch, Indicator, Pollak ..................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 2 2 1 1 2 1 1 1 1 1 1 1 Page 12-19 12 G E D 12 G E D 6 4 3 2 5 1 000016-010 Page 12-20 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List TRANSMISSION – DIESEL VEHICLES, SHIFT SHAFT AND BELL CRANK ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 102696001 N/A N/A 102699601 103239501 103239801 Nut, Lock Hex, Nylon, 5/16-24 ............................................................................................................... Ring, Retaining, External 9/16 ............................................................................................................... Washer, Flat, .58 X 1.08 X .05 .................................................................................................................. Seal, Dul Lip, .88 X .56 X .19 .................................................................................................................... Bellcrank, Alum ........................................................................................................................................... Shaft, Shift .................................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 1 1 1 Page 12-21 12 G E D 12 G E D RADIATOR AND COOLANT SYSTEM – DIESEL VEHICLES 13 G E D 13 G E 14 D 7 6 15 13 11 8 2 10 16 11 11 12 11 13 3 9 4 5 9 13 000541-001 Page 13-2 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List RADIATOR ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 N/A 1014471 102377801 102377901 102380301 102410301 102737301 N/A 102411207 102411208 102411301 102436701 102490301 102685001 102855501 96705199 Asm, Radiator (includes items 2 through 16) .................................................................................. Tape, Vinyl Foam 1/8" x 3/4" * .......................................................................................................... Hose, Coolant Lower Pipe ................................................................................................................. Hose, Coolant Lower Rad ................................................................................................................... Tee, Coolant Fill ..................................................................................................................................... Exchanger, Engine Coolant (includes items 7 and 8) .............................................................. Cap, Radiator .................................................................................................................................... Drain Cock, Radiator ..................................................................................................................... Clamp, Hose, Ctb 35mm .................................................................................................................... Clamp, Hose, Ctb 38mm .................................................................................................................... Nut, Self Retaining ............................................................................................................................... Fan, Cooling 12 In Elect ...................................................................................................................... Bolt, M6 X 1 X 16 Loctite .................................................................................................................... Isolator, Twin-Stud ............................................................................................................................... Shroud, Radiator Fan ........................................................................................................................... Washer, M6 .............................................................................................................................................. 1 A/R 1 1 1 1 1 1 2 1 4 1 8 2 1 4 * Note: Item not shown. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 13-3 13 G E D 13 G E D 4 2 7 5 8 3 6 000540-001 Page 13-4 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List COOLANT EXPANSION TANK ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 N/A 102411204 102411205 102427501 102973201 N/A N/A N/A Asm, Coolant Bottle (includes items 2 through 8) ......................................................................... Clamp, Hose, CTB 15mm ................................................................................................................... Clamp, Hose, CTB 22mm ................................................................................................................... Cap, Radiator .......................................................................................................................................... Bottle, Coolant ....................................................................................................................................... Hose, Cut, 5/8, 445 ............................................................................................................................... Hose, Cut, Coolant, 700 ...................................................................................................................... Hose, Cut, Coolant, 1100 .................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 2 1 1 1 1 1 1 Page 13-5 13 G E D 13 G E D 3 2 4 5 6 000539-001 Page 13-6 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List COOLANT PIPES AND HOSES ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 102628701 N/A N/A N/A N/A N/A Weldment, Group, Coolant Pipe (includes items 2 through 6) .................................................. Pipe, Coolant Upper ............................................................................................................................ Pipe, Coolant Lower ............................................................................................................................. Tab, Rear Mntg, Coolant Pipe ........................................................................................................... Pipe, Vent, Coolant ............................................................................................................................... Tab, Cooling Pipe Mount ................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 2 1 1 Page 13-7 13 G E D 13 9 G E D 22 5 2 19 6 18 4 14 2 6 20 21 2 7 3 17 13 16 12 9 9 10 11 12 15 8 9 000542-001 Page 13-8 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List COOLING SYSTEM CLAMPS, HOSES, AND HARDWARE ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 N/A 1011578 1015457 102288901 102289001 102298720 102377501 102377601 102411204 102411205 102411206 102411207 102411208 102427601 102435001 102480501 102618601 102684901 102946701 N/A 96704176 96704416 Instl, Cooling Sys, Diesel (includes items 2 through 22) .............................................................. Washer, 5/16 Type B Flat .................................................................................................................... Spacer, 0.720" ......................................................................................................................................... Bolt-hex Fl, M8 X 1.25 X 135 ............................................................................................................. Screw, M8X1.25X30, Hex .................................................................................................................... M8-1.25x20 Taptite .............................................................................................................................. Hose, Coolant Upper Rad .................................................................................................................. Hose, Coolant Lower Eng ................................................................................................................... Clamp, Hose, CTB 15mm ................................................................................................................... Clamp, Hose, CTB 22mm ................................................................................................................... Clamp, Hose, Ctb 30mm .................................................................................................................... Clamp, Hose, Ctb 35mm .................................................................................................................... Clamp, Hose, Ctb 38mm .................................................................................................................... Clamp, Bar ............................................................................................................................................... Hose, Vent Tube To Eng, Coolnt ...................................................................................................... Hose, Coolant, Return, Engine ......................................................................................................... Lock Nut, Flg M8 X 1.25 Nylon ......................................................................................................... Bumper, 19mm Stud ........................................................................................................................... Bracket, Radiator Support ................................................................................................................. Bolt, M8 X 1.25 X 110 ........................................................................................................................... Nut Flg, M6 X 1 Serrated .................................................................................................................... Nut Flg, M8 X 1.25 Serrated .............................................................................................................. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 3 1 1 4 2 1 1 4 1 1 5 1 1 1 1 3 2 2 1 2 2 Page 13-9 13 G E D 13 G E D 12 13 2 3 9 5 7 8 6 11 10 4 1 000059-001 Page 13-10 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List WATER FLANGE AND THERMOSTAT ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 102410001 102631301 102631401 102631601 N/A 102633201 N/A N/A 102633401 102654701 N/A 102731001 N/A Sensor, Coolant Temp ............................................................................................................................... Cover, Thermostat ..................................................................................................................................... Assy, Thermostat ....................................................................................................................................... Bolt, M6 X 1 X 20 ......................................................................................................................................... Band, Pipe ..................................................................................................................................................... Flange, Water (includes items 7 and 8) .............................................................................................. Pipe, Water Return, D722 ................................................................................................................... Flange, Water ......................................................................................................................................... Gasket, Thermostat ................................................................................................................................... Gasket, Water Flange ................................................................................................................................ Bolt, Alt, D722, Stay Lower ...................................................................................................................... Pipe, Water Return, D722 ........................................................................................................................ Bolt, D722, Thermostat Cover ............................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 1 1 1 2 2 1 1 1 1 1 1 1 2 Page 13-11 13 G E D 13 G E D 2 3 1 000060-001 Page 13-12 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List WATER PUMP ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 N/A 102632701 102731201 Bolt, M6 X 1 X 22 ......................................................................................................................................... Gasket, Water Pump, D722 ..................................................................................................................... Water Pump Assembly ............................................................................................................................. 4 1 1 13 G E D 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 13-13 13 G E D 1 5 3 2 1 4 000061-001 Page 13-14 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List BLOCK COOLANT PIPE ITEM PART NO. DESCRIPTION QTY 1 2 3 4 1 2 3 4 5 102631701 102631801 N/A N/A N/A Band, Pipe, with Nut ................................................................................................................................. Pipe, Water, Bent ........................................................................................................................................ Nut, Flange, M6 ........................................................................................................................................... Pipe, Water, Bent ........................................................................................................................................ Stud, M6 X 15 ............................................................................................................................................... 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 2 1 1 1 1 Page 13-15 13 G E D 13 G E D MAINTENANCE AND SERVICE TOOLS 14 G E D 14 G E D 1 2 4 3 7 6 5 8 9 15 14 10 16 Page 14-2 11 12 17 13 18 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 19 MAINTENANCE AND SERVICE TOOLS ITEM PART NO. QTY DESCRIPTION DIESEL QTY GAS QTY ELEC G 1 2 3 4 The following tool list includes all tools available from Club Car for maintenance and service procedures for gasoline, electric, and/or diesel vehicles, both past and present models. Be sure to carefully examine the tool list for applicability to your vehicle before ordering. 1 2 3 4 5 6 7 8 9 10 11 101871001 101813202 101641202 101831901 1014305 1011767 1016417 1016416 1012811 1012812 1013582 12 13 102555501 102249901 14 15 16 17 18 19 **** **** 101887101 101808401 102562401 102686101 Accelerator Pedal Adjustment Tool ....................................................................... Adhesive, Guide Ring, 3-Gram Tube ..................................................................... Arbor ................................................................................................................................ Battery Discharge Machine, 36/48 Volt ................................................................ Battery Terminal Protector Spray ........................................................................... Battery Thermometer ................................................................................................. Bearing and Oil Seal Remover Assembly ............................................................ Bearing Driver Set ........................................................................................................ Bearing Puller ................................................................................................................ Bearing Puller Wedge Attachment ........................................................................ Brake Adjustment Tool (used only on vehicles with manually adjusted mechanical brakes) ............................................................... Brake Cable Release Tool ........................................................................................... Brake Pedal Adjustment Tool Kit (used for the Carryall Electric Industrial Truck only) (includes items 14 and 15).............................................. Brake Pedal Adjustment Tool ............................................................................. Brake Pedal Tension Tool ..................................................................................... Calibration Test Module ............................................................................................ Cam Installation Tool .................................................................................................. Charger Bezel Tool ....................................................................................................... Clutch Removal Tool (for 4x4 vehicles) ................................................................. E D 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Please refer to the maintenance and service manual for proper tool application. **** 14 Special order item available upon request 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page 14-3 14 G G IN N R A W E D 21 24 23 22 27 26 25 20 28 30 29 32 31 COMMUNICATION DISPLAY MODULE DISPLAY FUNCTIONS: PRESS AND HOLD BUTTON TO SHOW FUNCTION NUMBER. RELEASE BUTTON TO SHOW FUNCTION VALUE. Func1 - Battery voltage. Func2 - Energy units removed since last charge cycle. Func3 - Total accumulated energy units removed. Func4 - Last charge termination type (1 = Incomplete, 2 = DVDT, 4 = Normal, 8 = Max. timer). POWER ON OFF R Club Car PART #17075 33 38 Page 14-4 39 36 35 34 40 41 42 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 37 43 MAINTENANCE AND SERVICE TOOLS, CONTINUED ITEM PART NO. QTY DESCRIPTION DIESEL QTY GAS QTY ELEC G 1 2 3 4 20 21 1014510 1014498 22 23 24 25 26 27 28 1014496 1014497 1014508 1014507 1015524 101809101 102601501 29 102603501 30 102605201 31 102606101 32 102607501 33 34 35 36 37 38 39 40 101831801 101641002 1011273 102773801 102773901 102774101 102774101 102675401 41 42 43 102774201 102774301 102774401 Clutch Tool Kit (includes items 21 - 27) ................................................................ Clutch Alignment Tool (for pre-unitized transaxle vehicles built prior to 1997 model year) ........................................................ Drive Clutch Puller (for Kawasaki engines only) .......................................... Drive Clutch Hub Puller (for Kawasaki engines only) ................................ Driven Clutch Cam Puller (for Kawasaki engines only) ............................. Driven Clutch Puller Plug (for Kawasaki engines only) ............................. Drive Clutch Holder Tool Assembly (for Kawasaki engines only) .......... Press Weldment (for Kawasaki engines only) ............................................... Drive ClutchFixed Sheave Tool (for 4x4 vehicles) ........................................................................................................... Driven Clutch Spring Compression Base (for use with items 30 and 31) (for 4x4 vehicles) ........................................................................................... Driven Clutch Spring Compression Collar (for use with items 29 and 31) (for 4x4 vehicles) ........................................................................................... Driven Clutch Spring Compression Nut (for use with items 29 and 30) (for 4x4 vehicles) ........................................................................................... Drive Clutch Spider Removal Tool (for 4x4 vehicles) ........................................................................................................... Communication Display Module ........................................................................... Compression Gauge and Adapter ......................................................................... Continuity Tester .......................................................................................................... Cutter, Valve Seat, #122 .............................................................................................. Cutter, Valve Seat #115 ............................................................................................... Wrench, T, #505.............................................................................................................. Adapter, T-Wrench........................................................................................................ Cutter, Valve Seat, 60 Degree (requires item 51) (for Honda GX620 Gasoline Engines) ................................................................... Pilot, 6.6 MM ................................................................................................................... Pilot, 6.62 MM................................................................................................................. Pilot, 6.65 MM................................................................................................................. 1 E 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 D 1 1 1 1 1 1 1 1 1 1 1 1 Please refer to the maintenance and service manual for proper tool application. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 14 Page 14-5 14 G E D 44 45 46 47 48 49 50 51 2 56 57 3 54 52 53 58 Page 14-6 59 60 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 61 Liquid Gasket 55 MAINTENANCE AND SERVICE TOOLS, CONTINUED ITEM PART NO. QTY DESCRIPTION DIESEL QTY GAS QTY ELEC 1 1 1 1 2 3 4 44 45 46 1012151 1016627 102669901 47 48 49 1016418 101933101 102169401 50 51 52 1011478 1013593 102248803 53 102248804 54 55 56 57 58 59 59 59 59 59 59 59 59 59 59 60 61 102251501 102241502 102241501 101928701 102243402 101997201 101997207 101997212 101997211 101997205 101997209 101997204 101997203 101997206 101997202 102562301 102587201 Dry Moly Lubricant ...................................................................................................... Flywheel Puller Kit (for Kawasaki Engines) ......................................................... Gauge, Carburetor Float Level (for Honda GX620 Gasoline Engines) ................................................................... Gear Yoke ........................................................................................................................ Governor Shaft Installation Tool (for Kawasaki Engine Vehicles) ............... Hydraulic Brake Adjuster (for Turf/CA 272/472, Pioneer/XRT 1200, Bobcat 2100, HUV 4213) ............................................................................................ Hydrometer .................................................................................................................... Internal Retaining Ring Pliers .................................................................................. IQ Display Module (IQDM) Kit (IQ System and IQ Plus vehicles) ................. (includes items 54 and 55) IQ Display Module (IQDM-P) Kit (IQ System and IQ Plus vehicles).............. (includes items 54 and 55) Adaptor, Cable ......................................................................................................... IQDM Series 2 Cable .............................................................................................. IQDM Series 1 Cable (replacement) ...................................................................... Liquid Gasket (transaxle case) ................................................................................. Moly-Teflon Lubricant (4-oz. (113-gram) tube) ................................................. Paint, Touch-Up – Beige* .......................................................................................... Paint, Touch-Up – Black* ........................................................................................... Paint, Touch-Up – Burgundy* .................................................................................. Paint, Touch-Up – Classic Blue (Navy)* ................................................................. Paint, Touch-Up – Dark Gray* .................................................................................. Paint, Touch-Up – Dark Green* ............................................................................... Paint, Touch-Up – Gray* ............................................................................................. Paint, Touch-Up – Red* .............................................................................................. Paint, Touch-Up – Royal Blue (Pacific Blue)* ....................................................... Paint, Touch-Up – White* .......................................................................................... Paint, Precedent Underbody – Gray....................................................................... Paint Pen, Touch-Up, Precedent Underbody – Black ....................................... 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Please refer to the maintenance and service manual for proper tool application. * Item 59 is not for use on Surlyn® body material, which is used on Precedent vehicles. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List G E 1 1 14 Page 14-7 D 14 G E D 63 62 66 65 64 Safety First Never use a vehicle that is unsafe. Inspect each day. Inspect GOOD NEED(S) ATTENTION • Brakes • Park Brake • Steering • Accelerator • F & R Selector • Reverse Buzzer • Key Switch • Speeds • Tires • Bag Straps and Buckles Other Mechanical Problems • Unusual Noise • Will Not Run • Stopped on Course • Other: • • • Damage • Right Side • Left Side • Front • Rear • Other: ______________ No Damage NEED(S) ATTENTION Cleanliness • Seats • Floor Mat • Dash Compartments • Bag Well • Beverage Holders • Overall Appearance: ___________________ Date: _____________ Inspected By: _________________ Car No. ___________ (Over) CCI 1018231 69 68 67 71 70 72 AM10753 ON OFF STR SPK MAX MIN GAS DSL GAS/DIESEL TACHOMETER 73 77 Page 14-8 83 76 75 74 84 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 85 86 MAINTENANCE AND SERVICE TOOLS, CONTINUED ITEM PART NO. QTY DESCRIPTION DIESEL QTY GAS QTY ELEC G 1 2 3 4 62 63 64 65 66 67 68 69 1016414 1016415 102668801 1012549 1012560 101823101 1012809 102330901 70 71 72 73 74 75 76 77 78 1014264 1014259 102061201 AM10753 AM10771 1014162 1014161 1014115 101611003 79 AM11804 80 AM11805 81 AM1220301 82 AM1232401 83 84 1016413 102674601 85 86 101641201 102674401 Piston Ring Compressor Kit (FE290, FE350 and FE400 engines) ................. Piston Ring Pliers (for Kawasaki Engines) ............................................................ Puller, Special Use (for Kubota D722 Diesel Engines) ..................................... Retaining Ring Pliers, 45° External ......................................................................... Retaining Ring Pliers, 90° Internal .......................................................................... Safety First Card (50 per pack) ................................................................................. Seal Puller ....................................................................................................................... Spanner Wrench (for coil over shock front suspension vehicles only) ......................................................................................... Steering Column Bearing Press Tool ..................................................................... Steering Column Retaining Ring Tool .................................................................. Steering Wheel Puller Tool ....................................................................................... Tachometer (includes gasoline engine pick up lead only) ........................... Tachometer Diesel Probe (for use with item 73) .............................................. Transaxle Axle Seal Tool ............................................................................................. Transaxle Pinion Seal Tool ......................................................................................... Transmission Tool Kit .................................................................................................. Tune-Up Kit, All OHV (for FE290, FE350, FE400 only) (includes air filter, spark plug, oil filter, fuel filters) (not shown) .................................... Tune-Up Kit, Gx620 (for Honda Engines) (includes air filter, spark plug, oil filter, fuel filters) (not shown) ...................................................... Tune-Up Kit, D722 (for Kubota Engines) (includes air filter, oil filter, fuel filters, water separator filter) (not shown) ................................. Tune-Up Kit, Precedent (for FE290/350 Engines) (includes air filter, spark plug, oil filter, fuel filters) (not shown) ........................................... Tune-Up Kit, FH680D (for Kawasaki V-Twin Engines) (includes oil filter, fuel filter, air filter, and spark plugs) (not shown)................................... Valve Clearance Adjuster Screw Holder (for FE290 engines only) ............. Valve Guide Driver (for Honda GX620 Gasoline Engines) ................................................................... Valve Guide Reamer (FE290, FE350, and FE400 only) ...................................... Valve Guide Reamer, 6.6 mm (for Honda GX620 Gasoline Engines) ................................................................... 1 1 1 1 1 1 1 1 1 1 1 E 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 14 1 1 1 1 1 1 Page 14-9 D 14 G E D 87 88 - 45 45 89 90 + WAVETEK V 5XL 1000 V OFF 500 200 200 20 200 2m 2 200 m 20 m 200 m 2000 k 200k 20k V ! MAX 1000 --750V Page 14-10 200 A 2k ! COM 200nA FUSED 91 92 95 96 93 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 94 MAINTENANCE AND SERVICE TOOLS, CONTINUED ITEM PART NO. QTY DESCRIPTION DIESEL QTY GAS QTY ELEC G 1 2 3 4 87 88 89 90 91 92 93 94 95 96 1016552 1016551 1016553 1016554 101641101 1011480 102570401 103601401 103601701 103600501 Valve Seat Cutter Guide ............................................................................................. Valve Seat Cutter T-Wrench ...................................................................................... Valve Seat Cutter, 45° (32 mm diameter) (for FE290 engines only) ........... Valve Seat Cutter, 45°/30° (35 mm diameter) .................................................... Valve Spring Compressor .......................................................................................... Volt Ohm Meter ............................................................................................................ Tool, Tensioning, Starter Generator (For Precedent vehicles) ...................... Puller, Drive Clutch, XRT 950*................................................................................... Tool, Disassembly, Driven Clutch, XRT 950 .......................................................... Screw, Driven Clutch Disassembly, M6, XRT 950 ............................................... 1 1 1 1 1 1 1 1 1 1 1 E D 1 *Note: The XRT 950 Drive Clutch Puller requires the use of Screw, Driven Clutch Disassembly, CCI Part Number 103600501. 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 14 Page 14-11 INDEX Part Number and Page AM10753 14-9 AM10771 14-9 AM11807 6-9 AM11808 6-9 AM1241201 6-9 AM1241301 6-9 AM1245401 1-23 183 9-5 332 2-23, 2-25, 2-39, 2-43, 7-13 334 2-33 357 2-17, 2-37 403 2-35 451 2-23, 2-25 706 2-17 808 2-3, 2-17 1016 9-5 1017 1-21 1032 2-39 1035 5-15, 5-17 1108 7-13 1231 2-39 1241 7-17 1308 1-29, 1-31 1631 1-21 7049 2-39 7173 1-21 7174 1-21 7310 3-3 7473 2-35, 2-43, 7-17 7973 2-39 8233 2-13, 2-39, 2-43 8251 2-41 8639 5-11, 5-15 8717 1-21, 12-3 8754 2-35, 2-37 8755 2-35, 2-37 8797 9-5 8990 1-21, 2-37, 6-5, 9-7, 12-3 1010200 2-37 1010434 2-39 1010435 2-35, 2-39, 2-43 1010436 2-43 1010521 5-15 101082903 5-7, 5-9 1010934 2-39, 7-17 1011084 9-7 1011273 14-5 1011478 14-7 1011480 14-11 1011553 4-3 1011578 2-3, 2-21, 13-9 1011652 2-23, 2-25 1011767 14-3 1011779 5-15 1011931 1-21 1011990 2-39 1012151 14-7 1012295 7-13 1012303 2-35 1012328 7-17 1012438 1-21 1012549 14-9 1012560 14-9 1012769 8-3 1012809 14-9 1012811 14-3 1012812 14-3 1012830 2-23, 2-25 1013035 6-5 1013042 6-5 1013044 6-5 1013051 6-5 1013052 6-5 101313402 9-3 1013317 2-39 1013366 2-43 1013461 9-5 1013462 9-5 1013531 5-15 1013582 14-3 1013593 14-7 1013734 2-23, 2-25 1013746 9-3 1014063 1-21 1014115 14-9 1014161 14-9 1014162 14-9 1014259 14-9 1014264 14-9 1014305 14-3 1014306 2-41, 2-43, 5-7 1014321 2-39 1014375 7-17 1014387 2-39 1014415 2-39, 2-43 1014471 2-35, 13-3 1014496 14-5 1014497 14-5 1014498 14-5 1014507 14-5 1014508 14-5 1014510 14-5 1014537 2-39, 2-43 1015139 9-5 1015143 9-5 1015245 2-39 1015390 1015391 1015392 1015399 1015400 2-39 2-35 2-19 2-35, 2-39, 2-43 2-35, 2-39 1015457 13-9 1015524 14-5 1015583 2-35 1015597 6-13 1015741 7-13 101587703 9-3 1016078 2-33 101609401 4-3 1016103 1-21 101611003 14-9 101641002 14-5 101641101 14-11 101641201 14-9 101641202 14-3 1016413 14-9 1016414 14-9 1016415 14-9 1016416 14-3 1016417 14-3 1016418 14-7 1016551 14-11 1016552 14-11 1016553 14-11 1016554 14-11 1016603 2-37 1016627 14-7 1016630 7-15 1016916 2-13 1016967 2-11 1017162 2-37 1017167 2-37 1017774 2-37 101802601 7-15 101804301 2-13 101808401 14-3 1015246 1015277 1015313 1015363 101809101 101813202 101823101 101824401 101831801 101831901 101833101 101833201 101835601 14-5 14-3 14-9 9-3 14-5 14-3 8-3 8-3 2-33, 2-35 101856102 101871001 101879401 11-5 14-3 6-5 2-39 2-33 2-39 101879701 101879801 101879901 6-5 6-5 6-5 2-39 101880201 6-5 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page i-1 INDEX 101887101 101887601 14-3 2-23, 2-25, 5-11, 10-3 101894304 101898001 101928701 101932201 101933101 101958602 101963401 101972001 101972002 101972003 101972004 101972005 101972006 101972007 101972009 101972011 101972012 101991101 102010102 102022601 102022901 102023703 102025401 102030101 102030201 102047001 2-43 7-17 14-7 1-21 14-7 2-33 2-39, 2-43 14-7 14-7 14-7 14-7 14-7 14-7 14-7 14-7 14-7 14-7 7-15 6-5 6-5 6-5, 6-7 2-23, 2-25 1-33 2-39 2-39 2-23, 2-25 5-7 7-15 7-15 5-15 2-23, 2-25 2-23, 2-25 2-23, 2-25 14-9 2-35 2-37 14-7 2-35 5-7, 5-9 2-17 7-15 2-43 2-43 2-43 2-43 2-43 2-43 2-43 2-43 4-3 2-43 14-7 14-7 14-7 102051401 102051601 102051701 102052801 102059001 102059401 102061101 102061201 102065901 102066001 102169401 102171503 102176901 102185401 102198001 102221301 102221401 102221501 102221701 102221801 102222001 102222101 102222201 102224001 102239901 102241501 102241502 102243402 Page i-2 102248803 102249901 102251501 102274101 102276001 102288901 102289001 102290120 102292356 102292701 102298401 102298580 102298720 102301401 102323101 102323501 102324401 102330901 102355301 14-7 14-3 14-7 6-7, 6-13 12-13 13-9 2-3, 2-13, 9-3, 13-9 6-3 2-3 2-5, 2-7, 2-9 2-5, 2-7, 2-9 5-11 9-9 5-11, 11-3, 11-5 2-3, 2-5, 2-7, 2-9, 2-13 2-23, 2-25, 6-3 2-11, 2-23, 2-25, 5-9, 8-3, 10-5, 12-3 2-13 2-11, 10-3, 13-9 2-33 2-33 2-11, 5-17 2-29 14-9 7-17 102361901 102363802 102365601 102367101 102367601 102369901 102370101 102370501 102370601 102371701 102371801 102372101 102374901 102375401 102375901 102376001 102376602 102376603 102377501 102377601 102377801 102377901 102379001 102380301 102380601 102381701 102382401 102385601 102385701 102393501 102395601 6-7 6-3 6-11 6-3 5-3 11-11 8-3 8-3 8-3 12-11 12-7 12-11 11-7 7-15 12-3 12-3 12-13 5-11 13-9 13-9 13-3 13-3 9-11 13-3 5-13 12-5 8-3 11-9 11-11 6-13 9-11 102292801 102296140 102296401 102296716 102297230 102298130 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 102398901 102399201 102399202 102402801 102402901 102406701 102406801 102407801 102408401 102409301 102409501 102410001 102410301 102410602 102410603 102410801 6-13 5-5 5-5 5-7 5-7 9-5 9-5 5-11 6-7 10-5 10-3 13-11 13-3 9-3 8-3 9-3 102411203 102411204 102411205 102411206 102411207 102411208 102411209 102411210 102411301 102414501 102414801 102418101 9-3 13-5, 13-9 13-5, 13-9 13-9 13-3, 13-9 13-3, 13-9 9-11 9-11, 11-3, 11-5 13-3 11-5 8-3 2-33 102420201 102420401 102420501 102422301 102426301 102426601 102426901 102427501 102427601 102430001 102430101 102430201 102430301 102430401 102434601 102434701 102434801 102435001 102436701 102437001 102438201 102438301 102438401 102438501 102438601 102438701 102438801 102438901 1-21, 7-13 7-13 7-13 8-51, 10-5 9-3 2-33, 2-37 2-35 13-5 13-9 9-3 9-3 9-3 9-3 9-3 9-3 9-3 9-3 13-9 13-3 6-7 12-7 12-7 12-7 12-7 12-7 12-7 12-7 12-7 INDEX 102607301 102607401 8-7 8-7 102493301 102493801 102494401 102494701 102495801 102498201 102498601 102498801 102522001 11-5 11-5 11-5 5-3, 5-5 9-9 2-31, 8-3 8-3 13-3 8-3, 11-11 6-7 1-23, 1-25, 12-5 12-5 2-11, 2-27 2-11 1-15, 2-11, 2-13, 2-27 5-3, 5-5 2-41 7-13 7-13 5-3, 5-5 2-33 8-3 9-5 9-7 7-17, 8-3 9-11 9-7 9-5 102607501 102607601 102607602 102607801 102607901 102608101 102608501 102608801 102608804 102609001 102609101 102609301 102609601 102609801 102610001 102614101 102614401 102615701 102615801 102616003 102616101 102616301 102616501 102616701 102616801 102617001 14-5 8-23, 8-53 8-23 8-23 8-23 8-23 8-19 8-23 8-23 8-23 8-19 8-19 8-19 8-23 8-23 2-35, 2-37 2-43 12-3 9-7 11-5 11-5 6-7, 6-11 11-9 12-3 6-3 1-19 102538501 102541465 102555501 102562401 102570401 102571301 102600001 102600301 102600701 102600801 102601001 102601401 7-5 9-11 14-3 14-3 14-11 6-3 8-5 8-5, 8-9, 8-51 8-5 8-5, 8-9 8-5, 8-11 8-5 102601501 102602701 102603501 102604801 102605201 102605401 102605501 102605601 102605701 102605801 102606101 102606501 102606701 102606901 102607001 102607201 14-5 8-11 14-5 8-27 14-5 8-21 8-21 8-21 8-39 8-21 14-5 8-17 8-15 8-7 8-7 8-7 102617201 1-23, 1-25, 2-11, 2-27 102617501 6-7 102617701 6-7 102617801 6-7 102618101 5-13, 9-9 102618301 1-23, 1-25, 2-11, 2-33, 5-13, 5-15, 5-17, 9-9, 12-3 102618401 5-7, 5-9 102618601 1-23, 1-25, 2-13, 2-21, 2-33, 2-37, 5-7, 5-13, 5-15, 5-17, 6-3, 8-3, 9-3, 9-9, 13-9 102619801 6-13 102620401 6-13 102620501 6-7, 6-11, 6-13 102621201 9-11, 10-3 102621301 8-3, 10-5 102621501 8-3, 9-11 102626201 5-13 102628001 11-5 102628101 10-5 102628701 13-7 102629001 2-37 102630001 8-23 102630601 8-33 102630701 8-23 102630901 8-23, 8-53 102631001 8-23, 8-53 102631301 13-11 102631401 13-11 102481001 102481201 102481301 102488001 102489901 102490101 102490201 102490301 102490501 102490801 102491001 102491101 102491301 102491302 102491501 102491601 102447901 102448001 102448401 12-7 12-7 12-7 12-7 12-7 12-7 12-7 12-7 12-9 12-7 12-9 12-9 12-9 1-21, 2-23, 2-25 7-17 5-13, 9-9 7-13 7-13 7-17 102448501 102449101 102456001 102458901 102459001 102459101 102459201 102459301 102459401 102459501 102460201 102462301 102462401 102462501 102463501 102463601 102463801 102463901 102464001 102464101 102464201 7-17 12-13 2-23, 2-25 2-23, 2-25, 4-5 4-5 4-5 4-5 4-3 4-3 4-5 4-5 8-3 12-5 8-3 12-13 12-13 12-15 12-15 12-15 12-15 12-15 102464301 102464401 102464501 102465701 102465901 102466201 102473501 102473601 102473701 102474301 102475701 102475801 102475901 102477001 102478501 102480501 6-7, 12-15 12-15 12-15 2-37 8-3 9-3 2-23, 2-25 2-23, 2-25 2-23 5-11 5-11, 9-7 5-11 2-23, 2-25 6-13 9-5 13-9 102439101 102439201 102439301 102439501 102439601 102439801 102439901 102440101 102440201 102440301 102440401 102440501 102440601 102442001 102442201 102442901 102491701 102492201 102492301 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page i-3 INDEX 102631601 102631701 102631801 102632701 102633201 102633401 102634001 102634101 102634501 102635101 102635301 102635701 102635901 102637001 102637101 102640601 102640901 102641001 102641501 102642401 102642501 102642601 102642701 102643001 102643101 102643201 102643401 102643601 102643701 102644001 102644101 102644501 102645501 102646001 102646601 102647701 102647801 102648401 102648501 102652801 102653101 102653201 102653301 102653601 102653701 102654101 102654601 102654701 102668801 102669901 102670601 102670701 102670801 102671201 102672101 102672201 Page i-4 8-5, 8-33, 13-11 13-15 13-15 8-51, 13-13 13-11 8-51, 13-11 8-37, 8-51 8-37 8-37, 8-51 8-41 8-29, 8-37, 8-39, 8-51 8-29 8-29 8-29 8-29 8-31, 8-35 8-35 8-35 8-39 8-39 8-39 8-39 8-39 8-39 8-39 8-39 8-39 8-39 8-39 8-13, 8-51 8-13 8-51 8-43 8-47, 8-51 8-49, 8-51 8-33, 8-43 8-25 8-43 8-43 8-9 8-45 8-45 8-45, 8-51 8-45 8-45 8-9, 8-51 8-7, 8-51 8-51, 13-11 14-9 14-7 2-23, 2-25 1-15, 8-3 9-3 2-29 12-13 12-13 102672301 102672401 102673201 102674001 102674101 102674201 102674401 102674601 102675001 102675101 12-13 12-13 2-43 14-5 14-5 14-5 14-9 14-9 14-5 14-5 102697801 102698701 102699401 102699601 102699701 102703301 102710301 102711601 102712601 102714001 102675201 102675301 102675401 102682901 102684501 102684601 102684901 102685001 102685601 14-5 14-5 14-5 6-13 6-13, 12-3 12-3 13-9 13-3 6-13 102686101 102687801 102689001 102689101 102689102 102690201 14-3 6-5 5-11 6-11 6-11 11-9 102716001 102718101 102721501 102722301 102725501 102725601 102726201 102726301 102726401 102727701 102727901 102728101 102690301 102690401 102690501 11-9 11-9 11-9 102690701 102690801 102691401 102691701 102691801 102693301 11-9 11-9 11-9 11-9 11-9 12-13, 12-17 102728901 102729301 102729701 102730201 102730801 102731001 102731201 102731501 102731601 102693401 102693501 102693601 102694001 102694201 102694301 12-13 12-13, 12-17 12-15 12-15 12-13, 12-17 12-13 102731801 102731901 102732001 102732201 102732401 102732501 102694401 102694502 102694701 102694801 102695401 102695601 102695701 102695801 102695901 102696001 102696101 102696201 12-13 12-15 12-13 12-13 11-11 11-11 11-11 11-11 11-11 12-21 12-17 12-17, 12-19 102736901 102737101 102737301 102741501 102741601 102751301 8-29 8-11, 8-51 8-39 8-33 8-5 13-11 13-13 8-49 8-49, 10-5 8-51 8-51 8-53 8-23, 8-53 2-23, 2-25 8-33, 8-43 3-3 6-13 13-3 5-17 1-25, 1-33, 5-17 5-17 102696801 102696901 102697101 12-17, 12-19 12-17, 12-19 12-17, 12-19 12-19 102751501 102763301 102763401 102763701 102764201 102764901 102765101 102765201 102765301 102765401 5-17 5-15 5-15 2-23, 2-25 12-17 12-19 12-19 12-17 12-15 12-15 102697501 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 102728102 102728301 102728601 12-17 12-19 12-17 12-21 12-17 8-11 9-3 12-5 5-15 5-3, 5-5 5-17 2-23, 2-25, 2-27 12-17 6-7 9-11 9-11 8-5 8-5 8-5 8-15 8-17 8-23, 8-53 8-23 8-25 8-29 INDEX 102765501 102765801 102784001 102784003 102784201 102784601 102784701 102784801 102785001 102785101 102785401 102785501 102786101 102786201 102786301 102786401 102787101 102787201 102787501 102787601 102787602 102787701 102788701 102789101 102789201 102789301 102790001 102790801 102790901 102791001 102791301 102791701 102791702 102792001 102792002 102794801 102794901 102798001 102798101 102798401 102798501 102798701 102799501 102799601 102799701 102799801 102800101 102800201 102800401 102800701 102801001 102801201 102810701 102812801 102816801 102831501 12-15 12-15 1-29 1-33 1-23, 1-25 1-23, 1-25 1-23, 1-25 1-23, 1-25 1-25, 1-33 1-25, 1-33 1-33 1-23, 1-25 1-15, 1-17, 1-19, 1-23, 1-25 10-3 6-11 7-9 1-23, 1-25 1-23, 1-25 1-23, 1-25 1-23 1-25 1-23, 1-25 6-11 1-19 1-19 1-19 1-19 1-19 1-19 1-19 1-19 6-7 6-7 6-7 6-7 1-25, 1-33 1-25, 1-33 8-9 8-11 8-13 8-13, 8-51 8-13 8-29 8-31 8-31 8-31 8-35 8-41 8-37 8-33 8-33 8-45 9-11 10-3 6-5 12-13 102839401 102849801 102850501 102854401 102854501 102854601 102854801 102854901 102855501 102859101 11-9 1-21 1-21 1-21 1-21 1-21 1-21 1-21 13-3 1-23, 1-25 102866510 102866514 102866515 102866518 102866610 102866614 102866615 102866618 102866710 102866714 102866715 102866718 102866719 102866810 102866814 102866815 102866818 102866819 102866901 102867001 102867101 102867202 102867301 102867602 102869401 102874201 102874301 102874501 102882401 102882501 102883401 102885001 102892401 102895101 102895401 102895701 102896401 102896501 102896601 102913801 102913901 102914001 102914101 102914102 102918501 102921601 2-5, 2-9 2-5 2-9 2-5, 2-7, 2-9 2-5, 2-9 2-5 2-9 2-5, 2-7, 2-9 2-5, 2-9 2-5 2-9 2-5, 2-9 2-7 2-5, 2-9 2-5 2-9 2-5, 2-9 2-7 2-3 2-3 2-13 2-15 2-13 2-3 7-15 6-7 6-7 6-7 2-3 2-37 2-13 2-3 5-17 2-3 2-3 2-19 2-5, 2-7, 2-9 2-5, 2-7, 2-9 5-17 2-41 2-41 2-41 2-41 2-41 1-21 1-15, 1-17, 1-19, 1-23, 1-25 102921701 102922601 1-23, 1-25 1-25, 1-33 102922701 102923001 102923101 1-25, 1-33 1-23, 1-25 1-23, 1-25 1-17 1-19 1-17 1-25, 1-33 1-15 4-11 1-19, 4-3 1-27 1-27 1-27 1-9, 1-11, 1-27 1-27 1-27 6-7 102923201 102923301 102923401 102923801 102925201 102925601 102926101 102926301 102926401 102926501 102926601 102926701 102926801 102927101 102927102 102927201 102927301 102927401 102928001 102928101 102937401 102937501 102937601 6-7 1-5 1-5 1-5, 1-9, 1-11 1-29, 1-31 1-29, 1-31 1-29, 1-31 1-21, 1-29, 1-31 1-29, 1-31 1-29, 1-31 1-29, 1-31 1-31 1-29, 1-31 1-11 1-9, 1-11 1-11 1-9, 1-11 1-5 1-7 1-9 1-11 1-27 4-3 10-3 8-3 8-33 8-33 8-33 2-11 1-21, 7-9 1-21 1-21 1-21 102943101 102943201 102943807 3-3 12-17 3-3 102943808 3-3 102928201 102928301 102928401 102928501 102928601 102928701 102928901 102929501 102929601 102929701 102929801 102930001 102930101 102930201 102930301 102930501 102930801 102930901 102934601 102934701 102934801 102934901 102935501 102936801 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page i-5 INDEX 102943809 102945701 102946701 102950402 102950503 102950601 102952101 102961201 102961301 102961401 102961501 102961601 102967901 102977201 102977501 102978801 3-3 3-3 13-9 2-17 2-17 4-3 9-5 4-3 12-15 12-15 12-15 12-15 1-21, 2-5, 2-7, 2-9, 2-23, 2-25 13-5 1-25, 1-33 1-25, 1-33 2-11 7-15 2-3 102978901 102983201 102983601 102988701 102989801 103174301 103179901 103180001 103180101 103182701 103182702 103182801 103185501 103185801 103185901 103187501 103188601 103188701 103189001 103191201 103191301 2-3 2-11 2-11 2-27, 2-29, 2-31 6-3 5-11 2-13 2-13 7-15 2-15 2-15 2-15 11-9 11-9 11-9 12-3 4-3 4-5 5-15 2-39 2-39 103191401 103191501 103192101 103193401 103200501 103208801 103210801 103210802 103210901 103213201 103213401 103213501 103215201 103215901 103216401 103218107 102973201 102973501 102973601 Page i-6 103218213 103218901 103225801 103227001 103233001 103233410 103233415 103233417 103233510 103233515 103233517 103233614 103233617 103233714 103233717 103234201 103234401 103234503 103237501 103237701 103239501 103239801 103239901 103243001 103243101 103243201 103243501 103243601 103243701 103243801 103243901 5-7 2-25 2-29 2-37 2-13 4-9 4-9 4-9 4-9 4-9 4-9 4-7 4-7 4-7 4-7 4-7, 4-9 7-15 3-3 1-3 2-39 2-39 2-29 7-15 2-41 7-15 2-29 2-29 2-29 2-3 7-11 2-3 1-21 2-29 2-23, 2-25, 2-27, 2-29, 2-31 103244001 103244701 103245801 103250301 103250401 103253801 103256401 103256501 103256701 103267001 103267002 103268001 103273101 103274502 103274602 103277001 103277002 103277501 103282301 103283801 103289001 103289002 103289101 103289102 1-3 12-21 12-21 8-33 1-9 1-9 1-9 1-9, 1-11 1-9 1-9 1-9 1-9, 1-11 1-9, 1-11 12-5 7-9 12-17 12-17 2-13 6-7 6-7 6-7 2-23 2-25 2-13 5-13, 9-9 2-31 2-31 6-7 6-7 7-5 6-13 2-31 2-41 2-41 2-41 2-41 2-3 103289103 2-41 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 103289104 103293201 103296001 103296201 103305001 103305101 103319601 103319701 103319901 103320601 2-41 5-7 2-11 6-7 5-17 5-17 2-21 2-21 4-5 11-3, 11-5 103327201 103331201 103345801 103355401 103361701 103376101 103377501 103379401 103400001 103409001 103418701 103418801 7-5 2-41 6-7 1-15 2-27 5-9 2-27 2-39 2-21 1-33 5-5 5-3, 5-5 103538701 2-35 103538901 2-35 95293643 12-11 96701412 96704176 96704416 96704721 96705199 96705587 96706825 96715552 96718978 96727003 96741038 96741046 8-3 13-9 13-9 8-3 13-3 9-3 9-9 2-11 8-3 1-15 8-3 1-23, 1-25, 2-31, 8-3 96742515 2-23, 2-25 A A-arm 6-7 accelerator cable 9-7 accelerator pedal 9-9 accelerator pedal adjustment tool accessory receptacle 7-15 actuator 2-37 adapter actuator 2-37 cable (IQDM) 14-7 tube 9-3 adhesive, guide ring 14-3 adjuster hydraulic brake 14-7 adjuster, forward/aft 2-23, 2-25 adjuster, slide 6-7 adjuster, slider 2-23, 2-25 14-3 INDEX air clean support 9-11 air filter 9-11 air filter canister 9-11 air filter evacuator 9-11 alternator 8-33 alternator belt 8-33 arbor 14-3 arm A- 6-7 rocker 8-45 arm attachment 1-17 arm, swing 6-13 assembly accelerator pedal 9-9 adjusting bolt 8-29 bearing case cover 8-19 brake line 5-11 brake pedal 5-13, 5-17 brake rotor 5-11, 12-13 bucket seat 2-23 camshaft 8-21 case, main bearing 8-19 connecting rod 8-23 cylinder head cover 8-13 drain cock 8-5 filler cap 5-7 fuel camshaft 8-27 fuel cap 9-5 fuel filter 9-3 fuel injection pump 8-35 fuel pump 9-3 fuel tank vent 9-5 gear case 12-15, 12-17 governor fork 8-41 governor fork lever 8-41 idle apparatus 8-29 inner ball joint 6-5 intake manifold 8-47 latch, tilt bed 2-35 muffler 12-5 nozzle holder 8-39 oil pump 8-17 overflow pipe 8-39 pinion 12-15 piston ring 8-23, 8-53 reservoir, remote 5-7 rocker arm 8-45 speed plate 8-37 tailgate 2-43 tether 2-43 thermostat 13-11 tilt bed 2-35 tire 3-3 water pump 13-13 wire 7-17, 9-5 assembly, sub- gear case 12-17 moveable drive clutch 11-9 spider 11-9 stationary 11-9 swingarm 6-13 weight clutch 11-9 attachment bucket 1-7 mower 1-13 pallet fork 1-5 push broom 1-11 snow blade 1-9 attachment arm 1-17 axle 12-13 axle tube 12-15 axle, rear, guard mounts 12-13 B ball check 8-21 crankshaft 8-23 governor 8-27 injection pump 8-27 valve 8-11 ball joint 6-7, 9-7 ball stud 12-3 band, pipe 13-11, 13-15 banjo bolt 5-3, 5-5 bar clamp 13-9 barb, vent 9-3 barrel, plastic 2-39 barrier, heat 1-23, 1-25 base, seat holder 2-23, 2-25 battery clamp 7-17 battery discharge machine 14-3 battery terminal protector spray 14-3 battery thermometer 14-3 battery, 12-volt 7-17 bearing 6-7, 12-15 ball (steering pinion) 6-5 lower pinion 6-5 needle 12-7, 12-15, 12-17, 12-19 bearing and oil seal remover 14-3 bearing case cover 8-19 bearing case, main 8-19 bearing driver set 14-3 bearing puller 14-3 bearing puller wedge 14-3 bed floor plate 2-35 bed latch 2-39 bed latch spring 2-39 bed, tilt 2-35 bellcrank 5-17, 12-21 bellows 6-5, 12-13 belt guard 8-33 belt, alternator 8-33 belt, drive 11-7 bezel, fuel fill 9-3 blade, snow 1-9 block, differential spacer 12-5 block, engine 8-5 block, fuse 7-13 bobbin, coil with press fit 12-7 bolt adjusting 8-29 banjo 5-3, 5-5 boot kit, boxed 6-9 boot replacement kit 6-9 boot, half shaft 6-9 bottle, coolant 13-5 box cargo 2-43 box, hydraulic control 1-21 bracket actuator 2-37 bed latch 2-33 brake line 5-11 brake pedal 5-13 cover inlet 11-5 draw latch 2-3 equalizer 5-15 hood support 2-13 hydraulic line 5-11, 6-11 muffler 10-3 park brake 5-17 radiator support 13-9 rocker arm 8-45 seatbelt 2-23, 2-25 steering column 2-11 transmission cable 8-3 transmission mounting 8-3 brake adjustment tool 14-3 brake cable 5-15 brake cable release tool 14-3 brake caliper 5-3, 5-5 brake caliper return spring 5-5 brake fluid reservoir 5-7 brake line 5-11 brake line, front 5-11 brake pad service kit 5-3, 5-5 brake pedal 5-13, 5-17 brake pedal adjustment tool 14-3 brake pedal tension tool 14-3 brake return spring 5-15 brake rotor 5-11, 12-13 breaker, circuit 1-21, 7-9 breather cover 8-13 breather shield 8-13 breather tube 8-13 breather valve 8-13 broom weldment 1-11 broom, push 1-11 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page i-7 INDEX brush, FNR 2-13 bucket attachment 1-7 bucket seat 2-23, 2-25 bullet, detent 12-19 bumper 13-9 bed 2-33, 2-37 rubber 2-43 bushing 2-37 A-arm 6-7 flanged bronze 8-21 forward/reverse 12-3 greaseless 5-13, 9-9 lower arm 6-7 nylon 2-39 Permiglide 12-7 piston pin 8-23, 8-53 pivot, urethane 6-13 plain 12-9 return line 9-5 cap, front corner 2-43 carburetor air vent tube 9-3 carburetor float level tool 14-7 card, safety first 14-9 cargo box 2-43 case gear 8-11, 12-13, 12-15, 12-17 governor ball 8-27 main bearing 8-19 case cover, bearing 8-19 center console 1-21 center console cover 2-23, 2-25 chain, transmission 12-17 charger bezel tool 14-3 circuit breaker 1-21, 7-9 clamp bar 13-9 battery 7-17 breather tube 8-13 self-lubricating 12-7 snap-in 2-39 steel 2-35 teflon 6-13 urethane 2-35 button, thrust 12-7 hose 9-3 p- (fuel filter) 8-3, 9-3 pipe 8-39 clevis pin 5-7, 5-9 clip hair pin 2-43 clip, body trim 2-5, 2-7, 2-9 clip, brake line 5-11, 9-7 clip, return pipe 8-39 closeout 2-41 clutch 11-11 clutch alignment tool 14-5 clutch cover 11-9 clutch housing 12-7 clutch removal tool 14-3 clutch tool kit 14-5 clutch, diesel 11-9 coil pocket insert 12-7 coil over shock 6-11 coil with press-fit bobbin 12-7 collar, alternator assembly 8-33 collar, crankshaft 8-23 collar, idle gear 8-21 collar, lever 8-37 collet 8-45 column, steering 6-3 communication display module 14-5 compression gauge 14-5 compressor, piston ring 14-9 compressor, valve spring 14-11 connecting rod 8-23 connector, relay 7-13 console, center 1-21 continuity tester 14-5 Control assembly, hydraulic 1-21 C cable accelerator 9-7 bell crank 5-15, 5-17 brake 5-15 IQDM 14-7 main bell crank 5-15 transmission 9-7 cage, roll 12-7 calibration test module 14-3 caliper, brake 5-3, 5-5 cam installation tool 14-3 camshaft 8-21 camshaft, fuel 8-27 canister, air filter 9-11 cap air filter 9-11 bolt assembly 8-29 corner 2-39 filler 5-7 fuel 9-5 inlet 11-5 pressure 13-5 radiator 13-3 rubber 6-7, 6-13 sealing 8-5, 8-9 speed control plate 8-37 steering wheel 6-3 valve 8-45 cap, filler 5-9 Page i-8 control box, hydraulic 1-21 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List coolant bottle 13-5 coolant exchanger 13-3 coolant fill tee 13-3 coolant lamp sensor 13-11 coolant pipe 13-7 coolant pipe mounting tab 13-7 coolant temperature indicator light cooling fan 13-3 cord, glow plug 8-39 corner cap 2-43 cotter, rue ring 6-13 coupling 1-25, 1-27, 1-33 cover bearing case 8-19 breather 8-13 CCI dash storage 2-15 clutch 11-9 CVT 8-3, 11-3, 11-5, 11-9 cylinder head 8-13 electrical 7-13 fuel camshaft 8-5 heat proof 8-49 input 12-9 rocker switch hole 7-15 thermostat 13-11 cover plate, output 12-7 cover, joystick 1-21 cover, steering column 6-3 cowl panel 2-5, 2-7, 2-9 cowl panel, driver-side 2-5, 2-9 cowl panel, passenger-side 2-5, 2-9 crank 8-23 crankshaft 8-23 C-type stop ring 6-5 cup holder 2-13 cup holder, seat 2-23, 2-25 cutter, valve seat 14-5, 14-11 CVT 11-11 CVT cover 11-3 CVT cover kit, sealed 11-5 CVT cover kit, unsealed 11-5 cylinder head 8-9 cylinder head cover 8-13 cylinder, master 5-7, 5-9 D dash 2-13 decal 4x4 4-7, 4-9 bed 4-9 bed warning 4-3 CA 295 4-7 Club Car tailgate 2-43 crush area warning 4-3 driver/passenger 4-5 ground warning 4-5 7-15 INDEX hot manifold warning 4-5 hot surface warning 2-23, 2-25, 4-5 hydraulic controls 1-21 hydraulic pump 4-3 IntelliTach 4-11 joystick on/off 4-5 lock lever 1-19, 4-3 on/off 4-5 operating instructions 4-5 rollover warning 4-3 ROPS warning 4-3 rotating parts 4-3 rotating parts and hot manifold rotating parts warning 4-5 tailgate 2-39 trailer hitch 4-3 under 16 warning 4-3 deflector oil 12-17 diesel tachometer probe 14-9 differential housing 12-15 differential, front 12-7 diode 7-5 exhaust valve 8-45 extension, spring latch G 2-35 F 4-5 dowel pin 12-7 drag link 6-5 drain cock 8-5 drive belt 11-7 drive clutch fixed sheave tool 14-5 drive clutch holder tool 14-5 drive clutch hub puller 14-5 drive clutch puller 14-5 drive clutch spider removal tool 14-5 drive clutch, moveable 11-9 drive shaft 12-11 driven clutch base sheave 11-11 driven clutch cam puller 14-5 driven clutch puller plug 14-5 driven clutch spring compression base tool 14-5 driven clutch spring compression collar tool 14-5 driven clutch spring compression nut tool 14-5 dry moly lubricant 14-7 E E-clip 5-15 elbow 9-5 electric motor 1-29, 1-31 end, tie rod 6-5 engine block 8-5 engine, diesel, Kubota D722 with closed breather 8-3 equalizer 5-15 exchanger, engine coolant 13-3 exhaust installation 10-3 exhaust pipe 10-3 fan shroud 13-3 fan, cooling 13-3 fascia 2-3 fastener, push-in 7-13 fender, front 2-3 fender, left rear 2-41 fender, rear 2-41 filler cap 5-7, 5-9 filter air 9-11 fuel 9-3 inlet cover 11-5 oil 8-7, 8-11 filter, air, canister 9-11 fitting, thread-forming grease 6-13 flange, water 13-11 floor mat 2-19 floor plate, bed 2-35 floorboard 2-21 fluid, hydraulic 1-23 flywheel 8-25 flywheel puller 14-7 FNR brush 2-13 FNR brush strip 2-13 FNR shifter bracket 8-3 fork pallet 1-5 fork, pallet 1-5 fork, transmission 12-17 Forward/Reverse shifter 12-3 frame, tilt bed 2-35 front brake line 5-11 front differential 12-7 front gear case 12-17 front panel 2-7, 2-39, 2-41 fuel camshaft 8-27 fuel cap 9-5 fuel filter 9-3 fuel gauge 7-15 fuel gauge sending unit 9-5 fuel injection pump 8-35 fuel pickup tube 9-5 fuel pump 9-3 fuel system 9-3 fuel tank (diesel) 9-5 fuel tank strap 9-3 fuel tank vent 9-5 fuel tank, diesel 9-5 fuse 10-amp 7-13 25-amp 7-13 30-amp 7-13 fuse block 7-13 gasket bearing case 8-19, 8-51 clutch cover 11-9 control plate 8-37, 8-51 cover 8-19, 8-51, 11-5 cylinder head 8-9, 8-51 cylinder head cover 8-13, 8-51 drain plug 8-7 exhaust 8-51, 10-5 ex-manifold 8-49, 8-51 fuel pump 8-5, 8-51 gearcase 8-11, 8-51 head cover 8-51 head cover nut 8-29, 8-37, 8-39, 8-51 idle apparatus 8-29, 8-51 intake manifold 8-47, 8-51 liquid 14-7 nozzle 8-39 oil pump 8-17, 8-51 sending unit 9-5 thermostat 8-51, 13-11 water flange 8-51, 13-11 water pump 8-51, 13-13 gauge, compression 14-5 gauge, fuel 7-15 gauge, oil 8-15 gear cam 8-21 case 8-11, 12-13, 12-15, 12-17 crank 8-23 helical 12-19 idle 8-21 injection pump 8-27 oil pump drive 8-17 ring 8-25, 12-7, 12-15 gear case, front 12-17 gear ring engagement 12-19 gear yoke 14-7 glow plug 8-39 glow plug cord 8-39 governor fork lever 8-41 governor lever 8-37 governor shaft installation tool 14-7 governor shield 10-3 grill 2-3 grip tape, accelerator pad 9-9 grip, tilt latch hand 2-35, 2-39 grommet 9-5, 12-7 guard, belt 8-33 guard, splash 2-11 guide accelerator cable 9-9 detent bullet 12-19 exhaust valve 8-9 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page i-9 INDEX inlet valve 8-9 oil gauge 8-15 valve seat cutter guide ring adhesive hydraulic hose 1-23, 1-25, 1-27 hydraulic power unit 1-29, 1-31, 1-33 14-11 14-3 hydraulic power unit harness hydraulic tube 1-23, 1-25 hydrometer 14-7 7-9 H hair pin clip 2-43 half shaft 6-7 half shaft boot 6-9 handbook, operator 1-3 handle, park brake 5-17 handle, tilt steering 6-3 harness 2-3, 2-37, 7-5 harness, control panel wire 7-9 harness, headlight 2-3 harness, hydraulic power unit 7-9 harness, seatbelt light 7-11 head restraint 2-31 head restraint kit 2-31 head, cylinder 8-9 headlight 2-3 headlight harness 2-3 heat barrier 1-23, 1-25 heat seal 8-39 helical gear 12-19 hinge plate 2-23, 2-25 hinge, hood 2-5, 2-7, 2-9 holder FNR strip brush 2-13 fork lever 8-41 holder, cup 2-13 hood 2-5, 2-7, 2-9 hood hinge 2-5, 2-7, 2-9 hood latch 2-3 hood prop 2-5, 2-7, 2-9 hook, engine 8-9 hose 1-23, 1-25, 1-33, 13-5 coolant 13-3, 13-5, 13-9 fuel filter 9-3 fuel pump 9-3 fuel return 9-3 inlet cover 11-5 intake 9-11 overflow 8-39 vent 8-3, 12-5, 13-9 hose, hydraulic 1-23, 1-25, 1-27 hose, outlet 11-3, 11-5 housing clutch 12-7 differential 12-15 Mate-N-Lock 12-7 steering gear 6-5 hub, race/output 12-7 hydraulic brake adjuster 14-7 hydraulic control box 1-21 hydraulic fluid 1-23 Page i-10 I idle apparatus 8-29 idle gear 8-21 injection pump gear 8-27 inlet valve 8-45 insulation, heat barrier 1-23, 1-25 intake manifold 8-47 internal retaining ring pliers 14-7 IQ display module (IQDM) 14-7 isolator ring and bushing 8-3 isolator, twin stud 13-3 J joint ball 6-7, 9-7 eye 8-35 pipe 8-11 joystick control 1-21 joystick control box 1-21 joystick cover 1-21 K keeper, push-close latch 2-15 key feather 8-17, 8-21, 8-23, 8-27 key (pair) 7-15 key switch 7-15 key switch spacer 7-15 keyswitch nut 7-15 kick panel 2-41 kit bolt 12-7 brake pad service 5-3, 5-5 brake pedal adjustment tool 14-3 clutch 12-7 cover plate, input 12-9 cover plate, output 12-7 drain plug 12-7 forward gear repair 12-19 gasket 8-51 H-clip spring 12-7 head restraint 2-31 IQ display module (IQDM) 14-7 neutral switch repair 12-19 nozzle holder 8-39 piston rebuild 8-53 race output hub 12-7 rear axle gear repair 12-15 repair, minor 12-7 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List reverse gear repair 12-17 roll cage 12-7 roller 12-7 ROPS 2-29 tune-up 14-9 kit, boot replacement 6-9 knob, forward/reverse 12-3 L latch 2-15 latch bracket 2-3 latch keeper 2-15 latch plate, tilt bed 2-33 latch, bed 2-39 latch, hood draw 2-3 latch, slam 2-43 latch, spring 2-43 latch, tilt bed 2-35 lever engine stop 8-37 fork 8-41 governor 8-37 lost motion 9-9 speed control 8-37 light oil 7-15 light, coolant temperature indicator light, head 2-3 light, seat belt 7-15 line, brake reservoir 5-7 link, drag 6-5 liquid gasket 14-7 low oil warning light 7-15 lubricant, dry moly 14-7 lubricant, moly-teflon 14-7 M manifold exhaust 8-49 intake 8-47 master cyliner 5-9 mat, floor 2-19 Mate-N-Lock housing 12-7 Mate-N-Lock pin 12-7 meter, volt ohm 14-11 module calibration test 14-3 communication display moly-teflon lubricant 14-7 motor 1-29, 1-31 starter 8-43 moveable drive clutch 11-9 mower attachment 1-13 muffler 10-3, 12-5 14-5 7-15 INDEX N nongrease/spacers locker nozzle holder 8-39 nut, keyswitch 7-15 12-15 O oil deflector 12-17 oil filter 8-7, 8-11 oil pan 8-7 oil pressure switch 8-5 oil pump 8-17 oil pump drive gear 8-17 oil seal 8-11, 8-19, 12-7, 12-9 oil slinger 8-23 oil warning light, low 7-15 operator handbook 1-3 O-ring 8-5, 8-7, 8-9, 8-11, 8-13, 8-23, 8-31, 8-37, 8-51, 12-7, 12-9 overflow pipe 8-39 P paint, touch-up 14-7 pallet fork 1-5 pallett fork 1-5 pan center 1-21, 2-23, 2-25 oil 8-7 seat 2-23, 2-25 panel center cowl 2-5, 2-7, 2-9 driver-side 2-41 driver-side cowl 2-5, 2-9 front kick 2-41 left 2-43 passenger-side 2-41 passenger-side cowl 2-5, 2-9 right 2-43 side 2-39 panel, front 2-7, 2-39, 2-41, 2-43 panel, side 2-41 park brake pedal 5-17 p-clamp (fuel filter) 8-3, 9-3 pedal, accelerator 9-9 pedal, brake 5-13, 5-17 pin, clevis 5-7, 5-9 pin, dowel 12-7 pin, Mate-N-Lock 12-7 pin, piston 8-23, 8-53 pin, slide, caliper slide pin 5-3, 5-5 pinion 12-15 pinion, steering 6-5 pipe breather 8-47 coolant 13-7 exhaust 10-3, 10-5 injection 8-39 overflow 8-39 water 13-15 water return 8-13, 13-11 pipe band 13-11, 13-15 pipe clamp 8-39 pipe, coolant 13-7 piston 8-23, 8-53 piston pin 8-23, 8-53 piston ring 8-23, 8-53 piston ring compressor 14-9 piston ring pliers 14-9 plate armature 12-7 back 2-35, 2-37 cover, output 12-7 electrical 7-13 engine block 8-5 engine mounting 8-3 fuel/oil 9-3 hinge 2-23, 2-25 latch 2-33 shroud 8-25 speed 8-37 speed control 8-37 tailgate latch wear 2-39 thrust 12-7 plate, closeout 2-41 pliers internal retaining ring 14-7 piston ring 14-9 retaining ring 14-9 plug 1-29, 1-31, 12-17 drain 8-7 driven clutch puller 14-5 engine block 8-5, 8-9, 8-11, 12-13 expansion 8-5 gearcase 12-13, 12-17 glow 8-39 hole 7-15 oil drain 12-7 oil fill 12-7 oil filler 8-13 power unit, hydraulic 1-31, 1-33 press weldment 14-5 prop rod 2-33 prop shaft 12-11 prop, hood 2-5, 2-7, 2-9 protector spray, battery terminal 14-3 puller bearing 14-3 clutch 14-3 drive clutch 14-5 drive clutch hub 14-5 driven clutch cam 14-5 flywheel 14-7 seal 14-9 special use tool 14-9 pulley fan drive 8-33 water pump 8-33 pullrod, compression spring pump fuel 9-3 fuel injection 8-35 oil 8-17 water 13-13 push broom 1-11 push rod 8-21 9-9 R rack guide pressure spring rack, steering 6-5 radiator 13-3 radiator cap 13-3 radiator pipe 13-7 6-5 reamer, valve guide 14-9 receiver, rear 6-13 receptacle, accessory 7-15 relay 1-21, 7-13 relay connector 7-13 remover, bearing and oil seal 14-3 reservoir, brake fluid 5-7 reservoir, remote 5-7 restraint, head 2-31 retainer spring (driven clutch) 11-11 valve spring 8-45 retaining ring pliers 14-9 ring piston 8-23, 8-53 snap 6-5 ring gear 8-25, 12-7, 12-15 ring, C-type stop 6-5 ring, retaining, ext 6-7 rivet, blind push 2-11 rocker arm 8-45 rocker switch 1-21, 2-37 rocker switch (lights) 7-15 rod connecting 8-23 crank crank rod 8-23 prop 2-33 push 8-21 roll cage 12-7 roller weight 11-9 roller, torque 11-9 ROPS front base weldment 2-11 ROPS kit 2-29 ROPS support tube 2-29 ROPS top 2-29 ROPS warning decal 4-3 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page i-11 INDEX rotor, brake 5-11, 12-13 rubber bumper 2-43 S safety first card 14-9 screw, valve clearance adjuster 14-9 seal dual lip 12-15, 12-17, 12-21 heat 8-39 oil 8-11, 8-19, 12-7, 12-9 steering pinion dust 6-5 triple lip 12-17 valve stem 8-45, 8-51 seal puller 14-9 seat bucket 2-23 valve 8-11 seat belt light 7-15 seat holder base 2-23, 2-25 seat, bucket 2-23, 2-25 bucket seat 2-25 seatbelt light harness 7-11 sending unit, fuel gauge 9-5 sensor, coolant lamp 13-11 service kit, brake pad 5-3, 5-5 shaft CVT adapter 8-3 drive 12-11 fork lever 8-41 governor lever 8-37 idle gear 8-21 intermediate 12-19 pinion 12-9 prop 12-11 rock arm 8-45 shift 12-21 shaft, half 6-7 sheave, drive clutch base 11-11 sheave, driven clutch 11-11 shield, breather 8-13 shield, exhaust 10-5 shield, governor 10-3 shim 11-9, 12-15 shim, armature plate 12-7 shim, injection pump 8-35 shim, latch plate 2-33 shock absorber 6-11 shock absorber, coil over 6-11 shoe, skid 1-9 shroud, fan 13-3 side panel 2-41 side panel weldment 2-39 side stringer 2-17 skid shoe 1-9 slam latch 2-43 sleeve Page i-12 steering wheel puller tool 14-9 stem, valve 3-3 stop solenoid stay 8-31 stopper, camshaft 8-21 stopper, fuel camshaft 8-27 strap, fuel tank 9-3 stringer, side 2-17 strip, FNR brush 2-13 stud 8-3, 8-35, 8-49, 13-15 idle adjustment 8-29 self-clinching 2-39, 2-43 stud, ball 12-3 support yoke (steering) 6-5 support, structural 2-13 swingarm 6-13 switch 1-21, 1-29, 1-31 indicator (transmission) 12-19 key 7-15 light rocker 7-15 crankshaft 8-23 governor 8-27 lower arm 6-7 upper suspension 6-7 slide adjuster 6-7 slide pin 5-3, 5-5 slide, adjuster 6-7 slinger, oil 8-23 snap ring 6-5 snow blade 1-9 snow blade weldment 1-9 solenoid, stop 8-31 spacer engine 8-3 key switch 7-15 spacer block, differential 12-5 spanner wrench 14-9 speed plate 8-37 spider 11-9 splash guard 2-11 spray, battery terminal protector spring brake caliper return 5-5 brake return 5-15 compression 11-9, 11-11 detent bullet 12-19 exhaust 10-3 governor 8-41 idle apparatus 8-29 latch tilt 2-39 pedal 9-9 pedal stop 9-9 rack guide pressure 6-5 return 8-37 rocker arm 8-45 start 8-9, 8-41 torsion 9-9 valve 8-11, 8-45 spring latch 2-43 sprocket 12-17 start spring 8-41 starter motor 8-43 stay cylinder head 8-9 spring 8-11 stop solenoid 8-31 steel bushing 2-35 steering column 6-3 steering column bearing press tool steering column bracket 2-11 steering column cover 6-3 steering column retaining ring tool steering gear housing 6-5 steering pinion dust seal 6-5 steering rack 6-5 steering wheel 6-3 14-3 oil pressure 8-5 switch, rocker 1-21, 2-37 T 14-9 14-9 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List 12-volt battery 7-17 tab, coolant pipe mounting 13-7 tachometer 14-9 tachometer probe, diesel 14-9 tailgate 2-39, 2-43 tailgate angle 2-39, 2-43 tailgate latch wear plate 2-39 taligate 2-39 tank, fuel 9-5 tank, fuel (diesel) 9-5 tape 2-17 tape, grip, accelerator pad 9-9 tape, vinyl foam 2-35, 13-3 tappet 8-21 tee, coolant fill 13-3 temperature indicator light, coolant 7-15 tester, continuity 14-5 tether 2-43 thermometer, battery 14-3 thermostat 13-11 thread-forming grease fitting 6-13 thrust button 12-7 thrust plate 12-7 tie rod end 6-5 tie wrap 1-21, 2-37, 5-11, 5-15, 6-5, 9-7, 12-3 tilt bed 2-35 tilt bed frame 2-35 tilt latch hand grip 2-35, 2-39 tire 3-3 tire assembly, black 3-3 tire, mud 3-3 tool accelerator pedal adjustment 14-3 INDEX belt tensioning, starter/generator 14-11 brake adjustment 14-3 brake cable release 14-3 brake pedal adjustment 14-3 brake pedal tension 14-3 cam installation 14-3 carburetor float level 14-7 charger bezel 14-3 clutch alignment 14-5 cT-wrench 14-5 drive clutch fixed sheave 14-5 drive clutch holder 14-5 drive clutch spider removal 14-5 driven clutch spring compression base 14-5 driven clutch spring compression collar 14-5 driven clutch spring compression nut 14-5 governor shaft installation 14-7 puller, special use 14-9 steering column bearing press 14-9 steering column retaining ring 14-9 steering wheel puller 14-9 transaxle axle seal 14-9 transaxle pinion seal 14-9 transmission 14-9 valve guide driver 14-9 valve seat cutter 14-5 tool kit, clutch 14-5 torque converter 11-11 torque roller 11-9 touch-up paint 14-7 track, prop rod 2-33 transaxle axle seal tool 14-9 transaxle housing 12-15 transaxle pinion seal tool 14-9 transmission cable 9-7 transmission cable bracket 8-3 transmission chain 12-17 transmission fork 12-17 transmission tool 14-9 transmission, diesel, parallel shaft tube axle 12-15 breather 8-13 carburetor air vent 9-3 fuel pickup 9-5 ROPS support 2-29 tube, hydraulic 1-23, 1-25 tune-up kit 14-9 T-wrench tool 14-5 U upright 6-7 urethane bushing 2-35 12-17 V yoke, support (steering) 6-5 valve 1-29, 1-31, 9-11 breather 8-13 exhaust 8-45 inlet 8-45 seat 8-11 valve clearance adjuster screw 14-9 valve guide driver tool 14-9 valve guide reamer 14-9 valve seat cutter 14-5, 14-11 valve seat cutter guide 14-11 valve seat cutter tool 14-5 valve seat t-wrench 14-11 valve spring compressor 14-11 valve stem 3-3 vent barb 9-3 vent, housing, upper 12-15 vent, transmission 12-17 volt ohm meter 14-11 W warning light, low oil 7-15 water flange 13-11 water pump 13-13 wedge, bearing puller 14-3 weight clutch 11-9 weldment press 14-5 ROPS base front 2-11 weldment, accelerator pedal 9-9 weldment, accelerator pedal bracket 9-9 weldment, actuator bracket 2-37 weldment, air cleaner support 9-11 weldment, brake pedal 5-13 weldment, coolant pipe 13-7 weldment, Forward/Reverse shifter 12-3 weldment, Forward/Reverse shifter bracket 12-3 weldment, front dash dash weldment 2-11 weldment, lever, lost motion 9-9 weldment, receiver 6-13 weldment, tilt bed frame 2-35 wheel 3-3 wheel, steering 6-3 wire assembly 7-17, 9-5 wire harness 2-3, 2-37, 7-5 wire harness, control panel 7-9 wire harness, headlight 2-3 wire harness, hydraulic power unit 7-9 wrap, tie 1-21, 2-37, 5-11, 5-15, 6-5, 9-7, 12-3 wrench, spanner 14-9 Y yoke, gear 14-7 2009 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List Page i-13 Club Car, Inc. P.O. Box 204658 Augusta, GA 30917-4658 USA Web www.clubcar.com Phone 1.706.863.3000 1.800.ClubCar Int’l +1 706.863.3000 Fax 1.706.863.5808